Case Study: Low-Drop Vision Counting Machine for Fragile Ceramic Parts
While basic material counting is the core function of a vision counting machine, real-world production lines often require tailored machine configurations to handle specialized materials. For fragile items like ceramic components, standard counters can cause chipping or cracking, which is why the VBP Low-Drop Series Vision Counting Machine is used to ensure damage-free processing.
Below is a detailed application case study featuring the Dual-Channel VBP Low-Drop Vision Counting Machine integrated with a Rotary Multi-Station Receiving Machine designed by Zhiwan Electronic Technology for handling ceramic parts.
Application Requirements
- Automated & Accurate Counting: Achieve fully automated product counting built upon a foundation of high speed and precision.
- Damage Prevention for Ceramics: The target materials are primarily ceramic products requiring strict anti-damage measures. The packaging quantity per bag varies, ranging from a minimum of 50 pieces to a maximum of 1,500 pieces.
- Standalone Operation: The counting system operates independently without being integrated into other production lines or equipment. If the count exceeds the preset standard, visual alerts must be triggered on both the receiving tray and the industrial control computer. (Note: Precise counting accuracy and efficiency are subject to actual material testing.)
- Continuous Supply Feed: Features manual bulk loading paired with a vibratory feeder hopper to store and convey materials, ensuring a continuous and stable supply.
- Smart Multi-Station Receiving Tray: Equipped with an 8-station rotary material receiver utilizing red, yellow, and blue three-color indicator lights to display three statuses: Over-limit, Empty Box, and Normal, with a small auxiliary screen displaying the real-time count.
Material Specifications
| Product Name | Dimensions / Size | Packaging Quantity | Remarks |
|---|---|---|---|
| Ceramic Parts | 5mm - 20mm | Variable (from 50 to 1,500 pcs based on material size) | Material: Ceramics. Demands strict anti-damage and anti-chipping measures. |
Solution Highlights & Workflow
Key Solution Highlights
- High Efficiency: Combines the VBP Series dual-channel vision counter with an automated material receiving system to achieve rapid counting and batching.
- Ultra-Low Drop Height: The maximum drop height is strictly controlled within 18 cm, significantly guaranteeing material integrity. A "first-in, first-out" material flow mechanism minimizes collisions between parts.
- Surface Protection: The system utilizes nylon vibratory trays or applies a PU (Polyurethane) coating to the tray surfaces to shield the delicate finish of the ceramic parts.
- Compact Footprint: With overall dimensions of 2,166mm (L) * 1,550mm (W) * 1,500mm (H), the layout is highly optimized for easy material feeding, inspection, and quick cleanouts.
Data Traceability: All production data is automatically saved locally, and it can be seamlessly integrated with ERP systems via informational cascading, allowing data uploads for full process traceability.
Operational Workflow
- Startup & Setup: The operator powers on the system, pours the bulk ceramic components into the counter's storage hopper, selects the corresponding pre-configured material recipe on the computer, and clicks "Start Counting" to initiate operation.
- Feeding & Counting: The vibratory feeder conveys parts to the counting machine's vibratory tray, where they are dispersed by vibration, slide down, and pass through the high-speed camera identification zone for precise counting. Once counted, they drop into the funnel of the automated receiving device until the target batch quantity is reached, prompting the rotary receiver to automatically index to the next empty bin.
- Exception Handling (Over-limit): If a batch exceeds the set quantity, it is channeled to a designated error station. An alarm light at this station immediately alerts the operator to retrieve the batch, while the industrial computer flags the "over-limit" status, pausing the machine until the operator processes the error batch and presses the "Reset" button to resume automated counting.