1. Project Overview

In the modern packaging and manufacturing industry, packaging accuracy is directly related to corporate brand reputation and compliance risks. This solution provides a highly versatile, high-speed and zero-threshold intelligent on-line mixed material inspection system. By efficiently connecting with the customer’s existing mechanical equipment, it effectively eliminates defects such as mixed products and position deviation, serving as the preferred supporting solution for enterprises to realize intelligent production.

2. System Working Principle

The system adopts a closed-loop inspection mechanism of "fully automatic photoelectric induction – high-speed visual comparison – real-time IO control". The specific process is as follows:

2.1 Trigger Induction:

When products on the production line pass through the inspection point, high-sensitivity sensors detect the products and send trigger signals to the camera.

2.2 Image Acquisition and Transmission:

Upon receiving the signal, the camera completes instant image acquisition and transmits high-quality images to the underlying visual inspection system.

2.3 Intelligent Analysis and Comparison:

The visual inspection system conducts precise analysis on the collected images, and compares the identified graphic and text information with the preset standard template data at high speed in real time.

2.4 Result Judgment and Linkage Control:

Qualified Product Judgment: If the detected information is consistent with the template, the system releases the product automatically, and the production line keeps running.

Defective Product Judgment: If the detected information is inconsistent with the template (judged as mixed material or position deviation defect), the system instantly sends instructions to the IO controller. The IO controller directly stops the host equipment and triggers an alarm synchronously to ensure defective products do not flow into the next process.

3. Core System Advantages, Parameters, Functions and Materials

3.1 Core Technical Parameters

Maximum Inspection Line Speed: Supports ultra-high-speed production lines up to 200 meters per minute.

Comprehensive Inspection Capacity: Adaptable to different machine models, with an inspection capacity of 50,000 to 60,000 pieces per hour.

3.2 Functional and Application Highlights

Full Compatibility (Universal Adaptation): Compatible with various packaging types and production machine models of most mainstream brands on the market.

Multi-type Inspection (Full-capability Identification): The algorithm supports mixed material inspection for various complex information including numbers, letters, graphics and texts (barcodes, QR codes, patterns).

Minimal Operation (Zero Technical Threshold): The system features a user-friendly interface, simple adjustment and convenient operation. It requires no professional industry skills for front-line operators and achieves extremely low line-changing and machine-adjustment costs.

Wide Industry Application: Applicable to high-standard industries including pharmaceutical packaging (medicine boxes), daily chemical products (cosmetic boxes) and food packaging.

3.3 Applicable Materials and Limitations

Fully Applicable Materials: All materials except transparent films.

4. Solution Summary

This on-line mechanical mixed material inspection solution is not only an inspection tool, but also a safety barrier for enterprises to guarantee factory quality and improve automation level.