Overview

We, Logiqal Space, partnered with a local glass bottle manufacturing facility to revolutionize their quality control process. Over a 40-day period, we designed and implemented an end-to-end automated inspection system that integrates advanced hardware and software solutions. Our innovative approach enabled the factory to detect and sort defective glass bottles in real time, significantly improving efficiency and reducing manual errors, all while maintaining strict confidentiality as per the client’s request.

Challenge

The client’s fast-paced production environment demanded a solution that could:

• Accurately detect defects: Both visible surface flaws and internal anomalies had to be identified reliably.
• Keep pace with production: The inspection system needed to handle high-speed conveyor lines without compromising on quality.
• Reduce manual intervention: The existing manual inspection process was inefficient and prone to human error.
• Maintain confidentiality: Certain details of the product and client information had to remain undisclosed due to proprietary concerns.

Our Solution

Logiqal Space delivered a comprehensive solution that combined state-of-the-art computer vision with a robust hardware setup. Key components of our solution include:

• High-Speed Imaging:
  • Cameras: High-speed grayscale cameras (80–120 FPS, 420p resolution) capture multiple images from various angles, ensuring no defect goes unnoticed.
  • Proximity Sensors: These ensure precise timing and synchronization, capturing the best possible shots as bottles travel along the conveyor.
• Advanced Sensor Technologies:
  • Ultrasonic Sensors: Detect internal defects or variations in glass thickness by analyzing reflected ultrasonic waves.
  • Infrared Sensors: Identify temperature-based anomalies and stress points that are not visible to the naked eye.
• Smart Software Integration:
  • Custom ML/DL Model: Utilizing OpenCV and a tailored convolutional neural network, our model processes images in real time to classify defects.
  • Internal Monitoring Application: A user-friendly dashboard displays live production metrics and alerts, empowering non-technical operators with actionable insights.
  • Robust Server Infrastructure: Deployed on a high-performance server equipped with an RTX 3080 to ensure seamless and rapid processing (further server details remain confidential).
• Automated Sorting Mechanism:
  • The system sorts bottles into four distinct categories. For public disclosure, only two categories are named:
    • Perfect: Bottles that meet quality standards.
    • Totally Defeated: Bottles with critical defects.
  • Confidential Note: The remaining two sorting categories are withheld as part of the client’s confidentiality requirements, this is also the primary reason we are unable to disclose the client’s name.