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Servo Camera Counting Machine
1. Equipment Overview
Infrared sensor counting systems have been used in electronic pill counters for over 20 years. However, they cannot distinguish small pills or detect stacked pills. They are prone to overcounting when pills are dusty and to miscounting when counting transparent fish oil capsules. These are the main limitations of this sensor technology, whereas camera-based counting has resolved these issues. The sensors used in photographic counting were initially deployed on a large scale in various photocopiers. Today, this technology is widely used in many industrial inspection devices and rice sorting machines. Israel’s DATA Company was a pioneer in applying this technology to electronic pill counters. However, due to the high initial investment costs and the lack of sufficiently optimized supporting software for electronic pill counters, its application remained extremely limited. Our company first developed infrared electronic counting sensors and control systems in 2011. In 2016, we introduced a counting sensor that combines a line-scan CCD camera with a high-speed ARM processor to replace traditional infrared counting systems—a major technological breakthrough that has revolutionized electronic counting machines.
CCD sensors are widely used across various industries, and it is well known that ARM processors are primarily used in the mobile phone industry, with new models and upgrades released annually. Therefore, for this product we have developed, we have utilized stable and mature components for everything from signal acquisition to signal processing.
2. Performance Features
2.1 The machine is a new model with compact structure and nice appearance. The shell of the whole machine is made of aluminum alloy material and high-quality 304 stainless steel plate, which meets the GMP requirements. The entire machine is lightweight and easy to handle.
2.2 Channel vibration is adopted for uniform feeding and stable operation with low noise;
2.3 The machine adopts visual inspection for automatic counting, which is very accurate, and bottling error is less than the national standard.
2.4 Simple operation, easy to disassemble, clean and replace parts;
2.5 The main transmission part of the machine is placed in the box to avoid the pollution of the material caused by the transmission mechanism wear and other reasons. The part in contact with the material is polished with high precision. And the machine is equipped with dust removal box to reduce dust pollution.
2.6 All system control components have international standardized certification with strict admission test to ensure the reliability of various functions.
2.7 The 16 channels adopt three-stage vibration feeding and spring combined vibration module so that the feeding status is more uniform and smooth.
2.8 Material identification uses the combination of linear array CCD camera and high-speed ARM processor with high resolution, accurate recognition and dust prevention. The equipment has a self-diagnosis system, which can detect and remove the debris, further ensuring the accuracy of counting.
2.9 The nozzle will firmly cover the bottle mouth, to ensure that the large material does not block during filling and the small one does not leak; The vibration device of the feeding nozzle ensures smooth feeding and avoid material blockage at bottle mouth, further ensuring the counting accuracy. Machine will automatically stop when detected with bottle shortage and bottle jam. Otherwise it will automatically start up and work.
2.10 CCD counting system is functioned with automatic light supplement and strong anti-dust ability It can ensure the counting precision even for large dust from plain tablet. The machine can keep running for a long time with accurate counting.
The whole equipment runs reliably, the replacement of drug specifications is simple and convenient, the control system of the equipment can store the working parameters of various drugs, and the HMI is user-friendly so that the general operator can master it.
Technical specifications are detailed in the table below for quick reference:
| Specification | Parameter |
|---|---|
| Equipment Name | Modular Visual Servo Rotary Gate Counting Machine |
| Model | CBPS-D16 |
| Production Speed | Max. 12,000 pcs/min (Varies by product and count) |
| Count per Bottle | 1-9999 (freely settable) |
| Applicable Product Size | Tablets (Ø 2-23mm), Capsules (0-5#), Pills (Ø 2-12mm) |
| Applicable Bottle Volume | 15 - 500 ml |
| Voltage / Frequency | Single Phase AC 220V, 50/60Hz |
| Air Pressure Source | 0.6 MPa |
| Dimensions (L×W×H) | 2200 × 1900 × 1850 mm (Height adjustable) |
| Power | 1.2 Kw |
| Air Consumption | 150 L/Min |
| Weight | 750 Kg |
3. Main Applications and Scope of Use
This equipment is primarily suitable for the pharmaceutical, chemical, and food industries. It is a mechatronic counting and filling machine designed for accurately counting and filling products such as tablets, pills, and capsules. By automating the counting and filling processes, it significantly improves labor productivity and eliminates the risk of contamination caused by manual counting and filling. This machine can be used independently or integrated into a continuous production line with other auxiliary equipment, such as bottle sorters, bottle cleaners, inserters, corkers, cappers, sealers, and labelers.
Benefits for customers include reduced labor costs, faster production cycles, and compliance with industry regulations. For instance, the vision system ensures consistent counts, preventing costly errors in packaging, while the automated process frees up staff for higher-value tasks. This leads to a quick ROI and scalable growth for businesses of all sizes.
With a 30,000-50,000 square meter factory and a dedicated team of 101-200 professionals, Zhejiang Zhong Shark guarantees reliable manufacturing and support. We serve diverse markets including North America, Europe, and Asia, with efficient shipping from Shanghai and Ningbo ports. Trust in our ISO9001-certified processes for consistent quality and on-time delivery. Elevate your operations with the BPS-D8—contact us today for a quote or consultation to tailor this solution to your specific needs.
FAQ:
Q: How accurate is the counting process? A: The machine achieves up to 99.9% accuracy using advanced vision sensors to detect and verify each item, reducing miscounts.
Q: Can it handle different pill sizes and shapes? A: Yes, it's fully customizable; adjustments can be made via the interface for various dimensions and forms.
Q: What maintenance is required? A: Minimal upkeep is needed; regular cleaning and occasional calibration ensure optimal performance.
Q: Is training provided for operators? A: Absolutely; we offer comprehensive installation support and training sessions to ensure smooth operation.
Q: What is the warranty coverage? A: A standard one-year warranty is included, with options for extension available upon request.
Q: Can it integrate with existing production lines? A: Yes, the design allows seamless integration with conveyors and packaging systems for automated workflows.
Q: How does it handle fragile items like capsules? A: Gentle handling mechanisms prevent damage, with adjustable speed settings for delicate products.
Q: What certifications does it have? A: It holds ISO9001 and other relevant certifications, ensuring compliance with international standards.
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