So, $coworker_who_thinks_I_am_part_ninja and I think in different ways. I try to make my profiles as widely-applicable as possible, so they are robust enough to withstand insane changes. He makes his profiles as quickly as possible, so dev time is short
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Hi, I used to work at a VGR company, so here's a quick idea that we used for situations like this - it may or may not apply to your particular application, though:
Depending on the edge that's causing issues, simply mount a bright area-light (or wide-angle spotlight) off to the side to create a stronger contrast for the cameras. I've seen applications with lights mounted in 3 or 4 different places, triggered sequentially (with camera captures for each light) - this is incredibly robust, will handle all kinds of box rotations and box dimensions, but requires that there's enough space for all the equipment, enough budget, enough time for all the imaging, and a way to control an I/O port for the lights (RS232 works wonders).
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"Memento Mori Ergo Carpe Diem"
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