CHECKING DEVICE AND METHOD FOR CHECKING THE QUALITY OF FOLDABLE BOXES, AND MANUFACTURING INSTALLATION COMPRISING THIS CHECKING DEVICE

Abstract

A quality-control device (200) includes: an illumination system (202) for illuminating one peripheral face of each folding box, an image capture device (204) for forming a multiple image of the respective peripheral faces of a bundle of folding boxes, an image processing system (206) for: i) detecting within the multiple image each peripheral end of the slots of each box that separate its adjacent flaps, ii) generating a data set indicative of the geometry of each peripheral end, and iii) analyzing the data set to determine the width of each peripheral end.

Claims

1. A checking device for checking the quality of foldable boxes and when each foldable box is in a folded state, in which each foldable box comprises at least two flaps folded toward each other and each folded over flap having a free end, the free ends defining and being separated by a slot, the slot having a peripheral end opening on a peripheral face of the foldable box and the slot delimiting a lateral interval between the free ends of the two flaps at the peripheral face; the checking device comprising: an illumination system configured for illuminating the foldable boxes in the folded state at the peripheral face; and the illumination system being configured to illuminate a pack formed of superimposed or juxtaposed ones of the foldable boxes, wherein the pack has at least one peripheral pack face defined by respective peripheral faces of all the foldable boxes comprising the pack; at least one imaging device configured for forming images of the foldable boxes in the folded state, the at least one imaging device is configured to form at least one plural image representing at least a part of the peripheral pack face when the illumination system illuminates the peripheral pack face; and at least one image processing system configured for: i) detecting each peripheral end of a slot in the plural image; ii) generating a set of data representing a geometry of each peripheral end; and iii) analyzing the set of data to determine the width of each lateral interval.

2. A checking device according to claim 1, further comprising: the image processing system is configured for: xii) extracting dark objects from each plural image; vii) comparing a height of each dark object with a nominal thickness of a foldable box in the folded state, wherein the height is measured perpendicularly to the largest dimension of the foldable box in the folded state, and viii) selecting each dark object having a height that is equivalent to the nominal thickness of a foldable box in the folded state subject to a predetermined tolerance, wherein each selected dark object corresponds to a lateral interval.

3. A checking device according to claim 2, further comprising each plural image is a binary image; the image processing system is configured for: xiii) detecting, in each binary plural image, boundaries of the foldable boxes far ling the ends of the pack perpendicularly to the largest dimension of a foldable box in the pack then in the folded state; and xiv) discriminating each foldable box in the pack.

4. A checking device according to claim 1, further comprising: the image processing system is also configured for: iv) comparing the width of each lateral interval with a predetermined lower limit and a predetermined upper limit; and v) generating an anomaly signal if the width of a lateral interval is either below the predetermined lower limit or above the predetermined upper limit.

5. A checking device according to claim 1, further comprising the at least one imaging device is a matrix camera.

6. A checking device according to claim 1, further comprising the at least one imaging device comprises a line scan camera configured to form an image of a respective one of the peripheral faces of each foldable box; and a conveying device configured and operable for moving each foldable box relative to the line scan camera.

7. A checking device according to claim 6, further comprising two of the imaging devices placed at two different heights of the pack to form plural images of a lower part and an upper part, respectively, of the peripheral pack face.

8. A checking device according to claim 1, further comprising the illumination system comprises at least one illumination source selected from the group consisting of fluorescent tubes, discharge lamps, light-emitting diodes, and a column of light-emitting diodes.

9. A checking device according to claim 8, further comprising the illumination system is configured to illuminate in a pulsed manner a peripheral face of each foldable box in the folded state.

10. A checking device according to claim 1, further comprising the illumination system comprises two illumination sources arranged on either side of the at least one imaging device, the illumination sources being configured for successive illumination of the same peripheral face of each foldable box in the folded state, so that the at least one imaging device successively forms two different images of the same peripheral face of each foldable box in the folded state.

11. A manufacturing installation, for manufacturing foldable boxes comprises, when each foldable box is in a folded state, each foldable box comprises panels linked by folds and comprises at least two folded flaps folded toward each other and each folded over flap having a free end, the free ends defining and being separated by a slot; the manufacturing installation comprising: a gluing device configured to apply glue to a gluing area of each foldable box; a folding device configured to fold the panels so as to glue an area to be glued onto the gluing area; a stacking device configured for stacking the foldable boxes in the folded state; a conveying device, configured to in succession place each foldable box at the gluing device, then at the folding device to be folded, then in the stacking device for the folded boxes to be stacked; and at least one checking device according to claim 1, the at least one checking device being placed downstream of the stacking device.

12. A manufacturing installation according to claim 11, comprising two of the checking devices so as to form respective images of two peripheral pack faces.

13. A checking method for checking the quality of foldable boxes, wherein when each foldable box is in a folded state, each foldable box comprises at least two flaps which are separated by a slot, the slot having a peripheral end opening on a peripheral face of the foldable box and delimiting a lateral interval between the two flaps; the checking method comprising the steps of: illuminating, by means of an illumination system, a pack of the foldable boxes in the folded state wherein the pack is formed of superimposed or juxtaposed foldable boxes, the pack having at least one peripheral pack face defined by peripheral faces of all the foldable boxes composing the pack; forming, by means of at least one imaging device, images of the foldable boxes in the folded state; the checking method being characterized in that it further comprises the steps of: illuminating, by means of the illumination system, a pack formed of superimposed or juxtaposed foldable boxes, the pack having at least one peripheral pack face defined by peripheral faces of all the foldable boxes composing the pack; forming, by means of the at least one imaging device; forming, by means of at least one imaging device, images of the foldable boxes in the folded state wherein each of the images comprises at least one plural image representing at least a part of the peripheral pack face when the illumination system illuminates the peripheral pack face; and actuating at least one image processing system for the purpose of: i) detecting at least one peripheral end in the plural image; ii) generating a set of data representing the geometry of each peripheral end; and iii) analyzing the set of data for determining the width of each lateral interval.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0067] FIG. 1 is a schematic view illustrating a defective foldable box;

[0068] FIG. 2 is a schematic view of a manufacturing installation according to the invention;

[0069] FIG. 3 is a schematic top view of a part of the manufacturing installation of FIG. 2, comprising a checking device according to a first embodiment of the invention;

[0070] FIG. 4 is a schematic cross section in a horizontal plane when the checking device of FIG. 3 is in the operating position;

[0071] FIG. 5 is a schematic perspective view of the checking device of FIG. 4;

[0072] FIG. 6 is a schematic cross section, in a vertical plane when the checking device is in the operating position, of the checking device of FIG. 4;

[0073] FIG. 7 is a diagram illustrating a first type of slot to be checked;

[0074] FIG. 8 is a plural image of a pack of foldable boxes having slots of the first type, the plural image having been formed by an imaging device belonging to the checking device of FIG. 3;

[0075] FIG. 9 is a schematic view of the checking device of FIG. 3, during a step of a checking method according to the invention, in which two illumination sources simultaneously illuminate a pack of foldable boxes having a second type of slot to be checked;

[0076] FIG. 10 is a plural image resulting from the step shown in FIG. 9;

[0077] FIGS. 11 and 12 are schematic views of the checking device of FIG. 3, during a step of a checking method according to the invention, in which two illumination sources successively illuminate a pack of foldable boxes;

[0078] FIGS. 13 and 14 are images resulting from the steps shown in FIGS. 11 and 12 respectively;

[0079] FIG. 15 is a flow chart illustrating a checking method according to the invention;

[0080] FIG. 16 is an image of a pack of foldable boxes having slots of the first type, the image resulting from a step of the checking method shown in FIG. 15;

[0081] FIG. 17 is a binary image obtained from the image of FIG. 16;

[0082] FIG. 18 is a view on a larger scale of the detail XVIII in FIG. 17, showing a step of the checking method shown in FIG. 15;

[0083] FIG. 19 is a view on a larger scale of the detail XIX in FIG. 17, showing a step of the checking method shown in FIG. 15;

[0084] FIG. 20 is a schematic perspective view showing part of a checking device according to a second embodiment of the invention and comprising a line scan camera; and

[0085] FIG. 21 is a cross section along the plane XXI in FIG. 20.

DESCRIPTION OF EMBODIMENTS

[0086] FIG. 1 shows a foldable box 1 in the folded state, comprising i) panels 2 which are linked by folds 4, together with ii) flaps 6. Each panel 2 has a width W2, measured perpendicularly to the folds 4, corresponding to the height of the foldable box 1 in the unfolded state. Each flap 6 is linked to a respective panel 2 by a fold 8 formed by a corrugating machine.

[0087] Two neighboring flaps 6 are separated by a respective slot 10. Each slot 10 extends between a central region 11 and a peripheral face 12 of the foldable box 1. The slot 10 has a peripheral end 14 opening on the peripheral face 12 and delimiting a lateral interval 16 between the two neighboring flaps 6. The slot 10 has a central end located in the central region 11, and therefore opposite to the peripheral end 14.

[0088] As shown in FIG. 1, the foldable box 1 has a fault, because the slots 10 have oblique edges, instead of edges parallel to one another. One of the slots 10 has an excessively wide peripheral end 14, and therefore an excessively large lateral interval 16, while the other slot 10 has an excessively narrow peripheral end 14, and therefore an excessively small lateral interval 16. This fault may be due to incorrect cutting, incorrect gluing and/or incorrect folding. Sometimes, a width W10 of a slot 10 is determined near the folds 8, by measurement in a prior art device, or by extrapolation in the case of the present invention.

[0089] FIG. 2 shows a manufacturing installation 50 intended to manufacture foldable boxes 1 and comprising at least:

[0090] a gluing device 52 configured to apply glue to a gluing area of each foldable box 1,

[0091] a folding device 54 configured to fold panels 4 so as to glue an area to be glued onto the gluing area,

[0092] a stacking device 56 configured for stacking the foldable boxes 1 in the folded state,

[0093] a squaring device 60 configured for squaring the foldable boxes 1 so as to form packs 201,

[0094] a conveying device 58, configured to place the foldable boxes 1 in the gluing device 52, then in the folding device 54, then in the stacking device 56; in this case, the conveying device 58 is a belt conveyor providing an output rate of the installation equal to about 1800 foldable boxes 1 per hour, and

[0095] two checking devices 200 according to the invention.

[0096] In the example of FIGS. 2 and 3, the checking devices 200 are placed downstream of the stacking device 56 and of the squaring device 60. The gluing device 52, the folding device 54, the stacking device 56 and the squaring device 60 follow one another from the upstream to the downstream end, in the direction of circulation determined by the conveying device 58. Each checking device 200 therefore checks the foldable boxes 1 in packs 201.

[0097] Additionally, the two checking devices 200 are arranged so as to form respective images of two peripheral pack faces 212, particularly the two opposite faces of each pack onto which the respective slots open and where the interval of the flaps at each face are seen and measured. This arrangement can be used to check all the slots of each foldable box 1 contained in a pack 201.

[0098] FIGS. 3, 4, 5 and 6 show one of the checking devices 200. The checking device 200 comprises an illumination system 202 with two illumination sources 202.1 and 202.2, two cameras 204 forming an imaging device, and an image processing system 206. The illumination system 202 and the cameras 204 are mounted on a framework 203.

[0099] In this case, the checking device 200 is positioned in line; that is to say, the checks are made when the conveying device 58 brings the packs 201 to a position in front of the checking device 200. The conveying device 58 is arranged to convey the packs 201 in a horizontal direction.

[0100] The illumination system 202 is configured to illuminate a pack 201 formed from superimposed foldable boxes, wherein the illumination system 202 is configured to illuminate the foldable boxes 1 one by one. The pack 201 has two peripheral pack faces 212 on which the slots 210 open, which are defined by peripheral faces of all the foldable boxes composing the pack 201. The solid angle illuminated by one illumination system 202.1 is therefore larger than the solid angle illuminated by the other illumination system 202.2.

[0101] As shown in FIG. 6, the checking device 200 comprises two cameras 204. The cameras 204 are placed at two different heights, so as to form plural images 205 of a lower part and an upper part, respectively, of the peripheral pack face 212.

[0102] Thus the two cameras 204 can be used to form high-resolution plural images 205, even if the packs 201 contain large numbers of foldable boxes 1. In this case, the cameras 204 are configured for producing an overlap area between a plural image of the lower part of the pack 201 and a plural image of the upper part of the pack 201. The checking device 200 is arranged so that the optical axis of each camera 204 forms an angle (not shown) of about 60 degrees to the horizontal direction.

[0103] Each camera 204 is a matrix camera, while the camera 204 may be a line scan camera.

[0104] Each camera 204 is configured to form at least one plural image 205 (FIGS. 8 and 10) of the peripheral pack face 212 when the illumination system 202 illuminates the peripheral pack face 212. Each plural image 205 represents at least a part of the peripheral pack face 212 when the illumination system 202 illuminates the peripheral pack face 212. FIGS. 8, 10, 13, 14 and 16 show equivalent plural images 205. The field of view of one camera 204 is therefore greater than the field of view of the other camera 204.

[0105] The image processing system 206 is configured for:

i) detecting each peripheral end 214 (FIGS. 4 and 8) in the plural image, that is to say all the peripheral ends 214 of the slots 210 defined by the foldable boxes composing the pack 201,
ii) generating a set of data representing the geometry of each peripheral end 214,
iii) analyzing the set of data so as to determine the width of each lateral interval 216 (FIGS. 4 and 8).

[0106] In the example of FIGS. 2 to 6, the image processing system 206 is also configured for:

a) detecting the boundaries of the peripheral face 212 perpendicularly to the largest dimension of the peripheral pack face 212,
b) measuring a reference level of brightness between one of these boundaries of the peripheral pack face 212 and an edge 205 of the plural image, and
c) generating a binary plural image 207 (FIGS. 17 to 19) by using this reference brightness level to perform a thresholding operation on the plural image 205.

[0107] On the basis of a binary plural image 207, the image processing system 206 can then:

vii) compare the height H220 of each dark object 220 with the nominal thickness of a foldable box 1 in the folded state,
viii) select each dark object 220 having a height H220 equivalent to the nominal thickness of a foldable box in the folded state subject to a predetermined tolerance, so that each dark object of the height is one folded box, and its folded condition can be singled out for consideration by the image processing system,
xii) extract dark objects 220 from each binary plural image 207,
xiii) detect, in each binary plural image 207, the boundaries of the foldable boxes forming the ends of the pack 201 perpendicularly to the largest dimension of a foldable box 1 in the folded state, and
xiv) discriminate each foldable box in the pack 201; the image processing system 206 carries out the discrimination of each foldable box by processing a binary plural image 207 (FIGS. 17 to 19).

[0108] The image processing system 206 then generates a set of data representing the geometry of the peripheral ends 214 of the slots 210, so as to determine the width of each lateral interval 216, for all the foldable boxes appearing in the binary plural image 207, and therefore in the plural image 205.

[0109] By processing a single plural image 205, the image processing system 206 can thus determine the lateral intervals 216 of the slots 210 of all the foldable boxes composing a pack 201.

[0110] In practice, the image obtained from one camera 204 is larger than the plural image 205. The plural image 205 is the useful portion of the image obtained from a camera 204, that is the portion where the lateral ends can be detected. In other words, the other portions of the image obtained from a camera 204 show no lateral ends. The useful portion can be selected automatically on the basis of the dimensions of each foldable box 1, with a margin intended to compensate for imperfect alignment of the foldable boxes in the pack 201. By reducing the image obtained from a camera 204 to the useful portion forming a plural image 205, the duration of the image processing can be minimized.

[0111] FIGS. 7 and 9 show schematically, in cross section, the geometry of two types of slots. FIG. 7 shows a first type of slot called “straight”, because the edges of the slot are parallel to one another. FIG. 9 shows a second type of slot called “V-shaped”, because the edges diverge obliquely toward the peripheral end.

[0112] FIGS. 8 and 10 show the plural images 205 obtained for the first type of slot (FIG. 7) and for the second type of slot (FIG. 9), respectively, when the illumination sources 202.1 and 202.2 simultaneously illuminate the peripheral pack face 212.

[0113] The plural image 205 of FIG. 8 has peripheral ends whose edges have a high level of contrast. That is because the edges defining the slot do not project into the slot. The image processing system 206 can therefore easily process the plural image 205 of FIG. 8, in order to detect the peripheral ends of the slots and determine the width of each lateral interval.

[0114] Conversely, the plural image 205 of FIG. 10 has peripheral ends whose edges have a low level of contrast, because the slot is of the “V-shaped” type and the end edges of the flaps extend into the slot. The image processing system 206 therefore finds it more difficult to process the plural image 205 of FIG. 10 than the plural image of FIG. 8.

[0115] The two illumination sources 202.1 and 202.2 are arranged on either side of the cameras 204. As shown in FIGS. 11 and 13, the illumination sources 202.1 and 202.2 are configured to illuminate the same peripheral pack face 212 successively. Thus each camera 204 successively forms two different plural images 205.1 and 205.2, visible in FIGS. 12 and 14, for the same peripheral pack face 212.

[0116] The plural image 205.1 is formed during the illumination by the illumination source 202.1, and the plural image 205.2 is formed during the illumination by the illumination source 202.2. In the plural image 205.1, the left-hand boundary of each peripheral end 214 has a high contrast level, and in the plural image 205.2 the right-hand boundary of each peripheral end 214 has a very high contrast level. The illumination system 202 is configured to illuminate the peripheral pack face 212 in a pulsed manner. The duration of an illumination pulse is about 20 ms in this case. Between the two pulses, the pack 201 remains immobile, to ensure that the two successively formed images coincide.

[0117] The image processing system 206 then processes the plural images 205.1 and 205.2 for the purpose of:

i) detecting the left and right boundaries of each peripheral end 214,
ii) generating a set of data representing the geometry of each peripheral end 214,
iii) analyzing said set of data so as to determine the width of each lateral interval 216.

[0118] This configuration of the illumination sources 202.1 and 202.2 enables the illumination system 202 to produce alternating illumination, which improves the detection of all the peripheral ends 214 of the V-shaped slots.

[0119] In use, the checking device 200 is operated according to a checking method 2000 according to the invention, illustrated in FIG. 15. The checking method 2000 comprises the steps of:

2002. illuminating, by means of the illumination system 202, a peripheral pack face 212,
2004. forming, by means of each camera 204, plural images 205 of the peripheral pack face 212 when the illumination system 202 illuminates the peripheral pack face 212,
2006. actuating the image processing system 206 for the purpose of:
2008. i) detecting each peripheral end 214 in each plural image 205 of the peripheral pack face 212,
2010. ii) generating a set of data representing the geometry of each peripheral end 214, and
2012. iii) analyzing the set of data so as to determine the width of each lateral interval 216.

[0120] FIGS. 20 and 21 show part of a checking device 300 according to a second embodiment of the invention. To the extent that the checking device 300 is similar to the checking device 200, the description of the checking device 200 given above in relation to FIGS. 1 to 19 can be transposed to the checking device 300, with the exception of the notable differences stated below.

[0121] Any element of the checking device 300 which is identical or similar, in its structure and/or function, to an element of the checking device 200 carries the same reference, increased by 100. Thus an illumination system 302 with two light sources 302.1 and 302.2, a framework 303, a camera 304 and an image processing system 306 are defined.

[0122] The checking device 300 differs from the checking device 200, notably, in that the camera 304 is a line scan camera, whereas the checking device 200 comprises two matrix cameras 204. A line scan camera is a camera in which the photosensitive part is composed of a line of sensors (with a dimension of 1×n). The sensors may be CCD (“Charge-Coupled Device”) sensors, or CMOS (“Complementary Metal-Oxide-Semiconductor”) sensors. The camera 304 is configured to receive an optical beam 304.4.

[0123] The checking device 300 also differs from the checking device 200, notably, in that its imaging device is formed by a single camera 304, whereas the imaging device of the checking device 200 comprises two cameras 204. The camera 304 has an optical correction device 304.5 and a heat sink 304.6 configured to cool the camera 304 in use.

[0124] Furthermore, the checking device 300 differs from the checking device 200, notably, in that each illumination source 302.1 and 302.2 is composed of light-emitting diodes (LED) 302.5 arranged in a rectangular matrix, whereas the illumination system 202 is formed by two linear illumination sources. Each illumination source 302.1 and 302.2 comprises a respective heat sink 302.6 and 302.7.

[0125] Additionally, the checking device 300 differs from the checking device 200, notably, in that the checking device 300 further comprises a reflecting mirror 308 arranged so as to reflect the light received from each pack of foldable boxes toward the camera 304. This reflecting mirror 308 makes it possible to form a compact checking device 300. Each illumination source 302.1 and 302.2 directly illuminates each pack of foldable boxes through an aperture 309 formed in the framework 303.

[0126] In use, the checking device 300 can be operated according to the checking method 2000 illustrated in FIG. 15.

[0127] Clearly, the present invention is not limited to the specific embodiments described in the present patent application, nor to embodiments within the compass of a person skilled in the art. Other embodiments may be envisaged without departing from the scope of the invention, using any element equivalent to an element indicated in the present patent application.