OPTIMAL GLASS BOTTLE INSPECTION WITH ASEBI DEPT OF ECE, CREC 1 1. INTRODUCTION The Filtec Omnivision All Surface Empty Bottle Inspector (ASEBI), with a modular design that makes expandable functionality possible through available technology upgrades, meets the needs of small to medium size bottling facilities. Operating at speeds of up to 700 bottles per minute, the standard ASEBI comes equipped with a high resolution Camera Base Inspection system. Optional functions include inspection of the finish, thread, outer sidewall, inner sidewall, as well as the detection of residual liquid by infrared and RF techniques.Transparent films are detected with a special optical technique known as the Bright Field Analyzer. Reject verification, test bottle verification, rotating self-cleaning diffuser glass, serial interface port (MODBUS Protocol), isolated PLC outputs, and enclosure doors are also available as options. All of these options can easily be upgraded in the field, which assures maximum adaptability of the Filtec Omnivision. Filtec Omnivision is appropriate for bottling operations that fill returnable plastic or glass bottles for soft drinks, beer, and other products.The production conveyor powers the automatic starwheel drive system; this assures that the starwheel is always synchronized with bottle flow. Upstream sensors control the starwheel drive system and regulate gap closure of bottles entering the starwheel to provide smooth stops and starts which minimize breakage, jams, and noise. Handling bottles up to 104-mm-dia, the Filtec Omnivision improves productivity by reducing changeover related downtime to less than five min. The Filtec Omnivision offers a touchpad control panel and LCD color monitor that are both mounted on a swing arm that rotates for easy operator viewing.
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OPTIMAL GLASS BOTTLE INSPECTION WITH ASEBI
DEPT OF ECE, CREC 1
1. INTRODUCTION
The Filtec Omnivision All Surface Empty Bottle Inspector (ASEBI), with a
modular design that makes expandable functionality possible through available
technology upgrades, meets the needs of small to medium size bottling facilities.
Operating at speeds of up to 700 bottles per minute, the standard ASEBI comes
equipped with a high resolution Camera Base Inspection system. Optional functions
include inspection of the finish, thread, outer sidewall, inner sidewall, as well as the
detection of residual liquid by infrared and RF techniques.Transparent films are
detected with a special optical technique known as the Bright Field Analyzer.
Reject verification, test bottle verification, rotating self-cleaning diffuser glass,
serial interface port (MODBUS Protocol), isolated PLC outputs, and enclosure
doors are also available as options. All of these options can easily be upgraded in
the field, which assures maximum adaptability of the Filtec Omnivision.
Filtec Omnivision is appropriate for bottling operations that fill returnable
plastic or glass bottles for soft drinks, beer, and other products.The production
conveyor powers the automatic starwheel drive system; this assures that the
starwheel is always synchronized with bottle flow. Upstream sensors control the
starwheel drive system and regulate gap closure of bottles entering the starwheel to
provide smooth stops and starts which minimize breakage, jams, and noise.
Handling bottles up to 104-mm-dia, the Filtec Omnivision improves
productivity by reducing changeover related downtime to less than five min. The
Filtec Omnivision offers a touchpad control panel and LCD color monitor that are
both mounted on a swing arm that rotates for easy operator viewing.
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2. INTRODUCTION TO ASEBI
2.1. ASEBI
All Surface Empty Bottle Inspector (ASEBI), with a modular design that makes
expandable functionality possible through available technology upgrades, meets the needs
of small to medium size bottling facilities. Operating at speeds of up to 700 bottles per
minute, the standard ASEBI comes equipped with a high resolution Camera Base
Inspection system. Optional functions include inspection of the finish, thread, outer
sidewall, inner sidewall, as well as the detection of residual liquid by infrared and RF
techniques.Transparent films are detected with a special optical technique known as the
Bright Field Analyzer. Reject verification, test bottle verification, rotating self-cleaning
diffuser glass, serial interface port (MODBUS Protocol), isolated PLC outputs, and
enclosure doors are also available as options..
Figure 2.1: All Surface Empty Bottle Inspector (ASEBI)
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2.2 ASEBI DETECTION POINTS
All Surface Empty Bottle Inspector (ASEBI) having following detection points
They are:
1. OSW Detection
2.ISW Detection
3.Base detection
4.IR Residual Detection
5.RF Residual Detection
6.Finish Detection
7.Thread Detection
2.3 APPLICATIONS OF ASEBI
It is used in these areas like
1) Drug Companies
2) Beverages Companies
3) Water bottle companies
4) Pharmaceutical companies
5) Liquor companies
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3. DETECTION TYPES IN ASEBI
3.1 Inner side wall
The bottle's inner sidewall is made up of all the inside surfaces from the base up
through the neck. Damages in these surfaces can be difficult to see with the human eye,
but can easily grow mold internally or shed glass into the product after it has been filled.
Figure 3.1: Inner side wall
The bottle's inner sidewall is made up of all the inside surfaces from the base up through
the neck. Damages in these surfaces can be difficult to see with the human eye, but can
easily grow mold internally or shed glass into the product after it has been filled. The
CCD is a special integrated circuit consisting of a flat, two dimensional array of small
light detectors referred to as pixels. The CCD chip is an array of Metal-Oxide-
Semiconductor capacitors (MOS capacitors), each capacitor represents a pixel. Each pixel
acts like a bucket for electrons. A CCD chip acquires data as light or electrical charge.
During an exposure, each pixel fills up with electrons in proportion to the amount of light
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that enters it.The CCD takes this optical or electronic input and converts it into an
electronic signal. The electronic signal is then processed by some other equipment and/or
software to either produce an image or to give the user valuable information.
3.2 Outer side wall
Outer sidewall refers to the outside surface of a container, usually below
the thread and above the base. This outer surface can often become visibly
scuffed or chipped, especially in returnable glass or PET.
Figure 3.2: Outer side wall
Outer sidewall refers to the outside surface of a container, usually below the thread and
above the base. This outer surface can often become visibly scuffed or chipped, especially
in returnable glass or PET. While outer sidewall damages are unlikely to corrupt the
product itself, external container flaws are the indications of low quality standards most
obvious to the end consumer.
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15 independent inspection zones
ACL detection
Adjustable illumination
360 degree outer surface inspection
6000k LED panel strobe
Cellophane / brightfield detection
Adjustable illumination
3.3 Base detection
The base of a bottle receives the most amount of wear during the container's life,
and easily sustains scuffing or chips. Thorough inspection of both the inside and outside
of an empty container's base prevents flawed packaging and contaminated product from
reaching the market
Figure 3.3: Base detection
The CCD is a special integrated circuit consisting of a flat, two dimensional array of
small light detectors referred to as pixels. The CCD chip is an array of Metal-Oxide-
Semiconductor capacitors (MOS capacitors), each capacitor represents a pixel. Each pixel
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acts like a bucket for electrons. A CCD chip acquires data as light or electrical charge.
During an exposure, each pixel fills up with electrons in proportion to the amount of light
that enters it.The CCD takes this optical or electronic input and converts it into an
electronic signal. The electronic signal is then processed by some other equipment and/or
software to either produce an image or to give the user valuable information.
As stated, CCD cameras are useful in scientific imagery, especially in astronomy, where,
with the help of a telescope, they allow for high resolution images of stars, galaxies, and
other celestial bodies that human eye cannot detect. CCD cameras can also be used in a
laboratory to image in finer detail than a regular camera. The fact that CCDs are
extremely sensitive to light makes them useful in experimentation where faint light
detection is needed.
3.4 Thread Inspection
A bottle's thread refers to the molding at the top of the neck where the cap may be
screwed in place. Incorrectly formed or damaged thread can result in capping failures,
spillage, and contaminated product. with proper capping and sealing.
Figure 3.4: Thread Inspection
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3.5 finish Inspection
finish of a bottle or container is the very top surface where the cap is applied. For
returnable glass especially, this surface can easily chip while in the market or during the
washing process and cause problems with proper capping and sealing. If a chipped finish
does make its way back out into the market, sharp edges can harm the end consumer. The
CCD is a special integrated circuit consisting of a flat, two dimensional array of small
light detectors referred to as pixels. The CCD chip is an array of Metal-Oxide-
Semiconductor capacitors (MOS capacitors), each capacitor represents a pixel. Each pixel
acts like a bucket for electrons. A CCD chip acquires data as light or electrical charge.
During an exposure, each pixel fills up with electrons in proportion to the amount of light
that enters it.1 The CCD takes this optical or electronic input and converts it into an
electronic signal. The electronic signal is then processed by some other equipment and/or
software to either produce an image or to give the user valuable information. As stated,
CCD cameras are useful in scientific imagery, especially in astronomy, where, with the
help of a telescope, they allow for high resolution images of stars, galaxies, and other
celestial bodies that human eye cannot detect. CCD cameras can also be used in a
laboratory to image in finer detail than a regular camera. The fact that CCDs are
extremely sensitive to light makes them useful in experimentation where faint light
detection is needed.
For example, the 8-inch shutter pictured below leaks about 1/10,000ths of incident
light. Even in a dark room, the leaked light was imperceptible to experimenters. Though,
a 10 second integration time CCD exposure can resolve all the details of the leaked light
as shown in the picture. By applying IRAF image processing (to be described later), we
removed extraneous lighting by subtracting a dark image from the signal image.
It have:
• 1)High resolution CCD camera
• 2)Up to 720 degree inspection tracking
• 3)Adaptable for Press, Roll, and Twist finishes
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Figure 3.5: final Inspection
3.6 CAUSTIC DETECTION(RF-RLD)
Without additional inspection, leftover caustic and objects (like mold, cigarette butts, or
straws) not shaken out during the washing process can remain inside of returnable
containers through the filler and get sent back out to the market. Detects smallest amounts
of caustic, even once it has dried.
Figure 3.6: Caustic Detection
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4.CCD CAMERA OPERATION AND THEORY
4.1 INTRODUCATION
A CCD, or charged coupled device, is a device used in digital photography that converts
an optical image into electrical signal. CCD chips can detect faint amounts of light and
are capable of producing high resolution images needed in scientific research and
applications thereof. CCDs are particularly useful in astronomical imagery due to their
great sensitivity to light. In theory, CCDs are linear-producing accurate images,
transmitting the value they detect in a 1:1 ratio. This is usually not the case. Various
factors, such as dark noise, readout noise, saturation, along with the fact that each pixel
on a CCD is unique and varies from its neighbors, require that in-depth testing, analysis,
and data reduction be implemented when using a CCD for any type of scientific imagery.
Other variables, including the effects of a lens before a CCD and shutter speed of the
camera being used, along with others, must be taken into consideration and dealt with
accordingly in order to obtain a true image. There are various methods of testing for the
above factors, a few of which will be described, along with the appropriate data reduction
procedure.
4.2 Basic Theory of a CCD
The CCD is a special integrated circuit consisting of a flat, two dimensional array
of small light detectors referred to as pixels. The CCD chip is an array of Metal-Oxide-
Semiconductor capacitors (MOS capacitors), each capacitor represents a pixel. Each pixel
acts like a bucket for electrons. A CCD chip acquires data as light or electrical charge.
During an exposure, each pixel fills up with electrons in proportion to the amount of light
that enters it. The CCD takes this optical or electronic input and converts it into an
electronic signal. The electronic signal is then processed by some other equipment and/or
software to either produce an image or to give the user valuable information.
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4.3 Practical Applications of the CCD Camera
As stated, CCD cameras are useful in scientific imagery, especially in astronomy,
where, with the help of a telescope, they allow for high resolution images of stars,
galaxies, and other celestial bodies that human eye cannot detect. CCD cameras can also
be used in a laboratory to image in finer detail than a regular camera. The fact that CCDs
are extremely sensitive to light makes them useful in experimentation where faint light
detection is needed.
For example, the 8-inch shutter pictured below leaks about 1/10,000ths of incident
light. Even in a dark room, the leaked light was imperceptible to experimenters. Though,
a 10 second integration time CCD exposure can resolve all the details of the leaked light
as shown in the picture. By applying IRAF image processing (to be described later), we
removed extraneous lighting by subtracting a dark image from the signal image.
4.4 Use of a CCD in a Controlled Environment
For the purposes of this essay and the description of CCD operation, functionality, test
methods, and data reduction, it will be assumed that all CCD use is in a controlled
environment such as an indoor laboratory or dark room. A procedure for operation in this
type of environment will be described. Keep in mind that CCD usage in different
situations call for other procedures than the ones described below, although many of the
same principles still apply.
The CCD that was used for the actual data that will be represented is a product of
SBIG, Santa Barbara Instrumentation Group. The model used was the ST-8300M/C.
Table B. Specifications for the ST-8300
CCD Kodak KAF-8300
Pixel Array 3326 x 2504 pixels
Total Pixels 8.3 Megapixels
Pixel Size 5.4 x 5.4 microns
Shutter Type Electromechanical
Exposure 0.1 to 3600 seconds
Dimensions 4 x 5 x 2 inches
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When operating a CCD camera of these sorts, software must be used to acquire,
view, and edit images. CCDOps is the software that was used in the acquisition of all
images pictured. CCDOps is a free SBIG camera control software for Windows provided
with the purchase of an SBIG camera. While simple to operate, CCDOps effectively
controls all camera functions and is useful for basic image processing, although
limitations may exist.
When further image processing and data reduction is necessary, many other useful
programs exist, one of which is IRAF. IRAF stands for Image Reduction and Analysis
Facility, and is a general purpose software system for the reduction and analysis of
astronomical data. IRAF is written and supported by the IRAF programming group at the
National Optical Astronomy Observatories (NOAO) in Tucson, Arizona. NOAO is
operated by the Association of Universities for Research in Astronomy (AURA), Inc.
under cooperative agreement with the National Science Foundation. Basic IRAF
operations will be explained in further detail later on in this report.
4.5 Basic CCDOps Usage
1)The following process describes operation of CCDOps from a Windows XP
environment along with a few useful commands included in the program:
2)Install CCDOps onto a computer that runs Windows before connecting the camera to
the computer.
3)The process is simple and detailed instructions accompany the software package.
4)Make sure that the proper drivers for specific camera are installed.
5)SBIG cameras come equipped with a USB cable that connects the camera to the
computer.
6)Plug the camera‟s power supply into the wall and note that the internal fan comes on.
7)Connect the USB to the computer and follow instructions provided in the manual and
the “Found New Hardware Wizard” prompts.
Once CCDOps is installed and the camera is successfully connected to the computer, run
CCDOps. Once the temperature is reached, the percent capacity should be no more than
60-80 percent, and should never be operating at 100 percent.
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4.6 Conclusion
The CCD, charged coupled device, is an amazing piece of technology that is very
useful in science, particularly in Astronomy, as well as in everyday life. High resolution
CCD images have allowed scientists to observe realms of the universe that the human eye
had never seen. Using various means of imaging and data reduction, one can correct
variances and imperfections exhibited by a CCD, and obtain a very accurate image.
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5. WORKING AND OPERATION OF ASEBI
5.1 Working Principle
This machine works on the principle of empty bottle inspection.
Figure 5.1: Parts of ASEBI
Applications
Inspection of empty glass and PET containers
Output
Rated output: 72,000 containers per hour
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5.2 Inspection modules in overview
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5.3 POWER SUPPLY
5.3.1 AC POWER SUPPLY
Figure 5.3.1: AC POWER BLOCK DIGRAM
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5.3.2 DC POWER SUPPLY
Figure 5.3.2: DC POWER BLOCK DIGRAM
FIGURE 5.3.1 shows the circuit diagram for AC power supply in ASEBI
FIGURE 5.3.2 shows the circuit diagram for DC power supply in ASEBI
.
UPS Battery:
The Lead-Acid 24VDC UPS battery is charged with the 30VDC power supply
that is mounted in the Base Cabinet. CB-11, the breaker for this supply, is connected
directly to the in-coming 220VAC line to allow charging to take place regardless of the
state of the main power switch. The power for this circuit is not subordinate to the main
Power Switch.
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Theory/Functionality:
The OV-II UPS is not a typical AC UPS.
The OV-II UPS is a DC UPS whose sole purpose is to switch 24VDC from the power
supply in the Base Cabinet (which is killed when the main power switch is thrown) to the
24VDC battery for a period of one minute to allow Windows to have time to properly
shut down
1)Monitor The operating unit is a high-resolution 15" TFT colour touch-screen, which is
integrated in the machine head
2)Current display of all relevant operating data including rejection trend analysis with
possibility for display of all camera images
3)Access to user interface via individual passwords - optional as number code or with
coded transponders
4)Different access levels for individual operators, depending on the assigned
authorisation +
Documentation of production
1) data Recording of all relevant operating data such as production data, parameter
changes, the results of the test bottle programme, and special occurrences with the
machine function
2)Use of these data e. g. for quality management, or storing in a longtime memory
3)Saving of these data with exact time indications, operator names, and the respective
valid parameter values
4)Transfer possibility of defined operating data to an operating data acquisition system,
to the customer's network, or to an external PC (customer)
5)Different printout representations of production and test container data
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Automatic maintenance programme
1.Automatic information on display for machine operator or service technician about
upcoming maintenance tasks
2.Display of maintenance tasks by priorities and resetting jobs after termination
3.Interactive graphical malfunctions diagnostics system to support troubleshooting
Remote visualisation
1.Display of the machine’s operating condition through the company-own network to
several PCs by using an additional software
2.Monitoring of e.g. counter readings, malfunctions, test bottle programme runs
Change ovwe
1)Test container programme Semi-automatic function monitoring in regular intervals, as
well as every time after switching on the machine, and when changing over to a new
container type
2)Infeed of a prepared assortment of test containers to the machine in any sequence
3)Examination of the individual inspection units by error detection with the test container
4)Data indication on the display, and recording of results
5)Data transfer to operating data acquisition system, to a network, or to a printe
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6. LCD DISPLAY AND SETUP
6.1 Introducation
By using CCD camaras the detection of bottles seen in disply screen.It requires
windows 7 os with detection software.Below figure 6.1 shows the LCD display with
touchpad
Figure 6.1 LCD Display
Screen have:-
15-inch pivoting touch-screen
Display of all relevant operating data including a rejection trend analysis with
display of all camera images
Operation and adjustments via individual access levels with userdefined
transponders
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6.2 Base inspection setup
A camera takes an image of the container base, which is evenly illuminated by an
LED flash. The high grey-scale resolution guarantees consistently high image quality
even in containers with different levels of permeability to light.
In glass bottles, it detects
Contamination and damage on the base
Foreign objects
With an additional filter: film residues and glass splinters in the bottle
In returnable PET containers, it detects
Contamination and damage on the base
Foreign objects
Tension cracks on the base
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Figure 6.2 Base inspection setup
6.3 Inner side-wall inspection setup
Uses a CCD camera to inspect theinside of the container through itsopening
Utilises the LED illumination ofthe base inspection unit
Detects protruding dirt on theinner side-wall
This means that it inspects theinner side-wall precisely, even ifthere is a large-area
ACL label onthe container
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Figure 6.3 Base Inner side-wall inspection setup
6.4 Side-wall inspection setup
The side-walls of returnable PET and glass containers are inspected in two or four
modules, each with a CCD camera. An LED light box evenly illuminates the entire bottle
height. Using special optical components, each camera produces three images per
container. By overlapping the image sections, each millimetre of the bottles is recorded.
For gap-free, all-around inspection, the bottles are rotated between the infeed and
discharge of the machine.
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6.5 Infrared residual liquid detection setup
Residual liquid in the container is detected by two independently operating
systems: the infrared system detects all liquids, such as for example, cooking oil. As a
team, these two detection systems achieve a maximum degree of safety.