The visual ice cream stick sorting machine is a specialized device that integrates machine vision technology, automated control, and precision mechanical transmission. It is primarily used for automated inspection, sorting, and screening of ice cream sticks (wooden coffee sticks/tongue depressors). It uses a high-definition camera to capture stick images and, using image processing algorithms, identifies cosmetic defects (such as cracks, burrs, color differences, stains, etc.) and dimensional deviations. Mechanical actuators then separate qualified from unqualified products, enabling automated quality control within the ice cream stick production process.
Quality Inspection: Identifies cosmetic defects such as scratches, insect holes, mold, uneven color, and printing errors (such as patterns or text).
Dimensional Screening: Inspects sticks for parameters such as length, width, thickness, and straightness, rejecting products that fall outside tolerances.
Classification and Grading: Qualified products are sorted into different grades based on pre-set criteria (such as color depth and texture consistency) to meet the needs of different customers or scenarios. Improved Production Efficiency: Replaces manual sorting, solving problems such as low manual inspection efficiency, inconsistent standards, and fatigue, making it suitable for mass production on assembly lines.
Based on different design features and application scenarios, it can be divided into the following categories:
Single-channel sorters: Suitable for small-batch production, bars pass through the inspection area one by one, featuring a simple structure and low cost.
Multi-channel sorters: Equipped with multiple parallel inspection channels, they can process multiple bars simultaneously, offering high sorting efficiency and suitable for large-scale mass production.
Semi-automatic sorters: Require manual loading, but automate the inspection and sorting processes, making them suitable for small and medium-sized manufacturers.
Fully-automatic sorters: Integrate automatic loading, inspection, sorting, and unloading functions, enabling integration with front-end and back-end production lines for unmanned operation.
Economical sorters: Equipped with a basic vision system, they can detect obvious defects and large dimensional deviations, making them suitable for applications with lower precision requirements. High-precision sorting machine: Utilizing high-resolution cameras and advanced algorithms, it can detect minute defects (such as scratches as small as 0.1mm), meeting high-end quality requirements.
Loading mechanism: This mechanism is responsible for transporting the ice cream bars to be inspected to the inspection area in an orderly manner. Common methods include vibrating plates, conveyor belts, and feed wheels, ensuring that the bars are neatly arranged and do not overlap.
High-definition industrial camera: Captures images of the bar surface. Resolution typically ranges from 2 million to 12 million pixels, depending on the required inspection accuracy.
Light source: Provides uniform, stable illumination (such as ring lights or strip lights), eliminating shadow interference and highlighting defect features.
Image acquisition card: Transmits image signals captured by the camera to a computer for processing.
Image processing software: Equipped with defect recognition algorithms (such as edge detection, color analysis, and template matching), it analyzes images and determines product conformance.
Sorting Actuator: Based on the vision system's judgment, pneumatic actuators, air blowers, sorting flaps, and other mechanisms are used to remove defective products from the main stream or sort them into different bins according to grade.
Composed of a conveyor belt or rollers, it carries the bars through the entire inspection and sorting process, with adjustable speed to match the production rhythm.
Based on a PLC (Programmable Logic Controller) or industrial computer, it coordinates the operation of various components, supports parameter settings (such as defect thresholds and sorting speeds), and supports fault alarms.
A touchscreen or operation panel allows operators to easily set parameters, view inspection data (such as pass rate and defect type statistics), and equipment status.
1. Loading Phase: Ice cream bars are aligned in a uniform direction by a loading mechanism (such as a vibrating plate) and then fed into the conveyor mechanism.
2. Image Acquisition Phase: The bars enter the inspection area on a conveyor belt. A light source illuminates the surface, and an industrial camera captures images of the bars at pre-set positions. Image Processing and Judgment Stage: Images are transmitted to the software system, where algorithms pre-process the images. The system then detects dimensional parameters and cosmetic defects, comparing them against pre-set acceptance criteria to quickly determine "pass," "fail," or a specific grade.
3. Sorting Stage: When bars arrive at the sorting area, the control system triggers actuators based on the judgment results (such as activating an air blower at the location corresponding to a failed bar), diverting the bars to the appropriate bins.
4. Data Recording Stage: The equipment automatically records data such as the number of bars inspected, the pass rate, and the defect type, which can be displayed or exported through the interface for easy production quality traceability.
1. High Efficiency: Sorting speeds can reach hundreds to thousands of bars per minute, far exceeding manual efficiency (a human operator typically operates at no more than 50 bars per minute), significantly improving production throughput.
2. High Precision: The vision system can identify defects and dimensional deviations as small as 0.1mm. Standardized inspection standards eliminate errors caused by subjective human judgment.
3. Stability: The system operates continuously for long periods of time, unaffected by fatigue and mood, ensuring consistent quality across batches. Intelligence: Supports customizable parameters (such as defect sensitivity and sorting levels). Some high-end models can autonomously learn new defect types through AI algorithms to adapt to the inspection needs of different ice cream stick sizes.
4. Cost Savings: Reduces labor costs and mitigates the risk of customer complaints or returns due to missed inspections. Accurate sorting also improves raw material utilization.
Data-driven Management: Automatically records production data, providing a basis for quality analysis and process optimization, helping to improve production processes.
5. Use Scenarios: Ice cream stick manufacturers: Use this system during quality inspection after cutting, polishing, and printing to ensure that shipped products meet quality standards.
6. Food Packaging Companies: Perform quality screening of supplied ice cream and popsicle sticks to ensure food contact material safety.
1. Ice cream stick manufacturers: Use this machine during quality inspection after cutting, polishing, and printing to ensure that products meet quality standards.
2. Food packaging companies: Use this machine to screen the quality of ice cream and popsicle sticks to ensure food contact material safety.
3. Small processing workshops: Use semi-automatic sorting machines to improve product quality and meet the needs of small-batch, multi-format production.
4. Quality sampling: Conduct random inspections of products before storage or shipment to reduce the risk of substandard products entering the market.
After each day's work, clean dust and debris from the loading mechanism and conveyor belt to prevent clogging or scratching of the bar material.
Clean the camera lens and light source surfaces weekly to prevent dust from affecting image acquisition accuracy (use a dedicated lens cloth or alcohol pad).
Regularly check the conveyor belt tension and adjust if loose to prevent slippage and affect conveying speed.
Inspect the air hose connections of the pneumatic actuator to ensure there are no leaks and for smooth operation. Lubricate the pneumatic components monthly.
Back up equipment parameters and test data monthly to prevent data loss due to system failures.
Update the image processing software regularly to fix vulnerabilities and optimize algorithms (technical support provided by the manufacturer).
Maintain a dry and dust-free working environment to prevent moisture from causing electrical shorts or rusting of metal components.
Keep the equipment away from strong light sources or vibration sources to minimize interference with the vision system and mechanical structure.
