In the course of market development, the shift from manual inspection to machine vision systems is an inevitable trend in modernization. Machine vision offers high precision, rapid data acquisition, and automated processing, making it a powerful tool widely adopted in industrial inspection.
Since the reform and opening up 30 years ago, industrial production has placed increasingly higher demands on quality control, with rising costs of testing. Traditional contact-based methods have struggled to meet customer expectations and ensure consistent product quality. This growing need has driven the advancement of domestic machine vision technology, leading to the adoption of non-contact techniques such as optical, mechanical, electrical, visual, and chemical methods in many industrial inspection projects.
Below is an example of how key machine vision technologies are applied in a tobacco debris removal system.
From the moment tobacco leaves enter the cigarette factory to the final production of finished cigarettes, they gradually move away from human intervention. After the leaves are processed into sheets, there's no longer a manual leaf-laying step, which means that foreign particles and moldy leaves can't be effectively removed. These contaminants significantly affect the quality of the final cigarette product.
The tobacco debris removal system is designed to eliminate such impurities using a wire-making production line. It integrates various components and leverages machine vision technology to achieve efficient and accurate sorting. Here’s how the machine vision inspection system is applied in the removal of tobacco debris:
1. **Material Single-Layer Processing Device**: This device transforms thick, layered materials like tobacco leaves into a thin, single-layer state. Using "pressing wind" and "bearing wind," it ensures the material flows smoothly along a predictable path, enabling accurate camera detection.
2. **Material Lighting System**: Providing sufficient illumination is crucial for capturing high-quality image signals. This system ensures optimal lighting conditions for the material under inspection.
3. **Optical System**: The optical system directs the reflected light from the material surface to the photodetector (such as a CCD sensor), ensuring clear and accurate image capture.
4. **Image Acquisition System**: This system captures the material's image and converts the analog signal into a digital format that can be processed by computers. It includes industrial cameras and image capture cards.
5. **Real-Time Image Processing System**: Once the image is captured, this system processes the digital data, extracts relevant features, and makes intelligent decisions based on pre-set criteria. It then generates control instructions for the actuator. This system combines hardware (like DSP or image processing cards) and software.
6. **Debris Rejection System**: This component separates debris from the tobacco stream using compressed air injection. It consists of high-speed pneumatic solenoid valves and a blow chamber.
With the integration of advanced machine vision technology, and as the tobacco industry continues to implement quality improvement and cost-reduction initiatives, the application of these systems will become even more widespread. They will play a vital role in quality inspection, monitoring, and sorting, ultimately enhancing the global competitiveness of China’s tobacco companies and contributing to their long-term success.
Consumer Electronics
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