Laser Illuminating Camera System for Empty Tote Detection

A Fortune 500 company needed to utilize real-time vision inspection techniques to verify the absence of previous products from plastic totes before filling them with different products. EPIC’s team engineered and installed laser vision system that not only met the company’s requirements for empty tote detection but also enhanced overall production efficiency, safety, and product quality. 

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Hygienic Process System Design

Project

Overview

  • Industry: Consumer Goods
  • Company Size: Fortune 500
  • Location: USA
  • Customer Use Case: Empty Tote Inspection with Laser Vision System

Customer’s

Challenge

A prominent Fortune 500 consumer products company needed to implement real-time vision inspection techniques to verify that plastic totes were empty before filling them with different products. This requirement was driven by the need to ensure that no remnants from previous products remained in the totes. The inspection process faced several significant challenges: 

 

  • Varying product colors: The totes contained products of various colors, necessitating an inspection system that was not affected by color variations. 
  • Large surface area: The totes had a large surface area that needed to be inspected thoroughly and quickly. 
  • Short cycle verification time: The time available for verifying that the totes were empty was very limited, demanding a highly efficient inspection process. 
  • Variable object location and orientation: If any objects were left in the totes, their positions and orientations were unpredictable, complicating the inspection. 
  • Minimal disruption to existing production line: The company required a fast implementation of the automated inspection solution with minimal alterations to the existing production line. 

Epic

Solution

EPIC’s vision engineers devised an innovative solution to address these challenges by selecting a laser vision system. This system was chosen because laser inspections are not influenced by the color, position, size, or orientation of the objects within the totes. This created a simple and effective solution to the complexity caused by product color variations. 

A laser vision system was used to detect surface flatness. The system comprised a single camera and two lasers projecting lines across the bottom surface of the totes. Any deviation from flatness indicated the presence of an object. 

An integrated Programmable Logic Controller (PLC) generated high-speed triggers to the camera when a tote was correctly positioned. Photo-eyes communicated the position of the tote to activate the upstream and downstream lasers, ensuring accurate alignment. 

If an object was detected during the laser scan, the entire tote was automatically rejected downstream before reaching the filler station. This prevented mixing products from previous runs with the current batch. 

 

empty tote detection with laser vision and lockout tagout system

 

For safety, a laser-lockout unit was installed to prevent accidental exposure to the lasers. The lockable disconnect with status lights (red, yellow, green) ensured that maintenance personnel were aware of the system’s status and could safely enter the inspection area. 

Project

Impact

  • Increased Accuracy and Speed: The laser vision system provided a fast and reliable method to inspect totes, ensuring that only empty totes proceeded to the filling station. 
  • Minimal Downtime: The solution required minimal changes to the existing production line, allowing for rapid deployment and minimal disruption to operations. 
  • Improved Safety: The lockout-tagout system with clear status indicators significantly improved safety for maintenance personnel, reducing the risk of accidental laser exposure. 
  • Reduced Product Contamination: Automated rejection of totes containing objects prevented cross-contamination between different product batches, maintaining high product quality standards. 
  • Simplified Maintenance: The system’s simplicity in terms of programming and maintenance reduced the time and effort required for upkeep compared to other smart camera inspection solutions.  

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