Rubber cap production system and production method capable of achieving accurate waste removal

Abstract

The invention relates to a rubber cap production system and method, in particular to a rubber cap production system and method capable of achieving accurate waste removal, and solves the problem that waste cap tops cannot be completely removed through an existing rubber cap production system and method. The system comprises a cap top raw material processing system, an other raw and auxiliary material supply system, a rubber cap plastic packaging device and a quality inspection system. The quality inspection system comprises a hat top raw material in-factory quality control device and a hat top finished product out-factory quality control device. The system is characterized by further comprising code spraying equipment which is additionally arranged at the front end of the hat top raw material in-factory quality control equipment; the quality inspection system further comprises code recognition devices which are additionally arranged on the hat top raw material in-factory quality control equipment, the hat top finished product out-factory quality control equipment and the rubber cap plastic packaging equipment respectively. The quality inspection system forms a data set of all waste cap tops; and a control computer of the rubber cap plastic packaging equipment compares a code recognition result with a data set of all waste cap tops before combined processing of the cap tops and the cap bodies, and controls the rubber cap plastic packaging equipment to remove the waste cap tops when the cap tops are the waste cap tops.

Description

Technical Field

[0001] This invention relates to a plastic cap production system and method, and particularly to a plastic cap production system and method capable of precise rejection of defective products. Background Technology

[0002] The production of bottle caps typically involves using cap sealing equipment to laminate each cap tip onto the cap body. Then, online inspection equipment is used to inspect the laminated caps, removing defective caps and completing the production process.

[0003] For the structure of existing plastic cap sealing equipment, see [link to relevant documentation]. Figure 1 It includes a control computer, a programmable logic controller (PLC), a turntable 54, and a cap top feeding device 53 (not shown in the figure) containing a punching and shearing device 531, located on the outer side of the cylindrical surface of the turntable 54. The control computer controls the coordinated operation of each actuator in the cap sealing equipment through the PLC. The turntable 54 is used to transport the cap body 02. By rotating the turntable 54, the cap body receiving end 541 of the turntable receives the cap body 02 from other raw and auxiliary material supply systems and sequentially transports it to each station arranged around the turntable 54 in a clockwise or counterclockwise direction according to the process. The cap top feeding device 53 is one of the above-mentioned stations. It is used to flatly transport each cap top 01 on the cap top rewind to the punch position of the punching and shearing device 531, punching and shearing the cap top 01 from the cap top rewind and pasting it onto the top of the cap body 02 that has reached its punch position at this time, so as to composite and process it into a cap.

[0004] As can be seen from the above process of laminating caps using the cap sealing equipment, if there are defective cap tops, the laminated caps also become defective, resulting in the waste of qualified cap bodies laminated with defective cap tops. Defective cap tops can be caused by two main factors: firstly, the raw materials themselves are flawed; secondly, the cap top manufacturing process is complex, involving a long process chain and numerous steps, where defects can occur at any stage due to processing issues.

[0005] To reduce waste of qualified cap bodies during cap production, existing technologies typically employ two methods: before processing the cap top, the large reroll of raw cap top material is inspected by incoming quality control equipment to determine if the percentage of good quality material meets the feeding standard; and after processing the large reroll into smaller rerolls, the finished cap top is also inspected by outgoing quality control equipment to determine if the percentage of good quality material on the smaller reroll meets the feeding standard for the next process. However, these existing methods for preventing cap top quality risks only assess whether the entire roll of large and small rerolls of cap top material can proceed to the next process. Even when the percentage of good quality material meets the feeding standard, defective material from the entire roll also flows into the next process, failing to remove defective material. Although the percentage of defective material is small and the amount of qualified cap body wasted is small, it still results in the waste of qualified cap bodies. Although existing technologies also include methods to remove defective cap tops by cutting them off from the small re-roller and then splicing the cut ends together, this splicing method can only remove cap tops defective due to processing reasons, and cannot completely remove cap tops defective due to raw material reasons. In addition, it requires stopping the machine for offline removal, and if too many splicing operations are performed, it will cause unstable tension in the cap top support strip, resulting in low production efficiency.

[0006] In summary, using existing cap production systems and methods to produce caps results in the inability to completely eliminate defective cap tops, significant production quality risks, low production efficiency, and waste of qualified cap bodies and other auxiliary materials. Summary of the Invention

[0007] The purpose of this invention is to solve the technical problems of existing cap production systems and methods, which cannot completely remove defective cap tops, have high production quality risks, low production efficiency, and also cause waste of qualified cap bodies and other auxiliary materials. The invention provides a cap production system and method that can achieve precise defect removal.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0009] A cap production system capable of precise waste rejection includes a cap top raw material processing system, a other raw and auxiliary material supply system, a cap sealing equipment, and a quality inspection system. The cap top raw material processing system is used to process large re-rolls of cap top raw materials into small re-rolls. The other raw and auxiliary material supply system is used to process the cap body. The cap sealing equipment is used to laminate each cap top from the small re-rolls with the cap body to form a cap, and includes a control computer, a programmable logic controller, a turntable, and a cap top feeding device with a punching and shearing device located on the outer side of the turntable's cylindrical surface. The turntable is used to transport the cap body. The quality inspection system includes inbound quality control equipment for cap top raw materials, outbound quality control equipment for finished cap tops, and online testing equipment for cap sealing and lamination production. Its unique feature is that:

[0010] It also includes a coding device installed at the front end of the quality control equipment for the raw materials of the hat top entering the factory. The front end refers to the side that is first in the process. The coding device is used to code each area of ​​the hat top on the large re-roll of the raw materials of the hat top according to its unique hat top code.

[0011] The quality inspection system also includes a code recognition device installed on the raw material quality control equipment for the top of the hat, the finished product quality control equipment for the top of the hat, and the plastic sealing equipment for the hat.

[0012] The raw material quality control equipment for the top of the hat and the finished product quality control equipment for the top of the hat are respectively used to inspect the corresponding area of ​​each top on the large rewind and small rewind of the raw material for the top of the hat after inkjet printing. The inspection results are associated with the identification results of the identification device on each top and stored in the database. The database is then used to compile a dataset of all defective tops of the small rewind of the top of the hat identified by inkjet printing.

[0013] The control computer is used to compare the code recognition result of the code recognition device on the cap sealing equipment with the dataset of all defective cap tops before the cap top and cap body are laminated. Based on this comparison, the computer determines whether the cap top is a qualified cap top. If it is, the computer controls the cap sealing equipment to complete the lamination process. If not, the computer controls the cap sealing equipment to remove the defective cap top.

[0014] Furthermore, the incoming quality control equipment for the raw materials of the cap top performs quality inspection on the corresponding area of ​​each cap top on the large rewind of the raw materials after inkjet printing; the outgoing quality control equipment for the finished cap top performs quality inspection on the corresponding area of ​​each cap top on the small rewind of the cap top; and the online inspection equipment for the plastic sealing and lamination production of the caps performs quality inspection on the laminated caps. All of these are carried out through their respective machine vision inspection devices.

[0015] Furthermore, the coding equipment is a laser coding machine or a small character coding machine.

[0016] Furthermore, the cap encoding can be a hybrid character encoding, barcode, or QR code.

[0017] Furthermore, the code recognition device is an OCR code recognition device.

[0018] Meanwhile, this invention also provides a method for producing plastic caps that enables precise rejection of defective products, characterized by the following steps:

[0019] Step 1: Construct the above-mentioned cap production system that enables precise rejection of defective products;

[0020] Step 2: Encode the corresponding area of ​​each cap on the large rewind of the cap raw material, and the cap code should meet the following conditions: the cap code is unique; then use the inkjet printing equipment in the cap production system constructed in Step 1 to inkjet print the corresponding area of ​​each cap on the large rewind of the cap raw material in the area outside their respective cap area according to their unique cap code.

[0021] Step 3: The machine vision inspection device of the raw material quality control equipment for the cap top is used to inspect the corresponding area of ​​each cap top on the large reroll of the raw material for the cap top after inkjet printing in Step 2. At the same time, the code recognition device on it recognizes the inkjet printing in Step 2 on the corresponding area of ​​each cap top on the large reroll of the raw material for the cap top. Then, the quality inspection results and code recognition results of the corresponding area of ​​each cap top on the large reroll of the raw material for the cap top are correlated to obtain the waste information of the large reroll of the raw material for the cap top.

[0022] Step 4: Based on the large rewinding scrap information of the hat top raw material obtained in Step 3, determine whether the large rewinding scrap rate of the hat top raw material is less than or equal to N%, where N% is the required threshold for the large rewinding scrap rate of the hat top raw material; if not, proceed to Step 5; if yes, proceed to Step 6.

[0023] Step 5: Return the large re-rolled raw material for the hat top, select a new large re-rolled raw material for the hat top, and then return to Step 2;

[0024] Step 6: Store the waste information of the large rewound raw material of the hat top obtained in Step 3 into the database, and use the hat top raw material processing system to process the large rewound raw material of the hat top that has been stored in the database into small rewound raw materials of the hat top.

[0025] Step 7: The machine vision inspection device of the finished hat top product quality control equipment is used to inspect the corresponding area of ​​each hat top on the small rewinder of the hat top processed in Step 6. At the same time, the code recognition device on it identifies the inkjet code in Step 2 on the corresponding area of ​​each hat top on the small rewinder of the hat top. Then, the quality inspection results and code recognition results of the corresponding area of ​​each hat top on the small rewinder of the hat top are correlated, and the information of defective hat tops caused by processing reasons on the small rewinder of the hat top is stored in the database.

[0026] Step 8: Summarize the waste information of the large rewinding of the raw materials for the cap top stored in the database in Step 6 and the waste cap top information of the small rewinding of the cap top due to processing reasons stored in the database in Step 7, and verify the images of all waste cap tops due to raw materials and processing reasons in the quality inspection system, remove erroneous waste data, and summarize them in the database to form a dataset of all waste cap tops of the small rewinding of the cap top identified by inkjet coding;

[0027] Step 9: Install the small rewinder at the top of the cap onto the cap feeding device, and turn on the other raw and auxiliary material supply system and the cap sealing equipment;

[0028] Step 10: Using the code recognition device on the cap sealing equipment, identify the inkjet code of the caps to be laminated that are located at the forefront of the cap conveying direction on the small rewinder of the caps installed on the cap top feeding device but have not reached the punch position of the punching and shearing device in Step 2, and transmit the identified inkjet code to the control computer in real time. The control computer then compares the data with the dataset of all waste caps compiled in the database in Step 8 in real time.

[0029] Step 11: Based on the comparison results described in Step 10, determine whether the hat top is a qualified hat top; if not, proceed to Step 12; if yes, proceed to Step 13.

[0030] Step 12: Generate a rejection signal and transmit it to the programmable logic controller (PLC) in real time. The PLC controls the punching and shearing device to stop moving when the cap top reaches its punch position. The cap top feeding device continues to convey the cap top forward to achieve rejection. At the same time, the corresponding cap body continues to rotate with the turntable for the next composite processing cycle. During the rotation, other raw and auxiliary material supply systems do not input cap body to the cap body receiving end of the turntable where the cap body is located. Then execute step 14.

[0031] Step 13: The programmable logic controller controls the punching and shearing device to operate normally when the top of the cap reaches its punch position, punching and shearing the top of the cap from the small cap top rewinder and pasting it onto the top of the cap body that has reached its punch position at this time, so as to composite and process it into a plastic cap. The composite plastic cap is then conveyed forward through the turntable for collection.

[0032] Step 14: Determine whether there are cap tops to be composited on the small rewinder of the cap top installed on the cap top feeding device that have not reached the punch position of the punching and shearing device; if yes, return to step 10; if no, proceed to step 15.

[0033] Step 15: Use the machine vision inspection device of the online inspection equipment for plastic sealing and lamination production of the plastic caps to perform quality inspection on the plastic caps collected in step 13, so as to remove defective plastic caps and complete the production of plastic caps.

[0034] Furthermore, in the cap production system that enables precise rejection of defective products constructed in step 1, the code recognition device is an OCR code recognition device.

[0035] In steps 3, 7, and 10, each code recognition device identifies the inkjet code using a deep learning-based OCR algorithm.

[0036] Furthermore, step 8 specifically includes:

[0037] Step 8.1: Summarize the waste information of the large rewinding of the raw materials for the cap top stored in the database in Step 6 and the waste cap top information of the small rewinding of the cap top due to processing reasons stored in the database in Step 7, and verify the images of all waste cap tops due to raw materials and processing reasons in the quality inspection system, remove erroneous waste data, and summarize them in the database to form a dataset of all waste cap tops of the small rewinding of the cap top identified by inkjet coding;

[0038] Step 8.2: Based on the dataset of all defective hat tops compiled in the database in Step 8.1, determine whether there is a case where the number of consecutive defective hat tops is greater than or equal to M on the hat top mini-complex, where M is a set threshold for the number of consecutive defective hat tops; if yes, proceed to Step 8.3; if no, proceed to Step 9.

[0039] Step 8.3: Using the finished product quality control equipment, locate the positions of the continuous defective hat tops on the small reroll of the hat top one by one where the number of continuous defective hat tops is greater than or equal to M. When each position is located, cut off the continuous defective hat top at that position, and then splice the cut ends together until the last cut end is spliced ​​together to obtain a small reroll of the hat top where the number of continuous defective hat tops is less than M.

[0040] Furthermore, in step 8.3, when each location is identified, the continuous waste cap tops at that location are manually cut off, and then the cut ends are spliced ​​back together.

[0041] The beneficial effects of this invention are:

[0042] (1) This invention enables a precise waste removal system for cap production. A coding device is installed at the front end of the raw material quality control equipment for cap tops. This device assigns a unique coding code to each cap top corresponding to a specific area on the large rewind of the raw material. Then, using the coding as a tool, identification devices are installed on the raw material quality control equipment and the finished cap top quality control equipment, allowing the coding to be integrated horizontally into the quality information of the cap top processing from raw materials to finished products. This results in a database summarizing all waste cap tops identified by the coding on the small rewind of the cap top. Then, further... By adding a code recognition device to the cap sealing equipment, the code is recognized before the cap top and cap body are laminated. The recognition result is then compared with a dataset of all defective cap tops identified by inkjet printing in the database. Before the cap top and cap body are laminated, all defective cap tops caused by raw materials and processing are accurately removed, which greatly reduces the risk of production quality and avoids the waste of qualified cap bodies and other auxiliary materials caused by defective cap tops, thus saving production costs.

[0043] Furthermore, in this invention, when removing defective cap tops, the punching and shearing device is controlled to stop moving when the cap top reaches its punch position, while the cap top feeding device continues to convey the cap top forward. This method can achieve precise and automatic removal of defective cap tops, eliminating the need for splicing and thus avoiding the need to stop the machine for removal and excessive splicing, thereby significantly improving production efficiency.

[0044] Therefore, the present invention solves the technical problems of producing rubber caps using existing rubber cap production systems and methods, which cannot completely remove defective cap tops, have high production quality risks, low production efficiency, and also cause waste of qualified cap bodies and other auxiliary materials.

[0045] (2) The present invention enables a precise method for producing rubber caps that eliminates defects. Preferably, it combines splicing defect elimination with automatic defect elimination. When the number of consecutive defective caps on the cap top rewind is greater than or equal to a set threshold for the number of consecutive defective caps, the splicing defect elimination method is first used to remove all consecutive defective caps on the cap top rewind where the number of consecutive defective caps is greater than or equal to the set threshold for the number of consecutive defective caps. Then, the automatic defect elimination method is used to remove the remaining defective caps on the cap top rewind where the number of consecutive defective caps obtained after splicing defect elimination is less than the set threshold for the number of consecutive defective caps. When there is no consecutive defective cap on the cap top rewind where the number of consecutive defective caps is greater than or equal to the set threshold for the number of consecutive defective caps, the automatic defect elimination method is used directly to remove defective caps. The present invention preferably combines splicing defect elimination with automatic defect elimination, which not only reduces the number of splicing defect eliminations but also avoids the occurrence of excessive idle rotations of the turntable due to an excessive number of consecutive defective caps, thus further improving production efficiency.

[0046] (3) This invention relies on inkjet printing technology, deep learning OCR technology, and equipment PLC interface technology to link the quality inspection results of the raw material quality control equipment entering the factory and the finished product quality control equipment leaving the factory, so that the quality inspection results of the quality control equipment of each process can be effectively transmitted, forming a joint force for inspection, avoiding the repeated use of inspection resources, and reducing the risk of waste and omission.

[0047] (4) In this invention, the "data interconnection-detection-offline rejection" method is adopted. The original defects of the raw materials of the cap top are transmitted through inkjet printing and code recognition. Then, the defects of the cap top caused by processing are detected by quality inspection. Then, the defects of the cap top caused by processing and the original defects of the cap top raw materials are summarized and verified. The erroneous rejection data is eliminated by the offline rejection method. The data is summarized in the database to form a dataset of all defective cap tops identified by inkjet printing. Then, the dataset of all defective cap tops identified by inkjet printing is effectively transmitted in the entire production process. In this way, the cap top product is digitized, realizing the refined control of cap top production and the precise execution of composite quality control of the cap. The quality data can be effectively analyzed and traced, continuously improving the quality control of the production process, forming a closed loop of quality control, reducing the occurrence of tendency defects, and comprehensively improving the quality of the cap.

[0048] (5) The present invention enables a precise method for producing rubber caps that eliminates defects. By using inkjet printing as a tool, the inkjet printing is horizontally integrated into the quality information of the cap top during the processing of raw materials to finished products. Then, by identifying the code, the precise removal of defective cap tops from the small rewinding of the cap top is achieved. However, the removal of defective products from a roll of material containing multiple products cannot be achieved by simply inspecting individual discrete products, as is the case with the removal of defective products from discrete products. Therefore, the present invention's method for producing rubber caps that enables precise defect elimination can be extended to the removal of defective products from a roll of material containing multiple products in various fields, and its application range is wide. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the plastic cap sealing equipment mentioned in the background section, and also a structural diagram of the plastic cap production system that enables precise waste rejection in this invention.

[0050] Figure 2 This is a schematic diagram of an embodiment of the cap production system of the present invention that enables precise rejection of defective products;

[0051] Figure 3 This is a flowchart of an embodiment of the plastic cap production method of the present invention that enables precise rejection of defective products;

[0052] Figure 4 This is a schematic diagram of step 6 of the embodiment of the cap production method that enables precise waste removal of the present invention, showing a section of the processed cap top re-roll laid flat.

[0053] The labels in the diagram are explained as follows:

[0054] 1-Inkjet printing equipment, 2-Incoming quality control equipment for cap top raw materials, 3-Catatop raw material processing system, 4-Outgoing quality control equipment for finished cap top products, 5-Cap sealing equipment, 51-Control computer, 52-Programmable logic controller, 53-Cap top feeding device, 531-Punching and shearing device, 54-Turntable, 541-Cap body receiving end of the turntable, 6-Other raw and auxiliary material supply system, 7-Online testing equipment for cap sealing and composite production, 01-Cap top, 02-Cap body, 03-Corresponding area for each cap top, N%-Required threshold for large rewind scrap rate of cap top raw materials, M-Set threshold for the number of continuously scrapped cap tops. Detailed Implementation

[0055] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0056] See Figure 2This invention discloses a cap production system capable of precise defect rejection, comprising a coding device 1, an incoming quality control device for cap top raw materials 2, a cap top raw material processing system 3, an outgoing quality control device for finished cap top products 4, a supply system for other raw and auxiliary materials 6, a cap sealing device 5, and an online inspection device for cap sealing and lamination production 7. It also includes coding devices respectively installed on the incoming quality control device for cap top raw materials 2, the outgoing quality control device for finished cap top products 4, and the cap sealing device 5. The aforementioned incoming quality control device for cap top raw materials 2, outgoing quality control device for finished cap top products 4, online inspection device for cap sealing and lamination production 7, and coding devices installed on the incoming quality control device for cap top raw materials 2, outgoing quality control device for finished cap top products 4, and cap sealing device 5 collectively constitute the quality inspection system of this invention's cap production system capable of precise defect rejection.

[0057] See Figure 1 and Figure 2 The aforementioned inkjet printing device 1 is installed in front of the incoming quality control equipment 2 for the raw materials of the cap top, where "front" refers to the side that is first in the process. This inkjet printing device 1 is used to print a unique cap top code on each area 03 corresponding to the cap top on the large rewind of the raw materials. The inkjet printing device 1 can be a laser inkjet printer or a small character inkjet printer, or other equipment capable of printing codes. The cap top code can be a mixed character code, barcode, or QR code, or other code that can be recognized by a code recognition device. See also... Figure 4 In this embodiment, the above-mentioned hat top coding adopts a barcode; in this embodiment, the code recognition devices installed on the hat top raw material incoming quality control equipment 2, the hat top finished product outgoing quality control equipment 4, and the cap sealing equipment 5 are all OCR code recognition devices; the above-mentioned hat top raw material incoming quality control equipment 2 is used to perform quality inspection on each hat top corresponding area 03 on the large reroll of the hat top raw material after inkjet printing, and stores the quality inspection results in the database after correspondingly associating them with the code recognition results of the code recognition devices thereon; the above-mentioned hat top raw material processing system 3 is used to process the large reroll of the hat top raw material into small rerolls of the hat top; the above-mentioned hat top finished product outgoing quality control equipment 4 is used to perform quality inspection on each hat top corresponding area 03 on the small reroll of the hat top, and stores the quality inspection results in the database after correspondingly associating them with the code recognition results of the code recognition devices thereon, and then subsequently summarizes them in the database to form a dataset of all defective hat tops identified by inkjet printing on the small rerolls of the hat top; the above-mentioned other raw and auxiliary material supply system 6 is used to process the hat body 02.

[0058] See Figure 1 and Figure 2The aforementioned cap sealing equipment 5 is used to composite each cap top 01 on the cap top reroller with the cap body 02 to form a cap. It includes a control computer 51, a programmable logic controller 52, a turntable 54, and a cap top feeding device 53 containing a punching and shearing device 531 located on the outer side of the turntable 54's cylindrical surface. The turntable 54 is used to transport the cap body 02. Before the cap top 01 and cap body 02 are composited, the control computer 51 compares the code recognition result of the code recognition device on the cap sealing equipment 5 with the aforementioned dataset of all defective cap tops, and determines whether the cap top 01 is a qualified cap top. If so, it controls the cap sealing equipment 5 to complete the composite processing of the cap. In this embodiment, the programmable logic controller... When the cap top 01 reaches its punch position, the controller 52 controls the punching and shearing device 531 to operate normally, punching and shearing the cap top 01 from the cap top rewinder and pasting it onto the top of the cap body 02, which has now reached its punch position, to composite process it into a plastic cap. Otherwise, the plastic cap sealing device 5 controls the plastic cap sealing device 5 to remove the defective cap top. In this embodiment, a rejection signal is generated and transmitted to the programmable logic controller 52 in real time. The programmable logic controller 52 controls the punching and shearing device 531 to not operate when the cap top 01 reaches its punch position, and the cap top feeding device 53 continues to convey the cap top 01 forward to achieve rejection. At the same time, the corresponding cap body 02 continues to rotate with the turntable 54 for the next composite processing cycle.

[0059] In this embodiment, the raw material quality control equipment 2 inspects the corresponding area 03 of each cap on the large rewind of the raw material after inkjet printing; the finished product quality control equipment 4 inspects the corresponding area 03 of each cap on the small rewind of the cap; and the online inspection equipment 7 for plastic cap sealing and lamination production inspects the laminated caps. All of these are inspected by their respective machine vision inspection devices.

[0060] See Figure 3 The present invention also provides a method for producing plastic caps that enables precise rejection of defective products, comprising the following steps:

[0061] Step 1: See Figure 1 and Figure 2 The above-mentioned plastic cap production system capable of accurate rejection of defective products is constructed. In this embodiment, the above-mentioned code recognition device in the plastic cap production system capable of accurate rejection of defective products constructed in step 1 is an OCR code recognition device.

[0062] Step 2: Encode the cap top corresponding area 03 on the large rewind of the cap top raw material, and the cap top code should meet the following conditions: the cap top code is unique; then use the inkjet printer 1 in the cap production system constructed in Step 1 to inkjet print the cap top corresponding area 03 on the large rewind of the cap top raw material in the area outside the respective cap top area according to its unique cap top code;

[0063] Step 3: The machine vision inspection device of the raw material quality control equipment 2 is used to inspect the corresponding area 03 of each hat top on the large reroll of raw material after inkjet printing in Step 2. At the same time, the code recognition device on it recognizes the inkjet printing of the corresponding area 03 of each hat top on the large reroll of raw material in Step 2. Then, the quality inspection result and the code recognition result of each corresponding area 03 of each hat top on the large reroll of raw material are correlated to obtain the defect information of the large reroll of raw material. In this embodiment, the code recognition device on the raw material quality control equipment 2 recognizes the inkjet printing of the corresponding area 03 of each hat top on the large reroll of raw material in Step 2 by recognizing the inkjet printing of the corresponding area 03 of each hat top on the large reroll of raw material through a deep learning-based OCR algorithm.

[0064] Step 4: Based on the information on the scrap rate of the large rewinding of the hat top raw material obtained in Step 3, determine whether the scrap rate of the large rewinding of the hat top raw material is less than or equal to N%, where N% is the required threshold for the scrap rate of the large rewinding of the hat top raw material; if not, proceed to Step 5; if yes, proceed to Step 6.

[0065] Step 5: Return the large re-rolled raw material for the hat top, select a new large re-rolled raw material for the hat top, and then return to Step 2;

[0066] Step 6: Store the waste information of the large re-rolled hat top raw material obtained in Step 3 into the database, and use the hat top raw material processing system 3 to process the large re-rolled hat top raw material that has been stored in the database into small re-rolled hat tops; In this embodiment, the process of the hat top raw material processing system 3 processing the large re-rolled hat top raw material that has been stored in the database includes: printing, gluing, die-cutting, slitting, etc. Figure 4 This is a schematic diagram of a section of the processed small re-rolled hat top laid flat, where 01 represents the hat top and 03 represents the area corresponding to each hat top;

[0067] Step 7: The machine vision inspection device of the finished hat top product quality control equipment 4 performs quality inspection on the corresponding area 03 of each hat top on the small reel of hat top processed in Step 6. At the same time, the code recognition device on it identifies the above-mentioned inkjet code of each corresponding area 03 of hat top on the small reel of hat top in Step 2. Then, the quality inspection result and the code recognition result of each corresponding area 03 of hat top on the small reel of hat top are correlated, and the information of defective hat tops caused by processing reasons on the small reel of hat top is stored in the database. In this embodiment, the code recognition device on the finished hat top product quality control equipment 4 identifies the above-mentioned inkjet code of each corresponding area 03 of hat top on the small reel of hat top in Step 2 by using an OCR algorithm based on deep learning to identify the inkjet code.

[0068] Step 8: Summarize the waste information of large rewinding of hat top raw materials stored in the database in Step 6 and the waste hat top information of small rewinding of hat tops due to processing reasons stored in the database in Step 7. Then, verify the images of all waste hat tops due to raw materials and processing reasons in the quality inspection system, eliminate erroneous waste data, and summarize the data in the database to form a dataset of all waste hat tops of small rewinding of hat tops identified by inkjet printing. The verification can be performed manually or by software. To further improve production efficiency, in this embodiment, after summarizing the dataset of all waste hat tops of small rewinding of hat tops identified by inkjet printing in the database, before installing the small rewinding of hat tops onto the hat top feeding device 53, a step is added to determine whether there is a situation where the number of consecutive waste hat tops on the small rewinding of hat tops is greater than or equal to a set threshold M for the number of consecutive waste hat tops. Therefore, step 8 of this embodiment is specifically as follows:

[0069] Step 8.1: Summarize the waste information of the large rewinding of the raw materials for the cap top stored in the database in Step 6 and the waste cap top information of the small rewinding of the cap top due to processing reasons stored in the database in Step 7, and verify the images of all waste cap tops due to raw materials and processing reasons in the quality inspection system, remove erroneous waste data, and summarize them in the database to form a dataset of all waste cap tops of the small rewinding of the cap top identified by inkjet coding;

[0070] Step 8.2: Based on the dataset of all defective hat tops compiled in the database in Step 8.1, determine whether there is a case where the number of consecutive defective hat tops is greater than or equal to M on the hat top mini-complex, where M is a set threshold for the number of consecutive defective hat tops; if yes, proceed to Step 8.3; if no, proceed to Step 9.

[0071] Step 8.3: Using the finished hat top quality control equipment 4, locate the positions of all consecutive defective hat tops on the small reroll where the number of consecutive defective hat tops is greater than or equal to M. Each time a position is located, cut off the consecutive defective hat top at that position, and then splice the cut ends together until the last cut end is spliced ​​together, resulting in a small reroll of hat tops with fewer than M consecutive defective hat tops. In this embodiment, the cutting and splicing in this step are done manually.

[0072] Step 9: Install the small rewinder at the top of the cap onto the cap feeding device 53, and turn on the other raw and auxiliary material supply system 6 and the cap sealing equipment 5.

[0073] Step 10: Using the code recognition device on the cap sealing equipment 5, the code of the cap 01 to be laminated that is located at the forefront of the conveying direction of the cap 01 before reaching the punch position of the punching device 531 on the cap top rewinding device 53 is identified in step 2, and the identified code is transmitted to the control computer 51 in real time. The control computer 51 compares the code with the dataset of all the defective caps compiled in the database in step 8 in real time. In this embodiment, the code recognition device on the cap sealing equipment 5 identifies the code of the cap 01 to be laminated that is located at the forefront of the conveying direction of the cap 01 before reaching the punch position of the punching device 531 on the cap top rewinding device 53 in step 2 by using a deep learning-based OCR algorithm.

[0074] Step 11: Based on the comparison results in Step 10, determine whether the cap top 01 is a qualified cap top; if not, proceed to Step 12; if yes, proceed to Step 13.

[0075] Step 12: Generate a rejection signal and transmit it to the programmable logic controller 52 in real time. The programmable logic controller 52 controls the punching and shearing device 531 to not move when the cap top 01 reaches its punch position. The cap top feeding device 53 continues to convey the cap top 01 forward to achieve rejection. At the same time, the corresponding cap body 02 continues to rotate with the turntable 54 for the next composite processing cycle. During the rotation, other raw and auxiliary material supply systems 6 do not input the cap body 02 to the cap body receiving end 541 of the turntable where the cap body 02 is located. Then, proceed to step 14.

[0076] Step 13: The programmable logic controller 52 controls the punching and shearing device 531 to operate normally when the cap top 01 reaches its punch position, punching and shearing the cap top 01 from the cap top rewinder and attaching it to the top of the cap body 02, which has now reached its punch position (see...). Figure 4 While punching out the top 01 of the cap, the inkjet code outside the area of ​​the top 01 on each cap corresponding to the area 03 is also removed, so as to composite the cap into a plastic cap. The composite plastic cap is then conveyed forward through the turntable 54 for collection.

[0077] Step 14: Determine whether there is a cap top 01 to be composite processed on the small rewinder of the cap top installed on the cap top feeding device 53 that has not reached the punch position of the punching and shearing device 531; if yes, return to step 10; if no, proceed to step 15.

[0078] Step 15: Use the machine vision inspection device of the online inspection equipment 7 for plastic sealing and lamination production to inspect the plastic caps collected in Step 13 to remove defective plastic caps and complete the production of plastic caps.

[0079] In summary, this invention enables a precise defect-removing production system and method for caps. By adding a coding device to the front end of the raw material quality control equipment at the cap top, and adding a code recognition device to the raw material quality control equipment, the finished cap product quality control equipment, and the cap sealing equipment, the coding is integrated horizontally into the quality information of the cap top from raw materials to finished products during the processing. Then, through code recognition, the precise removal of defective cap tops from the small rewinding process is achieved. Using this precise defect-removing cap production system and method significantly reduces production quality risks and greatly improves production efficiency. It also avoids the waste of qualified cap bodies and other auxiliary materials caused by defective cap tops, saving production costs. The system digitizes cap top product data, enabling refined control of cap top production and precise execution of cap composite quality management. It allows for effective analysis and traceability of quality data, continuously improving quality control in the production process, forming a closed-loop quality management system, reducing the occurrence of predisposed defects, and comprehensively improving the quality of caps.

Claims

1. A cap production system capable of precise waste rejection, comprising a cap top raw material processing system (3), other raw and auxiliary material supply system (6), cap sealing equipment (5), and a quality inspection system; the cap top raw material processing system (3) is used to process the cap top raw material into a cap top small rewinding; the other raw and auxiliary material supply system (6) is used to process the cap body (02); the cap sealing equipment (5) is used to composite each cap top (01) on the cap top small rewinding with the cap body (02) to form a cap, comprising a control computer (51), a programmable logic controller (52), a turntable (54), and a cap top feeding device (53) containing a punching and shearing device (531) disposed on the outer side of the cylindrical surface of the turntable (54); the turntable (54) is used to transport the cap body (02); the quality inspection system comprises a cap top raw material incoming quality control equipment (2), a cap top finished product outgoing quality control equipment (4), and a cap sealing composite production online inspection equipment (7); characterized in that: It also includes a coding device (1) installed at the front end of the quality control equipment (2) for raw materials entering the hat top, where the front end refers to the side that comes first in the process; the coding device (1) is used to code each area (03) of the hat top on the large re-roll of the raw materials for the hat top according to its unique hat top code. The quality inspection system also includes a code recognition device installed on the raw material incoming quality control equipment (2), the finished product outgoing quality control equipment (4), and the plastic sealing equipment (5) of the cap. The raw material quality control equipment (2) for the top of the hat and the finished product quality control equipment (4) for the top of the hat are respectively used to inspect the corresponding area (03) of each top on the large re-roll and small re-roll of the raw material of the top of the hat after inkjet printing. The inspection results of each are associated with the identification results of the identification device on each and stored in the database. The database is used to summarize and form a dataset of all defective tops of the small re-roll of the top of the hat with inkjet printing as the identifier. The control computer (51) is used to compare the code recognition result of the code recognition device on the cap sealing equipment (5) with the dataset of all defective cap tops before the cap top (01) and cap body (02) are composite processed, and to determine whether the cap top (01) is a qualified cap top; if so, the control computer (5) is used to complete the composite processing of the cap; if not, the control computer (5) is used to remove the defective cap top.

2. The cap production system capable of precise rejection according to claim 1, characterized in that: The raw material quality control equipment (2) inspects the area (03) of each cap on the large rewind of the raw material after inkjet printing. The finished product quality control equipment (4) inspects the area (03) of each cap on the small rewind of the cap. The plastic cap sealing composite production online inspection equipment (7) inspects the composite processed plastic cap. All of these are inspected by their respective machine vision inspection devices.

3. The cap production system capable of precise rejection according to claim 1, characterized in that: The coding device (1) is a laser coding machine or a small character coding machine.

4. The cap production system capable of precise rejection according to claim 1, characterized in that: The cap code is a hybrid character code, barcode, or QR code.

5. The cap production system capable of precise waste rejection according to claim 1, characterized in that: The code recognition device is an OCR code recognition device.

6. A method for producing rubber caps that enables precise rejection of defective products, characterized in that, Includes the following steps: Step 1: Construct the cap production system as described in claim 1, which enables precise rejection of defective products; Step 2: Code the cap top of each area (03) corresponding to the cap top on the large rewind of the cap top raw material. The cap top code should meet the following conditions: the cap top code is unique. Then, use the inkjet printer (1) in the cap production system constructed in Step 1 to inkjet print the cap top of each area (03) corresponding to the cap top on the large rewind of the cap top raw material in the area outside the cap top area according to its unique cap top code. Step 3: The machine vision inspection device of the raw material quality control equipment (2) is used to inspect the area (03) of each hat top on the large reroll of raw material after inkjet printing in Step 2. At the same time, the code recognition device on it recognizes the inkjet printing in Step 2 on the area (03) of each hat top on the large reroll of raw material. Then, the quality inspection result and the code recognition result of each area (03) of each hat top on the large reroll of raw material are correlated to obtain the waste information of the large reroll of raw material. Step 4: Based on the large rewinding scrap information of the hat top raw material obtained in Step 3, determine whether the large rewinding scrap rate of the hat top raw material is less than or equal to N%, where N% is the required threshold for the large rewinding scrap rate of the hat top raw material; if not, proceed to Step 5; if yes, proceed to Step 6. Step 5: Return the large re-rolled raw material for the hat top, select a new large re-rolled raw material for the hat top, and then return to Step 2; Step 6: Store the information on the large re-rolled waste of the hat top raw material obtained in Step 3 into the database, and use the hat top raw material processing system (3) to process the large re-rolled hat top raw material that has been stored in the database into small re-rolled hat tops. Step 7: The machine vision inspection device of the finished hat top product factory quality control equipment (4) is used to inspect the corresponding area (03) of each hat top on the small rewind of the hat top processed in step 6. At the same time, the code recognition device on it recognizes the inkjet code of each corresponding area (03) of the hat top on the small rewind of the hat top in step 2. Then, the quality inspection result and the code recognition result of each corresponding area (03) of the hat top on the small rewind of the hat top are correlated, and the information of defective hat tops caused by processing reasons on the small rewind of the hat top is stored in the database. Step 8: Summarize the waste information of the large rewinding of the raw materials for the cap top stored in the database in Step 6 and the waste cap top information of the small rewinding of the cap top due to processing reasons stored in the database in Step 7, and verify the images of all waste cap tops due to raw materials and processing reasons in the quality inspection system, remove erroneous waste data, and summarize them in the database to form a dataset of all waste cap tops of the small rewinding of the cap top identified by inkjet coding; Step 9: Install the small rewinder at the top of the cap onto the cap feeding device (53), and turn on the other raw and auxiliary material supply system (6) and the cap sealing device (5); Step 10: Using the code recognition device on the cap sealing equipment (5), the cap tops (01) to be composited that have not reached the punch position of the punching and shearing device (531) on the cap top feeding device (53) installed on the cap top small rewinder are identified by the inkjet code in step 2 of the cap tops (01) to be composited that are at the forefront of the cap top (01) in the transmission direction of the cap top (01), and the identified inkjet code is transmitted to the control computer (51) in real time. The control computer (51) compares the data with the dataset of all waste cap tops compiled in the database in step 8 in real time. Step 11: Based on the comparison results described in Step 10, determine whether the cap top (01) is a qualified cap top; if not, proceed to Step 12; if yes, proceed to Step 13. Step 12: Generate a rejection signal and transmit it to the programmable logic controller (52) in real time. The programmable logic controller (52) controls the punching and shearing device (531) to not move when the cap top (01) reaches its punch position. The cap top feeding device (53) continues to convey the cap top (01) forward to achieve rejection. At the same time, the corresponding cap body (02) continues to rotate with the turntable (54) for the next composite processing cycle. During the rotation, other raw and auxiliary material supply systems (6) do not input the cap body (02) to the cap body receiving end (541) of the turntable where the cap body (02) is located. Then, execute step 14. Step 13: The programmable logic controller (52) controls the punching and shearing device (531) to operate normally when the cap top (01) reaches its punch position, punching and shearing the cap top (01) from the cap top rewinder and pasting it onto the top of the cap body (02) that has reached its punch position at this time, so as to composite process into a plastic cap, and then continue to transport the composite plastic cap forward through the turntable (54) for collection; Step 14: Determine whether there is a cap top (01) to be composite processed on the small rewinder of the cap top installed on the cap top feeding device (53) that has not reached the punch position of the punching and shearing device (531); if yes, return to step 10; if no, proceed to step 15. Step 15: Use the machine vision inspection device of the online inspection equipment (7) for plastic sealing composite production of the plastic caps to perform quality inspection on the plastic caps collected in step 13, so as to remove the defective plastic caps and complete the production of plastic caps.

7. The method for producing rubber caps with precise waste rejection according to claim 6, characterized in that: In the cap production system that enables precise rejection of defective products constructed in step 1, the code recognition device is an OCR code recognition device. In steps 3, 7, and 10, each code recognition device identifies the inkjet code using a deep learning-based OCR algorithm.

8. The method for producing rubber caps with precise waste rejection according to claim 6, characterized in that: Step 8 specifically involves: Step 8.1: Summarize the waste information of the large rewinding of the raw materials for the cap top stored in the database in Step 6 and the waste cap top information of the small rewinding of the cap top due to processing reasons stored in the database in Step 7, and verify the images of all waste cap tops due to raw materials and processing reasons in the quality inspection system, remove erroneous waste data, and summarize them in the database to form a dataset of all waste cap tops of the small rewinding of the cap top identified by inkjet coding; Step 8.2: Based on the dataset of all defective hat tops compiled in the database in Step 8.1, determine whether there is a case where the number of consecutive defective hat tops is greater than or equal to M on the hat top mini-complex, where M is a set threshold for the number of consecutive defective hat tops; if yes, proceed to Step 8.3; if no, proceed to Step 9. Step 8.3: Using the finished product quality control equipment (4), locate the positions of the continuous defective hat tops on the small reroll of the hat top one by one where the number of continuous defective hat tops is greater than or equal to M. When each position is located, cut off the continuous defective hat top at that position, and then splice the cut ends together until the last cut ends are spliced ​​together to obtain a small reroll of the hat top where the number of continuous defective hat tops is less than M.

9. The method for producing rubber caps with precise waste rejection according to claim 8, characterized in that: In step 8.3, when each location is identified, the continuous waste cap tops at that location are manually cut off, and then the cut ends are spliced ​​back together.

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