DJ-CA100 Cleanliness Analyser
High-performance Technical Cleanliness Inspection System
Fast, Accurate measurement data
Ease of use and efficient
Contaminant particles ranging from 2.5 µm up to 42 mm
Image stitching of large particles
Reproducible observation conditions
Results automatically classified
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  • DJ-CA100 Cleanliness Analyzer is a high-performance particle size testing system used in auto parts, aerospace, and hydraulic lubrication industries. It has the advantages of professional, standardization, and test results traceable. The system integrates imported optical microscope, high stable motorized stage, automatic analysis software, HD image scanning CCD, with high automation, workflow design mode, simple operation, capture images fast and efficient, automatic compensation and focus to ensure that each frame of image is clear, seamless browsing, Intelligent recognition statistics, and according to selection criteria generate results and reports. All the analysis process based on ISO16232, VDA19 and other standards to meet the cleanliness testing standards of major automobile factories such as Volkswagen, BMW, GM, Ford, and support user-defined standards.

  • DJ-CA100 Cleanliness Analyzer full compliance with the requirements of VDA 19.1-2015, ISO 16232, ISO4406 and ISO 4407, QV11111 and customer-defined standards. Adopted optical polarization technology, manually rotate the polarization device, the metallic luster reflection properties of all pollutants on the entire filter can be determined by two scans. At the same time, according to the morphological definition of fiber in VDA19.1 (stretch length/maximum inscribed circle diameter>20, maximum inscribed circle diameter≦50 microns), the classification and classification of the following four types of particles can be quickly and automatically completed within a few minutes. Size measurement: reflective particles, reflective fibers, non-reflective particles, non-reflective fibers.

    Microscopic image analysis

    Scale

    4.3801 μm/Pixel

    Analysis diameter[mm]

    46.31

    Particle count

    26585

    Filter membrane coverage

    0.55%

    Standard

    VDA19

    Class

    X range μm

    Measured count (Without fiber)

    Measured count of metal

    Measured count of fiber

    Equivalent count (Without   fiber)

    Equivalent count of metal

    Equivalent count of fiber

    B

    5<=X<15

    11619

    10

    0

    11619

    10

    0

    C

    15<=X<25

    6954

    14

    0

    6954

    14

    0

    D

    25<=X<50

    5477

    49

    0

    5477

    49

    0

    E

    50<=X<100

    1775

    97

    0

    1775

    97

    0

    F

    100<=X<150

    406

    134

    0

    406

    134

    0

    G

    150<=X<200

    158

    105

    0

    158

    105

    0

    H

    200<=X<400

    139

    118

    19

    139

    118

    19

    I

    400<=X<600

    10

    9

    8

    10

    9

    8

    J

    600<=X<1000

    6

    6

    6

    6

    6

    6

    K

    1000<=X<1500

    2

    2

    5

    2

    2

    5

    L

    1500<=X<2000

    0

    0

    1

    0

    0

    1

    M

    2000<=X<3000

    0

    0

    0

    0

    0

    0

    N

    X>=3000

    0

    0

    0

    0

    0

    0

    Testing sample image

                                                                                    spacer.gif  20210610162816267.png

    20210610162829646.png20210610162853632.png

    Regular image

     Polarization image

    No. 1   non-metallic particles 572.25 X 171.33 μm

    20210610162810821.png

    Area = 71282.89μm2

    Long axis = 572.25μm

    Short axis = 171.33μm

    Circumference = 1568.47μm

    Length-width ratio = 0.30μm

    Shape ratio = 0.28μm

    Center coordinates [7922.0,7763.9]

    particles type = Non-Metal

    No. 2   non-metallic particles 396.85 X 168.42 μm

    20210610162803331.png

    Area = 19444.28μm2

    Long axis = 396.85μm

    Short axis = 168.42μm

    Circumference = 1499.89μm

    Length-width ratio = 0.42μm

    Shape ratio = 0.16μm

    Center coordinates [6654.9,4611.2]

    particles type = Non-Metal

    No. 1 metal   particle 1436.59 X 434.10 μm

     

    20210610162756763.png

    Area = 411476.21μm2

    Long axis = 1436.59μm

    Short axis = 434.10μm

    circumference = 5221.75μm

    Length-width ratio = 0.30μm

    Shape ratio = 0.25μm

    Center coordinates [6455.9,9917.5]

    particles type = Metal

    No. 2 metal   particle 1171.79 X 230.73 μm

    20210610162745332.png

    Area = 147045.55μm2

    Long axis = 1171.79μm

    Short axis = 230.73μm

    Circumference = 3263.66μm

    Length-width ratio = 0.20μm

    Shape ratio = 0.14μm

    Center coordinates [4678.7,7678.0]

    particles type = Metal

    No.1 largest   fiber particle 1977.19 X 2648.01 μm

    20210610162738361.png

    Area = 27003.28μm2

    Long axis = 1977.19μm

    Short axis = 2648.01μm

    Circumference = 5363.93μm

    Length-width ratio = 1.34μm

    Shape ratio = 0.01μm

    Center coordinates [3570.4,6157.0]

    Particle type = Fiber

    No.2 largest   fiber particle 1311.49 X 1253.41 μm

    20210610162729446.png

    Area = 15357.81μm2

    Long axis = 1311.49μm

    Short axis = 1253.41μm

    Circumference = 3467.01μm

    Length-width ratio = 0.96μm

    Shape ratio = 0.01μm

    Center coordinates [7672.8,4207.4]

    Particle type =Fiber


  • HD Optical Microscopic

    Adopt HD Microscopic with a large zoom ratio, the zoom body is adjustable from 0.75-4.5X, and the total magnification is adjustable from 7.5-45X, suitable for Testing of impurities above 15 microns; 5MP color CMOS digital camera, pixel size 2.2× 2.2 μm, which meets the requirements of at least 10 pixels arranged on the maximum length of particles specified in the VDA19.1-2015 and ISO 16232-2007 standards;

    High-precision electric stage

    Using high-precision two-axis electric scanning platform and high-precision auto-focusing system (optional), one-key auto-focusing of the filter membrane can be used to make the scanning accuracy more accurate, make the Testing uniform, and the intelligent cleanliness analysis software can automatically take pictures, Automatic focus, automatic control scanning, automatic identification and analysis to ensure that the particles are not missed or misjudged, and the Testing efficiency is high;

    The automatic inspection and analysis process automatically scans the entire sample (usually filter paper), automatically takes pictures, automatically recognizes, counts, and analyzes particles, automatically checks cleanliness, and automatically generates professional analysis reports;

    XYZ three-axis mouse automatic control

    Maximum range 70×70mm*50mm

    Maximum speed 120 mm/s

    Digital camera

    HD true color, HD, high-resolution, high dynamic response, USB3.0 high-speed interface, real-time acquisition and simultaneous capture of images; support Chinese and English display and input operations; and include an interface with the microscope, effective physics 5MP.

    Internal automatic polarized light source (optional)

    With a dedicated digital light source controller, the software automatically controls normal light and polarized light, automatically sets the brightness of the light source, scans the filter once, and realizes the identification of metal and non-metal reflective particles. Low power consumption, high-brightness LED, lifespan of up to 20,000 hours, lifelong maintenance-free.

    Simple and intelligent operation interface, the scanning range and automatic or manual polarization mode can be set in the software.


    20210610163105235.png       

    20210610163123617.png

    Multiple testing standards

    Support multiple national and international standards: including ISO4406, ISO4407, ISO16232, NAS1638, VDA19, GB/T 20082, GB/T 14039, etc.;

    standards can be entered for automatic Testing of cleanliness and particle size; fiber statistics can be performed; The system regularly updates the latest standards.

    Scanning sample and settings diversified

    Supports scanning areas of various shapes: rectangular area, circular area, etc., supports multiple scanning paths to meet the needs of various applications;


    Auto-capture, positioning, and retrospective remake 

    Auto-capture in the scanning process, auto-save, progress is visible in real time; photo information save to the database and simply to inquire;

    And the information and pictures of the sample can be encrypted to prevent unauthorized viewing and modification. Provides the viewing and checking function of the field of view pictures, which can realize the functions of Positioning backtrack, fixed-point view or re-photograph of each field of view.

    20210610163150837.png

    Innovative automatic polarized light technology, scanning the filter once, realize the identification of metallic and non-metallic reflective particles

    The cleanliness testing system adopts innovative automatic polarized light technology. It only needs to scan the filter film once to appraisal the metallic and non-metallic reflections of the particles on the filter film. Compared with the traditional polarized light technology, the filter film needs to be scanned twice ( 1 time under orthogonal polarized light and 1 time under parallel polarized light), the scanning Testing time is doubled.

    20210610163159746.png

     

    The system can auto-set the prescribed exposure time and threshold  in compliance with VDA19.1-2015

    It can auto-set the prescribed exposure time and threshold, perform sample testing to meet the requirements of the above-mentioned standards. At the same time, the functions of manual exposure and manual threshold are still retained, and users can freely choose according to their needs.

    In order to make the analysis results comparable,VDA19.1-2015 has clearly stipulated the threshold parameter of the image gray scale of the optical microscope that uses the polarization to distinguish between particles and the background of the filter film.: the maximum gray value of the filter film background must be set At 55%±5% of the entire gray value (by adjusting the light source brightness and camera exposure time), the binary threshold is set at 70% of the maximum gray value, and the part on the left side of the gray threshold is recognized as particles.

    20210610163228367.png20210610163232944.png

     

    Supports super-large particles across the field of view and auto-calibration the offset, so that pictures can be seamlessly stitched.

    The system auto-recognizes particles, auto-analyzes particle types, auto-counts particle parameters, and supports modification of particles; provides multiple statistical analysis tools: particle list, statistical results, etc.;

     20210610163240597.png

    Measurement statistics and analysis

    The system auto-recognizes particles, auto-analysis particle types, and auto-counts particle parameters. multiple statistical analysis tools can be provided: particle list, statistical results, etc.;

    20210610163259948.png

  •  Item

    Specification

    HD optical microscopy

    HD imported upright optical microscope

    High-precision electric scanning platform

    Magnify and scan the particles on the filter membrane and image splice accuracy ≥1.0um

    High-precision autofocus system

    Special cleanliness filter membrane holder

    Special software package for cleanliness analyzer

    Auto-completion of cleanliness image splice and analytical work

    LED adjustable polarized light source

    Adjustable polarized light irradiation, simply accurately distinguish between metal and non-metal particles

    Special filter membrane clamp for detection

    Fix the tested filter membrane for easy testing and analysis

    Scanning platform control box

    Control the scanning platform to scan the image of the filter membrane

    HD image scanning CCD

    Capture scanning microscope field of view images

    Performance computer

    Performance computer, control the scanning platform to scan the particle image and perform image synthesis and splice and statistical analysis according to the   cleaning standards, and automatically print the report with pictures and   texts

    Color inkjet printer

    Quickly   print out the analysis report

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