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In response to the practical issues of labor-intensive and low automation levels in particle feed size detection, a vibratory rectification-based particle feed size detection device was designed by using image processing technology. A simulation model of the interaction between the particle feed and the chute-type rectification plate was established by using the discrete element method software Rocky Dem. The amplitude, vibration frequency, installation angle, and chute deflection coefficient of the rectification plate were considered as experimental factors, while the average slip velocity and coefficient of slip velocity variation of the particle feed were used as evaluation indicators. Through single-factor simulation experiments, the slip motion characteristics of the particle feed within the chute-type rectification plate were analyzed. The results showed that the main factors influencing the particle feed’s slip motion characteristics were the amplitude, vibration frequency, and installation angle. Orthogonal combination simulation experiments were conducted to establish mathematical models between the experimental factors and evaluation indicators, followed by parameter optimization of the models. The optimal configuration was found to be an installation angle of 6.33°, a vibration frequency of 101.49 Hz, and an amplitude of 0.50 mm. Under these conditions, the particle feed achieved the best overall performance with an average slip velocity of 0.31 m/s and a coefficient of slip velocity variation of 4.10%. Particle feed samples with aperture sizes of 3 mm, 4 mm, and 5 mm were collected to validate the measurement accuracy of the detection device. Compared with manual measurements, the average absolute errors (MAE) of the automatic diameter measurements were 0.048 mm, 0.020 mm, and 0.012 mm, respectively. The MAE of the automatic length measurements were 0.164 mm, 0.162 mm, and 0.103 mm, respectively. The research results demonstrated that the designed particle feed size detection device exhibited good accuracy and reliability, meeting the requirements of practical production inspection.