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 widely adopted in industrial inspection. This technology has become essential for maintaining product quality and efficiency.
Since the reform and opening up 30 years ago, industrial production has placed increasing demands on testing, with rising costs. Traditional contact-based methods can no longer meet customer expectations or ensure consistent quality. As a result, there's been a growing need for advanced solutions, which has driven the development of domestic machine vision technology. More and more industrial inspection projects now rely on non-contact techniques such as optical, mechanical, electrical, visual, and chemical methods.
The following example illustrates the application of key machine vision technologies in a tobacco debris removal system.
From the moment tobacco leaves enter the cigarette factory to the final stage of producing finished cigarettes, the process has increasingly moved away from manual assistance. After the leaves are processed into individual components, there’s no longer a manual leaf-laying step. As a result, foreign materials and moldy leaves cannot be effectively removed, directly affecting the quality of the final product.
The tobacco debris removal device is designed to eliminate these impurities using a wire-making production line that processes leaves, stems, and other components. The system integrates various technologies, including machine vision, to achieve efficient and accurate sorting.
**Applications of the Machine Vision Inspection System in Tobacco Debris Removal:**
1. **Material Single-Layer Processing Device:** This component transforms thick layers of material, such as tobacco leaves, into a thin, single-layer state. It uses "pressing wind" and "bearing wind" to ensure smooth and stable movement along a predictable trajectory, enabling accurate camera detection.
2. **Material Lighting System:** Proper illumination is crucial for capturing high-quality image signals. The lighting system ensures that the material is well-illuminated, allowing for clear and detailed imaging.
3. **Optical System:** The optical system efficiently directs the reflected light from the material surface to the photodetecting element, such as a CCD sensor, ensuring accurate image capture.
4. **Material Image Acquisition System:** This system captures the image of the material 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, the system processes the digital signal, extracts relevant features, and makes decisions based on predefined criteria. It generates control signals for actuators, involving both hardware (like DSPs or image processing cards) and software.
6. **Debris Rejection System:** This system separates unwanted debris from the tobacco stream using compressed air. It consists of high-speed pneumatic solenoid valves and a blow chamber, ensuring quick and precise rejection.
With the integration of comprehensive machine vision technology, the tobacco industry is seeing improved quality and reduced waste. As these systems continue to evolve, they will play an even greater role in quality inspection, monitoring, and sorting, helping Chinese tobacco companies enhance their global competitiveness and contribute significantly to the industry's future growth.
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