Application Case of Bottle Cap Gasket Stacked Material / Missing Material / Reverse Installation Detection

1. Project Background

In the bottle cap production process, the correct assembly of gaskets directly affects the sealing performance of bottle caps, which in turn is related to product quality and shelf life. If problems such as stacked gaskets, missing gaskets, or reversed installation of gaskets occur inside the bottle cap, it will lead to seal failure, triggering risks such as liquid leakage and product deterioration, and bringing economic losses and impacts on brand reputation to the enterprise. To improve product quality and reduce the defective rate, a bottle cap manufacturing enterprise urgently needed an efficient and accurate bottle cap gasket detection solution to realize real-time detection of gasket status on the production line and screening of defective products.

2. Project Requirements

Production Line Working Conditions

Cap Diameter: 55mm

Production Rhythm: 50 pieces per minute (spm)

Detection Requirements

Real-time detection of the following statuses of gaskets inside bottle caps on the production line is required to screen out defective products:

Stacked gaskets (more than one piece)

No gaskets

Reversed installation of gaskets

3. Solution

Equipment Configuration

Installation Layout

The color mark sensor and square probe are installed above the assembly line to ensure clear alignment with the gasket area inside the bottle cap, without obstruction or interference from other components of the assembly line.

The in-position switch is installed on the side of the assembly line, and its sensing position corresponds precisely to the detection area. When the bottle cap is conveyed to the detection area, the in-position switch can identify the bottle cap in a timely and accurate manner.

The double-sheet detector MDSC-900E is integrated into the detection system, works in coordination with other equipment, and starts detection after receiving the signal from the in-position switch.

Workflow

Bottle caps are continuously conveyed on the production assembly line, and the color mark sensor remains in a real-time detection state. When a bottle cap reaches the detection area of the color mark sensor, the sensor immediately starts detecting the presence/absence and front/reverse status of the gasket.

When the bottle cap is further conveyed to the designated detection area, the in-position switch on the side identifies the bottle cap and sends a trigger signal. After receiving the signal, the double-sheet detector MDSC-900E starts detecting stacked gaskets, and this signal also provides a trigger condition for the subsequent action of the air-blowing device.

The color mark sensor completes detection first: if no gasket is detected or the gasket is installed in reverse, the product is directly determined as defective and the signal is fed back to the system; if the detection result is qualified, it waits for the detection result of the double-sheet detector.

After receiving the signal from the in-position switch, the double-sheet detector MDSC-900E simultaneously completes the detection of stacked gaskets: if more than one gasket is detected, the product is determined as defective and a signal is fed back; if the detection is qualified, a qualified signal is also fed back.

When the color mark sensor detects no gasket or reversed gasket, or the double-sheet detector detects stacked gaskets, any defective signal will trigger the air nozzle device to blow the defective product into the collection box on the side of the assembly line; if both detection results are qualified (with gasket, correct front/reverse position and no stacking), the bottle cap continues to flow down along the assembly line and enters the subsequent production process.

4. Implementation Effects

After the solution was implemented on the bottle cap production line, it achieved efficient and accurate detection of the bottle cap gasket status, with the following specific effects:

4.1 High Detection Accuracy: It accurately identifies defective conditions such as no gasket, reversed gasket installation, and stacked gaskets, effectively preventing defective products from flowing out.

4.2 Adaptation to Production Rhythm: It fully matches the production rhythm of 50 pieces per minute, with no delay in the detection process and no impact on the overall production efficiency of the production line.

4.3 High Automation Level: The entire detection and screening process requires no manual intervention, realizing automated detection and sorting, reducing labor costs and improving the intelligence level of production.

4.4 Good Stability: All equipment works in coordination stably and reliably. During long-term operation, the equipment failure rate is low, ensuring continuous and stable production of the production line.