Bottle cap aluminum foil gasket single and double piece detection scheme - dual station dual sheet detection

summary:

Aluminum foil gasket is the core component of bottle cap sealing. The gasket is thin and lightweight, and it is prone to two pieces sticking and stacking due to electrostatic adsorption and surface tension. Once the double gasket is installed in the bottle cap, it will cause improper rotation and sealing failure, directly leading to product leakage and deterioration, causing customer complaints and quality and safety hazards. MDSC-2102L focuses on online identification of single and double gaskets before assembly, intercepting stacking defects in advance and safeguarding packaging sealing safety.

1、 Project Background

The fields of food, medicine, daily chemical, etc. have strict requirements for the reliability of bottle cap sealing, and the sealing performance directly determines the shelf life and safety of product use. A large packaging supporting enterprise in South China supplies bottle cap components to numerous fast-moving consumer goods brands. The production line adopts vibration disc automatic feeding to feed aluminum foil gaskets into bottle caps. Due to the thin thickness and light weight of aluminum foil gaskets, static electricity and adsorption often cause gasket adhesion, and double or multiple sheets are stacked together and sent to the assembly station. Traditional detection methods are difficult to distinguish ultra-thin aluminum foils that are tightly adhered together, and the risk of missed detections is prominent under high-speed production. The customer urgently needs a testing solution that is compatible with the existing pad punching machine and can automatically identify single and double pieces online, to prevent double pads from entering the finished product from the source.

2、 Production line operating conditions and core pain points

Customer pain points:

1. The gasket is ultra-thin and lightweight, and it is prone to electrostatic adhesion. Stacking the gasket into the bottle cap can cause sealing failure, resulting in customer complaints and quality accidents;

2. It is difficult to identify when two gaskets are tightly attached, and conventional sensors are prone to missed detections;

3. The high-speed operation of the production line requires high sensor response speed and continuous stability;

4. The equipment layout is compact, requiring small probes that are compatible with existing mechanical structures and have low renovation costs.

3、 AtonmMDSC-2102L Dual Detector Detection Solution

In response to the characteristics of ultra-thin aluminum foil gaskets, the solution uses Atorm MDSC-2102L contact eddy current dual tension detection sensor, specifically developed for non-magnetic ultra-thin metal materials.

Deploy a one to two solution at the gasket feeding station of the punching machine, equipped with two M12 single probes, to achieve real-time online judgment of gasket single and double pieces. Based on the principle of contact eddy current testing, even if the aluminum foil gasket is tightly adhered, it can still stably distinguish between single/double sheet states; 50ms ultra fast response, perfectly matching the 310/minute high-speed production line rhythm. The M12 probe has a compact structure and supports single-sided installation, without the need for significant changes to the original device structure, making it suitable for compact packaging equipment layouts.

4、 Program value

1. Pre intercept defects to ensure sealing quality. Double piece testing is completed before gasket assembly to prevent stacking defects from flowing into the next process, reducing the risk of bottle cap sealing failure from the source and avoiding quality accidents and brand losses.

2. An eddy current algorithm optimized for ultra-thin aluminum foil detection scenarios, targeting the calibration of thin and non-magnetic aluminum foil, with stable and reliable identification of adhesive laminates, solving the problem of missed detections in traditional detection solutions.

3. The high-speed production line follows a stable response time of 50ms and continuously matches 310/min high-speed bottle cap assembly production lines, without slowing down production efficiency.

4. Easy to install, low cost of modification M12 compact probe, single-sided installation method, suitable for compact space of punching pad machine, convenient for on-site integration, reducing the workload of production line modification.

5. Flexible configuration, adapting to workstation requirements with a one to two dual probe solution, which can be flexibly deployed according to workstation layout to meet the standardization of gasket automation testing in the packaging industry.

5、 Project implementation effect

1. Controllable interception of defects: 100% online identification and timely alarm shutdown of gasket double adhesion defects are carried out before the assembly station, completely eliminating the flow of double gaskets into the finished bottle cap and eliminating the hidden danger of sealing failure.

2. Root cause of missed detections: For ultra-thin aluminum foil that adheres tightly to electrostatic adsorption, the detection stability is greatly improved, and there are no sustained missed detections or false alarms during long-term operation.

3. Production efficiency guarantee: The sensor responds quickly within 50ms, synchronizes 310 high-speed beats per minute throughout the entire process, without lagging or slowing down the production line, maintaining the original production capacity.

4. Simple and worry free operation and maintenance: The probe is installed on one side, with a simple layout that is not easily affected by gasket debris and dust interference, and requires minimal daily maintenance.

5. Quality cost reduction: significantly reducing rework, finished product re inspection, customer complaints, and return and exchange losses, helping customers stabilize delivery quality, and enhancing downstream brand customer trust.