1, Common knowledge about gas source and pressure
The color sorter relies on high-pressure air valves to remove impurities, and a stable gas source is the key to sorting. The standard working pressure is maintained at 0.4-0.6MPa, and if the pressure is too low, impurities cannot be blown away, resulting in missed selection; Excessive air pressure can blow away good products and consume raw materials.
The air source must be equipped with a drying and filtering device. The adhesion of water vapor and oil stains in the air to the lens will permanently damage the optical components. The root cause of many equipment failures is the failure to purify the air source properly.
2, Environmental temperature affects sorting efficiency
The equipment is suitable for a working environment of 10-35 ℃. High temperatures can cause camera sensors to overheat, leading to color distortion in recognition; Low temperature will slow down the jet reaction of solenoid valves and delay sorting.
Workshop dust and direct sunlight can also interfere with imaging. It is recommended to avoid light and ventilation in the factory to prevent strong light from directly shining on the sorting glass.
3, The difference between AI intelligent color sorter and traditional ordinary models
Old style color sorting machines rely solely on fixed color difference thresholds for sorting, resulting in poor sorting performance for materials with uneven dryness and weak color differences.
The new generation AI color sorter can autonomously learn defect features, accurately identifying mold spots, insect eyes, black spots, discolored debris, and insect infested particles. It also supports one click storage of multiple material formulas, and there is no need to repeatedly adjust parameters when changing materials.
4, Simple adjustment logic for running materials and bringing out more
Mixing defective products in finished products is called missed selection; Good products are blown into the waste bin and are called to be taken out.
Missed selection: increase recognition sensitivity, clean lens dust, reduce material discharge flow rate;
Bring out too much: reduce the jet duration, adjust the air pressure of the small valve, slow down the material falling speed, without blindly replacing large models.
5, How to control the proportion of waste materials
Under normal processing conditions, the proportion of waste is generally controlled at 1% -5%. If the waste exceeds 8%, it is highly likely that the raw material itself has too many defects. A pre cleaning screen can be used to remove large impurities, reduce the load on the color sorter, and improve overall production capacity.
6, Differentiation of core components with service life
Optical lenses and sensors: can be used for 5-8 years after proper cleaning and maintenance, and belong to high-value precision parts;
High speed jet solenoid valve: consumable parts that need to be replaced after six months to one year of long-term 24-hour production;
Chute and conveyor belt: According to the material hardness loss, the sorting of miscellaneous grains and ores wears out faster, and accessories can be replaced separately without the need for complete machine replacement.
7, Solving the problem of color difference in nighttime production
The yellowing and uneven brightness of the lighting in the factory at night can change the visual color difference of materials and cause unstable sorting.
It is recommended to use cold white industrial LED lights uniformly in the workshop to avoid warm yellow light, ensure that the material imaging color is consistent with daytime, and maintain stable sorting standards.
8, Precautions for sorting dry and wet materials
Wet grains and washed medicinal herbs cannot be directly fed into the machine, as the surface moisture will reflect light and the camera will mistake them for defective products with different colors, resulting in a large number of good products being removed. The materials must be air dried and air dried to the standard moisture content before sorting. At the same time, residual damp materials inside the machine should be regularly cleaned to prevent mold from blocking the channels.