The application of K series industrial endoscope in an electronic cigarette manufacturing plant in Xiamen has significantly improved the inspection efficiency and quality of threaded holes in electronic cigarette shells through its technical advantages such as high-definition imaging, flexible control and durability.The following is an analysis from three aspects: technical principles, application scenarios and implementation effects:
High-definition imaging system
The K series endoscope is equipped with a megapixel camera, combined with a high-brightness LED light source, which can clearly present the microstructure of the threaded hole. Through fiber optic image transmission technology, the image is distortion-free and highly restored, and the number of thread lines, shape and foreign matter in the hole (such as metal debris and burrs) are accurately identified.
Flexible control and guidance
The equipment supports 360° all-round probe rotation, and the insertion tube can be bent with a radius of ≤4mm, which meets the detection needs of the narrow space of the electronic cigarette shell. The operator can accurately lock the position of the threaded hole to avoid missed detection or repeated detection.
Durability and environmental adaptability
The insertion tube meets the IP67 waterproof and oil-proof standards and can work stably in humid and oily environments. The tube diameter specifications cover 0.8-8mm and support customized length (up to 30m) to meet the needs of different detection scenarios.
Limitations of traditional detection
Manual detection is inefficient (about 200-300 pieces/hour) and is easily affected by subjective factors, with a missed detection rate of up to 5%-8%. Although mechanical gauge detection improves efficiency, it cannot identify microscopic defects in the hole.
Targeted optimization of K series endoscopes
Multi-parameter synchronous detection: complete the detection of indicators such as thread count, shape, and hole cleanliness at one time.
Real-time image analysis: The detection screen is displayed in real time through the host LCD screen, supporting two people to observe at the same time, improving the accuracy of defect determination.
Data traceability function: It can store detection images and videos to provide a basis for quality traceability.
Improved production efficiency
The detection speed reaches 800-1000 pieces/hour, matching the beat of the e-cigarette production line.
Labor costs are reduced by 75% (the number of single-line operators is reduced from 4 to 1), reducing downtime.
Product quality improvement
The missed detection rate is reduced to below 0.3%, and the defective product outflow rate is reduced by 90%.
Through the data traceability function, defective batches can be located and the production process can be optimized (such as adjusting the tapping speed and coolant flow).
This solution has been promoted to many e-cigarette companies, for example:
In the e-cigarette assembly line of Jiuju Automation, the endoscope inspection module is linked with the dispensing and pressing processes, and the overall yield rate is increased to 99.2%.
Pumis's 4K zoom lens solution has also been successfully applied in the fields of FPC defect detection and wafer detection.
The K series industrial endoscope is not limited to threaded hole detection, and its technology can be extended to:
Appearance defect detection: identification of electronic cigarette shell scratches, color difference, etc.
Character recognition: verification of product model, batch number and other identification.
Dimension measurement: accurate measurement of shell length, diameter and other parameters.
By docking with MES (manufacturing execution system), real-time monitoring and analysis of production data can be achieved to provide data support for intelligent manufacturing.
The K series industrial endoscope has become a key tool for quality control in the electronic cigarette manufacturing industry with its advantages of high precision, high efficiency and high flexibility. The application case of an electronic cigarette manufacturing plant in Xiamen shows that automated detection technology can not only significantly improve production efficiency and product quality, but also promote the transformation of enterprises to intelligent manufacturing through data-driven process optimization. With the iteration of technology, such systems will play a core value in more precision manufacturing fields.
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