Sheet matching method of automatic sheet sorting system suitable for laminated glass

Abstract

The invention relates to the technical field of glass production, and discloses a sheet matching method suitable for an automatic laminated glass sheet arranging system. According to the system, a plurality of parameters such as thickness, size, flatness, surface quality and optical performance of glass are detected through a sensor and an image processing unit which are connected with a control processing unit. In the detection process, the system automatically inputs acquired data into a database and classifies the glass according to a preset standard. And the classification result is managed through an MES system, and finally qualified products and unqualified products are automatically sorted. By means of the method, comprehensive detection and efficient classification of the laminated glass can be achieved, the product quality is ensured, meanwhile, the production efficiency is improved, and the problems of errors and omission possibly occurring in traditional manual detection are avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of glass production, and in particular relates to a method for dispensing laminated glass in an automatic sheet sorting system. Background Art

[0002] In modern architecture and the photovoltaic industry, laminated glass has become one of the most widely used materials due to its excellent safety, sound insulation and UV resistance. Laminated glass consists of two or more pieces of glass bonded together by one or more layers of laminated film (such as PVB film), which can effectively prevent glass fragments from flying when broken, greatly improving safety performance. Therefore, in the fields of building curtain walls, automobile windshields and high-standard photovoltaic glass, the demand for laminated glass is increasing year by year, and the requirements for its production process are also increasing.

[0003] In the production process of laminated glass, the cutting and laying of the laminated film are key steps to ensure the quality of the finished product. Traditional laminated glass production methods often rely on manual operation or semi-automatic equipment to cut and lay the laminated film. However, with the diversification of order requirements and the increasing complexity of glass specifications, traditional operation methods have been unable to meet the requirements of efficient and high-precision production. Especially when the order quantity is large or there are many personalized customization requirements, manual operation has obvious problems of low efficiency and high error rate. This not only affects the production efficiency of laminated glass, but also easily leads to unstable quality of finished products, thereby increasing the production cost of the enterprise.

[0004] To solve this problem, the automated sheet sorting system came into being and gradually became an important equipment in the production of laminated glass. The automated sheet sorting system manages and schedules the specifications and order requirements of the glass in a unified manner through the MES (Manufacturing Execution System), making the cutting and laying of the laminated film more accurate and efficient. In this system, the laminated film cutting process can be dynamically adjusted according to the glass specifications and order requirements entered into the MES system to ensure that the cutting results accurately match the shape and size of the glass sheets. In this way, the automated sheet sorting system can significantly improve the quality of the finished product and production efficiency, and reduce the error rate in the production process.

[0005] In the production process of laminated glass, the automatic sheet sorting system is a key link to ensure product quality and production efficiency. At present, the automatic sheet sorting system usually includes multiple sensors, such as thickness detectors, edge detectors, etc. These sensors can monitor the various parameters of the glass sheets in real time and automatically complete the sheet sorting task according to the set standards. The system uses a high-precision positioning device to ensure that each piece of glass can be accurately aligned before entering the next process to avoid misalignment problems in subsequent processing.

[0006] In order to better adapt to the requirements of modern production and improve the production efficiency and product quality of laminated glass, it is particularly necessary to develop an intelligent laminated glass sorting method based on the MES system. Through the dynamic adjustment of the laminated film cutting process, it can effectively solve the shortcomings of traditional processes, achieve automated and refined production goals, and create greater market competitive advantages for enterprises. The sorting system includes an automatic sorting device: an automatic sorting device is set at the key nodes of the production line. When the detector finds unqualified glass, the system can automatically start and separate the unqualified products to ensure that the glass on the production line meets the quality requirements.

[0007] Therefore, in order to solve the above problems, a more intelligent automatic laminated glass sorting system is needed, which can automatically adjust the sorting method according to the specific parameters of the glass and production requirements, improve production efficiency and ensure product quality. Summary of the invention

[0008] The present invention provides an automatic film sorting system matching method applicable to laminated glass, using a new system film sorting method to solve the technical problems that the existing identification method relies on manual judgment, depends on the level of personnel, or judges the products through the production of a large number of products, resulting in waste of materials and labor.

[0009] In order to solve the above technical problems, the present invention provides the following technical solutions: The present invention provides a method for automatically sorting laminated glass in a sheet sorting system, comprising: S1: Use X-ray scanning to inspect glass raw materials and enter the glass specifications (such as thickness and size) into the MES (Manufacturing Execution System).

[0010] S2: Order input and matching, the system retrieves data according to order requirements.

[0011] S3: Laminated film cutting, start cutting the laminated film according to the glass and order requirements.

[0012] S4: Edge grinding: Grind the edges of the cut glass to remove burrs.

[0013] S5: Wash and dry, remove surface dirt and dust and ensure that the surface is free of water stains and impurities.

[0014] S6: Laying of laminated film: Laying a layer of cut laminated film (PVB film) between two pieces of glass.

[0015] S7: Initial pressing: the glass and laminated film are initially pressed together through heat pressing and vacuum degassing.

[0016] S8: Autoclave, which uses high temperature and high pressure to make the laminated film and glass bond thoroughly.

[0017] S9: Inspection and trimming, conduct appearance and quality inspection to ensure that the dimensions meet the requirements.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. The automatic laminated glass sorting system designed by the present invention uses advanced high-resolution image acquisition technology and intelligent algorithms to conduct comprehensive inspection of laminated glass. Specifically, the following steps are included: first, the image of the glass raw material is collected using X-ray scanning technology and entered into the MES system to accurately record the specifications of the glass; second, according to the order requirements, the system automatically retrieves and displays the glass models that meet the conditions; then, the selected results are transmitted to the laminated film cutting process to accurately cut the laminated film; then, the edge of the glass is polished, cleaned and dried to ensure that there are no burrs, dirt and water stains on the surface; then, the laminated film is evenly laid between the glass sheets, and the laminated film is pressed through the primary pressing machine and the autoclave to ensure that the laminated film is thoroughly bonded to the glass sheets; finally, after inspection and trimming, the size and quality of the glass are ensured to meet the requirements.

[0019] 2. The present invention uses high-precision detection methods such as Canny edge detection algorithm, laser interferometry, Fourier transform analysis, edge detection and morphological analysis, photoelastic effect detection, spectrophotometer measurement, etc. to comprehensively analyze the edge state, flatness, surface cleanliness, internal stress distribution, optical performance, etc. of the glass, significantly improving the detection accuracy and quality control level. At the same time, the detection data is intelligently classified through machine learning algorithms (such as support vector machines SVM), and the glass is divided into qualified products, slightly defective products or unqualified products, further improving the automation and intelligence level of the production process.

[0020] 3. The method of the present invention can efficiently and accurately complete the automatic sheet sorting of laminated glass, reduce manual operation errors, improve production efficiency and product quality, and meet the requirements of modern industrial production for high precision and high quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. It is understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0022] Figure 1 is a flow chart of the method of the present invention; Figure 2 The Canny algorithm of the present invention extracts the edge contour map; Figure 3 is the Fourier transform analysis characteristic diagram of the present invention; Figure 4is the infrared spectrum of the glass of the present invention; Figure 5 is a stress-strain graph of the glass of the present invention; Figure 6 It is an image analysis process diagram of the present invention. DETAILED DESCRIPTION

[0023] In order to make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0024] Example

[0025] The invention discloses a sheet matching method for an automatic sheet sorting system suitable for laminated glass.

[0026] Please refer to Figure 1 The present invention provides a flowchart of a method for automatically sorting laminated glass in a system for sorting laminated glass.

[0027] The present invention provides a method for matching laminated glass in an automatic sheet sorting system, which ensures the quality and processing efficiency of laminated glass through multi-step precision detection and dynamic adjustment. The first is the glass preparation stage S1: X-ray scanning is used to detect glass raw materials, and the specifications of the glass (such as thickness and size) are entered into the MES (manufacturing execution system). The system is used for data call and process control in subsequent steps to ensure that each piece of glass can be accurately identified and processed during the processing.

[0028] After the glass enters the processing line, S101: preliminary scanning and classification, the thickness and size of the glass are determined by scanning, and the data is entered into the database for subsequent processing. The system uses the Canny edge detection algorithm to identify the glass edge in the X-ray scan image, as shown in formula (1)-formula (2); Formula (1) Formula (2) in, is the image pixel value, is the gradient image, is the area of ​​the region, is the edge length; Next, the flatness, edge integrity and surface cleanliness of the glass are tested. S102: Flatness and surface testing: The flatness of the glass is tested, and the edge integrity and surface cleanliness are checked, mainly to detect oil stains, stains or other surface contaminants. The flatness, edge integrity and surface cleanliness of the glass are tested using laser interferometry and smoothing algorithms, as shown in formulas (3) to (5); Formula (3) Formula (4) Formula (5) in, is the laser measurement image, is the surface image, Threshold is the threshold for detecting stains; S103: Optical quality inspection, inspect the optical quality of the glass, focusing on defects that affect the appearance, such as bubbles, ripples, and impurities. In the optical quality inspection step, professional inspection equipment is used to scan the glass surface to find defects that affect the appearance, such as bubbles, ripples, impurities, etc. This step ensures that the appearance quality of the glass meets the requirements, especially for high standards in applications such as building curtain walls and photovoltaic glass. Use Fourier transform to analyze optical images and detect bubbles, ripples, and impurities in the glass, as shown in formula (6); Formula (6) Among them, through Fourier transform The optical image Transformed to the frequency domain, defects will present characteristic patterns in the frequency domain; formulas are used to detect these characteristic patterns to identify defects; S104: Surface defect detection, check the scratches and stains on the glass surface, which directly affect the appearance quality of the glass. Through surface defect detection, focus on checking the scratches and stains on the glass, which will directly affect the appearance quality of the glass. This detection uses edge detection and morphological analysis algorithms to detect scratches and stains on the glass surface, as shown in formula (7)-formula (8); Formula (7) Formula (8) is the gradient of the surface image, which is used to identify intensity changes in the image that may indicate scratches; Represents morphological opening or closing operations, and Structuring Element is the structural element of morphological operations; Uneven internal stress distribution may cause the glass to spontaneously break during processing or use. Therefore, this step ensures that the internal stress of the glass is within a reasonable range to prevent future safety hazards. S105: Internal stress detection, using equipment such as polarizers to detect the internal stress distribution of the glass to prevent the glass from spontaneously breaking due to uneven stress during processing or use. The stress distribution inside the glass is detected using the photoelastic effect and the polarizer image, as shown in formula (9); Formula (9) The formula for calculating the light intensity under the polarizer is Angle with optical axis The relationship between the stress distribution inside the glass can be inferred. In order to ensure that the light transmittance and optical properties of the glass meet the standards, optical instruments are used to measure the glass in detail. These properties are difficult to judge by visual inspection, especially in applications with extremely high requirements, such as building curtain walls and photovoltaic glass. S106: Testing the light transmittance and optical properties of glass, using optical instruments to measure the light transmittance and optical properties of glass to ensure that they meet the requirements of high-standard applications (such as building curtain walls or photovoltaic glass). Use a spectrophotometer to measure the light transmittance and other optical properties of the glass, as shown in formula (10)-formula (11); Formula (10) Formula (11) The transmittance is calculated by the incident light intensity. and transmitted light intensity The ratio calculation is is the wavelength of light; the formula combines the transmittance of different wavelengths and weights to evaluate the overall optical performance of the glass; After all tests are completed, the system classifies the glass into qualified and unqualified products based on the data obtained. Qualified products are further divided into complete products and slightly defective products. Slightly defective products can be used for applications with lower appearance requirements, while complete products are used for high-standard applications. S107: Classification and rating. Based on the above test results, the glass is classified into qualified and unqualified products, and qualified products are further classified into slightly defective products and complete products.

[0029] Using a machine learning algorithm, such as a support vector machine (SVM) or a decision tree, based on the detected data, the glass is classified into qualified products, slightly defective products, or unqualified products, as shown in formula (12); Formula (12) The support vector machine (SVM) algorithm is used to classify the glass. The input feature vector f includes thickness, flatness, optical quality, surface scratch stress, transmittance, etc. The SVM model is used to determine the type of glass. The algorithm and formula of each step are specially designed to optimize the detection process of the automatic glass sorting system to ensure the accuracy and efficiency of each detection process.

[0030] According to the specific requirements of the customer's order, the order information is entered into the MES system. The system automatically retrieves the glass models that match the order requirements from the database and displays them on the operator's screen for selection. S2: Order input and matching, the order requirements are entered into the system, the system retrieves data according to the order requirements, and displays the glass models that meet the requirements.

[0031] After the selection is completed, the system transmits the glass model and order requirements to the laminated film cutting unit. The laminated film cutting process is dynamically adjusted according to the glass specifications and order requirements entered into the MES system to ensure that the laminated film after cutting accurately matches the glass sheet in shape and size. Before cutting, the system will also perform a second scan of the shape and size of the glass sheet to further optimize the cutting accuracy of the laminated film. S3: Laminated film cutting, after selecting the glass that meets the order requirements, the results are transmitted to the laminated film cutting process, and the laminated film is cut according to the glass and order requirements.

[0032] The cut glass will enter the edge grinding process to remove burrs on the glass edge and grind the edge. This step ensures that the glass edge is smooth and burr-free, improving the safety and processing quality of the glass. S4: Edge grinding, grind the edge of the cut glass to remove burrs.

[0033] The edge-grinded glass will enter the cleaning machine for cleaning, using deionized water and special cleaning agents to remove surface dirt and dust. The cleaned glass will be dried to ensure that there are no water stains and impurities on the surface, reaching the best clean state, in preparation for the subsequent laying of laminated film. S5: Cleaning and drying, the edge-grinded glass will be sent to the cleaning machine, and deionized water and cleaning agents will be used to remove surface dirt and dust; after cleaning, the glass will pass through the drying section to ensure that there are no water stains and impurities on the surface.

[0034] Place the two cleaned and dried glass sheets on the workbench, and lay a layer of cut laminated film (PVB film) between the two glass sheets. This step ensures that the laminated film is laid evenly without wrinkles and bubbles. S6: Laying laminated film, place the two cleaned and dried glass sheets on the workbench, and lay a layer of cut laminated film (PVB film) between the two glass sheets, ensuring that the film is evenly covered without wrinkles and bubbles.

[0035] In the initial pressing step, the glass sheet with laminated film is placed in the initial pressing machine, and the glass and the laminated film are initially pressed together through hot pressing and vacuum degassing. The initial pressing ensures that the laminated film and the glass sheet are tightly fitted, and the bubbles in the interlayer are eliminated, laying the foundation for the subsequent autoclave treatment. S7: Initial pressing, the glass sheet with laminated film is placed in the initial pressing machine, and the glass and the laminated film are initially pressed together through hot pressing and vacuum degassing, ensuring that the film and the glass are tightly fitted and the bubbles in the interlayer are eliminated.

[0036] After the initial pressing, the glass sheets are sent into the autoclave, and the laminated film is completely bonded to the glass sheets through high temperature and high pressure treatment. The autoclave treatment is usually carried out at 130-145℃ and 10-15 atmospheres of pressure for 1-2 hours to ensure that the final laminated glass has high strength and high quality. S8: Autoclave, the glass sheets after the initial pressing are sent into the autoclave, and the laminated film is completely bonded to the glass through high temperature and high pressure; the autoclave treatment is usually carried out at 130-145℃ and 10-15 atmospheres of pressure for 1-2 hours.

[0037] After the laminated glass after autoclave treatment cools down, it is subjected to final appearance and quality inspection to ensure that there are no defects such as bubbles, impurities and cracks. The edges of the glass are trimmed to ensure that the glass size meets the requirements and meets the customer's quality standards. S9: Inspection and trimming, after the glass after autoclave treatment cools down, it is subjected to final appearance and quality inspection to ensure that there are no defects such as bubbles, impurities and cracks, and the edges are trimmed to ensure that the size meets the requirements.

[0038] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention has various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for arranging laminated glass in an automatic sheet sorting system, characterized in that: The following steps are involved: S1: Use X-ray scanning to inspect glass raw materials and enter the specifications of the glass (such as thickness and size) into the MES (Manufacturing Execution System); S2: Order input and matching, the system retrieves data according to order requirements; S3: Laminated film cutting, start cutting laminated film according to glass and order requirements; S4: Edge grinding, grinding the edges of the cut glass to remove burrs; S5: Clean and dry, remove dirt and dust from the surface and ensure that there is no water stains and impurities on the surface; S6: Laying of laminated film: Laying a layer of cut laminated film (PVB film) between two pieces of glass; S7: Initial pressing, through heat pressing and vacuum degassing, the glass and laminated film are initially pressed together; S8: Autoclave, which makes the laminated film and glass bond thoroughly through high temperature and high pressure; S9: Inspection and trimming, conduct appearance and quality inspection to ensure that the dimensions meet the requirements.

2. The automatic sheet sorting system for laminated glass according to claim 1 is characterized in that In S1, the processing method of the matching glass is: S101: Preliminary scanning and classification, determining the thickness and size of the glass through scanning, and entering the data into the database for subsequent processing; S102: Flatness and surface inspection: perform flatness inspection on the glass, check edge integrity and surface cleanliness, and mainly detect oil stains, stains or other surface contaminants; S103: Optical quality inspection, inspecting the optical quality of the glass, focusing on defects that affect the appearance, such as bubbles, ripples and impurities; S104: Surface defect detection, check the scratches and stains on the glass surface, which directly affect the appearance quality of the glass; S105: Internal stress detection, using polarizing mirrors and other equipment to detect the internal stress distribution of the glass to prevent the glass from spontaneously breaking due to uneven stress during processing or use; S106: Glass transmittance and optical performance testing, using optical instruments to measure the glass's transmittance and optical performance to ensure that it meets the requirements of high-standard applications (such as building curtain walls or photovoltaic glass); S107: Classification and grading: According to the above test results, the glass is classified into qualified products and unqualified products, and the qualified products are further classified into slightly defective products and complete products.

3. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S101: using the Canny edge detection algorithm to identify the glass edge in the X-ray scan image, as shown in formula (1)-formula (2); Formula (1); Formula (2); in, is the image pixel value, is the gradient image, is the area of ​​the region, is the edge length.

4. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S102: Using laser interferometry and smoothing algorithm to detect the flatness, edge integrity and surface cleanliness of the glass, as shown in formula (3) to formula (5); Formula (3); Formula (4); Formula (5); in, is the laser measurement image, is the surface image, and Threshold is the threshold for detecting stains.

5. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S103: Analyze the optical image using Fourier transform to detect bubbles, ripples and impurities in the glass, as shown in formula (6); Formula (6); Among them, through Fourier transform The optical image Transformed to the frequency domain, defects present characteristic patterns in the frequency domain; formulas are used to detect these characteristic patterns to identify defects.

6. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S104: Detect scratches and stains on the glass surface using edge detection and morphological analysis algorithms, as shown in equations (7) to (8); Formula (7); Formula (8); is the gradient of the surface image, which is used to identify intensity changes in the image that may indicate scratches; Represents a morphological opening or closing operation. Structuring Element is a structural element of a morphological operation.

7. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S105: Detecting stress distribution inside the glass using photoelastic effect and polarized mirror image, as shown in formula (9); Formula (9); The formula for calculating the light intensity under the polarizer is Angle with optical axis , and thus infer the stress distribution inside the glass.

8. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S106: Use a spectrophotometer to measure the light transmittance and other optical properties of the glass, as shown in formula (10)-formula (11); Formula (10); Formula (11); The transmittance is calculated by the incident light intensity. and transmitted light intensity The ratio calculation is is the wavelength of light; the formula combines the transmittance of different wavelengths and weights to evaluate the overall optical performance of the glass.

9. The method for arranging laminated glass in an automatic sheet sorting system according to claim 2, characterized in that In step S1, the size analysis of the glass is specifically performed according to the following steps: S107: using a machine learning algorithm, such as a support vector machine (SVM) or a decision tree, based on the detected data to classify the glass into qualified products, slightly defective products, or unqualified products, as specifically shown in formula (12); Formula (12); The support vector machine (SVM) algorithm is used to classify the glass. The input feature vector f includes thickness, flatness, optical quality, surface scratch stress, transmittance, etc. The SVM model is used to determine the type of glass. The algorithm and formula of each step are specially designed to optimize the detection process of the automatic glass sorting system to ensure the accuracy and efficiency of each detection process.

10. The method for arranging laminated glass sheets in an automatic sheet sorting system according to claim 3, characterized in that: In the step S3, the cutting process of the laminated film is dynamically adjusted according to the glass specifications and order requirements entered into the MES system to ensure that the cut laminated film accurately matches the glass sheet in shape and size.

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