Multi-Scan Aggregation System

Multi-Scan Inspection System – Electrical & Automation Leadership

I engineered and led the electrical and automation framework for the Multi-Scan system — a high-precision inspection platform designed for multi-side scanning and verification of packaged products. My role combined hardware design, software coordination, and field commissioning to deliver a robust industrial solution

Overview

The Multi-Scan system provides comprehensive scanning of products from multiple angles (top, sides, bottom) to ensure complete verification of label placement, seal integrity, product shape and code readability
This project required meticulous synchronization between mechanical transport, optical sensors, lighting, and high-speed data capture — and I took charge of the electrical and automation architecture that made it all work seamlessly

My Role & Responsibilities

• Designed the electrical control cabinet, including power distribution, signal routing, lighting control and safety interlocks

• Developed PLC and HMI logic for multi-camera coordination, asynchronous image capture, reject decision making and production reporting.

• Integrated sensors and encoders to guarantee that each product zone (top, side, bottom) is scanned at exactly the right moment

• Coordinated with mechanical design and vision-software teams — guiding layout of scan zones, lighting positioning and optimization of camera trigger points

• Oversaw factory commissioning and on-site fine-tuning to reach verified detection rates, minimal false rejects, and high uptime

Key Technical Features

• Multi-angle imaging (top + sides) synchronized via encoder feedback

• Adaptive lighting control (LED tower, short-pulse strobes) for consistent image clarity

• Motion-controlled belt using servo drive with closed-loop feedback for product stability

• Real-time communication with the verification server for code read-out and reject logic

• Comprehensive HMI interface: scan status, reject counts, diagnostics, operator override

Results & Impact

• Inspection coverage increased to 100% of visible surfaces versus previous 70%

• Reject rate due to mis-print or mis-label dropped by over 60%

• Electrical and automation architecture allowed maintenance time to fall by 30%

• The system is now set up as a modular platform, ready for future line expansion and adaptation

Future Development

My next iteration will focus on

• AI-based defect detection (shape, label skew, missing perforation)

• Smart panel with remote monitoring and predictive maintenance alerts

• A series of plug-and-play modules to reduce deployment time on new lines