Pharmaceutical Automatic Light Inspection Machine

Product Overview of Ampoule Inspection Machine

The automatic light inspection machine uses machine vision technology and automatic control principles to make the inspected products rotate at a high speed and brake instantaneously through mechanical methods. It uses a special light source system and ultrahigh-speed sophisticated industrial camera to obtain images of the inspected product. The self-developed image processing algorithm software system compares, calculates and analyzes the images. The unqualified products detected are rejected by the actuator of the automatic control system.

This series of equipment is mainly composed of the following parts:

Main components:

1) Bottle feeding part: the product to be inspected is transferred from the bottle feeding conveyor belt to the bottle feeding dial, and then conveyed to the inspection rotating table.

2) Inspection part: The inspected product rotates at a high speed and is inspected by multiple special light sources to form multiple images for comparison and identification by the processing system.

3) Bottle discharging part: After inspection, the discharging dial uses Bernoulli's principle to lead the qualified and unqualified products into the collecting trays respectively.

The neatly arranged products to be inspected enter the feeding star wheel in an orderly and smooth manner under the action of the conveyor belt, and the feeding star wheel drives them to enter the inspection plate. The products to be inspected are rotated at high speed on the continuously rotating bottle holder, and sequentially go through multiple inspection stations. Before entering the inspection beam, the high-speed rotating products are instantly braked under the action of a special patented brake mechanism, while the liquid in the bottle is still rotating at high speed. Then the inspected products enter the photoelectric inspection area, the light source shines on the products, and the industrial cameras take photos of the products at high speed, forming multiple images for the processing system to compare, analyze and judge. Afterwards, the products after inspection are transferred to the discharging dial, discharging screw and rejection mechanism successively. The rejection mechanism sends the qualified and unqualified bottles to the qualified product tray and the unqualified product tray respectively.

This series of light inspection machines use high-resolution industrial cameras to magnify the inspected products dozens of times, which are more visible and thus the inspection accuracy is much higher than that of manual light inspection. The whole machine is controlled by a motion controller, with corresponding detection, control, and failure alarms. A communication interface is reserved, which makes it easy for senior management to use information technology for remote monitoring. Powerful software functions make parameter setting, correction, and function expansion more convenience.

This series of light inspection machines can detect glass crumbs, aluminum crumbs, rubber crumbs, hair, and other foreign objects in oral liquids, as well as defective glands, to ensure accurate removal of unqualified products. Compared with manual light inspection, it greatly improves the inspection speed and accuracy, avoids the instability of manual inspection, and realizes high-quality inspection of products. The inspection methods and standards are balanced and unified, and unqualified products are completely prevented from entering the market, which effectively releases human resources. Incomparable price advantages make this series of products have huge economic and social benefits, and have a broad market prospect.

 

Main advantages

• We are professional in the production of automatic light inspection machines (linear automatic, rotary automatic) and semi-automatic light inspection machines.
• Our software has independent intellectual property rights.
• Bottle caps and bottle heads are inspected by 3 cameras, so the inspection effect is much better. Before the bottles enter the inspection turntable, bottles with unqualified heads are rejected to prevent broken bottles in the inspection turntable due to cracks in the bottle heads, affecting the inspection.
• Menu hierarchical system, only the administrator can set and modify the parameters, avoiding the possibility of misoperation and modification of the parameters by operators.
• The images of unqualified products are saved, which is convenient for users to analyze the problems in order to improve the process. It has the function of on-line inspection image playback, which is convenient for on-line monitoring.
• The inspection parameters can be set freely and saved according to customer requirements.
• Imported servo motors are used as the driving force to ensure the accuracy of equipment operation.
• The centrifugal belt adopts well-known brands and is highly wear resistant.
• The operation interface can effectively display the working status of each camera, thereby ensuring the safety of product inspection.
• The electrical control system adopts Omron motion controller, each motor can independently and accurately output, and the motion position is accurate without dislocation. This effectively avoids signal jam and delay caused by the traditional PLC that triggers signals through the photoelectric sensor, and achieves the consistency of tracking speed and millisecond-level non-deviation of the images taken with the cameras, thereby leading great improvement of the inspection effect and equipment stability.
• Machine fault information feedback can be set.
• Reserved communication interface can facilitate remote fault diagnosis.
• The centrifuge bottle holders are made of high-strength alloy material, which does not need to be replaced within 2 years of normal operation, which greatly saves use and maintenance costs.
• Light source illuminance, camera status and centrifugal bottle spinning status are monitored real time. Fault information can be displayed on the control panel in real time, and an alarm will be triggered to stop the machine at same time.
• The height of the whole machine is completely suitable for ordinary female operators.

Product Parameters of Ampoule Inspection Machine​

Main features

• The transmission components, the imaging system and the control system adopt well-known foreign brands, with stable performance.
• Bottles feeding and discharging use the star-wheel Bernoulli principle mechanism, and the rate of broken bottles is low.
• The image analysis software has been repeatedly optimized and tested, with good repeatability and high reliability.
• 3-channel inspection, rate of missed inspection is low.
• Parameter setting is simple, users can operate the machine after a short time of training.
• More than 50 different specifications and parameters can be stored.
• Equipped with communication interface, which can realize remote diagnosis.
• The inspection sensitivity can be adjusted according to customer needs.
• Continuously optimized software system, friendly operation interface.
• Inspection sensitivity and parameters can be easily set to meet user needs.
• The average broken bottle rate of the whole machine is less than 0.02%.
• A communication interface is reserved to realize remote monitoring and provide free remote online technical services.
• The images of unqualified products are saved and can be accessed online for users to make statistics and process adjustment.
• Self-monitoring system in working state (when important operating points fail, the machine will automatically alarm.)
• The operation of the equipment must not only meet the needs of product light inspection efficiency, but also ensure the product quality after light inspection. The inspection speed and sensitivity of the equipment can be adjusted within a certain range according to user needs.
• Entry: After bottles are loaded by the upstream equipment or the turntable, this machine can be fully automatically and stably connected with the upstream equipment or the turntable, not causing physical damage to products.
• After the bottles are loaded, the machine automatically transfers the bottles for light inspection through a conveyor belt or other means. The automatic conveying process is stable and smooth, and it is designed to prevent the bottles from falling and minimize squeezing, scratching and bumping. The conveying position is accurate and the conveying speed can be adjusted. The conveying equipment is easy to disassemble and assemble, change, maintain and clean.
• Sample inspection: The samples can be fully rotated before the inspection to suspend and move the foreign objects, so the foreign objects are relatively concentrated and easy to detect, and products with unqualified filling volume can also be detected.
• Different foreign objects can be detected in different stations, and the speed of each station can be adjusted individually.
• During the inspection process, defective and qualified products can be automatically separated.
• The efficiency ratio of knapp (quality factor method) test is greater than 1.
• Human-machine batch inspection comparison, and equipment data is better than manual inspection.
• Control system: The equipment adopts PLC automatic control system, with a 3-level password protection program, which can prevent parameters from being modified arbitrarily. The system can automatically run according to the set parameters, and can input and store product information, including equipment model, equipment number, and product name, batch number, production date, operation start date/time & end time and operators. The number of infed and discharged bottles, the number of rejects, and the number and classifications of wastes can be recorded and saved.
• Mold replacement: The equipment can adapt to products of different specifications by changing molds. The replacement of molds is simple and fast, can be accurately aligned, and molds of various specifications are clearly marked and distinguished.
• Equipped with verified and effective light inspection process procedures.
• Easy to operate and maintain, and can prevent errors and cross-contamination.
• The process data when any alarm occurs will be stored and printed as operating data.
• With automatic storage function, it can store system data for one month, and can automatically select and record frequent operating data during the expected continuous operation process. The time of each processing stage will be automatically accumulated as operating data. The data can be exported or printed.
• When the equipment is started, the date/time, product information, etc. can be set and recorded.
• The operating parameters of the equipment can continuously record the various parameters and operating conditions of the equipment.