Solution: Implemented our fully self-developed integrated solution combining vision software, high-precision motion control, and automated machinery. The system utilizes multi-perspective area scan industrial cameras, customized ring lighting, and an automatic rejection mechanism.
Vision Software Development Dept.: Customized filling inspection algorithms for high-speed detection of caps, liquid levels, labels, codes, and bottle defects. Supports quick changeovers between beverage types with extremely low false rejection rates.
Motion Control Dept.: Multi-axis synchronous control adapts to high-speed line rhythms, ensuring precise positioning, rapid response, and smooth detection/rejection actions without bottlenecks.
Automation Dept.: Designed for seamless in-line integration without production stoppage, enabling a fully unmanned process from feeding and inspection to sorting and discharge.
Core Inspection Items: Cap defects (crooked/high/missing), fill level, label placement/alignment, OCR/OCV for lot codes, bottle scratches/cracks, tamper-evident band integrity.
Implementation Results:
Inspection Speed: Up to 60,000 bottles/hour
Defect Detection Rate: ≥ 99.98%
False Rejection Rate: ≤ 0.1%
Impact: Replaced 6-8 manual inspectors, saving over 500,000 RMB annually in labor costs. Reduced defective product outflow to zero, significantly enhancing line quality and reducing costs.