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Label Print Quality Inspection System R210

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01 System Introduction   

       

Industrial label printer is widely used for various industries. Due to the long hours of intense use, some print defect and error will inevitablely happen. So human mannual is required to perform label inspections. However, mannual visual inspection is not reliable, not mentioning the labor cost added. Rosetta R210 label inspection system is developped to perform inline inspection to improve efficiency and save cost.

 

The R210 system consists of both hardware and software components. The major components are:

 

R210 Flat-field Sensor Hardware:

 

This is the hardware part of the system which handles the image capture and processing. It consists of a flat-field tube and one image capture circuit board (developed by Rosetta). Flat-field tube is a new type of image sensor, composed of photoelectric sensor array, LED light source array, and columnar lens array. This flat-field sensor has more advantages than regular sensors like CCD or CMOS. Rosetta’s flat-field sensor generates higher resolution image at 1:1 scale ratio, and will not sacrifice any resolution loss due to image distortion or edge blurring. It can significantly reduce the burden of subsequent image processing task. 

 

R210 Server Software:

 

This software is developed with Rosetta’s latest algorithm, working as the brains of the system. It runs as a server on a customer supplied computer and communicates with the flat-field sensor through Gigabit Ethernet ports. The R210 server analyzes image data received from the flat-field sensor hardware to determine if it meets the specified quality standards. It also has a friendly user interface that allows an operator to set inspection criteria, run or pause the print job, check the data statistics.

 

02 Main Features 

 

  1. Adopts deep learning technology. This system is a combination of software and hardware, based on machine vision algorithm.

  2. Can be easily installed to various industrial label printers. Inline inspection with printing on going, matching print speed.

  3. Inspect code readability, grade, defects, and classification display.

  4. Replacing human mannual visual inspection, this system provides accurate, reliable and inexhaustibleinspection job. 

  5. Automatic filing of inspection data and graphic for future traceability.

  6. Generate report and data analysis for effective production management.

  7. Easy and quick pattern change.

 

03 Inspection Content  

Printing quality

Checks out label printing defects caused by wrinkled carbon belt, broken pin, etc.

Detect print missing, position deviation, distortion.

Detect contamination or dirty on labels

Checks if the printing position is deviated.

 

OCR word recognition

Recognition of letters, numbers and symbols.

Checking on garbled code

 

Code Readability Verification

Recognition of one-dimensional code and two-dimensional code.

Verification of correct readability based on ISO standard.

 

Content comparison

Comparison with original data base.

Comparison with wording or graphic template.

 

Data statistics

Counting of labels quantity

Calculation of pass rate or defective rate

 

 

04 System Advantages   

 

      (1)   CIS soul of the system - software & algorithm system

  1. Detection ability, effect ability, response speed, development efficiency, iteration, precision.

     

  2. The unique self-developed deep learning algorithm prevents label printing errors and improves "label security".

     

  3. Identify defects, avoid fines and disputes, reduce rework, control waste, and avoid legal liability.

     

  4. Some typical errors like, duplicate label, content missing, MES&PLC communication data printing anomaly, label appearance defects, database mismatch might happen due to printer's carbon tape wrinkles, print head missing needle, self-adhesive foreign body, printing communication and other factors. These erros might result in commodity identification confusion and complaints.

  5.  

       (2)  The Inspection accuracy can reach 0.1 mm  (label size 128 x 60 mm)

 

 

       (3)  Easy and flexible installation

  1. Can be installed in the original hole position of the printer, without changing printer structure.

    Can be installed on new and old Zebra printers (ZT105, ZT110, ZT410/411, ZT510, ZT610, etc.).

    Two structures available, integrated or stand-alone.  

 

 

05 Application 

  

Inspection category: system allows to set specific inspection category, like barcode verification, characters analysis, scratch detection.

 

 

Label Inspection: system performs inline label inspection.

 

Printer control:  System can connect external devices and printer to control them.

 

Data statistics: System can generate labels data statistics, pass rate, print speed, etc.

 

 

06 Technical Specs 

 

  1. Supported label width:                     110 mm

  2. Resolution:                                        600 dpi

  3. Label motion speed:                         < 500 mm/s

  4. Inspection speed:                              5 labels / sec.

  5. Overkill rate:                                      < 0.01%

  6. Underkill rate:                                     0

  7. Setting time for pattern change:      < 5 mins.

 

07 Customer Application and Defect Sample 

  

Here shows some actual inspection examples from customer site.

 

 

 

08 Application Industries 

 

R210 system is widely used serving many industries, where correct and compliant labels are required.

 

 

 

09 Real Application Case Videos