3D Vision Solutions for Consumer Product Applications

Empty medicine bottle on conveyor belt with screenshots from 3D-L4000 inspection software

Consumer product applications have different requirements than industrial applications. Text and images on packaging are important to brand recognition, communication, and even consumer safety.

The following three vignettes show how quickly and easily the In-Sight 3D-L4000 vision system provides both 2D and 3D capabilities to consumer product applications. 

Painless Label and Packaging Inspection

A pain reliever manufacturer needed a machine vision system for label and packaging inspection that could:

  • Inspect boxes
  • Detect defects
  • Confirm presence and readability of labels

The In-Sight 3D-L4000 was selected for its capabilities and easy-to-use software. With an advanced smart camera and 2D and 3D software working simultaneously in a single compact design, setup was fast and intuitive. The system verified packaging and label quality and communicated results in a simple user interface. Moreover, the user-friendly interface allowed in-house technicians and operators to manage, monitor, and change the software as needed to meet specific application requirements. The In-Sight 3D-L4000 was integrated quickly into the pain reliever production line, successfully preserving package quality, brand recognition, and consumer safety.

As part of the inspection of packaged goods, the In-Sight 3D-L4000 smart camera detects 3D features by imaging displacements of a projected laser line. High-quality 2K resolution and patented speckle-free blue laser optics allow the camera to capture details on labels, text, and images on the surface of packages. These 2D capabilities leverage the tools in the industry-proven Cognex In-Sight software. The software has also been upgraded, with a new 3D toolset to solve multiple machine vision challenges simultaneously.  

Additionally, the  In-Sight 3D-L4000’s unique blue-laser optical design has several benefits including: 

  • Eye safe operation
  • More light delivered to the surface than competing solutions
  • Accurate 3D point clouds for measurements
  • Capability to capture a scan even with a percentage of the laser is blocked by debris

This last feature is an unprecedented achievement in 3D laser scanning, made possible by the patented speckle-free laser optics. Most laser scanning applications limit the designer’s option to mount the scanner upside down because of concerns about debris blocking the laser light.

Best-Fit Volume Inspection 

Some vision system applications take longer to integrate than others. Often, the more complex processes are, the more time and costs are required for integration. However, with new streamlined technology, the situation is changing. The following is an example of how a consumer product manufacturer solved a complex 2D and 3D vision inspection challenge quickly. In an inspection system for shoes, a vision system was needed to:

  • Inspect for the presence of both shoes
  • Measure volume to determine the size of shoes

3D-L4000 camera scanning shoes boxes on conveyor belt and screenshot from inspection software

For this inspection, the  In-Sight 3D-L4000 smart camera with In-Sight software and 2D and 3D tools provided quick setup and easy integration for accurate, repeatable results.. The In-Sight 3D-L4000’s precise volume data determined that both shoes were in the box and verified shoe size. This 3D solution used advanced 3D technology to expand what was possible to achieve in a consumer product environment with short turnaround times.

High-Precision Surface Inspection

In another situation, the In-Sight 3D-L4000 inspected floorboards. The smart camera detected 3D defects on the floorboard surfaces, such as bumps and dents, while 2D capabilities verified that surfaces were free of visual imperfections like paint splats. The smart camera’s ability to inspect continuously was important due to the length of the boards and the speed of the process.

3D-L4000 camera scanning wood panels on conveyor belt and screenshot from inspection software

The In-Sight 3D-L4000's unique speckle-free laser system is hardened against debris blocking the laser light through a unique optical solution. As a result, designers can confidently install the  In-Sight 3D-L4000 upside down, scanning the bottom of the boards without unnecessary fear that airborne contaminants will render the system useless. 

Machine Vision Solutions for Every Application and Skill-Level  

The  In-Sight 3D-L4000 vision system from Cognex comes with In-Sight software that enables users to quickly integrate and change tools. All data is presented clearly in the user-friendly Spreadsheet environment. Technicians and operators can monitor, manage, and maintain complex jobs with minimal training.

In-Sight 3D-L4000 consumer product inspection applications are successful in detecting 2D and 3D defects and surface quality. With its compact design, the smart camera is easy to integrate and manage. Finally, the intuitive and extensive software offers flexibility for future inspection requirements and applications.


Isabel Pagliaccio

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