Advantages and applications of non-contact online color detection system

Overview

Traditional color detection systems use a contact-type, off-line method for color detection of products. The so-called contact type means that when detecting the color, the product or sample must be in close contact with the measuring instrument, otherwise accurate color data will not be obtained. Non-online testing requires the product to be removed from the production line for inspection, so that real-time color data on the production line cannot be obtained in time.

In contrast, the non-contact online color detection system maintains a certain distance between the product and the inspection instrument when performing color detection, and can also directly detect the product on the production line, breaking through the limitations of the traditional color detection method.

In general, non-contact online color detection systems include color detection instruments, control software, and ancillary equipment. The color detection instrument is mainly used to detect the product to get the raw data of the color. Software is primarily used to control instruments and analyze data. Auxiliary equipment is used to assist in the implementation of specific functions. For example, a warning light is used to display the color status of the product, and when the red light is blinking, the color difference of the color is too large.

Advantages of non-contact detection

Conventional color detection requires a certain amount of pressure on the surface of the product being tested, but this often causes some damage to the product. In contrast, because non-contact color detection allows the product to be kept at a certain distance from the instrument, it does not cause damage or damage to the product or sample.

Non-contact color detection systems can detect non-planar products. Although the conventional inspection system can detect some non-planar products with the help of some fixtures, the accuracy of this detection method is not satisfactory. Obviously, the measurement range of the non-contact detection system is much wider, and the accuracy and accuracy of the detection are greatly improved.

In general, when detecting granular and powdery products such as masterbatches, the instrument needs to be tested through glass. Due to the limitations of the measurement area and the uncertainty of the particle arrangement and the influence of the glass, the repeatability of the measurement is often not guaranteed. Non-contact measurements can avoid the effects of the container, and because of the larger measurement area, the effect of product alignment on the measurement results can be significantly impaired, making it easier to obtain accurate color data.

In addition, the non-contact inspection system can also detect wet samples, such as smeared paint. Traditional instruments are difficult to measure such wet samples because they can contaminate or even damage the instrument when measured directly. This problem does not exist with non-contact measurements.

Advantages of online testing

On-line inspection can monitor the quality of each product on the production line in real time and enhance the color adhesion, which not only helps to reduce production waste, but also can effectively improve production efficiency. The "online" here has two meanings: one is that the detection system is installed on the production line, and the other is that the detection system is connected to the control system of the production line.

Traditional color detection usually lags behind production. When it is detected that the product has a color problem, many or a large number of unqualified products have been produced, which leads to waste of materials, and online detection can overcome this shortcoming. For example, in the production of building profiles, the product inspection system can be installed on the extruder. When the product reaches the detection position or reaches the set time limit, the detection system will automatically detect the color of the product and obtain real-time color data in time. In this way, before cutting the product, you can master the quality of the product in detail, and if there is any problem, you can adjust it immediately. In the process of testing, the product does not have to leave the production line, nor stop production of the production line, thus greatly saving time and labor costs.

The detection system is connected to the control system of the production line to form a closed loop control system. When the color data does not meet the requirements, the inspection system can issue a warning to the control system and even stop production directly. The inspection system installed on the fire board production line is a successful application case. When the deviation of the product color exceeds the warning value, the system will issue a warning to the relevant department. If the product's error is outside the allowable range, the system will automatically issue instructions to transfer unqualified products on the production line to a specific area.

Another benefit of connecting to the control system of the production line is that color data can be monitored remotely. Production managers or quality management personnel can monitor the color of the product in the office, or directly issue relevant command instructions through the control system. The traditional color detection system needs to manually convey the quality of the color by means of e-mail or telephone, that is, time-consuming and laborious, and the accuracy is also poor.

Vericolor Spectro non-contact online inspection system

The Vericolor Spectro non-contact online inspection system developed by X-Rite is such a cost-effective detection system that enables high-quality measurements. The successful development of this detection system has also created conditions for the wide application of non-contact online detection systems in plastics and other industries.

The system includes the Vericolor Spectro spectrophotometer and VericolorSpectro software. Among them, the spectrophotometer is a 0/30 illumination measurement geometry with full-spectrum LED illumination, measuring area of ​​25.4mm, average inter-station difference of 0.3DE*, and weight of only 2.81kg. Vericolor Spectro software is based on the Windows operating system, easy to install, easy to interface, and the generated data can be recorded in the form of EXCEL files.

The system uses a dual-beam 31-channel with high accuracy and short-term repeatability of only 0.03 DE* on average. Thanks to the patented light source design, the system is not sensitive to ambient light such as incandescent, fluorescent and sodium lamps, without changing the lighting conditions of the factory. The operating temperature range of the system is 0~50°C, the measuring distance is 10.16cm, and the deviation of ±5.0mm is allowed. Therefore, it is less affected by the distance fluctuation. It is worth mentioning that the system has passed the NEMA-4/IP67 standard audit, which is dust-proof, pollution-proof and can withstand shock and vibration. In addition, the system is not only sturdy, but also easy to maintain, requiring little special maintenance, and only requires daily cleaning and monthly calibration.