In the production of small flat parts such as electronic accessories and printed display cards, the labeling step is often followed by quality issues: barcodes that cannot be read, crooked labels, and scratched surfaces. Manual visual inspection is inefficient and prone to missed defects due to eye fatigue. Building an efficient, stable quality barrier with consistent inspection standards is key to improving yield.

Inspection challenges for small flat parts and our vision inspection solution

On automated packaging lines, labeling or assembly equipment alone cannot guarantee a 100% good-part rate. Defects such as offset labels, blurred barcodes, and missing parts, if they reach the next process, greatly increase rework costs and can even trigger customer complaints. To close the loop on CCD vision labeling and inspection, an inline vision inspection system must replace manual checks.

To address this industry pain point, Wanzhi Automation developed the WZ-3022 CCD vision inspection machine. As the intelligent inspection eye of an automated line, it integrates automatic conveying, image capture, intelligent judgment, and data storage, and can simultaneously detect appearance defects, missing parts, assembly errors, and barcode anomalies, effectively blocking defective products and ensuring outgoing quality.

WZ-3022 core technology

Wanzhi AutomationThe WZ-3022 (full name: CCD vision inspection machine) is thoroughly optimized in both hardware and software algorithms. It uses a Hikvision 6-megapixel industrial vision imaging system whose high-definition images reliably capture fine defects, greatly reducing missed and false detections.

In terms of inspection logic, the machine performs multiple functions in one station. A single unit can simultaneously handle missing-material detection, print defects, assembly errors, and barcode verification, without the need for several machines handling separate stages, and inspection throughput reaches 2000 pieces per hour. The machine also uses an industrial touch-screen control system, and inspection programs can be stored and recalled quickly, making changeover easy.

For data management, the system automatically records the inspection image and judgment data for every product, enabling full-process quality traceability. In addition, an optional pneumatic or belt-type reject mechanism can automatically separate good and NG products for unattended inspection. The machine has a modular design, and the applicable product size is customized to the workpiece; both the inspection field of view and the conveyor length can be adjusted flexibly.

Line integration and selection tips

When introducing vision inspection equipment, companies should focus on the following selection criteria:

  • Define the inspection tasks: review the main defect types on the line, whether only barcode verification is needed or surface scratches and missing parts must also be checked, so the right vision algorithms can be configured.
  • Assess line throughput: calculate the parts per minute from the running speed of your existing labeling and packaging equipment, and make sure the inspection machine’s 2000 pcs/hour capacity matches the line or leaves some margin.
  • Plan rejection and integration: based on floor space and downstream packaging needs, choose a pneumatic blow-off or belt-diverter reject mechanism so the machine integrates seamlessly with the existing automated line.

With the right selection and customization, the WZ-3022 fits perfectly into full inspection of all kinds of small flat parts, helping companies improve both quality and efficiency.

FAQ

Is changeover on the WZ-3022 complicated?

The machine runs an industrial touch-screen control system with built-in recipe management. When changing products, simply recall the inspection program for that product and, thanks to the modular mechanical structure, complete changeover quickly. Rapid switching between products is supported.

How is inspection data stored and traced?

The industrial control system automatically stores inspection images and judgment data for every product. Companies can retrieve historical records at any time from the system backend for later quality reviews, data analysis, and complaint traceability.

Can the machine connect directly to an existing labeling line?

The machine has a modular design: the inspection field of view, conveyor length, and number of stations can all be customized to the customer’s product sizes and line layout, so it integrates seamlessly with upstream and downstream processes such as labeling, film lamination, and packaging.

This article was written by Wanzhi Automation.