Device and method for detecting inclusion defects and deformation of flat glass using a knife block

Abstract

The present invention discloses a device and method for detecting inclusion defects and deformation in flat glass using a knife baffle. The device comprises a light source, a knife baffle assembly, and a camera. The knife baffle assembly is disposed near the light source, and the camera is aligned with the light path emitted by the light source through the knife baffle assembly. Glass to be tested is disposed behind the light source and the knife baffle assembly. The knife baffle assembly comprises a light baffle and a diffuser, and the diffuser is disposed closely to the light baffle. Through a method of the device, the light source is shielded by the light baffle and the diffuser, and a knife baffle area is formed in the transition area between the bright luminous area and the dark knife baffle area under the illumination of the light source. The camera is aligned with the knife baffle area to detect and identify light deflection caused by inclusion deformation, thereby realizing online identification and control of the quality of glass inclusion deformation.

Description

Technical Field

[0001] The present invention relates to the field of detecting defects and deformation of flat glass, and in particular to a device and method for detecting defects and deformation of flat glass due to inclusions by using a knife block. Background Art

[0002] The flat glass production process can be broadly divided into raw material processing, preparation and coordination, melting and clarification, cooling, forming, and cutting. During each production process, defects may occur in the original glass due to manufacturing processes and human factors. According to the current flat glass production standards, common inclusion defects in glass include bubbles, platinum, zircon, and other inclusions. These defects cause minor concave or convex deformations on the upper and lower surfaces of the glass.

[0003] Liquid crystal panels use two glass substrates with an ITO film layer evaporated on the surface. Inclusion deformation can cause the film to fall off or break, which has a serious impact on the yield rate of the LCD panel process. Therefore, it is necessary to accurately detect inclusion deformation in the glass substrate process, control the missed detection of inclusion deformation defects, and prevent glass substrate quality risks. Summary of the Invention

[0004] In response to the problems existing in the prior art, the present invention provides a device structure that utilizes a knife baffle to detect inclusion defects and deformation in flat glass. The light source is shielded by a light baffle and a diffuser. A knife baffle area is formed in the transition area between the bright luminous area and the dark knife baffle area under the illumination of the light source. A camera is aimed at the knife baffle area to detect and identify light deflection caused by inclusion deformation, thereby realizing online identification and control of glass inclusion deformation quality.

[0005] The present invention is achieved through the following technical solution: a device for detecting inclusion defects and deformation of flat glass using a knife baffle, characterized in that it includes a light source, a knife baffle assembly and a camera, the knife baffle assembly is arranged near the light source, the camera is aligned with the light path emitted by the light source through the knife baffle assembly, and the glass to be tested is arranged behind the light source and the knife baffle assembly, wherein the knife baffle assembly includes a light baffle and a diffuser, and the diffuser is arranged close to the light baffle.

[0006] Furthermore, the distance between the blade blocking assembly and the light source is 30mm-60mm.

[0007] Furthermore, the light source is a white LED lamp bead with a size of less than 3mmx3mm and a beam angle between 80° and 150°.

[0008] Furthermore, the light blocking plate is fixed at a position 40%-50% of the width of the light source.

[0009] Furthermore, special fuel is added into the light shield.

[0010] Furthermore, the substrate of the light diffuser plate is polymethyl methacrylate (PMMA).

[0011] Furthermore, the camera is a high-speed and high-resolution dual-line camera.

[0012] The present invention also provides a method based on the above-mentioned device for detecting inclusion defects and deformation of flat glass using a knife baffle, S1: shielding a light source by a knife baffle assembly, and light emitted by the knife baffle assembly is divided into a bright area, a knife baffle area, and a dark area;

[0013] S2: The camera is aligned with the knife blocking area;

[0014] S3: The camera recognizes the light signal;

[0015] S4: Detecting the bright photoelectric signal and the dark photoelectric signal of the knife blocking area;

[0016] S5: Calculate the sum and difference of the bright photoelectric signal and the dark photoelectric signal;

[0017] S6: Analyze and obtain the test results.

[0018] Furthermore, in step S1, the light blocking plate in the knife blocking assembly adjusts the intensity of the emitted light by adjusting the insertion depth.

[0019] Furthermore, in step S2, the camera scans the moving glass line by line and pixel by pixel at a distance of ≤0.020 mm.

[0020] Compared with the existing technology, the present invention has the following beneficial technical effects: the present invention can ensure the distinction between the bright area, knife-blocking area and dark area of ​​the light source by closely arranging the light-blocking plate and the diffuser plate; the light diffuser plate can effectively ensure that the centers of the bright area, knife-blocking area and dark area of ​​the light source are uniform.

[0021] Furthermore, by selecting the light source, it is possible to achieve the effect of focusing light, producing high brightness in a small area, and an illumination of ≥10kLux; after blocking the light source through the light-blocking plate, the light source is divided into a ≤50% bright area, a ≤10% knife-blocking area, and a ≥40% dark area; and the special fuel can filter out ≥90% of the light after being added.

[0022] Furthermore, through the method of this device, it can be effectively ensured that the deformation of the inclusion can be detected through signal processing; the size of the knife block can be adjusted by plugging and unplugging the light blocking plate, thereby controlling the size of the knife block area. The smaller the area of ​​the knife block area, the higher the sensitivity and the higher the accuracy of detecting the deformation of the inclusion. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or technical descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0024] Figure 1 A schematic diagram of a system for detecting inclusion defects and deformation of flat glass using a knife block provided by an embodiment of the present invention.

[0025] Figure 2 A schematic structural diagram of a light source assembly of an apparatus for detecting inclusion defects and deformation of flat glass using a knife baffle provided by an embodiment of the present invention.

[0026] Figure 3 A schematic diagram of the light source structure of a device for detecting inclusion defects and deformation of flat glass using a knife baffle provided by an embodiment of the present invention.

[0027] Figure 4 A schematic diagram of detection results of a device for detecting inclusion defects and deformation of flat glass using a knife baffle provided by an embodiment of the present invention.

[0028] Figure 5 A schematic diagram of the bubble deformation structure of a device for detecting inclusion defects and deformation of flat glass using a blade stopper provided by an embodiment of the present invention.

[0029] Figure 6 A schematic diagram of the optical path of a device for detecting inclusion defects and deformation of flat glass using a knife baffle provided by an embodiment of the present invention.

[0030] In the figure: light baffle 1, diffuser 2, knife baffle assembly 3, glass to be tested 4, camera 5, light source cover 6, light source 10, bright area 11, knife baffle area 12, dark area 13, bubble 40, fixed base plate 101, lamp bead 102, light source module 103, light path 201 caused by bubble inclusions, defect-free light path 202, bubbles inside the glass 204, concave deformation of the glass surface caused by bubble inclusions 205, bright photoelectric signal Ⅰ1 and dark photoelectric signal Ⅰ2. DETAILED DESCRIPTION

[0031] Hereinafter, only certain exemplary embodiments are briefly described. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are to be considered as illustrative in nature and not restrictive.

[0032] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0034] In the present invention, unless otherwise expressly specified or limited, terms such as "mounted," "connected," "connect," and "fixed" should be understood broadly. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0035] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0036] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0037] The present invention discloses a device for detecting inclusion defects and deformation of flat glass using a knife block, that is, a light source 10 is blocked by a light block plate 1 and a diffuser plate 2, so that the light source 10 is divided into a bright area 11 that emits light, a dark area 13 that blocks light, and a knife block area 12 with a transition between light and dark, and a camera 5 is focused on the knife block area 12 of the light source 10.

[0038] In actual use, when detecting inclusions inside the moving glass, an inclination angle of 25-35 degrees is set between the light source 10 and the glass to be tested 4. Parallel light is emitted through the glass to be tested 4 into the camera 5 facing the light source 10. When the light encounters the inclusions in the glass to be tested 4, the light path will be deflected. The deflection of the light path will be partially concentrated and dispersed after the knife-blocking area 12. After the segmentation processing of the photoelectric signal threshold, the image of the deformation of the inclusion can be effectively detected and identified, thereby realizing online control of the deformation quality of the inclusion.

[0039] Specifically, the light source 10 uses white light LED lamp beads, the size of which is set to be within 3mmx3mm, and the beam angle is selected to be 80°-150°, which is used to focus light, and a small area can produce high brightness, with an illumination of ≥10kLux; the knife-blocking assembly 3 consists of two parts, namely the light-blocking plate 1, which is fixed at a position of approximately 40%-50% of the width of the light source 10. After blocking the light source 10, the light source 10 is divided into a ≤50% bright area, a ≤10% knife-blocking area and a ≥40% dark area, wherein the knife-blocking area 12 is a light-dark transition area. The other is a diffuser 2 that is close to the light baffle 1. The diffuser can ensure that the centers of the bright area 11, the knife-blocking area 12, and the dark area 13 of the light source are evenly distributed. In this embodiment, the light baffle 1 is made of plastic with a special dye added, which can effectively block and filter out ≥90% of the light. The size of the knife-blocking area 12 can be adjusted by plugging and unplugging the light baffle 1. The smaller the area of ​​the knife-blocking area 12, the higher the sensitivity and the higher the accuracy of detecting deformation of inclusions. The base material of the diffuser 2 of the light source is polymethyl methacrylate (PMMA).

[0040] At the same time, a high-speed, high-resolution, dual-line TDⅠ8K, 12-bit CMOS camera 5 is used to align the camera 5 with the knife-blocking area 12 of the light source 10, and the glass to be tested 4 is scanned line by line and pixel by pixel at a distance of ≤0.020 mm to detect the bright photoelectric signal Ⅰ1 and the dark photoelectric signal Ⅰ2 in the knife-blocking area 12. The signals are digitized, and the sum and difference of signals Ⅰ1 and Ⅰ2 are calculated. For defect-free glass to be tested 4, the digitized signals Ⅰ1 and Ⅰ2 each reach an amplitude of 128 bits, the sum of the two signals is 256 bits, and the difference between signals Ⅰ1 and Ⅰ2 is always zero (0). Surface dirt defects on the glass to be tested 4 will not affect the signal difference because they will reduce the two intensity signals to the same extent, that is, the surface dirt particles will reduce the light intensity and reduce the sum, but will not reduce the difference; when encountering inclusion defects inside the inspected glass and generating optical deflection, as the glass inspection area moves, certain pixel positions of the camera see changes in the signal, and the difference between the two intensity signals I1 and I2 is no longer 0. The I1 and I2 signals will exceed the control threshold of the dark or bright signal, and the deformation of the inclusion can be detected through signal processing.

[0041] like Figure 1 As shown, the present invention relates to a method for detecting inclusion defects and deformation of a flat glass plate by using a knife. A light blocking plate 1 and a diffusion plate 2 are used to block the width of a line light source within a range of 50%-30%, and the light source 10 is divided into a bright area 11, a knife blocking area 12 and a dark area 13. The principle of forming the knife blocking area 12 is described.

[0042] Figure 1 In the figure, a light blocking plate 2 and a diffuser plate 3 are attached together on the upper part of each light source 1. After the light from the light source 10 is blocked by the light blocking plate 2, the light is homogenized by the diffuser plate 3. The light blocking plate 2 can be plugged in and out for adjustment, and the size of the blade blocking area 12 is adjusted accordingly.

[0043] Figure 2 In the figure, it is shown that the light source 10 is composed of 2 modules, each module has 12 lamp beads 102, the lamp beads 102 of the light source 10 are not blocked by the bright area 11, the light source 10 is blocked by the dark area 13 after the light blocking plate 1, and the transition area between the bright area 11 and the dark area 13 is the knife-blocking area 12 for detection.

[0044] Figure 3In the figure, the deformation signal characteristics of the internal inclusions of the glass 4 to be tested are shown. For the defect-free glass 1, the digitized signals of the bright photoelectric signal Ⅰ1 and the dark photoelectric signal Ⅰ2 each reach an amplitude of 128 bits, the sum of the two signals is 256 bits, and the difference between the signals Ⅰ1-Ⅰ2 is always zero (0); the dirt defects on the glass 4 to be tested will not affect the signal difference, because they will reduce the two intensity signals to the same extent, that is, the surface dirt particles will reduce the light intensity and reduce the sum, but will not reduce the difference; when encountering the internal inclusion defects of the glass 4 to be tested and optical deflection occurs, as the inspection area moves, some pixel positions of the camera see changes in the signal, and the difference between the two intensity signals of bright photoelectric signal Ⅰ1-dark photoelectric signal Ⅰ2 is no longer 0, and the bright photoelectric signal Ⅰ1-dark photoelectric signal Ⅰ2 will exceed the threshold of the dark or bright signal preset by the detection system. After signal processing, the deformation of the inclusion can be detected.

[0045] exist Figure 1 、 Figure 4 In the figure, an example of using a knife to detect bubble deformation inside flat glass is shown. The glass to be tested moves in the direction shown in the figure to detect internal inclusion bubbles 40. The light source 10 is tilted 25-35 degrees to the glass 4. The transmitted light is incident parallel to the camera 5 facing the knife. The camera 5 is focused on the knife-blocking area 12 of the light source 1. When the light is detected, the light path of the bubble 40 is deflected.

[0046] Figure 5 In the enlarged view of the light path deflected by the deformation of bubble 40, the light beam passes parallel to the glass 4 under test. In the absence of bubbles, the light path is as shown by the dashed line and is undeflected. However, after encountering a bubble inclusion, which causes a concave deformation 205 on the glass surface, the light path deflects and partially converges, as shown by the solid line. The solid line light is transmitted to the camera, and after photoelectric signal threshold segmentation processing, an image of the bubble deformation is detected.

[0047] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, from all perspectives, the embodiments should be regarded as illustrative and non-restrictive. The scope of the present invention is defined by the appended claims, not the foregoing description, and it is intended that all variations that come within the meaning and range of equivalents of the claims be included within the present invention. Any reference signs in the claims should not be construed as limiting the claim to which they relate.

[0048] In addition, it should be understood that although this specification describes the embodiments, not every embodiment contains only one independent technical solution. This description is for clarity only. Those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is only for the purpose of illustrating the technical concept of the present invention and cannot be used to limit the scope of protection of the present invention. Any changes made based on the technical solution in accordance with the technical concept proposed by the present invention fall within the scope of protection of the claims of the present invention.

Claims

1. A device for detecting inclusion defects and deformation of flat glass using a knife block, characterized in that: The invention comprises a light source (10), a knife block assembly (3) and a camera (5), wherein the knife block assembly (3) is arranged near the light source (10), the camera (5) is aligned with the light path emitted by the light source (10) through the knife block assembly (3), and the knife block assembly (3) is 30 mm to 60 mm away from the light source (10); a glass to be tested is arranged behind the light source (10) and the knife block assembly, and the light source (10) uses a white light LED lamp bead with a size of less than 3 mm x 3 mm and a light beam angle of between 80° and 150°; wherein the knife block assembly (3) comprises a light block plate (1) and a diffuser plate (2), and the diffuser plate (2) is arranged close to the light block plate (1); The light blocking plate (1) is fixed at a position of 40%-50% of the width of the light source.

2. The device for detecting inclusion defects and deformation of flat glass using a knife block according to claim 1, characterized in that: The base material of the diffusion plate (2) is polymethyl methacrylate (PMMA).

3. The device for detecting inclusion defects and deformation of flat glass using a knife block according to claim 1, characterized in that: The camera (5) is a high-speed and high-resolution dual-line camera.

4. A method for detecting inclusion defects and deformation of flat glass using a baffle, using the device for detecting inclusion defects and deformation of flat glass using a baffle according to any one of claims 1 to 3, characterized in that: S1: The light source (10) is shielded by the knife-blocking assembly, and the light emitted by the knife-blocking assembly (3) is divided into a bright area (11), a knife-blocking area (12), and a dark area (13); S2: The camera (5) is aligned with the knife blocking area (12); S3: the camera (5) recognizes the light signal; S4: Detecting the bright photoelectric signal (Ⅰ1) and the dark photoelectric signal (Ⅰ2) in the knife blocking area; S5: Calculate the sum and difference of the bright photoelectric signal (Ⅰ1) and the dark photoelectric signal (Ⅰ2); S6: Analyze and obtain the test results.

5. The method for detecting inclusion defects and deformation of flat glass using a baffle according to claim 4, characterized in that: In step S1, the light blocking plate (1) in the knife blocking assembly (3) adjusts the intensity of the emitted light by adjusting the insertion depth.

6. The method for detecting inclusion defects and deformation of flat glass using a baffle according to claim 4, characterized in that: In step S2, the camera (5) scans the moving glass line by line and pixel by pixel at a distance of ≤0.020 mm.

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