Multi-site AOI data association defect detection method and detection system

Abstract

The invention particularly relates to a multi-station AOI data association defect detection method and detection system, and the detection method comprises the following steps: a first process station step: starting production, and manually inputting a roll number by an operator; the detection system receives a signal of the AOI encoder and sets a delay distance; a Data Matrix two-dimensional bar code containing the production batch number of the coil stock and the length meter number of the position where the coil stock is located is printed in a jet printing mode per meter; in the back-end process station step, acquiring defect associated data of the roll in the previous process station from the database; the detection system receives a signal of the AOI encoder and reads a two-dimensional bar code at each meter by using a line scanning detection module; analyzing information in the two-dimensional bar code, and matching the information with defect information in a database; according to a matching result, screening, correcting and outputting a defect coordinate position; when a roll changing signal is received, defect associated information in the database is updated; and in the final process station, jet printing and marking are accurately carried out according to the defect coordinate position.

Description

Technical Field

[0001] The present invention belongs to the field of optical detection, and in particular relates to a multi-site AOI data-related defect detection method and a detection system. Background Art

[0002] In the manufacturing process of continuous roll products such as optical films, textiles, and metal foils, companies need to detect defects in products. In order to help subsequent processes better handle these defects, such as evaluating yields, sorting materials, and allowing workers to quickly find problem areas for review, these defects usually need to be marked.

[0003] Taking the production of polarizing film as an example, the whole process is divided into several stations: first PVA stretching and dyeing, then PSA coating, and finally coil processing. Each station needs to use AOI (automatic optical inspection) system to detect defects, and sometimes defects are marked on site.

[0004] In order to save costs, some factories have adopted a new strategy: only detect defects in the early stage without marking them immediately, but save the defect information and mark them uniformly in the later process. This can reduce the initial investment and the cost of maintaining printing equipment. According to the defect information detected in the early process, the factory can decide whether to cut, screen or rework as needed, and mark it in the last step. In this way, the marking standard can be adjusted according to different customer needs to ensure product quality.

[0005] There are two traditional ways to transmit defect information: one is to simply mark near the defect, but this can only tell the subsequent process the approximate location, and cannot accurately determine where the problem is; the other is to print a two-dimensional barcode next to the defect location, which contains a lot of information, such as defect type, specific location, and roll number. This barcode can be read in the subsequent process to accurately mark the defect location. However, this method also has disadvantages. If the width of the product changes, an additional system is required to adjust the position of the scanning device, which increases costs and space requirements. In addition, the amount of information that a barcode can carry is limited. If there are many defects, it cannot hold all the information. Summary of the invention

[0006] The purpose of the present invention is to provide a multi-site AOI data correlation defect detection method. It is another purpose of the present invention to provide a multi-site AOI data correlation defect detection system to solve the problems raised in the above background technology.

[0007] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0008] A multi-site AOI data correlation defect detection method, comprising the steps of:

[0009] First process station steps:

[0010] Production starts and the operator manually enters the roll number;

[0011] The detection system receives the AOI encoder signal and sets the delay distance;

[0012] A Data Matrix 2D barcode containing the production batch number and the length of the location is printed on each meter.

[0013] Confirm the correctness and recognizability of the 2D barcode;

[0014] When receiving the roll change signal, stop printing and save the defect data of the current roll to the database;

[0015] Complete defect detection and 2D barcode marking at the first process station;

[0016] Back-end process station steps:

[0017] Production starts, using a handheld barcode reader to enter the pre-arranged roll number;

[0018] Obtain the defect-related data of the roll at the previous process station from the database;

[0019] The inspection system receives the AOI encoder signal and uses the line scan inspection module to read the 2D barcode at every meter;

[0020] Parse the information in the 2D barcode and match it with the defect information in the database;

[0021] According to the matching results, the defect coordinates are screened, corrected and output;

[0022] When a roll change signal is received, the defect-related information in the database is updated;

[0023] At the final process station, precise printing marks are performed based on the defect coordinates.

[0024] Furthermore, in the back-end process station, "the information in the two-dimensional barcode is parsed and matched with the defect information in the database, and the defect coordinate position is screened, corrected and output according to the matching result;" specifically, the steps include:

[0025] Data transmission:

[0026] After the line scanning detection module reads the two-dimensional barcode on the side, the read barcode information is sent to the database management unit through the communication module;

[0027] The database management unit searches for defect information related to the received two-dimensional barcode information, including defect type and relative distance, and organizes the information into a format suitable for use by the second printing module;

[0028] Type comparison:

[0029] After receiving the defect information transmitted by the database management unit, the control module of the second printing module will compare the defect information and determine which defects need to be marked;

[0030] Filter the defects that need to be marked:

[0031] The control module selects the defects that need to be marked according to the results of type comparison and prepares the corresponding printing instructions;

[0032] For each defect that needs to be marked, the system generates a printing instruction containing the defect type, location coordinates and other necessary information;

[0033] Use the coordinates provided by the associated data to print at precise locations:

[0034] According to the selected defects and their coordinate position information, the control module will instruct the second printing module to perform precise printing on the coil;

[0035] The printing module will mark the defects at the corresponding positions according to the printing instructions issued by the control module to ensure the accuracy and reliability of the marking.

[0036] "The control module of the second printing module will compare the defect information by type to determine which defects need to be marked;" Specifically, the database management unit presets a set of quality standards, which define the maximum allowable number and severity of various defect types. On this basis, the threshold value of the quality standard can be manually input. The database management unit sets the screening rules according to the preset quality standards and the threshold value of the manually input quality standard. The control module compares the types based on the screening rules, and according to the results of the type comparison, it screens out the defects that need to be marked and generates printing instructions. The printing instructions will guide the second printing module to print the mark at a specific location on the web.

[0037] Further, the screening rules include:

[0038] Defect size: Defects exceeding a threshold size need to be marked;

[0039] Defect location: Defects that occur in a specific area need to be marked;

[0040] Defect severity: Defects that exceed the threshold need to be marked.

[0041] Defect Type: Defects of the set type are always marked.

[0042] A multi-site AOI data association defect detection system, comprising:

[0043] Defect Detection Unit:

[0044] Including AOI modules equipped at each process station. The AOI modules detect product surface defects in real time at each process station of the continuous roll-to-roll process and record the specific information of the defects;

[0045] Includes AOI encoder to record the position information of the coil running;

[0046] A control module is included, which is used to control the operation of the AOI module and receive a position signal from an encoder;

[0047] Location division unit:

[0048] It includes a first printing module arranged on the side of the product at the first process station, and prints a two-dimensional bar code containing position information and a production batch number on the side of the coil at a certain length (per meter);

[0049] It includes a control module, which is used to control the operation of the first printing module and ensure that the barcode printed is accurately positioned;

[0050] Includes an encoder to record the position information of the coil to ensure accurate printing of the barcode;

[0051] Defect information transmission unit:

[0052] A data processing module is included to process defect information detected by the AOI module and calculate the relative distance between the defect and the nearest two-dimensional barcode;

[0053] It includes a communication module for transmitting defect information and corresponding two-dimensional bar code associated data to a database management unit;

[0054] It includes a control module, which is used to control the workflow of the data processing module and the communication module to ensure accurate transmission of information;

[0055] Defect information reading unit:

[0056] It includes a line scanning detection module configured at the back-end process station to read the two-dimensional barcode on the side of the coil;

[0057] It includes a control module for controlling the operation of the line scanning detection module and ensuring that the read barcode information is accurate;

[0058] It includes a communication module for transmitting the read barcode information to the database management unit to obtain the corresponding defect information;

[0059] Defect marking unit:

[0060] It includes a second printing module configured at the back-end process station, which is used to accurately print defect marks on the coil according to the defect information obtained from the database;

[0061] It includes a control module, which is used to control the operation of the second printing module and ensure the accuracy of the printing position;

[0062] A communication module is included for obtaining defect information from a database management unit and transmitting it to a control module;

[0063] Database Management Unit:

[0064] It includes a data storage module for storing defect information uploaded by all process sites and its associated data with the two-dimensional barcode;

[0065] Includes a data processing module for processing and updating data in the database to ensure data consistency and integrity;

[0066] Includes a communication module for exchanging data with other units.

[0067] Furthermore, the two-dimensional barcode adopts the Data Matrix encoding format. The two-dimensional barcode contains the position length in meters and the production batch number, wherein the position length in meters records the specific position of the barcode in the entire roll of continuous roll products.

[0068] The production batch number is measured in meters and identifies the production batch to which the coil belongs, ensuring that it can be traced back to the specific production time and production line.

[0069] Furthermore, the line scanning detection module includes a line scanning camera fixedly installed at the back-end process station, and the line scanning camera adopts a CCD line scanning camera with a 4K resolution.

[0070] Beneficial effects: The present invention is a mode for transmitting AOI defect data across process sites, creating the advantage of larger capacity data flow transmission. The two-dimensional barcode mark information is recorded completely, and through record tracking, it supports the front and back multi-site processes. The product defect data is still accurately associated, and the defect coordinate position is accurately analyzed. When the printing and marking operation is implemented at the back-end process station, the defects can be more accurately and without omissions. In the two-dimensional barcode reading mode, a line scanning detection module is used to replace the traditional barcode scanner. The vertical position coordinates of the two-dimensional barcode mark can be defined with high precision, greatly improving the accuracy of data association, and a fixed position for large-scale horizontal detection. The two-dimensional barcode mark and the film edge position are read simultaneously, without the need for a motor to drive the edge search, and the structure is simple.

[0071] It is mainly reflected in the following aspects:

[0072] High-precision defect detection and marking: Through the multi-site AOI data association platform, efficient and accurate transmission of defect detection information between multiple process sites is achieved. By printing a two-dimensional barcode (Data Matrix) containing location information at the first process station and reading these barcodes using a line scan detection module at the subsequent process station, the defect position is accurately located, allowing the back-end process to accurately mark defects.

[0073] Information capacity and data transfer optimization: Compared with the traditional method of printing marking points or two-dimensional barcodes, the Data Matrix encoding format used in this invention has a higher information density and can record more data, thus overcoming the problem of limited information capacity in traditional methods. By recording the production batch number and the length of the position in meters of the coil, an accurate association between defects and barcodes is established, optimizing the data transfer process.

[0074] Simplify system architecture and reduce costs: The present invention utilizes a fixed-position line scan detection module (with a 4K resolution CCD line scan camera) to replace the traditional barcode scanner that needs to be moved, avoiding the need to adjust the scanner position as the width of the roll changes, simplifying the system architecture, and reducing equipment investment and maintenance costs.

[0075] Improve production efficiency and flexibility: This solution not only improves the accuracy of defect detection and marking, but also enhances production flexibility. By storing and managing defect information through the database management unit, defect control conditions can be adjusted according to different customer needs to ensure that the quality of the final product meets the requirements.

[0076] In summary, the technical solution of the present invention significantly improves the accuracy and efficiency of defect detection and marking in a continuous roll-to-roll process through a series of innovative means, while simplifying the system structure and reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] Figure 1 It is a diagram illustrating the principle of the present invention;

[0078] Figure 2 It is a partial method flow chart of the present invention;

[0079] Figure 3 It is a partial method flow chart of the present invention. DETAILED DESCRIPTION

[0080] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0081] The present invention provides a multi-site AOI data correlation defect detection method, such as Figure 1-Figure 3 As shown, the steps include:

[0082] First process station steps:

[0083] Production starts and the operator manually enters the roll number;

[0084] The detection system receives the AOI encoder signal and sets the delay distance;

[0085] A Data Matrix 2D barcode containing the production batch number and the length of the location is printed on each meter.

[0086] Confirm the correctness and recognizability of the 2D barcode;

[0087] When receiving the roll change signal, stop printing and save the defect data of the current roll to the database;

[0088] Complete defect detection and 2D barcode marking at the first process station;

[0089] Back-end process station steps:

[0090] Production starts, using a handheld barcode reader to enter the pre-arranged roll number;

[0091] Obtain the defect-related data of the roll at the previous process station from the database;

[0092] The inspection system receives the AOI encoder signal and uses the line scan inspection module to read the 2D barcode at every meter;

[0093] Parse the information in the 2D barcode and match it with the defect information in the database;

[0094] According to the matching results, the defect coordinates are screened, corrected and output;

[0095] When a roll change signal is received, the defect-related information in the database is updated;

[0096] At the final process station, precise printing marks are performed based on the defect coordinates.

[0097] In a specific embodiment, a multi-site AOI data correlation defect detection method includes the steps of:

[0098] like Figure 2 As shown, the first process station steps:

[0099] 1. Production starts

[0100] 2. The staff manually enters the AOI roll number of the secondary roll

[0101] 3. Receive AOI encoder signal

[0102] 4. Delay setting distance

[0103] 5. Print and mark 2D barcode positioning points every meter

[0104] 6. Confirm the correctness and legibility of the 2D barcode

[0105] 7. Receive the roll change signal

[0106] 8. The database records the correlation data between the two-dimensional barcode and the process defect

[0107] 9. End of production

[0108] like Figure 3 As shown, the second and third process steps are:

[0109] 1. Production starts

[0110] 2. Input the pre-arranged AOI volume number using the handheld barcode reader

[0111] 3. Database captures relevant information of previous processes

[0112] 4. Receive AOI encoder signal

[0113] 5. Read 2D barcode positioning points every meter

[0114] 6. Screening, correction and output of defect coordinates

[0115] 7. Receive the roll change signal

[0116] 8. The database records the correlation data between the two-dimensional barcode and the process defect

[0117] 9. End of production

[0118] In a preferred embodiment, the back-end process station "parses the information in the two-dimensional barcode and matches it with the defect information in the database, and selects, corrects and outputs the defect coordinate position according to the matching result;" specifically includes the steps of:

[0119] Data transmission:

[0120] After the line scanning detection module reads the two-dimensional barcode on the side, the read barcode information is sent to the database management unit through the communication module;

[0121] The database management unit searches for defect information related to the received two-dimensional barcode information, including defect type and relative distance, and organizes the information into a format suitable for use by the second printing module;

[0122] Type comparison:

[0123] After receiving the defect information transmitted by the database management unit, the control module of the second printing module will compare the defect information and determine which defects need to be marked;

[0124] Filter the defects that need to be marked:

[0125] The control module selects the defects that need to be marked according to the results of type comparison and prepares the corresponding printing instructions;

[0126] For each defect that needs to be marked, the system generates a printing instruction containing the defect type, location coordinates and other necessary information;

[0127] Use the coordinates provided by the associated data to print at precise locations:

[0128] According to the selected defects and their coordinate position information, the control module will instruct the second printing module to perform precise printing on the coil;

[0129] The printing module will mark the defects at the corresponding positions according to the printing instructions issued by the control module to ensure the accuracy and reliability of the marking.

[0130] In a preferred embodiment, "the control module of the second printing module will perform a type comparison on the defect information to determine which defects need to be marked;" specifically, the database management unit presets a set of quality standards, which define the maximum allowable number and severity of various defect types. On this basis, a threshold value for manually input quality standards is configured. The database management unit sets screening rules based on the preset quality standards and the threshold value for manually input quality standards. The control module performs a type comparison based on the screening rules, and based on the results of the type comparison, screens out defects that need to be marked, generates printing instructions, and guides the second printing module to print marks at specific locations on the web through the printing instructions.

[0131] In a preferred embodiment, the screening rules include:

[0132] Defect size: Defects exceeding a threshold size need to be marked;

[0133] Defect location: Defects that occur in a specific area need to be marked;

[0134] Defect severity: Defects that exceed the threshold need to be marked.

[0135] Defect Type: Defects of the set type are always marked.

[0136] A multi-site AOI data association defect detection system, comprising:

[0137] Defect Detection Unit:

[0138] Including AOI modules equipped at each process station. The AOI modules detect product surface defects in real time at each process station of the continuous roll-to-roll process and record the specific information of the defects;

[0139] Includes AOI encoder to record the position information of the coil running;

[0140] A control module is included, which is used to control the operation of the AOI module and receive a position signal from an encoder;

[0141] Defect Detection Unit Details

[0142] 1. Components

[0143] The defect detection unit mainly includes the following components:

[0144] AOI module: Automatic optical inspection system, used to detect defects on the surface of continuous roll products.

[0145] AOI encoder: used to record the position information of the coil running.

[0146] Control module: controls the operation of the AOI module and receives the position signal from the encoder.

[0147] 2. Functional Description

[0148] Real-time detection: The AOI module detects defects on the surface of the coil in real time at each process station and records the specific information of the defects.

[0149] Position recording: The AOI encoder records the position information of the coil on the production line so that it can be associated with the defect information.

[0150] Data transmission: The control module transmits the detected defect information and location information to the defect information transmission unit for further processing and storage in the database.

[0151] 3. Working Principle

[0152] Inspection process: The AOI module is installed at each process station. When the coil passes through the AOI module, the system automatically scans and identifies surface defects.

[0153] Information recording: After the AOI module detects a defect, the AOI encoder records the location information of the coil when the defect occurs.

[0154] Data synchronization: The control module receives the defect information detected by the AOI module and the position information of the AOI encoder, ensures the synchronization of the two, and passes this information to the next link.

[0155] 4. Cooperate with other units

[0156] Cooperate with the position division unit: After the AOI module detects a defect, it calculates the relative distance between the defect and the nearest two-dimensional barcode and passes the information to the position division unit.

[0157] Cooperate with the defect information transmission unit: The defect information detected by the AOI module is transmitted to the defect information transmission unit through the control module for further processing and storage.

[0158] Cooperate with the database management unit: The defect information detected by the AOI module is ultimately stored and managed by the database management unit.

[0159] Location division unit:

[0160] It includes a first printing module arranged on the side of the product at the first process station, and prints a two-dimensional bar code containing position information and a production batch number on the side of the coil at a certain length (per meter);

[0161] It includes a control module, which is used to control the operation of the first printing module and ensure that the barcode printed is accurately positioned;

[0162] Includes an encoder to record the position information of the coil to ensure accurate printing of the barcode;

[0163] Specific details of the location division unit

[0164] 1. Components

[0165] The location division unit mainly includes the following components:

[0166] The first printing module: installed in the first process station, used to print a two-dimensional barcode on the side of the coil.

[0167] Control module: responsible for controlling the operation of the first printing module and ensuring the accurate position of the printed barcode.

[0168] Encoder: Used to record the position information of the coil to ensure accurate printing of the barcode.

[0169] 2. Functional Description

[0170] Periodic printing: The first printing module prints a two-dimensional barcode containing position information and production batch number on the side of the coil at regular intervals (for example, every meter).

[0171] Position recording: The control module records the position information of each printing through the encoder to ensure the consistency of the barcode and the coil position.

[0172] Information transmission: The printed barcode information is transmitted to the defect information transmission unit so as to be stored in association with the defect information.

[0173] 3. Working Principle

[0174] Printing process: At the first process station, when the web passes through the first printing module, the module automatically prints a two-dimensional barcode according to a preset distance parameter (e.g., per meter).

[0175] Information coding: The barcode content includes the length of the location in the entire roll of material and the production batch number, forming a unique combination of content.

[0176] Barcode Verification: After printing is completed, the system will automatically verify the correctness and legibility of the barcode.

[0177] 4. Cooperate with other units

[0178] Cooperate with the defect detection unit: After the AOI module detects a defect, it calculates the relative distance between the defect and the nearest two-dimensional barcode and passes the information to the position division unit.

[0179] Cooperate with the defect information transmission unit: the printed two-dimensional bar code information is transmitted to the defect information transmission unit through the control module, and is further processed and stored in the database.

[0180] Cooperate with the database management unit: The two-dimensional bar code information printed by the location division unit is ultimately stored and managed by the database management unit.

[0181] Through the above-mentioned specific details, the position division unit can effectively periodically print a two-dimensional barcode containing position information at the first process station, and coordinate with other units to ensure the accurate association of defect information with the barcode.

[0182] Defect information transmission unit:

[0183] A data processing module is included to process defect information detected by the AOI module and calculate the relative distance between the defect and the nearest two-dimensional barcode;

[0184] It includes a communication module for transmitting defect information and corresponding two-dimensional bar code associated data to a database management unit;

[0185] It includes a control module, which is used to control the workflow of the data processing module and the communication module to ensure accurate transmission of information;

[0186] Details of the defect information transfer unit

[0187] 1. Components

[0188] The defect information transmission unit mainly includes the following components:

[0189] Data processing module: used to process the defect information detected by the AOI module and calculate the relative distance between the defect and the nearest two-dimensional barcode.

[0190] Communication module: responsible for transmitting defect information and corresponding two-dimensional barcode associated data to the database management unit.

[0191] Control module: controls the workflow of the data processing module and the communication module to ensure accurate transmission of information.

[0192] 2. Functional Description

[0193] Information association: Associate the defect information detected by the AOI module with the nearest 2D barcode and calculate the relative distance between the defect and the barcode.

[0194] Data storage: Write defect type, relative distance and two-dimensional barcode code into the database to establish the correlation data between defects and barcodes.

[0195] Data transmission: The processed defect information and associated data are transferred to the database management unit for storage.

[0196] 3. Working Principle

[0197] Information processing: The data processing module receives the defect information from the AOI module and calculates the relative distance between the defect and the nearest two-dimensional barcode.

[0198] Data association: Associate defect type, relative distance and two-dimensional barcode code to form a complete defect information record.

[0199] Data synchronization: The control module ensures the synchronization of information processing and transmission, and transmits data to the database management unit through the communication module.

[0200] 4. Cooperate with other units

[0201] Cooperate with the defect detection unit: receive the defect information detected by the AOI module and calculate the relative distance between the defect and the nearest 2D barcode.

[0202] Cooperate with the position division unit: obtain the two-dimensional barcode information printed by the position division unit to calculate the relative distance between the defect and the barcode.

[0203] Cooperate with the database management unit: pass the processed defect information and related data to the database management unit for storage.

[0204] Through the above specific details, the defect information transmission unit can effectively associate the defect information detected by the AOI module with the two-dimensional barcode, and transmit this information to the database management unit for storage, ensuring the accurate association between the defect information and the barcode.

[0205] Defect information reading unit:

[0206] It includes a line scanning detection module configured at the back-end process station to read the two-dimensional barcode on the side of the coil;

[0207] It includes a control module for controlling the operation of the line scanning detection module and ensuring that the read barcode information is accurate;

[0208] It includes a communication module for transmitting the read barcode information to the database management unit to obtain the corresponding defect information;

[0209] Details of the defect information reading unit

[0210] 1. Components

[0211] The defect information reading unit mainly includes the following components:

[0212] Line scanning detection module: uses a 4K CCD camera to read the two-dimensional barcode on the side of the coil.

[0213] Control module: responsible for controlling the work of the line scanning detection module and ensuring the accuracy of the barcode information read.

[0214] Communication module: responsible for transmitting the read barcode information to the database management unit to obtain the corresponding defect information.

[0215] 2. Functional Description

[0216] Read barcode: The line scanning detection module reads the two-dimensional barcode on the side of the coil to obtain the position information and code.

[0217] Information parsing: The control module parses the location information (length in meters) and production batch number in the barcode.

[0218] Data transmission: The communication module transmits the parsed information to the database management unit to obtain the corresponding defect information.

[0219] 3. Working Principle

[0220] Reading process: The line scanning detection module reads the 2D barcode on the side when the coil passes.

[0221] Information parsing: The control module parses the location information and batch number in the barcode.

[0222] Data synchronization: The communication module matches the parsed information with the defect information in the database and obtains all defect information associated with the barcode.

[0223] 4. Cooperate with other units

[0224] Cooperate with the defect information transmission unit: receive the barcode information provided by the defect information transmission unit for reading and parsing.

[0225] Cooperate with the database management unit: pass the parsed barcode information to the database management unit to obtain the corresponding defect information.

[0226] Cooperate with the defect marking unit: pass the acquired defect information to the defect marking unit for accurate printing and marking.

[0227] Defect marking unit:

[0228] It includes a second printing module configured at the back-end process station, which is used to accurately print defect marks on the coil according to the defect information obtained from the database;

[0229] It includes a control module, which is used to control the operation of the second printing module and ensure the accuracy of the printing position;

[0230] A communication module is included for obtaining defect information from a database management unit and transmitting it to a control module;

[0231] Specific details of the defect marking unit

[0232] 1. Components

[0233] The defect marking unit mainly includes the following components:

[0234] Second printing module: installed at the back-end process station, used to print defect marks on the coil.

[0235] Control module: responsible for controlling the operation of the second printing module and ensuring the accuracy of the printing position.

[0236] Communication module: responsible for obtaining defect information from the database management unit and passing it to the control module.

[0237] 2. Functional Description

[0238] Printing mark: According to the defect information obtained from the database, the defect mark is accurately printed on the coil.

[0239] Position control: The control module controls the printing device to mark at the specified position according to the coordinate position in the defect information.

[0240] Information comparison: The communication module obtains defect information from the database and compares it with the actual test results to ensure the accuracy of the marking.

[0241] 3. Working Principle

[0242] Information acquisition: The communication module obtains defect information from the database management unit, including defect type, relative position and corresponding two-dimensional barcode information.

[0243] Position determination: The control module controls the second printing module to perform precise printing on the web according to the coordinate position in the defect information.

[0244] Marking execution: The second printing module prints defect marks on the web according to the instructions of the control module.

[0245] 4. Cooperate with other units

[0246] Cooperate with the defect information reading unit: obtain the two-dimensional barcode information read by the line scanning detection module to determine the printing position.

[0247] Cooperate with the database management unit: obtain defect information from the database management unit and pass it to the control module.

[0248] Cooperate with the defect information transmission unit: ensure that the acquired defect information is the latest and consistent with the actual test results.

[0249] Database Management Unit:

[0250] It includes a data storage module for storing defect information uploaded by all process sites and its associated data with the two-dimensional barcode;

[0251] Includes a data processing module for processing and updating data in the database to ensure data consistency and integrity;

[0252] Includes a communication module for exchanging data with other units.

[0253] 1. Components

[0254] The database management unit mainly includes the following components:

[0255] Data storage module: used to store defect information uploaded by all process sites and its associated data with the two-dimensional barcode.

[0256] Data processing module: used to process and update data in the database to ensure data consistency and integrity.

[0257] Communication module: responsible for data exchange with other units (such as defect information transmission unit, defect information reading unit, etc.).

[0258] 2. Functional Description

[0259] Data storage: Stores defect information uploaded by all process sites and its associated data with the two-dimensional barcode.

[0260] Data retrieval: Retrieve defect information and corresponding 2D barcode information for a specific batch as needed.

[0261] Data update: Update defect information in the database in real time to reflect the latest inspection results.

[0262] 3. Working Principle

[0263] Data entry: Receive defect information and its associated data with the two-dimensional barcode from the defect information transmission unit, and store it in the database.

[0264] Data query: When you need to obtain defect information for a batch, retrieve the corresponding defect information from the database based on the barcode code.

[0265] Data synchronization: Ensure that the data in the database is synchronized with the actual inspection results and update any new defect information in a timely manner.

[0266] 4. Cooperate with other units

[0267] Cooperate with the defect information transmission unit: receive the defect information sent by the defect information transmission unit and the associated data with the two-dimensional barcode, and store them in the database.

[0268] Cooperate with the defect information reading unit: retrieve corresponding defect information from the database according to the barcode information provided by the defect information reading unit.

[0269] Cooperate with the defect marking unit: provide defect information to the defect marking unit to ensure that the marking unit can accurately print marks at the specified position.

[0270] In a preferred embodiment, the two-dimensional barcode adopts the Data Matrix encoding format, and the two-dimensional barcode contains the position length in meters and the production batch number, wherein the position length in meters records the specific position of the barcode in the entire roll of continuous roll product, in meters, and the production batch number identifies the production batch to which the roll belongs, ensuring that it can be traced back to the specific production time and production line.

[0271] Specific details of 2D barcodes

[0272] 1. Encoding format

[0273] The present invention adopts Data Matrix encoding format, which is a matrix-type two-dimensional barcode with high information density, and can store a large amount of information even in a small area. This characteristic of Data Matrix makes it particularly suitable for use in the limited space on the side of continuous roll products.

[0274] 2. Content composition

[0275] Each two-dimensional barcode contains two parts: location length in meters and production batch number.

[0276] Position length in meters: record the specific position of the barcode in the entire roll of continuous roll product, in meters.

[0277] Production batch number: Identifies the production batch to which the coil belongs, ensuring that it can be traced back to the specific production time and production line.

[0278] 3. Printing frequency

[0279] At the first process station, a two-dimensional barcode is printed every meter to ensure sufficient information density and facilitate accurate positioning in subsequent processes.

[0280] 4. Printing quality

[0281] To ensure the readability of the barcode, the printing module is calibrated to ensure the clarity and contrast of the barcode. In addition, the printed barcode needs to be verified to confirm its legibility.

[0282] 5. Related Information

[0283] When the AOI module detects a defect, it calculates the relative distance between the defect and the nearest 2D barcode and stores the defect type, relative distance and 2D barcode code in the database. This allows an accurate association between the defect and the barcode to be established.

[0284] 6. Reading method

[0285] The back-end process station uses a line scan detection module to read the 2D barcode on the side of the coil. The line scan detection module uses a 4K CCD with a 375mm shooting range and a 90-micron resolution, which can accurately read the position information and code in the barcode.

[0286] 7. Information analysis

[0287] After parsing the information in the barcode, the relevant defect information is searched in the database through the barcode's unique code to obtain the specific location and type of the defect. This information will then be used for accurate printing and marking operations.

[0288] In a preferred embodiment, the line scanning detection module includes a line scanning camera fixedly installed at a back-end process station, and the line scanning camera is a CCD line scanning camera with a 4K resolution.

[0289] Module installation: The line scan detection module is installed in a fixed position at the back-end process station and does not need to be moved as the width of the coil changes. It can cover the width range from the edge to the center of the coil and is suitable for a maximum width change of 750mm.

[0290] Detection technology: Using 4K resolution CCD line scan camera with 375mm shooting range and 90 micron resolution, it can capture clear images on high-speed production lines to ensure the recognition accuracy of 2D barcodes.

[0291] Light source configuration: Equipped with high-intensity LED line light source to ensure that the 2D barcode on the side of the coil has sufficient contrast under different ambient lighting conditions, making it easy for the line scan camera to read.

[0292] Control system: The line scan detection module is driven by a dedicated controller. The controller starts or stops the scanning action and processes the scanning data synchronously by receiving the signal from the AOI module.

[0293] Data processing: The scanned image data is transmitted to the central processing unit through a high-speed interface. The processing unit is responsible for decoding the two-dimensional barcode and extracting the location information and production batch number.

[0294] Software support: Built-in decoding algorithm supports fast decoding of 2D barcodes in Data Matrix format, and can handle various complex barcode deformation situations to ensure high reading rate.

[0295] Integrated interface: Provides a standardized communication interface to connect with the database management system to achieve real-time reading and updating of defect information, ensuring the accuracy and timeliness of defect information.

[0296] Easy maintenance: The modular design makes maintenance easier. You only need to clean the lens and light source regularly and check the cable connections, which reduces maintenance costs and downtime.

[0297] Through the above configuration, the line scanning detection module can efficiently and accurately read the side 2D barcode, providing a reliable position reference for subsequent defect marking.

[0298] The present invention uses a line scanning detection module to replace the traditional barcode scanner to read the two-dimensional barcode mark on the side. The line scanning system uses a 4K CCD, with a shooting range of 375mm, a resolution of 90 microns, and a change in the web width of the web less than 750mm. The fixed detection unit position can be used for large-scale lateral detection. The two-dimensional barcode mark and the edge position are read simultaneously. There is no need for a motor to drive the edge search and no need for a mobile scanning detection unit that changes with the web width. The structure is simple and the construction cost is low. For traditional barcode scanners, the faster the scanning speed, the smaller the shooting range, and the larger the shooting range, the slower the scanning speed. Under the high-speed operation conditions of an online continuous production line, the scanner can only maintain a small-range shooting structure and then assist in moving the position of the scanner to respond to the change in the web width. The structure is complex and a device that assists in searching for the web edge at the front end is required to provide the traditional scanner with an accurate mobile shooting position, so the construction cost is high. The biggest innovation is to print a two-dimensional barcode per meter on the side of the product at the first process station. The content of the two-dimensional barcode does not record the type of defect, coordinates and other information, but records the length of the barcode in the entire roll of continuous roll products, as well as the specific code of this barcode. The code content is the production batch number of this roll of material, combined with the length information to generate a unique combination of content, presented in Data Matrix. Its high information density allows it to be printed in a very small size. When the defect is detected by the AOI of the station, the relative distance between the closest barcode is calculated, and the exclusive code of the barcode is captured at the same time. The type of defect is also written into the database (DataBase) to establish strict correlation data between the two-dimensional barcode and the defect. Data chain architecture of multi-site AOI data association platform ( Figure 1 ).

[0299] In the back-end process, the operator enters the roll number of the upcoming operation on the system, retrieves the associated file data of the roll at the previous station from the database, reads the fixed-pitch two-dimensional barcode on the side of the product with a line scanning detection module, analyzes the meter number and exclusive code in the barcode, searches the database with this code, obtains all the defect data associated with this barcode code, and obtains all the existing defects and their coordinate positions and defect types at the relative distance of this two-dimensional barcode. This data is transmitted to the back-end printing and marking system, and after type comparison, the defects that need to be marked are selected, and the coordinate positions provided by the associated data are used for precise position printing.

[0300] The present invention is a mode of transmitting AOI defect data across process sites, creating the advantage of larger data flow transmission. The two-dimensional barcode mark information is recorded completely. Through record tracking, it supports the front and back multi-site processes. The product defect data is still accurately associated, and the defect coordinate position is accurately analyzed. When the printing and marking operation is implemented at the back-end process station, the defects can be more accurately and without omissions. In the two-dimensional barcode reading mode, a line scanning detection system is used to replace the traditional barcode scanner. The vertical position coordinates of the two-dimensional barcode mark can be defined with high precision, greatly improving the accuracy of data association, and a fixed position for large-scale horizontal detection. The two-dimensional barcode mark and the film edge position are read simultaneously, without the need for a motor to drive the edge search, and the structure is simple.

[0301] The technical solution of this application not only improves the operating reliability of the high-voltage and high-power regulated power supply through a highly integrated and intelligent design, but also greatly enhances the maintainability and ease of operation of the system, providing an efficient, stable and easy-to-maintain solution for related fields, and has important practical value and technological innovation significance.

Claims

1. A multi-site AOI data correlation defect detection method, characterized in that: Includes steps: First process station steps: Production starts and the operator manually enters the roll number; The detection system receives the AOI encoder signal and sets the delay distance; A Data Matrix 2D barcode containing the production batch number and the length of the location is printed on each meter. Confirm the correctness and recognizability of the 2D barcode; When receiving the roll change signal, stop printing and save the defect data of the current roll to the database; Complete defect detection and 2D barcode marking at the first process station; Back-end process station steps: Production starts, using a handheld barcode reader to enter the pre-arranged roll number; Obtain the defect-related data of the roll at the previous process station from the database; The inspection system receives the AOI encoder signal and uses the line scan inspection module to read the 2D barcode at every meter; Parse the information in the 2D barcode and match it with the defect information in the database; According to the matching results, the defect coordinates are screened, corrected and output; When a roll change signal is received, the defect-related information in the database is updated; At the final process station, precise printing marks are performed based on the defect coordinates.

2. A multi-site AOI data association defect detection method according to claim 1, characterized in that: In the back-end process station, "the information in the two-dimensional barcode is parsed and matched with the defect information in the database, and the defect coordinate position is screened, corrected and output according to the matching results;" specifically, the steps include: Data transmission: After the line scanning detection module reads the two-dimensional barcode on the side, the read barcode information is sent to the database management unit through the communication module; The database management unit searches for defect information related to the received two-dimensional barcode information, including defect type and relative distance, and organizes the information into a format suitable for use by the second printing module; Type comparison: After receiving the defect information transmitted by the database management unit, the control module of the second printing module will compare the defect information and determine which defects need to be marked; Filter the defects that need to be marked: The control module selects the defects that need to be marked according to the results of type comparison and prepares the corresponding printing instructions; For each defect that needs to be marked, the system generates a printing instruction containing the defect type, location coordinates and other necessary information; Use the coordinates provided by the associated data to print at precise locations: According to the selected defects and their coordinate position information, the control module will instruct the second printing module to perform precise printing on the coil; The printing module will mark the defects at the corresponding positions according to the printing instructions issued by the control module to ensure the accuracy and reliability of the marking.

3. A multi-site AOI data association defect detection method according to claim 2, characterized in that: "The control module of the second printing module will compare the defect information by type to determine which defects need to be marked;" Specifically, the database management unit presets a set of quality standards, which define the maximum allowable number and severity of various defect types. On this basis, the threshold value of the quality standard can be manually input. The database management unit sets the screening rules according to the preset quality standards and the threshold value of the manually input quality standard. The control module compares the types based on the screening rules, and according to the results of the type comparison, it screens out the defects that need to be marked and generates printing instructions. The printing instructions will guide the second printing module to print the mark at a specific location on the coil.

4. A multi-site AOI data association defect detection method according to claim 3, characterized in that: The screening rules include: Defect size: Defects exceeding a threshold size need to be marked; Defect location: Defects that occur in a specific area need to be marked; Defect severity: Defects that exceed the threshold need to be marked. Defect Type: Defects of the set type are always marked.

5. A multi-site AOI data association defect detection system using the method of claim 1, characterized in that: include: Defect Detection Unit: Including AOI modules equipped at each process station. The AOI modules detect product surface defects in real time at each process station of the continuous roll-to-roll process and record the specific information of the defects; Includes AOI encoder to record the position information of the coil running; A control module is included, which is used to control the operation of the AOI module and receive a position signal from an encoder; Position division unit: It includes a first printing module arranged on the side of the product at the first process station, and printing a two-dimensional bar code containing position information and a production batch number on the side of the coil at regular intervals; It includes a control module, which is used to control the operation of the first printing module and ensure that the barcode printed is accurately positioned; Includes an encoder to record the position information of the coil to ensure accurate printing of the barcode; Defect information transmission unit: A data processing module is included to process defect information detected by the AOI module and calculate the relative distance between the defect and the nearest two-dimensional barcode; It includes a communication module for transmitting defect information and corresponding two-dimensional bar code associated data to a database management unit; It includes a control module, which is used to control the workflow of the data processing module and the communication module to ensure accurate transmission of information; Defect information reading unit: It includes a line scanning detection module configured at the back-end process station to read the two-dimensional barcode on the side of the coil; It includes a control module for controlling the operation of the line scanning detection module and ensuring that the read barcode information is accurate; It includes a communication module for transmitting the read barcode information to the database management unit to obtain the corresponding defect information; Defect marking unit: It includes a second printing module configured at the back-end process station, which is used to accurately print defect marks on the coil according to the defect information obtained from the database; It includes a control module, which is used to control the operation of the second printing module and ensure the accuracy of the printing position; A communication module is included for obtaining defect information from a database management unit and transmitting it to a control module; Database Management Unit: It includes a data storage module for storing defect information uploaded by all process sites and its associated data with the two-dimensional barcode; Includes a data processing module for processing and updating data in the database to ensure data consistency and integrity; Includes a communication module for exchanging data with other units.

6. A multi-site AOI data association defect detection system according to claim 5, characterized in that: The two-dimensional barcode adopts the Data Matrix encoding format. The two-dimensional barcode contains the position length in meters and the production batch number. The position length in meters records the specific position of the barcode in the entire roll of continuous roll products, in meters. The production batch number identifies the production batch to which the roll belongs, ensuring that it can be traced back to the specific production time and production line.

7. The multi-site AOI data association defect detection system according to claim 5, characterized in that: The line scan detection module includes a line scan camera fixedly installed at the back-end process station. The line scan camera adopts a CCD line scan camera with a 4K resolution.

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