Looking for a cost-effective solution to inspect pallets? Pallet Machinery Group is marketing and selling the Neocortex Pallet Inspection system developed by Universal Logic. Neocortex utilizes artificial intelligence (AI) technology to inspect new pallets in real-time for quality control.
Neocortex immediately identifies missing or protruding nails, broken boards, incorrect nailing patterns, and other issues. The system, which can inspect block or stringer pallets, eliminates the need for workers to manually inspect finished pallets. Two high resolution 3D sensors, top and bottom, scan the pallet to evaluate for defects. After the scan and analysis, the AI system designates the pallet with a pass or a failure distinction. Pallets designated as fails can be routed to alternate locations, such as a repair station or dismantling area, while the pallets that pass inspection can be conveyed to sorting or stacking areas.
Why does AI help the inspection process? David Peters, CEO of Universal Logic, explained, “With artificial intelligence, the longer it does something, the better it gets because it learns over time and can adapt to differing real-world scenarios. We have been doing this for sixteen years, so your model is more advanced than what some others may offer.”
The AI-driven inspection system can be easily installed and integrated with pallet manufacturing or recycling operations. Scans are completed very quickly, within 1,500 milliseconds. About ten of these systems have been deployed into the grocery industry, and four are doing pallet inspections today. The first prototype that can be added onto the end of a pallet nailing system has already been finished.
Once Neocortex evaluates a pallet, it logs the results into a database that allows the user to track key performance indicators. It gathers throughput metrics, tracks common defects and types, and other data. Pallet quality metrics are adjustable, adhering to industry standard metrics, and adaptable to a customer’s preferred tolerances.
With this system running through Neocortex, there is no specific hardware, and installation requirements are minimal. It works with many brands of sensors and most environmental conditions.
Neocortex is the ‘brain’ of the inspection system. It was developed for 15 years by a team of Ph.D. vision and machine learning experts. It uses 3D vision to gather and analyze tens of thousands of data points, then makes a probability-based decision at high speed.
Founded in 2008, Universal Logic provides automation solutions used to mimic light-duty, semi-skilled labor on supply chains. The Neocortex software uses sensor data, sophisticated machine control, and inference derived from artificial intelligence to handle high variability at high speeds.
“We have an agreement with Universal Logic to sell the unit for pallet inspection,” said Doug Jones, vice president of Pallet Machinery Group (PMG). “We looked at a lot of inspection technology and think this is the best fit right now for our customers.” PMG produces the Titan™ nailing machine and has decades of experience servicing the needs of pallet producers.
“Basically, this unit will be placed at the end of the nailing machine,” added Jones. “It eliminates the need to have a worker dedicated to performing quality control inspections of finished pallets, and it can keep up with all nailers on the market, no problem.”
PMG believes the inspection systems will have a three-year ROI or less. Jones noted, “I look at ROI from a pallet sales perspective. If you give me the ability to say I can do something different from the competition and can offer 100% perfect pallets with a readout documenting the quality, that opens up the opportunity to attract many new customers.”
The system is versatile and can learn new schools based on new parameters and examples. Jones commented, “This inspection system can look for pretty much anything you want. Some of the common issues include: nail pops, skewed boards, broken boards, missing boards, knots, cracks. It can even identify mold and blue stain as well as the color of the pallet.”
Currently, PMG is focusing on inspecting pallet quality at the end of a nailing line. But the system can also inspect and determine necessary repairs at the beginning of a repair line or other quality control and sortation processes.
Beyond the ability to collect real-time data that can be monitored from almost anywhere, the Neocortex system eliminates human error and variance. Clay Wells, a sales engineer with Universal Logic explained, “So a lot of times you get inconsistency on the back end, the operator on the number two nailer station who is supposed to handle the inspection. One operator does a really good job. But another does not. Our system offers consistency; everything is going to be done exactly the same. Our system takes away human error and variance.”
Also, the AI can identify areas that need to be addressed in the actual manufacturing process. Wells said, “We can track trends over time. For example, if you keep getting nail pops or are missing nails in the same spot, the AI will figure it out and may tell you that you need to replace a chuck or some other part on the nailer.”
For more information, call Pallet Machinery Group at (540) 644-9220.
The Neocortex Pallet Inspection:
- Can detect nail extrusions down to <1 mm
- Looks for missing boards
- Finds cracks or splinters
- Identifies pallet color and type
- Has a field of view of 400-2000 mm
- Scans while moving up to 2m/s
- Can work in hostile environments
- Inspects all wooden pallet types
