Advance Inspection Machine: Breaking through the quality inspection limit of high-speed production

Ultra-high-speed image acquisition: 0.03 seconds to lock the entire surface of 1 meter cable.

Equipped with industrial-grade line array camera and laser triangulation system, the device realizes ultra-high-speed image acquisition efficiency of 0.03 seconds / meter. When the cable passes through the inspection area at a speed of 400 meters per minute, the line array camera can capture 6.6 meters of 3D point cloud data of the cable surface per second, forming a high-precision point cloud matrix with a density of 100,000 points/square centimeter. Compared with the traditional surface array camera at high speeds in the drag shadow blur problem, the technology through the synchronization of the strobe flash source and trigger mechanism, to ensure that the details of the cable surface in motion is clearly reproduced, even if the micro-defects of 0.01mm can be accurately localized in the point cloud data.

Deep algorithm engine: milliseconds to complete the three-dimensional defect resolution

The built-in CNN algorithm has been trained on 100,000+ defect samples and constructed a 3D defect recognition model containing geometric, texture and spectral features. After acquiring the point cloud data, the algorithm completes the defect segmentation, classification and size measurement within 0.8 ms through the multi-scale feature pyramid network. For cyclical defects commonly found in high-speed production (such as regular bumps caused by mold wear), the system can predict the location of the defects 3-5 meters in advance through the correlation and analysis of time series data, triggering early warning or automatic adjustment of parameters on the production line, eliminating quality hazards in the embryonic stage.

Intelligent cooperative system: single operator control the efficiency revolution of dual production lines.

Through the Industrial Internet of Things (IIoT) technology, a single device can simultaneously access the real-time data of two production lines, realizing 360° circumferential defect mapping and cross-production line data comparison. The operation interface adopts dynamic heat map visualization technology to present key indicators such as defect density distribution and size trend changes on the cable surface in real time, assisting operators to quickly locate process anomalies. According to the measured data, the system enables the number of production lines under per capital control to be increased from 1 to 2, reducing labor costs by 75% and shortening the defect response time from 15 minutes to less than 30 seconds.

Extreme working condition adaptability: full temperature domain anti-interference detection program

For the complex environmental challenges in cable production, the equipment builds a multi-dimensional anti-interference system:

Optical system: Adopting 850nm infrared laser and diffuse reflection homogenizing structure, it effectively suppresses the interference of ambient light (daylight/fluorescent lamp) and penetrates the lubricants, water stains and other adherents on the cable surface to ensure the truthfulness of the three-dimensional data;

Temperature control system: Built-in semiconductor temperature control module stabilizes the working temperature of the camera at 25±2℃, and the fluctuation of the detection accuracy is no more than 0.005mm even under the low temperature of -30℃ or high temperature of 70℃;

Dynamic calibration: through the real-time acquisition of cable diameter, line speed and other parameters, automatically adjust the laser projection angle and algorithm threshold, to achieve 50-150mm caliber cable full-size compatible detection.

Closed-loop value of data: from quality control to process optimization

The inspection data generated by the equipment is not only used for defect rejection, but also builds a digital twin of production quality. Through the deep mining of historical data (such as the correlation between defect type and mold number, the correlation between temperature fluctuations and bubble defects), the system can output the “Process Optimization Proposal” to assist enterprises to achieve:

Mould life management: Predict the mould wear cycle through the defect distribution law, optimize the maintenance frequency from “timed” to “on-demand”, and reduce the maintenance cost by 20%;

Raw material traceability analysis: establish the correspondence between raw material batches and defect types, quickly locate poor quality raw materials and reduce return losses;

Energy efficiency optimization: correlating inspection data with equipment energy consumption parameters to achieve a 12% increase in energy efficiency ratio under high-speed production.

In the cable industry today, competition is white-hot, sharp knife vision 3D inspection equipment with  “speed × accuracy × intelligence” three-dimensional breakthrough, become a standard tool for high-end manufacturing. Whether it is the stringent quality inspection requirements of ultra-high-voltage cables or the large-scale mass production needs of civilian cables, the equipment can identify defects with a 99.98% defect recognition rate and an extremely fast response rate of 400 m / min , building a quality moat for the production line for the whole process from inspection to optimization.

Experience the Machine high-speed inspection solution that makes every meter of cable stand up to micron-level scrutiny!