The principle of customizing a dual-mode automated color detector is based on the integration of optical reflection, spectrophotometry, and multi-mode automation control technology. Its core lies in capturing the spectral characteristics of the reflected light on the surface of an object through a high-precision optical system, and combining intelligent algorithms to achieve quantitative analysis and automated operation of color data. The following is an explanation from four dimensions: principle foundation, dual-mode design, automation process, and key technologies:
1、 Principle basis: Optical reflection and spectrophotometry
Principle of Optical Reflection
The color of an object is determined by its spectral characteristics reflected from its surface. The detector emits stable light through a high brightness LED light source, which is then focused by a convex lens and directed onto the surface of the object. The reflected light is separated by a half lens and focused onto the color sensor. The sensor integrates a photodiode array with red, green, blue, and white filters to capture light intensity signals of different wavelengths and generate raw spectral data.
Spectrophotometry
The incident light is decomposed into a continuous spectrum using a spectroscopic system, and the reflected light intensity at each wavelength is recorded through a sensor array. Combining the CIE standard chromaticity system (such as Lab color space), convert spectral data into quantifiable color parameters (L, a, b * values), and calculate key indicators such as color difference (Δ E) and reflectance. For example, when the Δ E value is greater than 1, the human eye can distinguish color difference, providing objective basis for quality control.
2、 Dual mode design: adaptable to different detection scenarios
Normal batch testing mode
Function: Rapid batch testing for standard products, automatically marking qualified products (OK area) and unqualified products (NG area).
Process: The robotic arm grabs the sample to the measuring fixture, synchronously measures the designated points with two pieces, processes the data through algorithms, outputs Lab values and color difference results, and the cutting robotic arm sorts according to the results.
Advantages: High efficiency (such as completing CT calibration in two-point measurement mode), low error (Lab value error controlled within ± 1.0).
NG product retest mode
Function: Perform multi area re inspection on products that fail the initial inspection, and accurately locate color difference points.
Process: The operator marks the abnormal area through NGMap, and the equipment automatically adjusts the measurement point position. It supports marking with a marker pen or automatic coding (requires hardware upgrade) to mark NG points.
Advantages: Avoiding missed inspections and improving yield, especially suitable for high-precision scenarios such as glass products and printed materials.
3、 Automated process: full chain intelligent control
Automatic feeding and positioning
The robotic arm grabs the material box to the material preparation area, and uses a visual positioning system (such as a positioning camera) to ensure accurate placement of the sample and eliminate human operation errors.
Multi station synchronous measurement
The dual measurement fixture design supports dual piece synchronous detection, combined with the belt line module to achieve continuous sample transportation and improve detection throughput.
Data Management and Analysis
The software control interface displays real-time detection data (such as nebula charts and bar charts), supports custom data table naming (by inputting batch information through a scanning gun), and interfaces with the factory MES system to achieve production data traceability.
Intelligent maintenance and warning
The operation monitoring system monitors the real-time status of equipment (such as detecting cabin temperature), and the software interface prompts maintenance intervals to prevent faults from occurring.
4、 Key technology: supporting high precision and stability
High precision sensors and algorithms
Adopting high-resolution color sensors (such as TCS3200), integrating 64 photodiodes, and eliminating ambient light interference through white balance correction to ensure the accuracy of color data.
Standardized light sources and calibration
By default, the sensor is automatically calibrated every 8 hours, using a standard light source (such as D65 light source) to unify lighting conditions and avoid subjective judgment errors by the human eye.
modular design
The key components (such as automatic feeding robots and handling modules) adopt modular design, supporting customized functions according to customer needs (such as expanding measurement points and adjusting detection accuracy).
Application scenarios and advantages
Industrial production: The textile, printing, coating and other industries achieve rapid color matching and color difference control, improving product quality consistency.
Emerging fields: New energy materials (such as battery separator color detection), biomedical (such as tissue sample color analysis) expanding application boundaries.
Cost effectiveness: Domestic equipment (such as 3nh brand) is significantly more cost-effective than imported equipment through high-precision sensors and algorithm optimization, reducing enterprise procurement costs.
The customized dual-mode automated color detector achieves high precision, efficiency, and intelligence in color detection through the deep integration of optical reflection, spectrophotometry, and automation technology, providing key technical support for quality control in the Industry 4.0 era.