Selection and Application Guide for Cleaning Technology Scheme of CCD Industrial Camera for Visual Labeling Machine

1、 The necessity and challenges of cleaning CCD industrial cameras

The core component of the visual labeling machine, the CCD industrial camera, directly affects the accuracy of label positioning in terms of imaging quality. Dust, oil stains and other pollutants can increase image noise and positioning errors exceeding ± 0.1mm. According to statistics, 90% of labeling machine failures are caused by failure to clean CCD components in a timely manner. Cleaning requires balancing efficiency and safety to avoid damaging precision optical components.

2、 Comparison of mainstream cleaning solutions and technical principles

1. Physical dust removal method

• Compressed air cleaningUse an oil-free and waterless air pump (pressure ≤ 0.3MPa) to blow away particles on the surface of the CCD.

  • advantageEasy to operate, suitable for daily maintenance
  • defectUnable to remove oily stains, may leave tiny particles

• Cleaning microfiber toolsUse ultra-fine fiber cloth (diameter ≤ 1 μ m) for unidirectional wiping to avoid electrostatic adsorption.

  • advantage: Can remove mild fingerprint contamination
  • defectFiber shedding may cause secondary pollution

2. Chemical solvent cleaning

• High purity alcohol wipingEthanol with a concentration of ≥ 90% combined with dust-free cotton swabs can dissolve stubborn oil stains.

  • advantageThe removal rate of resin pollutants reaches 95%
  • defectVolatile residues may corrode sensor coatings

• Special cleaning agentLike Eclipse solution, compatible with jelly pen (sticky silicone head) for touch cleaning.

  • advantageNot damaging the low-pass filter, suitable for precision scenes
  • defectThe single use cost can reach up to 10-20 yuan/time

3. Intelligent cleaning system

Some high-end models integrate ultrasonic vibration modules, which automatically remove dust through 30-50kHz high-frequency vibration.

• advantageReduce manual intervention and extend cleaning cycle by 3 times
• defectThe cost of equipment renovation exceeds 5000 yuan

3、 Decision Model for Cleaning Scheme Selection

1. Match by pollution type

2. Select by application scenario

• High speed production line (>200 pieces/minute)Prioritize the use of intelligent cleaning systems to avoid downtime losses
• Multi variety flexible production lineEquipped with a replaceable cleaning head (such as dual mode air blowing/jelly pen)
• High humidity environmentProhibition of alcohol wiping, use moisture-proof compressed air instead

4、 Implementation points and risk avoidance

1. Operating Specifications

   • Confirm that the camera is powered off before cleaning, but the battery level is greater than 50% to prevent accidental shutdown
   • Adopting a "center to periphery" spiral cleaning path, with a single wiping distance of ≤ 5cm

2. environmental control

   • Maintain humidity at 40% -60% and temperature at 20-25 ℃ to reduce static electricity generation
   • Class 100 cleanrooms require the use of laminar flow operation consoles

3. injury prevention

   • Do not use metal tweezers or hard brush heads to prevent scratching the filter
   • Isopropanol and other aqueous solvents can cause coating cracking and should be strictly prohibited

5、 Typical industry application effectiveness

1. Beverage packaging field
   A certain carbonated beverage factory adopts a compressed air weekly alcohol wiping scheme, which reduces the CCD failure rate from 2.3 times per month to 0.5 times, saving maintenance costs of 120000 yuan per year.

2. Medical label machine
   The freeze-dried powder injection production line has introduced a jelly pen cleaning system, with a stable labeling positioning accuracy of ± 0.05mm, which meets GMP certification requirements.

3. Electronic product labeling
   The mobile phone battery production line is equipped with an ion wind ultrasonic cleaning module, which extends the service life of CCD to 35000 hours, a 40% increase compared to traditional methods.

Conclusion
The cleaning and maintenance of CCD industrial cameras is a key step in ensuring the accuracy of visual labeling machines. The selection should comprehensively consider the characteristics of pollutants, production environment, and economy. It is recommended to adopt a combination strategy of "deep maintenance of basic cleaning cycle". With the development of intelligent cleaning technology, the penetration rate of automatic dust removal systems in high-end manufacturing fields will significantly increase in the future.