1. Project Overview

In the packaging and printing industry, box pasting serves as the final forming process, and its glue application quality determines the pass rate of finished products. Traditional manual visual sampling inspection or hand testing carries huge risks of missed detection on modern high-tempo production lines, which may easily lead to cartons with glue overflow adhesion or insufficient glue dehiscence entering the market.

The ZY-TYPETNL400 glue volume inspection system is an intelligent on-line quality control solution custom-developed for folder gluers. Fitted with high-precision industrial sensors and an intelligent central control unit, the system scans glue volume and shape on high-speed moving cartons to effectively intercept defects such as excessive glue, insufficient glue, broken glue and skewed cartons. Integrated with automatic rejection/stop linkage and digital report functions, it realizes unmanned sampling inspection and digital quality control for the box pasting process.

2. System Working Principle

The system adopts industrial automatic control logic of "intelligent optical scanning + dynamic speed matching + closed-loop rejection control".

2.1 Triggering & Synchronization:

When cartons enter the conveyor belt of the folder gluer, the system tracks production line speed in real time via an encoder (supporting dynamic variable speed from 20 to 400 m/min).

2.2 High-speed Inspection:

After cartons pass the roller glue / spray glue station, dedicated high-precision sensors dynamically scan the 6mm-wide glue track at millisecond-level response speed to capture glue thickness, continuity and the position & shape of cartons.

2.3 Intelligent Comparison:

The central control unit conducts high-speed algorithm comparison between real-time collected data and the standard template generated via one-click system learning. It can identify broken glue as thin as 1mm and slight carton skew.

2.4 Closed-Loop Execution:

Qualified Judgment: Products pass normally, and the system automatically records output and pass rate statistics.

Defect Judgment (Excessive / Insufficient / Broken Glue, Skew): The system outputs control signals to link the folder gluer for on-line pneumatic rejection or trigger feeder alarm and shutdown to ensure defective products are removed.

3. Core Technical Advantages

Plug-and-Play, Zero Technical Threshold: Compact unit with fully concealed internal wiring. Equipped with a full-graphical 12-inch touch screen with intuitive interface, supporting one-click startup and autonomous intelligent learning. Easy for operators to master; system adjustment takes less than 1 minute to greatly reduce machine setup and product changeover time.

Ultra-fast Response & Matching: Inspection speed reaches 300~400 m/min (matching an output of around 100,000–130,000 pieces per hour), compatible with most mainstream high-speed folder gluers on the market.

Micron-level High-precision Capture: Sensor inspection width is 6mm, minimum detectable broken glue width is 1mm, and accurate triggering is available with carton spacing over 10mm. It avoids the defect of traditional vision systems susceptible to ambient light interference.

Digital Production Management: Built-in digital statistics module generates real-time production statistical reports and historical records for visualized quality data, facilitating lean production management and quality traceability for enterprises. Low Consumption, High Efficiency, Safe & Reliable: Total power consumption is only about 200W with air consumption of 0.4 m³/min. No modification to the original mechanical structure of the folder gluer, delivering quality assurance at ultra-low operating costs.

4. Applicable Industries & Scenarios

4.1 Applicable Industries

This solution is widely used in industries with strict packaging quality requirements: Pharmaceutical Packaging Industry: Drug boxes have stringent drug supervision standards against dehiscence and glue overflow; the system ensures safe forming of pharmaceutical cartons.

Cosmetic & Light Luxury Packaging: Premium cardboard gift boxes and cosmetic boxes requiring zero surface contamination from overflow glue.

Food & Electronic Product Packaging: High-speed production lines for mass-produced food boxes and 3C electronic accessory boxes with high line tempo.

4.2 Applicable Materials & Limitations

Fully Applicable Materials: Standard cardboard and grey-backed white board paper with basis weight ranging from 200 to 450 g. Inapplicable Materials: Gold and silver cardboard, corrugated paper, aluminum foil paper.

5. Solution Summary

By retrofitting this system onto existing folder gluers, enterprises can realize automatic in-process interception with reasonable equipment upgrade investment and simple operation requirements. While significantly improving production capacity utilization (supporting 130,000 pieces per hour), it effectively mitigates risks of returns, rework and customer churn caused by abnormal glue volume.