Cap, Fill‑Level & Ink‑Jet Code Inspection
1. Equipment Introduction
The equipment consists of main control module, cap inspection module, fill‑level inspection module, ink‑jet code inspection module and reject module.
- Main Control Module: Built‑in core electrical components including image processor and PLC controller. It governs overall equipment operation, processes and displays images captured by inspection‑module cameras. Meanwhile, it sends reject signals to reject module via PLC system. Complete alarm design can notify on‑site operators timely upon production faults for prompt troubleshooting to guarantee production efficiency.
- Cap Inspection Module: Composed of 3 sets of cameras, light sources and other vision components. It captures 360‑degree blind‑spot‑free cap images and transmits image data back to main control module.
- Fill‑Level Inspection Module: Composed of 1 set of camera, light source and other vision components. It captures images of over‑filled or under‑filled products and transmits image data back to main control module.
- Ink‑Jet Code Inspection Module: Composed of 1 set of camera, light source and other vision components. Images are acquired horizontally aligned with product coding station for fast and accurate image capture & transmission.
- Reject Module: Consists of air cylinder, solenoid valve and reject mechanical accessories. Installed downstream of inspection modules. Upon receiving reject signals together with positioning data from encoder, it rejects defective products on‑line to complete full inspection workflow.
2. Equipment Layout
(Standard dimensions shown in drawing; actual dimensions adjusted according to product size)
2.1 Image Acquisition Module 2.2 Reject Module
Layout drawing for cap, fill‑level & ink‑jet code inspection equipment
2.1 Image Acquisition Module This module captures images for cap, fill‑level and ink‑jet code inspection, specially designed for cap‑quality assurance on high‑speed filling lines. Its straddle‑type design fits plastic caps, crown caps, screw‑thread caps and more. It delivers high‑performance judgment for PE / PET / glass‑bottled beverages, dairy products, beer etc. Automatic production is realized in coordination with rejector.
2.2 Reject Module Matching standard rejector, applicable for line speed up to 50000 BPH. The standard rejector adopts FESTO single‑acting cylinder coupled with nylon reject block. PLC and relay control cylinder via MAC high‑speed solenoid valve to drive nylon reject block for linear rejection of upstream defective products with high precision & efficiency.
2.3 Main Control Module Composed of Xinshi vision analysis system and general control system. It governs operation of all modules, analyzes and judges captured information of product inspection zones. Once defective product is identified, reject signal is transmitted to reject module for product removal.
Touch screen is installed inside control cabinet for daily operation. Touch screen reaches IP65 industrial protection grade with good adaptability to field environment. Multi‑channel alarm system triggers acousto‑optic alarm upon abnormal conditions.
Control cabinet is manufactured in compliance with German Rittal standard. Full panels are made of SUS304 stainless steel.
2.4 Recovery Module Recovery platform made of mechanical accessories for collection of rejected defective products.
3. Inspection Accuracy\
| Inspection Content | Inspection Item | Sketch | Inspection Accuracy | Rejection Rate | False‑Rejection Rate |
|---|---|---|---|---|---|
| Cap Inspection | Missing cap |  |
No bottle cap | 100% | ≤0.3% |
| Cracked cap | L×W×D ≥5×0.5×0.5 mm | ≥99.9% | |||
| High cap |  |
Max height of cap top relative to reference: h＞1.0 mm | ≥99.5% | ||
| Tilted cap |  |
Max height difference of cap top relative to reference: h＞1.0 mm | ≥99.8% | ||
| Broken tamper‑evident band |  |
100% tamper‑evident band missing | 100% | ||
| 50% tamper‑evident band missing | ≥99.5% | ||||
| 30% tamper‑evident band missing | ≥99.3% | ||||
| Fill‑Level Inspection | Low fill level |  |
Deviation from standard fill level: 1.5 mm (static / stable conveying); Deviation from standard fill level: 2 mm (conveyor running status) | ≥99.9% | |
| Ink‑Jet Code Inspection | Missing code / missing lines |  |
‑ | 100% | ≤0.3% |
| Duplicated code / blurred code |  |
‑ | ≥99.9% | ||
| Partial code missing |  |
More than 1/2 of single‑code character missing | ≥99.9% | ||
| Overall offset / overall tilt |  |
Out‑of‑range offset | ≥99.9% | ||
| Code tilt | Vertical offset ≥2 mm | ≥99.9% | |||
| Abnormal scaling ratio |  |
20% deviation from normal range | ≥99.9% |
Glossary
‑ Rejection Rate: Number of rejected test samples / total test quantity
‑ False‑Rejection Rate: Total false‑rejected quantity / total production quantity
4. Technical Notes
4.1 Products shall be conveyed stably without shifting or tilting. Conveyor chain speed shall remain stable without fluctuation.
4.2 Products shall pass through inspection system free of external pressure. Consistent gap between adjacent products must be maintained to guarantee inspection reliability & accuracy.
5. Technical Features
5.1 Hardware configuration & appearance design comparable with fully‑imported equipment
5.2 Flexible remote technical service: parameter modification, program upgrade etc. can be completed without on‑site personnel support.
5.3 User‑friendly software interface; camera parameters can be flexibly modified via configuration files.
5.4 7×24‑hour technical service standard. 3.5.5 MES system interface available.
6. Equipment Characteristics
6.1 User‑friendly software interface complying with industrial operation habits; data output meets customer production‑inspection requirements.
6.2 Standardized, modular and universal software‑platform architecture; customized system features easy deployment and outstanding stability.
6.3 Self‑developed core algorithm, flexibly satisfying diversified personalized inspection requirements.
6.4 Simple mechanical‑structure design for easy system maintenance.
6.5 Non‑contact inspection with high speed & high accuracy. Capable of operating under variable conveyor‑speed conditions; strong anti‑interference capability, high reliability and excellent long‑term stability.
6.6 Digital cumulative counter for qualified & defective bottles/cans. Acousto‑optic alarm with automatic rejection of non‑conforming products.
6.7 Equipped with inspection mode & commissioning mode, featuring automatic fault diagnosis.
6.8 Compatible with multiple rejector types for automatic defective‑product removal.
6.9 360‑degree blind‑spot‑free full‑range cap inspection.