In the field of precision plastic mold manufacturing, even the tiniest defects—such as a missing pin, a short needle, metal shavings, deformed terminal rings, or excess metal on connectors—can lead to product failure and costly recalls. Traditional manual inspection is inefficient, prone to fatigue, and suffers from high miss rates, becoming a bottleneck in quality control and cost management.

Now, advanced vision inspection equipment, built on a servo tray inspection machine platform, delivers high precision, speed, and intelligence—revolutionizing plastic mold quality assurance.

Servo Tray Inspection Machine: Precision Meets Efficiency

The core of this solution is a high-precision servo-driven tray handling system, ensuring accurate positioning and fast transfer of molds (inspection cycle time ≤5 sec/piece). The system integrates three high-resolution CCD industrial cameras, forming a comprehensive inspection "eye" with no blind spots:

• Top-mounted high-resolution area-scan camera: Equipped with a telecentric lens for global imaging of the mold’s top surface and key structural features.

• Top coaxial ring-light camera: Specialized for reflective metal surfaces and tiny contaminants (e.g., metal shavings), providing shadow-free, high-contrast imaging.

• Bottom high-precision camera: Focused on detecting the mold’s underside, holes, and terminal base details.

Targeting Five Critical Defects—Backed by Data

Powered by AI-powered vision algorithms, this vision inspection equipment reliably identifies and quantifies key defects with an accuracy of ±0.015mm:

• Missing/Short Pins (Detection Rate >99.99%)

  Uses template matching and dimensional measurement to instantly verify pin presence and length compliance (e.g., pin length must be ≥1.50mm ±0.03mm).

  Test data shows near-100% detection for pins as small as 0.4mm in diameter.

•  Metal Shavings/Foreign Particles (Minimum Detectable Size: 0.03mm²)

  Leverages high-contrast imaging from the ring-light camera and advanced texture/spot detection algorithms to distinguish metal debris, plastic burrs, and other contaminants.

• Deformed Terminal Rings (Accuracy ±0.02mm)

  Performs sub-pixel edge extraction and roundness/position analysis to detect ovality, eccentricity, or dents (e.g., roundness tolerance <0.05mm), ensuring reliable electrical connections.

1. Excess Metal/Contaminants on Connectors

   The bottom camera, combined with specialized lighting, clearly captures terminal areas. Metal reflection analysis and feature comparison detect misplaced metal inserts or residual metal fragments.

Three Key Advantages—Redefining Quality Control

Near-Zero Miss Rate: 3-CCD synergy + AI algorithms ensure 360° coverage, reducing defect escape rates to <0.001%, far surpassing manual inspection (typically >3%).

300% Efficiency Boost: High-speed servo tray handling + millisecond-level image processing enables 720 inspections/hour, seamlessly integrating with automated production lines.

Data-Driven Decisions: Real-time defect reports (with images, locations, and measurements) and SPC statistical analysis support process optimization, improving yield by 5%-15% (verified in customer cases).

Conclusion

The servo tray-based plastic mold vision inspection system, with its 3-CCD imaging, AI algorithms, and precision servo control, establishes an unbreakable "zero-defect" defense for plastic mold manufacturing. Eliminate inspection risks and ensure no flaw goes undetected—this is the essential step toward higher product quality, lower costs, and smarter manufacturing.

Choosing professional vision inspection equipment means choosing absolute control over quality.