Liquid Level Capping Detection Machine

I. Project Equipment Overview

1. Project Name: PET Bottle Capping, Anti-theft Ring, Liquid Level, and Inkjet Printing Inspection Project

2. Project Description: Inspect and automatically reject caps, anti-theft rings, liquid levels, and inkjet printing on PET bottles

3. Maximum Output: 60,000 bottles/hour

4. Bottle Type: PET Bottle

5. Product Capacity: 200ml-2L

II. Environmental Conditions:

1. Optimum Altitude: 5-3000 meters above sea level;

2. Optimum Ambient Temperature: 5°C-40°C;

3. Optimum Ambient Humidity: 50-65% RH;

4. Factory Conditions: Parameters such as floor levelness and load-bearing capacity must meet relevant national standards and meet the normal operating requirements of the machine;

5. Factory Storage Conditions: After arriving at the factory, parts and machines must be stored in a location that meets relevant national standards. During storage, proper lubrication and maintenance must be performed to prevent damage to the surface of the parts or deformation that could affect normal installation, commissioning, and operation of the machine.

III. Equipment Production Status:

1. Power Supply: 220V, 50Hz, single-phase; provided by the customer (special voltages require prior notification; equipment specifications, delivery time, and price may vary).

2. Total Power: Approximately 2.4kW;

3. Control Voltage: 24VDC.

4. Compressed Air: Minimum 4 Pa, Maximum 12 Pa (customer provides the air line connection from the air source to the equipment main unit).

IV. Equipment Introduction

1. Installation Location

2. Inspection Contents

◆ No cap

◆ High cap

◆ Crooked cap

◆ Broken ring

◆ Low liquid level

◆ Presence of inkjet printing

◆ Excessive inkjet printing

3. Detection principle

1). A PET bottle passes through a positioning sensor. Upon detection, the control unit records the bottle ID and the current encoder signal.

2). The positioning sensor signals a camera to capture an image of the bottle cap, liquid level, and inkjet printer. After capturing the image, the image processor processes the image and transmits the result to the human-machine interface for dynamic display and to the control unit PLC to prepare for the rejection of unacceptable bottles.

3). Upon receiving the unacceptable signal, the control unit notifies the rejector to reject the bottle with the corresponding ID.

4. Equipment mechanical components

5. Electrical composition of the equipment

6. Testing cabinet structure diagram

Capping liquid level detection (capping liquid level detection at stations one and three)

Inkjet printing inspection (station 2, single-camera inkjet printing inspection)

7. Cap Inspection

This module uses three CCD cameras to capture images of bottles from different angles, reducing blind spots. Special optical lenses filter light from all directions to ensure efficient image acquisition. Its primary function is to detect defective bottles such as missing caps, overhanging caps, crooked caps, and broken caps.

8. Liquid Level Detection

This module uses a CCD camera to capture liquid level images from the front, ensuring that the liquid level in the bottle is nearly horizontal when the bottle is stationary. This module employs image processing principles that render the portion below the liquid level black in the image and the portion above the empty bottle white. A special method is used to distinguish between levels below and above the specified liquid level.

9. Inkjet Printing Inspection

This module uses a CCD camera to capture images of the inkjet printing on bottles and caps from the front. It then digitally analyzes the captured images and automatically and accurately rejects bottles with unqualified inkjet printing. It is compatible with both yellow caps with black ink and black caps with white ink.

10. Detection accuracy