Technology
Advanced Tablet & Capsule Detection Technology
Adaptive optical detection with integrated product simulation, audit counting and configurable processing for modern tablet counting machines.
A complete detection platform, not just a sensor.
What it is
The XIAC Advanced Tablet Detection System is a modular sensing platform for tablet and capsule counting machines. It combines high-speed optical detection with configurable adaptive processing, real-time diagnostics, integrated product simulation and independent audit counting.
The system is designed to be tailored to each machine design, typically supplied from 4 to 16 detection channels per module and integrated with EtherCAT, Modbus or MultiLink communication.
The objective is reliable product detection in real production conditions: dust, reflections, translucent products, high speed, changing product types and multi-lane flow.
These sensor modules can be tailored to your machine requirements and integrated into new tablet and capsule counters. The system supports scalable channel counts, configurable detection behaviour and modern industrial communication options.
The detection system
The platform is built from three functional elements: an emitter unit, a detector unit and a coordinator unit. This separates product illumination, optical measurement, signal processing, communication and diagnostics into a clean modular architecture.
Emitter unit
High-intensity multi-channel LED emitter with adaptive light control and built-in product simulation capability.
Detector unit
High-speed multi-channel detector for free-fall tablet and capsule sensing with advanced signal tracking.
Coordinator unit
System control, signal processing, diagnostics, audit counting and communication to the machine controller or HMI.
Free-fall detection at the tray exit
Products are detected as they leave the vibratory tray and pass through the detection channels in controlled free-fall. This helps separate the optical measurement from tray vibration and gives the detector a repeatable measurement window.
Special guide geometry can be used above the detection area to keep tablets and capsules aligned through the channels, reducing wall impact and preventing product bounce that could disturb the free-fall trajectory.
Configurable adaptive detection
Many detection values that were traditionally fixed inside firmware can now become configurable product parameters. This allows one sensor platform to support many different tablets, capsules and operating conditions without replacing hardware or reprogramming firmware.
Product sensitivity
Adjust detection response to suit tablet size, shape, colour, opacity and production speed.
Dynamic tracking
Follow slow signal changes caused by dust clouds, light variation or normal production drift.
Emitter compensation
Adapt light output to maintain useful optical range as the machine environment changes.
Parameters may be linked to product recipes in the machine HMI, allowing operators or OEMs to select appropriate settings for each product type.
Integrated product simulator
The emitter side can generate realistic virtual product events by modulating the optical channels as though tablets or capsules were passing through the machine. The detector and coordinator respond as if real products are present.
This allows a machine builder or service engineer to test counting performance, PLC integration, audit counting and diagnostics without running physical product.
The simulator can be used for factory validation, installation checks, service troubleshooting and PLC count verification. For example, the system can generate a defined number of virtual products across multiple channels and compare the expected count against the machine result.
Independent audit counter
The coordinator can maintain an independent audit count in parallel with the machine controller. This gives the system a second view of the product flow and supports diagnostics when investigating missed counts, double counts or PLC integration issues.
Machine count
The PLC or main controller performs the production count used by the machine process.
Audit count
The sensor platform independently records what the detection system believes passed through the channels.
Communication and integration
The system is designed for integration into modern industrial automation environments. Depending on the machine architecture, the coordinator can be supplied with EtherCAT, Modbus or MultiLink communication.
EtherCAT
High-performance machine integration for modern PLC systems and deterministic automation architectures.
Modbus
Simple and widely supported communication for HMIs, PLCs, service tools and retrofit-friendly systems.
MultiLink
XIAC high-speed distributed communication for compact wiring, scalable sensor nodes and future machine architectures.
Why it matters
| Area | Traditional fixed sensor | XIAC advanced detection platform |
|---|---|---|
| Detection tuning | Often fixed internally or changed only by firmware update. | Configurable adaptive parameters suitable for product recipes and field adjustment. |
| Diagnostics | Limited status outputs or basic channel signals. | Real-time signal levels, statistics, audit counts and system health information. |
| Validation | Requires physical product or external test equipment. | Integrated product simulator and independent audit counting. |
| Integration | Usually tied to one interface or fixed I/O style. | EtherCAT, Modbus or MultiLink options for different machine architectures. |
| Scalability | Often specific to one machine width or channel count. | Modular 4–16 channel units, tailored for compact or larger multi-lane counters. |
Designed for real production
The XIAC detection platform is intended for machines that need more than basic product detection. It combines optical sensing, mechanical flow understanding, adaptive algorithms, diagnostics and communication into one integrated system.
A complete detection and verification system
The system is not simply an optical beam sensor. It is a detection and verification platform for OEMs and machine builders who need reliable counting, flexible configuration, built-in test functions and clean industrial integration.
By combining adaptive detection with a product simulator and audit counter, the same hardware can support development, production, validation and service throughout the life of the machine.
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