Color sorter performance and quality evaluation
With the in-depth development of China's reform and opening up situation, the comprehensive national strength is getting stronger and stronger, the people are getting richer, the living standards of the citizens are getting higher and higher, people pay more and more attention to the accuracy and hygiene of food, and the raw materials for processed foods. The requirements for precision and purity are also becoming more stringent. The quality of many high-grade food materials has been significantly improved after color selection, and the value has doubled. The application of the color sorter in China was first developed rapidly in the rice industry, followed by development in the fields of seeds, oil extraction and fruit. Recently, China has taken the lead in successfully applying color-selection technology to the larger-scale flour processing industry, enabling it to produce high-grade food-specific flours with higher grades and purer textures, with excellent market response. 1, the type of color sorter 1.1 Color Sorter Identification System 1.2 color sorter performance level 2, the function of the color sorter The color sorting machine can be divided into one-way and two-way from the detection structure, and can be divided into two types: one-time selection and second-checking. 3, the color index machine process indicators 3.1, processing capacity 4, the difference between rice and wheat color sorting machine The rice color sorting machine refers to the color sorting machine used in rice factory to produce refined rice. It is mainly used to select rice grains with yellow and black lesions. It has been used in foreign countries for decades and used color selection in rice factories in China. The machine is a matter after the reform and opening up. The wheat color sorting machine is used in the processing of high-precision flour in the flour mill. It is mainly used to remove black impurities and mildew granules and black granule wheat in wheat. Its history is very short. It was developed by our scientific and technical personnel in 2001. Successfully, it was first used in the 1000t flour production line of Zhengzhou Jinyuan Noodle Co., Ltd. The output of rice color sorting machine is relatively small, because the proportion of rice grains containing yellow spots and black spots in rice is relatively large, generally about 5%~10%; the output of wheat color sorting machine is large, the reason It is the color sorter installed in the last process before the wheat is milled. After one clean and second cleaning of the wheat, about 90% of the black impurities (including organic impurities and inorganic impurities) have been removed, and the remaining black impurities account for only A few thousandth of the total amount of wheat flow (if the proportion of moldy grains and black granules increases, it is another case). The output of the rice color sorter is 50~100kg per channel, and the output of the wheat color sorter can reach 150~250kg per channel. The same 96-channel color sorter can handle about 6t/h of rice and 12~15t/h of wheat. The above-mentioned color sorting machines are all equipped with a CCD sensor recognition system, and if the conventional sensor recognition system is configured, the effect is much worse. Therefore, when selecting a color sorter, it is first necessary to clarify the object to be processed and its impurity, otherwise it will not achieve the desired effect. 5, the use of color sorter
Since the role of the color sorter is valued by many people of insight, the color sorter market has been optimistic in recent years, producers have a lot of profit, and the entire color sorter market is getting bigger and bigger. China's color sorter market generally has three aspects: 1. In the early stage of reform and opening up, it was mainly introduced, and most of the exporting countries are industrial developed countries, such as the United States, Germany, Japan, etc., the price is very expensive; 2. Entering the 20th century In the era, some enterprises in China began to imitate, while some Sino-foreign joint ventures were established, and foreign technology production was introduced. Their performance is close to imported products, and the price is relatively cheap. 3. In recent years, some enterprises in China have absorbed and absorbed the latest foreign technology and independently developed. Based on CCD sensor, the latest performance high-grade color sorter has a high starting point and rapid development. Its performance can be comparable with that of imported products, but the price is not high, which makes many companies economically affordable and popular with most companies. In order to cope with the challenge of imported flour, the flour industry needs to improve its product quality. Therefore, the application range of the color sorter is becoming wider and wider, and the role presented is more and more important.
The types of color sorters vary, and their performance, quality and price vary widely. How to comprehensively examine the performance of the color sorter, the quality of the quality, in order to choose the high-performance price ratio of the color selection equipment, is not an easy thing for the user, must have a certain understanding of the color sorter knowledge . From a technical point of view, the following aspects should be known. Related reading: melon color sorting machine
The heart of the color sorter is the identification system. The core of the identification system is the sensor. The sensors of the color sorter are mainly classified into two types: a conventional sensor type (photocell, a silicon photocell, etc.) and a CCD (or MOS) sensor type. The sensor consists of an optical system and a photoelectric conversion device. Its function is to accurately identify the particles of different colors from the high-speed flow, and quickly react and blast through the other components of the configuration.
Early color sorters used photocells, photodiodes, and silicon photocells to detect optical signals. The biggest advantage is that the cost is low, production, debugging, and fabrication are easy. The subsequent signal processing circuits are simple, and the matching optical system is adopted. The simple electric eye consists of two simple lenses that do not need to be adjusted and cost less. Its disadvantage is low resolution, poor recognition ability for particles with small lesions and light colored impurities. Because this type of color sorter uses only one sensor per slide, it observes the total light signal in the entire slide range, and cannot distinguish several rice grains or wheat flowing down simultaneously in one slide. The respective colors of the grains. For example, if there is a black spot and a white spot on a grain of rice, then its signal is a signal of normal rice that is not black or white, and the light yellow spotted rice signal may also be brightened by other colors. The signals are averaged and cannot be identified. At the same time, its optical system has poor image quality, the optical path cannot be adjusted, and the consistency is poor, which directly affects the performance of the color sorter, which inevitably limits the production capacity and color selection effect of the color sorter.
With the development of science and technology, the international mainstream color sorting machines have adopted advanced devices as identification systems. The device is an array of tiny photosensors that use high-quality camera-specific high-definition lenses. For each material flowing in each channel range, there are usually several to dozens of identical sensors. Independent detection (can be compared to a compound eye structure, while a monolithic silicon photo cell is a monocular structure). In this way, a grain of rice is also divided into several parts and observed by different photoelectric units. The tiny lesions or pale yellow rice grain signals are not averaged by other signals, and the rice grains or grains of the lesions in the case of large flow rate. As well as heterochromatic impurities can be accurately identified, which can improve the production capacity and quality of the color sorter, and can be well adapted to small particle materials such as sesame.
In addition, the color sorter made by technology has different performance grades. One is a color sorter that can only detect one color, such as color-selected rice, or only yellow or yellow rice, or only It can identify white or white heavier white rice grains; another design color sorter is used for rice color selection. It can not only recognize yellow or yellow rice, but also recognize white or belly white rice. Both functions can be considered at the same time. Such a color sorting machine can be used for two tops. Of course, the manufacturing cost of this color sorting machine will increase accordingly, but it is lower than the cost of two single-function color sorting machines. Most users are the biggest beneficiaries.
The color sorting machine using silicon photocells must have a set of discrete signal detection, conversion, amplification and processing systems. Each circuit has a large number of components and a large number of circuit boards, which inevitably reduces the reliability of the system and causes the equipment to be stable. Poor sex. The color sorting machine of the configuration technology adopts a large-scale integrated system, optical imaging, and signal processing are detected by a system using a high-speed scanning method, so that the reliability of the device is much higher. Therefore, the color sorting machine adopting technology is superior to the performance of the silicon light battery color sorting machine, and the output is relatively large, which should be the first choice for users to purchase equipment.
Old-fashioned color sorters use one-way inspection. They only observe the material from one direction. For particles with disease spots on the back or materials that are blocked when they overlap, they cannot be detected and are leaked. Therefore, in principle, it is imperfect. The two-way detection is observed simultaneously from the front and rear directions. It overcomes the defects of one-way detection, and is therefore a more advanced and more complete color sorting machine. At the same time, it can greatly increase the output and increase the stability of the color sorter. Sex and reliability.
The primary color sorter selects only one material, and contains more normal rice or wheat grains in the secondary material. Usually, when the user accumulates a certain amount, the color sorting machine is used again to re-color the color once, which is laborious, time consuming, and troublesome. If you want to make a color selection without secondary color selection, it is to reduce the output to a certain level to reduce the ratio of good rice grains or good wheat grains in the waste. This method is too expensive and generally not willing to use. . The color sorting machine with secondary re-selection automatically re-selects the secondary material containing more normal particles after one color selection, and is equipped with a returning device such as a hoist, which is equivalent to having two machines simultaneously performing two Level color selection. Therefore, the color sorting machine with secondary re-selection can minimize the content of good rice and good wheat in the waste, saves a lot of manpower and time, and is also beneficial to the improvement of production and color selection precision.
The working indicators of the color sorter mainly have the following three aspects:
The throughput is the amount of material that can be processed per hour in 1/h. Factors affecting the amount of processing In addition to the configuration and structure of the color sorter identification system described above, there is an important factor that is the specification. The size of the general color sorter is determined by the number of channels configured, and the color sorter Specifications generally range from 32, 48, 80, 96 and 128 channels. At the same time, the amount of treatment is closely related to the size of the raw materials and the proportion of impurities contained therein, as well as the required accuracy of the selection.
3.2, the selection rate
The selection rate refers to the percentage of impurities selected from the original grain as a percentage of the total amount of impurities contained, which is also called color selection accuracy. The factors affecting the selection rate are mainly determined by the type of flow and color sorter, that is, the performance. Generally speaking, the CCD method is higher than the silicon photocell method, and the reselected structure is better than the single-selective structure. The selection rate of the color sorting machine with CCD sensor technology can reach more than 99%, and the ordinary color sorting machine with one color selection of the traditional sensor is difficult to reach the calibration index in actual production. In addition, the selection rate is high or low. It is also affected by the height of the ratio.
3.3, bring out the ratio
The take-out ratio refers to the ratio of the amount of impurities in the waste selected by the color sorter to the normal rice or grain. The ratio of the take-out ratio can be set, generally about 1.3~1.5. If the take-out ratio is too high, it will affect the two indexes of the selection rate and the throughput. If it is set too low, the selected waste will be selected. If there are too many normal rice grains or wheat grains in the middle, it will cause waste. If it is processed again, it will require a certain amount of manpower and material resources, which will cause a lot of trouble and economic loss.
In fact, in the daily production, the processing volume, the selection rate and the take-out ratio are all integrated, and they are all indispensable. They are all key indicators and must be examined at the same time. In the rated processing capacity of the equipment to be calibrated to achieve the established selection rate and take-off ratio, there are many manufacturers of color sorting machines in the actual production is far from reaching, should pay attention to more inspections, more comparisons. In addition, it is necessary to examine the actual impurity content and impurity type of the original grain. If the proportion of impurities contained in the selected material is small and very simple, it is another case, which should be based on actual indicators. The rice color sorting machine usually has impurities within 5%, and the wheat color sorter impurities are usually within 1%, otherwise the production should be reduced.
The long-term stability of the color sorter is very important. The stability of the 6-color sorter is directly or not, which directly affects the user's production and efficiency. Many color sorters have just been debugged, and the performance is greatly reduced after a period of time, even without much effect, requiring frequent maintenance and re-commissioning. Most of this is due to the low stability of the optical system consisting of the light source, background and imaging system of the color sorter, especially on equipment using a simple optical system. The application environment of the color sorter has more dust and dust, and the vibration and interference are also large. The change of temperature and the difference of rice and wheat will affect the working state of the color sorter, causing the detection signal to be inaccurate or controlling the high pressure valve to open. The change in the delay time thus affects the accuracy of the blowing action of the impurities. In order to improve the stability of the equipment, in addition to the use of high-stability light sources and high-quality imaging lenses, the corresponding control technology should be used to compensate for the impact of environmental changes on the color sorter, and automatically adapt to different grain sources and Miscellaneous conditions, so that the color sorter can always maintain the best working condition.
In summary, when selecting a color sorter, the focus is on the advancement of the technical performance of the color sorter, the reliability of the equipment quality, and the long-term stability of the use. It should be comprehensively consulted and widely compared. Because the color sorter is a high-tech product, the price is much more expensive than ordinary grain processing equipment. Therefore, when choosing a color sorter, be cautious and careful, and make a basic understanding of the products of different manufacturers, choose a satisfactory product, let it play. Out of the investment benefits.