A high-speed marking system for optical film rolls

Abstract

This invention relates to a marking system. To address the problems of existing marking devices, such as complex structure, large footprint, difficult maintenance, high power consumption, and slow marking speed, this invention provides a high-speed marking system for optical film rolls. The system includes an encoder electrically connected to a pulse distributor, which in turn is electrically connected to multiple marking modules. Each marking module is electrically connected to a camera at a corresponding detection position and triggers the camera to take a picture. The resulting image is transmitted to a defect detection host. The defect detection host compares data showing defects or suspected defects with data in a database via a switch, and then sends the defect coordinate information to a coding host via the switch. The coding host determines the printhead's operating time based on the defect coordinate information and sends an inkjet signal to the marking module. The marking module then controls the printhead to perform inkjet marking. This invention features a simple structure, small footprint, easy maintenance, low power consumption, and high marking speed.

Description

Technical Field

[0001] This invention relates to marking systems, and more particularly to a high-speed marking system for optical film rolls. Background Technology

[0002] To meet customer needs, defects in the polarizer extension composite section and coating section are marked. After the surface defect detection system detects the defects, when the roll material moves to the inkjet printing system, the inkjet printing system receives the defect coordinates transmitted by the surface defect detection system and marks the roll material defects according to different work stations and severity.

[0003] The existing machines have roughly the following two defects. First, in order to ensure the accuracy of defect detection and to cooperate with the final marking operation, the rolling speed is extremely slow, usually around 15m / s. Second, while ensuring the accuracy of defect detection, the detection speed has been increased by installing marking components at each detection station. This results in an extremely complex structure for the entire machine, a huge footprint, difficult maintenance, and extremely high power consumption.

[0004] In summary, existing marking devices suffer from problems such as complex structure, large footprint, difficult maintenance, high power consumption, and slow marking speed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a high-speed marking system for optical film rolls, in order to solve the problems of existing marking devices, such as complex structure, large footprint, difficult maintenance, high power consumption and slow marking speed.

[0006] The technical solution adopted by the present invention to solve its technical problem is: a high-speed marking system for optical film rolls, including an encoder, the encoder being electrically connected to a pulse distributor, and the pulse distributor being electrically connected to multiple marking modules;

[0007] The marking module is electrically connected to the camera at the corresponding detection position and triggers the camera to take a picture. The resulting image is transmitted to the defect detection host for defect detection. The defect detection host compares the data of existing defects or suspected defects with the data in the database through a switch, and sends the defect coordinate information to the inkjet printer host through the switch. The inkjet printer host determines the printhead opening time based on the defect coordinate information and sends the inkjet signal to the marking module. The marking module controls the printhead to perform inkjet marking operation based on the data given by the inkjet printer host.

[0008] Furthermore, the multiple marking modules share a single inkjet printer host. The inkjet printer host determines the number of printheads that need to be activated and the activation duration of each printhead based on the defect coordinate information, and sends inkjet signals to the marking modules that need to activate the printheads for inkjet marking operations. The marking modules that receive the signals control the printheads to perform inkjet marking operations.

[0009] Furthermore, the multiple marking modules also share a single defect detection host and switch. The defect detection host simultaneously receives images captured by cameras at multiple workstations and performs image processing.

[0010] Furthermore, the nozzle is installed at the outlet position of the roll material.

[0011] Furthermore, the printhead includes a first connection port for connecting the ink tank and the cleaning agent tank, and a second connection port for connecting to the wastewater tank.

[0012] Furthermore, the encoder is installed on the path of the roll material and is driven to rotate by the roll material. The signal emitted by the encoder rotation serves as the pulse input signal for the pulse distributor, which uses the row signal as the input signal for the marking module.

[0013] Furthermore, the marking module is electrically connected to the printhead assembly, which is composed of several printheads arranged in a distributed manner. The marking module controls one or more printheads in the printhead assembly to perform inkjet marking operations based on the data provided by the inkjet printer.

[0014] Furthermore, the marking module is a microcontroller with an FPGA chip.

[0015] Furthermore, the nozzle is installed at a distance of 5mm to 20mm from the surface of the roll film via an adjusting bracket.

[0016] Furthermore, the pulse distributor is electrically connected to up to ten marking modules, and each marking module controls up to sixteen nozzles; the marking module and each nozzle form a data output channel, and each output channel can buffer up to two thousand data entries.

[0017] The beneficial effects of the present invention are that the high-speed marking system for optical film rolls of the present invention firstly has the marking nozzles uniformly installed at the exit position of the roll, which simplifies the internal structure of the whole machine, reduces the footprint of the whole machine, and facilitates later maintenance.

[0018] Secondly, a combination of encoder and pulse distributor is used to control up to 10 marking modules to work simultaneously. Each marking module can control 16 printheads at the same time, so 10*16 means that up to 160 printheads can be controlled to mark ink simultaneously. There is also a data output channel between the marking module and each printhead. Each data output channel can buffer up to 2,000 data points. 160*2,000=320,000. The whole system can mark up to 320,000 defects at the same time, which is sufficient to handle the marking of defects in roll material at a maximum line speed of 60m / s.

[0019] In summary, this invention features simple structure, small footprint, easy maintenance, low power consumption, and fast marking speed. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Figure 1 This is a simplified flowchart of the present invention.

[0022] Figure 2 This is a simplified flowchart of a single-channel nozzle.

[0023] Figure 3 This is a schematic diagram showing the positional relationship between the nozzle and the roll material.

[0024] In the picture: 1. Nozzle, 2. Roll material, 3. Adjustment bracket. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings and preferred embodiments. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0026] like Figures 1 to 3 The high-speed marking system for optical film rolls shown includes an encoder, which is electrically connected to a pulse distributor via a wire. The pulse distributor is electrically connected to ten marking modules via a wire. Each marking module can control up to sixteen nozzles 1 (nozzle groups) simultaneously. Each marking module and each nozzle form a data output channel. Each output channel can buffer up to two thousand data entries. The number of marking modules multiplied by the number of nozzles that each marking module can control, and then multiplied by the number of data entries that each output channel can buffer, is 10 * 16 * 2000 = 320,000. This application can buffer up to 320,000 data entries, which corresponds to 320,000 defect data entries for the roll 2 in this application.

[0027] The marking module is electrically connected to the camera at the corresponding detection position and triggers the camera to take a picture. The resulting image is transmitted to the defect detection host for defect detection. Defect detection is an existing detection method. The applicant has filed many such visual defect detection patents before this application, so they will not be described in detail here.

[0028] The defect detection host compares the data of existing or suspected defects with the data in the database through the switch to obtain the defect coordinate information. The defect coordinate information is then sent to the inkjet printer host through the switch. The inkjet printer host determines the printhead operating time based on the defect coordinate information and sends the inkjet signal to the marking module. The marking module controls the printhead to perform inkjet marking operations based on the data (signals) given by the inkjet printer host.

[0029] The complete equipment has been applied for separately. Here is a brief introduction to the installation position of the encoder and printhead 1. First, the encoder is installed on the path of the roll 2. When the roll 2 moves forward, it drives the encoder to rotate. The signal emitted by the encoder rotation is used as the pulse input signal of the pulse distributor. The pulse distributor uses the line signal as the input signal of the marking module.

[0030] To facilitate installation and reduce the overall footprint of the machine, the nozzle 1 is installed at the outlet position of the roll 2 (the whole machine) and is installed at a distance of 5mm to 20mm from the film surface of the roll 2 via the adjusting bracket 3. A 5mm spray distance results in a shorter reaction cycle, and vice versa. The roll 2 supports marking at a maximum linear speed of 60m / s.

[0031] To achieve printhead cleaning-free operation, the printhead has a first connection port and a second connection port, commonly known as the inlet and outlet. The first connection port is connected to the ink tank and the cleaning agent tank via a conduit, and the second connection port is connected to the wastewater tank. The ink tank and the cleaning agent tank have pressurized air pipes. The pressurized air forces the ink or cleaning agent from the ink tank or the cleaning agent tank into the printhead. There is a solenoid valve between the ink tank and the printhead, and there is also a solenoid valve between the cleaning agent tank and the printhead. By switching the solenoid valves, the printhead can perform inkjet operation or cleaning operation. During cleaning operation, the solenoid valve connected to the wastewater tank is opened to directly discharge the cleaning waste liquid into the wastewater tank.

[0032] Ten marking modules share one inkjet printer, one defect detection unit, and one switch;

[0033] The inkjet printer determines the number of printheads that need to be activated and the duration of each printhead activation based on the defect coordinate information, and sends inkjet signals to the marking modules that need to activate the printheads for inkjet marking operations. The marking modules that receive the signals control the printheads to perform inkjet marking operations.

[0034] The defect detection host simultaneously receives images captured by cameras at multiple workstations and performs image processing.

[0035] The marking module is a commercially available microcontroller with an FPGA chip. "FPGA (Field Programmable Gate Array) is a product of further development based on programmable devices such as PAL (Programmable Array Logic) and GAL (General Purpose Array Logic). It emerged as a semi-custom circuit in the field of Application-Specific Integrated Circuits (ASIC), which not only solved the shortcomings of custom circuits, but also overcame the limitation of the limited number of gate circuits in the original programmable devices."

[0036] The above description is only a specific embodiment of the present invention. Various examples and illustrations do not constitute a limitation on the substantive content of the present invention. Those skilled in the art can make modifications or variations to the above-described specific embodiments after reading the specification without departing from the substance and scope of the invention.

Claims

1. A high-speed marking system for optical film rolls, characterized in that: Includes an encoder, which is electrically connected to a pulse distributor, and the pulse distributor is electrically connected to multiple marking modules; The marking module is electrically connected to the camera at the corresponding detection position and triggers the camera to take a picture. The obtained image is transmitted to the defect detection host for defect detection. The defect detection host compares the data of existing defects or suspected defects with the data in the database through a switch, and sends the defect coordinate information to the inkjet printer host through the switch. The inkjet printer host determines the printhead opening time based on the defect coordinate information and sends the inkjet signal to the marking module. The marking module controls the printhead to perform inkjet marking operation based on the data given by the inkjet printer host. The multiple marking modules share a single inkjet printer host. The inkjet printer host determines the number of printheads that need to be activated and the duration of each printhead activation based on the defect coordinate information, and sends inkjet signals to the marking modules that need to activate the printheads for inkjet marking operations. The marking modules that receive the signals control the printheads to perform inkjet marking operations. The encoder is installed on the path of the roll material and is driven to rotate by the roll material. The signal emitted by the encoder rotation is used as the pulse input signal of the pulse distributor, and the pulse distributor uses the row signal as the input signal of the marking module. The marking module is a microcontroller with an FPGA chip; The pulse distributor is electrically connected to up to ten marking modules, and each marking module controls up to sixteen nozzles; the marking module and each nozzle form a data output channel, and each output channel can buffer up to two thousand data entries.

2. The high-speed marking system for optical film rolls as described in claim 1, characterized in that: The multiple marking modules also share a single defect detection host and switch. The defect detection host simultaneously receives images captured by cameras at multiple workstations and performs image processing.

3. The high-speed marking system for optical film rolls as described in claim 1, characterized in that: The nozzle is installed at the exit position of the roll material.

4. The high-speed marking system for optical film rolls as described in claim 3, characterized in that: The printhead includes a first connection port for connecting an ink tank and a cleaning agent tank, and a second connection port for connecting to a wastewater tank.

5. The high-speed marking system for optical film rolls as described in claim 1, characterized in that: The marking module is electrically connected to the printhead assembly, which consists of several printheads arranged in a distributed manner. The marking module controls one or more printheads in the printhead assembly to perform inkjet marking operations based on the data provided by the inkjet printer.

6. The high-speed marking system for optical film rolls as described in claim 3, characterized in that: The nozzle is installed at a distance of 5mm to 20mm from the surface of the roll film via an adjustable bracket.

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