How efficient is the detection of online defect detectors
The detection efficiency of online defect detectors is much higher than manual detection, and they can adapt to the high-speed production line rhythm of different industries. The core is reflected in three dimensions: fast detection speed, high full inspection efficiency, and low time cost. The efficiency performance in different scenarios is as follows:
The detection efficiency of online defect detectors is much higher than manual detection, and they can adapt to the high-speed production line rhythm of different industries. The core is reflected in three dimensions: fast detection speed, high full inspection efficiency, and low time cost. The efficiency performance in different scenarios is as follows:
1、 Detection speed: matching high-speed production lines, millisecond level response
1. High speed scanning and processing capability
The scanning line frequency of the online defect detector can reach 300kHz, and the defect processing speed is as high as 3.2g/s, far exceeding the processing speed of traditional detection equipment of 640M/s; Some systems have a single product processing time of ≤ 25ms and a detection speed of up to 30 per second. Even high-speed production lines such as electronic components and automotive parts can be tested without reducing production speed to cooperate with detection.
2. Efficient detection of large-sized/continuous materials
For materials such as films, aluminum profiles, and paper that are continuously produced, the detector can achieve a detection efficiency of tens to hundreds of meters per minute. For example, in film production, the system can process tens of thousands of frames of images per second at a production line speed of 300 meters per minute; In electrical material testing, the equipment testing speed can even reach 800 meters per minute, and the testing accuracy can still maintain a level of 0.01 millimeters.
2、 Full inspection efficiency: replaces manual sampling and covers 100% of products
1.24 hours of uninterrupted work
The online defect detector can operate stably for 7 × 24 hours and work continuously for 6 months without any lag, freeing itself from the fatigue limitations of manual inspection. Taking mobile screen detection as an example, manual detection of a single panel takes 120 seconds, while the detector only takes 1.5 seconds, increasing efficiency by 80 times and achieving a detection accuracy rate of 99.95%.
2. Full process automation linkage
The system can be linked with PLC control system and automatic sorting equipment to detect defects and provide real-time feedback, automatically removing non-conforming products without the need for manual secondary review. In the production of automotive cover steel plates, this linkage mode has achieved "zero defects" in the products before leaving the factory. Compared with the missed detection rate of manual sampling (about 3%), the missed detection rate of the detector can be controlled within 0.01%.
3、 Cost efficiency: significantly reducing time and labor costs
1. Significant time cost savings
The detector can save 80% of the detection time cost, and relying on AI algorithms, it can automatically classify and label defects, saving 90% of manual labeling costs. After a certain medical dressing enterprise introduced the system, not only did it improve the impurity detection efficiency of medical films several times, but it also reduced the risk of microbial contamination by more than 90%.
2. Outstanding benefits of manual substitution
A single detector can replace 2-4 quality inspectors, and a mobile phone screen manufacturer has saved over 8 million yuan in labor costs annually after introducing it; Aluminum profile production enterprises have also saved 75% of warehousing and logistics labor costs through automated testing.
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