2026
Cap, Fill‑level & Coding All‑in‑one Inspection Machine (Model: DY‑FBI‑4)
2. Main Advantages & Features
2.1 DAVUE AI Vision Industrial Intelligent Quality Inspection System
Independently developed with world‑leading AI software architecture and full independent intellectual property rights. Equipped with deep‑learning‑based AI inspection technology and complete algorithm system.
Combined with conventional quality‑inspection algorithms, it identifies subtle differences among samples from multiple dimensions, covering application scenarios including product defect detection, classification, measurement and monitoring.
Inspection throughput reaches 200,000 objects per hour. It realizes ultra‑high‑speed, high‑precision real‑time identification and rejection of defective products, so as to achieve precise quality control in production and guarantee product quality.
The inspection & control system adopts modular design, high‑efficiency image‑processing algorithms and distributed computing architecture, featuring high‑speed inspection, high reliability and great adaptability.
Good expandability and interoperability; flexible modular configuration. New inspection modules and functions can be added on the existing control center according to production & customer requirements to reduce future equipment investment. It supports communication with customer‑existing MES production‑management systems for Industry 4.0 & smart‑factory interconnection.
2.2 World‑class Hardware Configuration
Adopts high‑resolution CCD area‑scan cameras, high‑definition industrial lenses and optical glass with light transmittance＞98 %, to capture sharp, high‑resolution distortion‑free raw images. High‑brightness long‑life LED cold light sources; brightness maintains stable after 100 000 running hours.
Deep‑learning‑powered AI inspection delivers faster & more stable calculation than embedded computing boards inside smart cameras. Genuine Windows‑based software with user‑friendly intuitive GUI.
Straight‑through signal & image transmission without intermediate repeaters, minimizing signal degradation & distortion. It supports ultra‑high‑speed lossless data transmission to ensure valid image processing & output signals, laying the foundation for extremely low false‑rejection rate and escape‑rejection rate.
2.3 Systematic Equipment Maintenance & Operation Support
Built‑in self‑diagnosis, debugging guidance, operation status display, system help and operation log functions. Product recipe & inspection‑algorithm switching can be finished within 10 minutes. Intuitive workflow, easy‑to‑learn operation.
Complete system‑help functions for storage, query and timely updates. SOPs for system operation, equipment maintenance and technical documents are accessible locally on machine, including troubleshooting guides for common faults.
On‑board diagnostic & remote‑maintenance function for real‑time global technical support & remote commissioning.
Rich optional functions for adaptation to different production‑line processes. Multi‑source collected data can be tracked, aggregated, correlated and traced for precise process control & data management.
Multi‑year production‑data storage; data export for third‑party use. Customizable & printable production reports for customer quality analysis.
Full intellectual property rights, lifelong system upgrade service with zero hidden charges.
2.4 Control Cabinet & Inspection Cabinet Assembly
Touch‑screen control cabinet with IP65 industrial protection rating.
Multi‑channel audible‑visual alarm beacon for machine status indication & fault alert.
Control cabinet is made of SUS304 stainless steel, manufactured per Rittal standard with positive‑pressure protection, suitable for harsh working conditions.
The inspection cabinet is installed in an “over‑bridge” non‑contact way above the existing customer conveyor, compatible with various conveyor layouts.
Fully‑sealed inspection cabinet protects cameras, light sources, lenses and precision optical components.
Light‑blocking glass fitted on both ends to eliminate ambient natural‑light interference against inspection accuracy.
Hand‑wheel height adjustment for bottle‑format change; graduated scale for recording height positions.
Rejector is adjustable vertically & horizontally for stable ejection of defective bottles to designated position.
3. Inspection Functional Modules
- Cap Inspection Module
Detects missing caps, high caps, tilted caps, wrong caps and broken tamper‑evident bands.Hardware: 3 sets industrial cameras; 3 sets optical components & control assemblies - Fill‑level Inspection Module (shares optical hardware with cap‑inspection module)
Detects over‑fill / under‑fill (high / low liquid level).Hardware: 1 set industrial camera; 1 set optical components & control assemblies - Coding Inspection Module
Detects presence / absence of characters, missing segments, position offset, scaling distortion and duplicate coding.Hardware: 1 set industrial camera; 1 set optical components & control assemblies - Pneumatic Rejection Unit
Rejects defective products upon receiving trigger signals from vision system. Rejection capacity: 72 000 bottles/hour, driven by high‑speed pneumatic cylinder.
4. Inspection Specifications & Acceptance Criteria
| Inspection Module | Inspection Requirement | Defect Description | Inspection Accuracy | False‑Rejection Rate |
|---|---|---|---|---|
| Cap Inspection | Cap presence / absence | Missing cap | ≥99.99 % | 0 |
| High cap | Cap bottom edge ≥ 0.7 mm above support ring | ≥99.95 % | ≤0.02 % | |
| Tilted cap | Cap bottom edge ≥ 0.7 mm offset OR cap tilted by 3° | ≥99.95 % | ≤0.02 % | |
| Tamper‑evident band ≥ 50 % broken | Gap ≥ 0.7 mm | ≥99.95 % | ≤0.02 % | |
| Tamper‑evident band ≥ 30 % broken | Gap ≥ 0.7 mm | ≥99.90 % | ≤0.02 % | |
| 100 % tamper‑evident band missing | - | ≥99.99 % | ≤0.02 % | |
| Fill‑level Inspection | Over‑fill / under‑fill | Liquid‑level deviation ± 1.5 mm | ≥99.99 % | ≤0.02 % |
| Coding Inspection | Coding presence / absence | No print code | 100 % | 0 |
| Duplicate coding | Double printed codes | ≥99.99 % | ≤0.02 % | |
| Partial missing code | ≥30 % total‑character loss | ≥99.99 % | ≤0.02 % | |
| Coding position offset | Print out‑of‑target zone | ≥99.99 % | ≤0.02 % |
Technical Notes
- Residual water droplets on bottle surface may affect inspection performance and cause false rejection. A blow‑off unit is recommended to minimize such external interferences.
- Bottles must travel through the inspection cabinet freely without squeezing. Center‑to‑center bottle spacing should be at least 50 % of cap diameter to guarantee full‑angle 360‑degree inspection.
- Coder and inspector shall be installed on the same single‑lane straight conveyor. To avoid bottle rotation after coding, the straight‑line distance between coder and inspector shall not exceed 0.5 m.
- Liquid‑level bubbles after filling may interfere coding reading. It is recommended to place the print zone below liquid‑level line.
