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 InstrumentOperation steps:
Step 1: Preparation before startup
Environmental inspection:
Confirm that the work area is clean, dry, and free from strong electromagnetic interference.
Check if the pressure of the compressed air source is within the required range of the equipment (usually 0.4-0.7MPa), the FRL triple component is working properly, and there is no leakage in the air circuit.
Ensure that the power supply voltage is stable and meets the equipment requirements.
Equipment inspection:
Appearance: Check whether the equipment casing and protective cover are intact, and whether each component is loose or damaged.
Internally: Open the access door (if any) and check if the camera lens and light source are clean and free of dust, oil, or water stains. Carefully wipe with specialized lens paper and cleaning agent.
Mechanical: Check if the vibrating feeder and conveyor belt (if any) are functioning properly and if there are any foreign objects stuck.
Gas path: Check if the nozzle array is blocked and if the air pipe connection is secure.
Material path: Ensure unobstructed access to the feeding hopper, discharge outlet, and waste outlet.
Material preparation:
Prepare the materials to be sorted, ensuring they are dry and free of lumps.
Check whether the material contains foreign objects that are too large or too long, which may damage the equipment.
Step 2: Power on and System Startup
Connect the power supply:
Turn on the main power switch of the device.
Start the power supply of the electrical control cabinet.
Start the control system:
Turn on the power to the HMI panel and start the control system.
Wait for the system self-test to complete and enter the main operating interface.
Start the auxiliary system:
Turn on the air compressor and wait for the air pressure to reach the set value.
Turn on the cooling system (if the equipment has a laser or high-power light source, it needs to be water-cooled or air-cooled).
Step 3: Parameter Setting and Mode Selection
Select sorting mode/formula:
Select the preset sorting program (Recipe) corresponding to the current material on the HMI. Devices typically have the ability to store sorting parameters for multiple different materials.
Key parameter settings (if adjustment is required):
Color recognition:
Set color recognition modes (such as RGB, HSI, grayscale).
Set the color range of qualified products (color difference threshold, brightness range).
Adjust sensitivity (ability to distinguish small color differences).
Alien identification:
Set the size range (length, width, area, perimeter).
Set shape features such as circularity, aspect ratio, and contour complexity.
Adjust the exclusion threshold.
Comprehensive settings:
Set the exclusion delay time (the time from recognition to jetting, which is related to the material velocity).
Set the exclusion pressure (affecting the exclusion force).
Set the amplitude of the vibrating feeder (control the feeding speed and uniformity).
Image calibration and validation (optional):
Run the equipment idle or add a small amount of material, and observe the real-time image displayed on the HMI.
Confirm that the material imaging is clear and evenly distributed.
Check whether the system accurately identifies and marks known impurities (a small amount of typical foreign objects can be manually placed).
Step 4: Feeding and Operation
Start device:
Press the "Start" or "Run" button on the HMI.
The equipment starts in sequence: vibrating feeder → conveying system (if any) → detection system → removal system on standby.
Slow feeding:
Add the materials to be sorted evenly and slowly into the feeding hopper to avoid sudden influx of large amounts of materials causing blockage or overlapping imaging.
Observe the spreading of materials in the testing area, adjust the amplitude of the feeder through HMI, and ensure that the materials are in a single-layer and dispersed state through the camera field of view.
Monitoring operation:
Real time image: closely observe the material image displayed on the HMI to see if the system accurately marks out particles of different colors (usually highlighted with boxes or colors).
Elimination action: Observe whether the jet of the nozzle array is precise and timely.
Discharge situation: Check whether the discharge of qualified products and waste materials is smooth and whether there is any blockage.
Alarm message: Pay attention to whether there are alarms such as "no material", "blocked material", "low air pressure", "camera malfunction", etc.
Production and efficiency: Monitor sorting speed and rejection rate.
Step 5: Shutdown and Cleaning
停止投料：
Stop adding materials to the feeding hopper first.
Empty materials:
Keep the equipment running until the materials inside the feeding hopper and equipment are completely discharged.
Stop the device:
Press the 'Stop' button on the HMI.
The equipment stops in sequence: removal system → detection system → conveying system → vibrating feeder.
Shut down the system:
Turn off the air compressor.
Turn off the main power of the device.
Equipment cleaning:
Internal cleaning: Open the maintenance door and thoroughly remove residual materials and dust from the feeding hopper, screen surface, discharge port, and waste channel. Use a soft bristled brush, vacuum cleaner, or compressed air (low pressure).
Optical components: Recheck and clean the camera lens and light source again, which is the key to ensuring accuracy during the next startup.
External cleaning: Wipe the device casing.
Step 6: Maintenance and Recording
Daily inspection: Record running time, output, and fault conditions.
Regular maintenance: Conduct more in-depth maintenance according to the plan, such as lubricating moving parts, checking air circuit sealing, and backing up system data.
Parameter optimization: Based on the actual sorting effect, fine tune the sorting parameters and continuously optimize the sorting accuracy and efficiency.