Heterochromatic and Alien Screening InstrumentIt is an instrument specifically designed for detecting and analyzing color and shape defects in materials, which combines optical principles, image processing technology, and automation control technology. It illuminates the material through a light source and uses optical sensors to capture the light signals reflected and transmitted by the material. These light signals are analyzed by an image processing system to determine the presence of color or shape defects based on the characteristics of the material. Once abnormal colors or shapes are detected, the system will transmit a signal to the rejection system to control the corresponding device to remove defective products.
Heterochromatic and Alien Screening InstrumentIt usually consists of the following main modules:
1. Feeding System
Function: Send the materials to be sorted evenly and stably into the detection area, ensuring that the materials are in a single layer and dispersed state through the camera field of view.
Main components:
Feeding hopper/bin: stores materials to be sorted.
Vibration Feeder: By controllable vibration, materials are smoothly and quantitatively transported from the silo to the next level. It is the key to achieving uniform distribution of materials.
Uniform plate/splitter: located at the outlet of the feeder, it further distributes the material evenly across the entire width of the screen to prevent material accumulation.
Acceleration chute/conveyor belt: guides materials into the detection area at a suitable initial speed, ensuring that the materials form a "material curtain" in the air.
2. Detection System - Core
Function: Real time imaging and analysis of materials passing through at high speeds, accurately identifying particles of different colors and shapes.
Main components:
High Resolution Industrial Cameras:
Usually equipped with multiple (2 or more) line or area cameras, capturing material images from different angles (such as top, side).
High resolution (up to millions of pixels), capable of capturing tiny defects.
Specialized Illumination System:
Type: LED light source as the main source, including backlight, forward diffuse light, coaxial light, multispectral light, etc.
Function: Provide stable, uniform, and shadow free lighting, highlighting the color, texture, and contour features of materials. Multispectral light sources can enhance the recognition ability of specific substances, such as mold and insect infestation.
Key: The combination of light source and camera determines the image quality.
High performance Image Processing Unit:
Usually it is an embedded industrial computer or server.
Run complex image processing algorithms such as edge detection, color space conversion, pattern recognition, and deep learning AI models.
Real time analysis of each frame image, based on the preset "qualified product" standard, quickly determine whether each particle is "heterochromatic" or "irregular".
Calculate the precise position coordinates where particles need to be removed.
3. Ejection System - Execution Mechanism
Function: After the image processing unit issues instructions, accurately and quickly blow out the material particles judged as unqualified from the qualified product stream.
Main components:
High Speed Solenoid Valve Array:
Composed of dozens or even hundreds of miniature solenoid valves arranged above the exclusion area.
The response time is extremely short (in milliseconds) and can be independently controlled.
Nozzle Array:
Corresponding to the solenoid valve one by one, installed in precise positions.
When a certain solenoid valve receives a "reject" signal, it instantly opens and compressed air is sprayed from the corresponding nozzle.
Air Supply Device:
Provide clean, dry, and pressure stable compressed air (usually 0.4-0.7MPa).
Including air compressor, air storage tank, filter, pressure reducing valve, etc.
Working principle: When an unqualified particle moves directly in front of a nozzle, the control system accurately calculates and triggers the corresponding solenoid valve of the nozzle. A brief and concentrated airflow "hits" it and blows it away from the main material flow, falling into the waste channel.
4. Material Separation&Collection System
Function: Effectively separate rejected non-conforming products from qualified products and collect them separately.
Main components:
Distribution hopper/deflector: located below the exclusion area, it guides the main material flow (qualified products) and the blown out material flow (unqualified products) to different collection channels.
Qualified product discharge outlet: Collect high-quality products that have been screened.
Waste/Impurity Discharge Port: Collect the removed particles with different colors and shapes.
Collection box/bag: used for temporarily storing sorted materials.
5. Control System
Function: The "brain" of the entire device, coordinating the collaborative work of various parts.
Main components:
HMI Human Machine Interface:
Touch screen operation panel, used for parameter settings (such as color threshold, size range, rejection sensitivity), mode selection, operation monitoring, fault alarm, data recording, etc.
Central Processing Unit (CPU/PLC):
Receive sensor signals, run control logic, and send instructions to actuators (solenoid valves, motors).
Communicate with the image processing unit and receive removal instructions.
Sensor:
Such as material flow sensors, air pressure sensors, threshold switches, etc., used to monitor equipment status.
6. Mechanical Structure and Framework
Function: Support and fix all components to ensure overall rigidity and stability of the equipment.
Key Features:
Made of high-strength steel or stainless steel, sturdy and durable.
The design conforms to ergonomics and is easy to operate and maintain.
It is usually a fully enclosed or semi enclosed structure, dustproof and moisture-proof, and meets food hygiene requirements (such as IP protection level).