As of the second quarter of 2026, the market share of the full servo electronic counting machine in the overall domestic electronic counting machine market is approximately 35% - 42%; in the high-end new addition and replacement market (mainly in the pharmaceutical and health supplement sectors), its share has reached over 70%, and it is continuously replacing traditional cylinder models.

The core technology of the fully servo electronic counting machine can be summarized as five major hard cores plus one soft core, which determines that it is faster, more accurate, more stable and more compliant than traditional cylinder machines.

1. Full servo drive and motion control technology (mechanical core)

Completely replace the cylinders, and use servo motors + encoders + linear/rotary actuators to achieve a closed-loop system for the entire machine's power.

Three-level servo vibrating tray feeding: hopper → initial vibration → middle vibration → final vibration. Each level is independently servo-controlled for frequency and amplitude adjustment. The materials are arranged in a single column and fall uniformly, without jamming, without debris, and with low noise.

Servo door (large and small) control:

Open the main door quickly, then the side door precisely. Proceed from fast to slow to approach the set value.

Response time **≤ 10ms**, repeatability positioning accuracy **± 0.01mm**.

Rotary servo material gate, no spraying of medicine, no edge damage, suitable for soft capsules / fragile items.

Servo continuous bottle feeding and automatic material collection:

Servo screw + servo conveyor belt, bottles are continuously and smoothly transported.

The follower hopper moves synchronously with the bottle, ensuring no impact or spillage during the material discharge.

Advantages: The lifespan is 5-8 times that of the cylinder, maintenance requirements are reduced by 70%, and speed is increased by 30% or more.

II. High-speed and High-precision Counting Sensing Technology (Core Function)

The mainstream is infrared light dynamic scanning, while the high-end version combines visual AI technology.

Infrared dynamic scanning photoelectric (standard configuration):

Each channel features 20kHz high-frequency scanning, with multiple sets of transmit-receive pairs (such as 8 sets per head).

Dynamic threshold + light compensation, resistant to dust and light interference, capable of stable detection for both transparent and dark capsules.

Accuracy: ≤ ±1‰. In high-speed operation, the error can be zero.

Visual Identification (High-end Optional Feature):

High-speed CMOS camera (20 million pixels) + multispectral light source.

AI algorithm: Five-dimensional discrimination based on form, size, color, defect, and orientation.

Detachable fragments, missing corners, adhesions, and foreign objects are detected and automatically eliminated with an alarm.

Channel design: 8/12/16/24 channels operate in parallel, with each channel counting independently and without interference.

III. High-speed Processing and Intelligent Control Algorithms (Software Core)

Based on PLC + high-speed MCU/DSP + industrial touch screen as the core, with dedicated algorithms as a supplement.

Fall trajectory analysis algorithm: Identifies single particles / adhesion / overlap, intelligently splits or eliminates, preventing overcounting and undercounting.

Pre-count cache + Merge Bottling Algorithm: Multi-channel pre-count → Staging → Merge into Bottles, without delaying the bottling process and maximizing efficiency.

Self-diagnosis and self-adaptive control:

Real-time monitoring of the amplitude of the vibrating belt, the position of the material gate, and the status of the sensors.

Automatically compensates for voltage fluctuations, temperature drifts, and dust attenuation.

Fault code + graphic instructions, enabling quick location and easy maintenance.

Data traceability and GMP compliance: Automatically generate electronic batch records (quantity, time, shift, pass rate), and can be connected to MES/ERP.

IV. Modularization and GMP Clean Design (Structural Core)

Fully modular: The vibrating table, counting head, material door, bottle feeding, and rejection mechanism are all independent modules. They can be disassembled in 10 minutes and are suitable for soaking and cleaning.

316L stainless steel + mirror finish: The contact area with the materials has no dead corners, no powder accumulation, and is easy to clean.

Fully sealed negative pressure dust removal: Each particle zone has a slight negative pressure, preventing dust from spilling out, protecting the drugs and the environment.

Toolless model change: Specification switching (capsules → tablets → pills), bottle type adjustment without tools, completed within 5 minutes.

V. Electrostatic Elimination and Anti-Adhesion Technology (Core Process)

High-frequency static eliminator: Ionized air neutralizes the static electricity on the material surface, preventing adsorption, adhesion, and blockage of the channels. It is particularly suitable for soft capsules and micro pills.

Air-flow assisted orientation: A slight air flow at the end of the vibrating tray helps the capsule cap face upwards and the body face downwards, thereby enhancing the stability of counting.

VI. Key Technical Indicators Overview (2026 Mainstream Level)

Counting accuracy: ≤ ±0.1% (optical); ≤ ±0.02% (visual)

Particle speed: 500 - 4000 particles per minute; 100 tablets per bottle can reach 300 bottles per minute

Channel count: 8/12/16/24 (as needed)

Servo response: ≤ 10ms; Positioning accuracy: ±0.01mm

Changeover time: ≤ 5 minutes; Cleaning time: ≤ 10 minutes

Summary in one sentence: The combination of full servo control, high-speed photoelectric/visual technology, intelligent algorithms, and modular GMP structure forms an irreplaceable technical barrier for the full servo counting machine.

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