A multi-site aoi data correlation defect detection method and detection system

Abstract

The application specifically relates to a multi-station AOI data correlation defect detection method and a detection system. The detection method comprises the following steps: a first process station step, production starts, and an operator manually inputs a roll number; an AOI encoder signal is received by the detection system, a delay distance is set, a Data Matrix two-dimensional barcode containing a production batch number of the roll material and a length meter number of a position is sprayed and printed every meter; defect correlation data of the roll at a previous process station is obtained from a database in a rear-end process station step; the detection system receives an AOI encoder signal, and a line scanning detection module is used to read the two-dimensional barcode at every meter; information in the two-dimensional barcode is analyzed, and is matched with defect information in the database; according to a matching result, defect coordinate positions are screened, corrected and output; when a roll changing signal is received, defect correlation information in the database is updated; and at a last process station, spraying and printing marks are accurately carried out according to the defect coordinate positions.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of optical detection, and particularly relates to a multi-station AOI data associated defect detection method and a detection system. BACKGROUND

[0002] In the manufacturing process of continuous roll products such as optical films, textiles, and metal foils, enterprises need to detect defects in the products. In order to help subsequent processes better handle these defects, such as evaluating yield, sorting materials, and allowing workers to quickly find problem areas for review, it is often necessary to mark these defects.

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

[0004] In order to save costs, some factories have adopted a new strategy: only detect defects at an early stage without immediate marking, but save this defect information for later unified marking in subsequent processes. This can reduce the cost of early-stage investment and maintenance of inkjet equipment. Based on the defect information detected in the early process, the factory can decide whether to cut, sort, or rework as needed, and finally mark, which can adjust the marking standard according to different customer needs to ensure product quality.

[0005] There are two traditional ways of defect information transfer: one is to simply mark near the defect, but this can only tell the approximate location to the subsequent process, not the specific problem; the other is to inkjet 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 product width changes, an additional system is needed to adjust the position of the scanning equipment, which increases cost and space requirements, and the amount of information that the barcode can carry is limited, and if there are many defects, it cannot hold all the information. SUMMARY

[0006] The present application aims to provide a multi-station AOI data associated defect detection method, and to provide a multi-station AOI data associated defect detection system, which is another purpose of the present application, to solve the problems raised in the background art.

[0007] To solve the above technical problems, the present application provides the following technical solutions:

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

[0009] First process station step:

[0010] Production starts, the operator manually inputs the roll number;

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

[0012] A Data Matrix two-dimensional barcode containing the production batch number of the roll material and the length of the position in meters is printed every meter;

[0013] The correctness and recognizability of the two-dimensional barcode are confirmed;

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

[0015] Complete the defect detection and two-dimensional barcode marking of the first process station;

[0016] Back-end process station steps:

[0017] Production starts, use a handheld code reader to input the pre-arranged roll number;

[0018] Get the defect association data of the roll from the previous process station from the database;

[0019] The detection system receives the AOI encoder signal and uses the line scan detection module to read the two-dimensional barcode at each meter;

[0020] Parse the information in the two-dimensional barcode and match it with the defect information in the database;

[0021] According to the matching result, filter, correct and output the defect coordinate position;

[0022] When a roll change signal is received, update the defect association information in the database;

[0023] At the last process station, accurately print the mark according to the defect coordinate position.

[0024] Further, in the back-end process station, "parse the information in the two-dimensional barcode and match it with the defect information in the database, according to the matching result, filter, correct and output the defect coordinate position;" specifically, it includes the following steps:

[0025] Data transmission:

[0026] After the line scan 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 looks up the defect information related to the received two-dimensional barcode information, including defect type, relative distance, and arranges these information into a format suitable for the second printing module;

[0028] Category comparison:

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

[0030] Screening defects that need to be marked:

[0031] The control module screens defects that need to be marked based on the results of the category comparison and prepares 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 coordinate position provided by the associated data to perform precise position printing:

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

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

[0036] The control module of the second printing module will compare the categories of the defect information to determine which defects need to be marked; Specifically, the database management unit has a set of quality standards that define the maximum allowed 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 based on the preset quality standards and the manually input threshold value of the quality standard. The control module performs category comparison based on the screening rules, selects defects that need to be marked according to the results of the category comparison, generates printing instructions, and guides the second printing module to perform printing marking at specific positions on the web material through the printing instructions.

[0037] Further, the screening rules include:

[0038] Defect size: defects larger than the threshold size need to be marked;

[0039] Defect location: defects appearing in a specific area need to be marked;

[0040] Defect severity: defects that exceed the threshold in terms of impact need to be marked;

[0041] Defect type: the defect of the set type always needs to be marked.

[0042] A multi-station AOI data correlation defect detection system, comprising:

[0043] A defect detection unit:

[0044] An AOI module is equipped at each process station, which detects product surface defects in real time at each process station of the continuous roll process and records specific information of the defects;

[0045] An AOI encoder is included for recording position information of the roll running;

[0046] A control module is included for controlling the operation of the AOI module and receiving position signals from the encoder;

[0047] A position division unit:

[0048] A first printing module is configured on the side of the product at the first process station, which prints a two-dimensional barcode containing position information and production batch number on the side of the roll every certain length (per meter);

[0049] A control module is included for controlling the work of the first printing module and ensuring the accurate position of the printed barcode;

[0050] An encoder is included for recording position information of the roll to ensure accurate printing of the barcode;

[0051] A defect information transmission unit:

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

[0053] A communication module is included for transmitting defect information and corresponding two-dimensional barcode correlation data to the database management unit;

[0054] A control module is included for controlling the workflow of the data processing module and the communication module to ensure accurate information transmission;

[0055] A defect information reading unit:

[0056] A line scanning detection module is configured at the back-end process station to read the two-dimensional barcode on the side of the roll;

[0057] A control module is included for controlling the work of the line scanning detection module and ensuring the accuracy of the read barcode information;

[0058] A communication module is included for transmitting the read barcode information to the database management unit to obtain corresponding defect information;

[0059] defect marking unit:

[0060] The second inkjet module configured at the back-end process station is used to accurately inkjet mark defects on the roll according to the defect information obtained from the database;

[0061] The control module is used to control the work of the second inkjet module and ensure the accuracy of the inkjet position;

[0062] The communication module is used to obtain defect information from the database management unit and deliver it to the control module;

[0063] Database management unit:

[0064] The data storage module is used to store all the defect information uploaded by the process station and its associated data with the two-dimensional barcode;

[0065] The data processing module is used to process and update the data in the database to ensure the consistency and integrity of the data;

[0066] The communication module is used for data exchange with other units.

[0067] Further, the two-dimensional barcode adopts Data Matrix encoding format, and the two-dimensional barcode contains position length in meters and production batch number, wherein the position length in meters records the specific position of the barcode in the whole continuous roll product,

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

[0069] Further, 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 application is a cross-process station AOI defect data transmission mode, which creates the advantage of larger capacity data flow transmission, the two-dimensional barcode mark information record is complete, and through record tracking, it supports multi-station process before and after, the product defect data is still accurately associated, the defect coordinate position is accurately analyzed, and when the inkjet marking operation is implemented at the back-end process station, the defect can be accurately marked without omission. In the reading mode of the two-dimensional barcode, the line scanning detection module is used instead of the traditional barcode scanner, which can define the longitudinal position coordinate of the two-dimensional barcode mark with high precision, greatly improve the data association accuracy, and fix the position for wide range of horizontal detection, the two-dimensional barcode mark and the film edge position are read at the same time, without the need for motor driving edge searching, the structure is simple.

[0071] Mainly embodied in the following aspects:

[0072] High-precision defect detection and marking: Through the multi-station AOI data correlation platform, efficient and accurate transmission of defect detection information between multiple process stations is realized. In the first process station, two-dimensional barcodes (Data Matrix) containing position information are printed, and in the subsequent process stations, line scanning detection modules are used to read these barcodes, thereby achieving precise positioning of defect positions, enabling accurate defect marking in the backend process.

[0073] Information capacity and data transmission optimization: Compared with traditional methods of printing mark points or two-dimensional barcodes, the Data Matrix encoding format used in the invention has higher information density and can record more data, thereby overcoming the problem of limited information capacity in traditional methods. By recording the production batch number and position length of the roll material, an accurate correlation between defects and barcodes is established, optimizing the data transmission process.

[0074] Simplified system architecture and reduced cost: The invention uses a fixed-position line scanning detection module (with a 4K resolution CCD line scanning camera) to replace the traditional moving barcode scanner, avoiding the need to adjust the scanner position with changes in roll width, simplifying the system architecture and reducing equipment investment and maintenance costs.

[0075] Improved 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 a database management unit, defect marking conditions can be adjusted according to different customer requirements to ensure that the quality of the final product meets the requirements.

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

[0077] Figure 1 A schematic diagram of the principles of the invention;

[0078] Figure 2 A partial method flowchart of the invention;

[0079] Figure 3 A partial method flowchart of the invention. DETAILED DESCRIPTION

[0080] With reference to the drawings, the embodiments of the present application will be described below. Obviously, the described embodiments are only a part of the embodiments of the present application, but not all the embodiments. Based on the embodiments of the present application, all the other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present application.

[0081] The present application provides a multi-station AOI data associated defect detection method, as shown in the following steps: Figures 1-3

[0082] The first process station step:

[0083] The production starts, and the operator manually inputs the roll number;

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

[0085] A Data Matrix two-dimensional barcode containing the production batch number of the roll material and the length of the position in meters is printed every meter;

[0086] The correctness and recognizability of the two-dimensional barcode are confirmed;

[0087] When the roll changing signal is received, the printing is stopped, and the defect data of the current roll is saved to the database;

[0088] The defect detection and two-dimensional barcode marking of the first process station are completed;

[0089] The back-end process station step:

[0090] The production starts, and the pre-arranged roll number is input using a handheld code reader;

[0091] The defect associated data of the roll at the previous process station is obtained from the database;

[0092] The detection system receives the AOI encoder signal and reads the two-dimensional barcode at each meter using a line scanning detection module;

[0093] The information in the two-dimensional barcode is parsed and matched with the defect information in the database;

[0094] According to the matching result, the defect coordinate position is screened, corrected, and output;

[0095] When the roll changing signal is received, the defect associated information in the database is updated;

[0096] In the last process station, the printing marking is accurately performed according to the defect coordinate position.

[0097] In one specific embodiment, a multi-station AOI data associated defect detection method includes the following steps:​

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

[0099] 1. Production begins

[0100] 2. Personnel manually input the secondary roll AOI roll number

[0101] 3. Receive the AOI encoder signal

[0102] 4. Delay the set distance

[0103] 5. Spray print a two-dimensional barcode positioning point every meter

[0104] 6. Confirm that the two-dimensional barcode is correct and recognizable

[0105] 7. Receive the roll change signal

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

[0107] 9. Production ends

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

[0109] 1. Production begins

[0110] 2. Handheld code reader input pre-arranged AOI roll number

[0111] 3. Database retrieves the previous process correlation data

[0112] 4. Receive the AOI encoder signal

[0113] 5. Read the two-dimensional barcode positioning point every meter

[0114] 6. Screen, correct, and output defect coordinates

[0115] 7. Receive the roll change signal

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

[0117] 9. Production ends

[0118] In the preferred embodiment, in the back-end process station, "analyze the information in the two-dimensional barcode and match it with the defect information in the database, according to the matching result, screen, correct, and output the defect coordinate positions;" specifically, it includes the steps:

[0119] Data transmission:

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

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

[0122] Category comparison:

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

[0124] Screening defects that need to be marked:

[0125] The control module screens out defects that need to be marked according to the results of the category comparison and prepares 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] Precise position printing using the coordinate position provided by the associated data:

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

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

[0130] In the preferred embodiment, the control module of the second printing module compares the categories of the defect information to determine which defects need to be marked. Specifically, the database management unit predefines a set of quality standards that define the maximum allowed 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 based on the pre-set quality standards and the manually input threshold value of the quality standard. The control module performs category comparison based on the screening rules. According to the results of the category comparison, the control module screens out defects that need to be marked, generates printing instructions, and guides the second printing module to perform printing marking at specific positions on the web material through the printing instructions.

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

[0132] Defect size: defects larger than the threshold size need to be marked;

[0133] Defect position: defects appearing in specific areas need to be marked;

[0134] Defect severity: needs to be marked according to the impact of the defect exceeding the threshold;

[0135] Defect type: the type of defect needs to be marked.

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

[0137] Defect detection unit:

[0138] Including AOI module equipped at each process site, AOI module detects product surface defects in real time at each process site of continuous roll process, and records specific information of defects;

[0139] Including AOI encoder, for recording position information of roll running;

[0140] Including control module, for controlling operation of AOI module, and receiving position signal from encoder;

[0141] Specific details of defect detection unit

[0142] 1. Components

[0143] Defect detection unit mainly includes the following components:

[0144] AOI module: automatic optical inspection system, for detecting defects on the surface of continuous roll products.

[0145] AOI encoder: for recording position information of roll running.

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

[0147] 2. Function description

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

[0149] Position recording: AOI encoder records position information of roll on production line, so as to correlate with defect information.

[0150] Data transmission: control module transmits detected defect information and position information to defect information transmission unit, for further processing and storage into database.

[0151] 3. Working principle

[0152] Detection process: AOI module is installed at each process site, when roll passes through AOI module, the system automatically scans and identifies surface defects.

[0153] Information recording: After the AOI module detects a defect, the position information of the roll material at the time of defect occurrence is recorded through the AOI encoder.

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

[0155] 4. Coordination with other units

[0156] Coordination with position division unit: After the AOI module detects a defect, the relative distance between the defect and the nearest two-dimensional barcode is calculated, and this information is passed to the position division unit.

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

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

[0159] Position division unit:

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

[0161] It includes a control module for controlling the work of the first jet printing module and ensuring the accurate position of the printed barcode;

[0162] It includes an encoder for recording the position information of the roll material to ensure accurate printing of the barcode;

[0163] Specific details of the position division unit

[0164] 1. Components

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

[0166] First jet printing module: installed in the first process station, used for printing two-dimensional barcodes on the side of the roll material.

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

[0168] Encoder: used to record the position information of the roll material to ensure accurate printing of the barcode.

[0169] 2. Function 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 roll at regular intervals (e.g. every meter).

[0171] Position recording: The control module records the position information of each printing through the encoder, ensuring the consistency of the barcode with the position of the roll.

[0172] Information transmission: The printed barcode information is transmitted to the defect information transmission unit for storage in association with defect information.

[0173] 3. Working principle

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

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

[0176] Barcode verification: After printing is completed, the system automatically verifies the correctness and recognizability of the barcode.

[0177] 4. Coordination with other units

[0178] Coordination with 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 transmits this information to the position division unit.

[0179] Coordination with defect information transmission unit: The printed two-dimensional barcode information is transmitted by the control module to the defect information transmission unit for further processing and storage in the database.

[0180] Coordination with database management unit: The two-dimensional barcode information printed by the position division unit is finally stored and managed by the database management unit.

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

[0182] Defect information transmission unit:

[0183] It includes a data processing module for processing defect information detected by the AOI module and calculating 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 barcode association data to the database management unit.

[0185] The control module controls the workflow of the data processing module and the communication module, ensuring accurate information transmission.

[0186] Details of the defect information transmission 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 the defect information and the corresponding two-dimensional barcode association data to the database management unit.

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

[0192] 2. Function description

[0193] Information association: associate the defect information detected by the AOI module with the nearest two-dimensional barcode, and calculate the relative distance between the defect and the barcode.

[0194] Data storage: write the defect type, relative distance and two-dimensional barcode code into the database to establish the association between the defect and the barcode.

[0195] Data transmission: transmit the processed defect information and association data 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 the 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 the 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 two-dimensional barcode.

[0202] Cooperates with the position division unit: obtains the two-dimensional barcode information printed by the position division unit, and is used for calculating the relative distance between the defect and the barcode.

[0203] Cooperates with the database management unit: transmits the processed defect information and the associated 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 these 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 arranged at the rear-end process station, which reads the two-dimensional barcode on the edge side of the roll material.

[0207] It includes a control module for controlling the operation of the line scanning detection module and ensuring the accuracy of the read barcode information.

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

[0209] Specific 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: a 4K CCD camera is used to read the two-dimensional barcode on the edge side of the roll material.

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

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

[0215] 2. Function description

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

[0217] Information analysis: the control module analyzes the position information (length in meters) and the production batch number in the barcode.

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

[0219] 3. Working principle

[0220] Reading process: The line scan detection module reads the two-dimensional barcode on the edge side as the web passes.

[0221] Information analysis: The control module analyzes the position 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. Coordination with other units

[0224] Coordination with defect information transmission unit: Receive barcode information provided by the defect information transmission unit for reading and analysis.

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

[0226] Coordination with defect marking unit: Transfer the obtained defect information to the defect marking unit for accurate inkjet marking.

[0227] Defect marking unit:

[0228] Including a second inkjet module configured in the backend process station, for accurately inkjet marking defects on the web according to the defect information obtained from the database;

[0229] Including a control module for controlling the work of the second inkjet module and ensuring the accuracy of the inkjet position;

[0230] Including a communication module for obtaining defect information from the database management unit and transferring it to the 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 inkjet module: installed in the backend process station for inkjet marking defects on the web.

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

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

[0237] 2. Function description

[0238] Spray Marking: Based on the defect information obtained from the database, accurately spray the defect mark on the roll material.

[0239] Position Control: The control module controls the spray equipment 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 detection results to ensure the accuracy of the mark.

[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 spray module to accurately spray on the roll material according to the coordinate position in the defect information.

[0244] Mark Execution: The second spray module sprays the defect mark on the roll material according to the instructions of the control module.

[0245] 4. Coordination with Other Units

[0246] Coordination with Defect Information Reading Unit: Obtain two-dimensional barcode information read by line scanning detection module to determine spray position.

[0247] Coordination with Database Management Unit: Obtain defect information from the database management unit and pass it to the control module.

[0248] Coordination with Defect Information Transmission Unit: Ensure that the obtained defect information is the latest and consistent with the actual detection results.

[0249] Database Management Unit:

[0250] Including data storage module, used for storing all defect information uploaded by process stations and its association data with two-dimensional barcodes;

[0251] Including data processing module, used for processing and updating data in the database to ensure data consistency and integrity;

[0252] Including communication module, used for data exchange with other units.

[0253] 1. Components

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

[0255] Data Storage Module: Used for storing all defect information uploaded by process stations and its association data with two-dimensional barcodes.

[0256] Data Processing Module: responsible for processing and updating data in the database, ensuring 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. Function Description

[0259] Data Storage: stores all defect information uploaded by process stations and its associated data with two-dimensional barcodes.

[0260] Data Retrieval: retrieves defect information and corresponding two-dimensional barcode information of a specific batch as needed.

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

[0262] 3. Working Principle

[0263] Data Entry: receives defect information and its associated data with two-dimensional barcodes from the defect information transmission unit and stores them in the database.

[0264] Data Query: when defect information of a certain batch is needed, retrieve the corresponding defect information from the database according to the barcode code.

[0265] Data Synchronization: ensures that the data in the database is synchronized with the actual detection results, and updates any new defect information in time.

[0266] 4. Cooperate with other units

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

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

[0269] Cooperate with defect marking unit: provide defect information to defect marking unit to ensure that marking unit can accurately mark at designated position.

[0270] In preferred embodiments, two-dimensional barcodes use Data Matrix encoding format, two-dimensional barcodes contain position length meters and production batch number, where position length meters record the specific position of the barcode in the whole continuous roll product, in meters, and production batch number identifies the production batch to which the roll belongs, ensuring traceability to specific production time and production line.

[0271] Specific details of two-dimensional barcodes

[0272] 1. Encoding format

[0273] The present invention employs the Data Matrix encoding format, which is a matrix-based two-dimensional barcode with high information density, capable of storing 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 of content: position length in meters and production batch number.

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

[0277] Production batch number: identifies the production batch to which the roll belongs, ensuring traceability to the specific production time and production line.

[0278] 3. Printing frequency

[0279] In the first process station, one two-dimensional barcode is printed per 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 recognizability.

[0282] 5. Associated information

[0283] When the AOI module detects a defect, the relative distance between the defect and the nearest two-dimensional barcode is calculated, and the defect type, relative distance, and two-dimensional barcode code are stored in the database. This establishes an accurate association between the defect and the barcode.

[0284] 6. Reading method

[0285] The line scan detection module used in the back-end process station reads the two-dimensional barcode on the side of the roll. The line scan detection module uses a 4K CCD with a 375mm shooting range and a 90 micron resolution, capable of accurately reading the position information and code in the barcode.

[0286] 7. Information analysis

[0287] After analyzing the information in the barcode, the relevant defect information is searched in the database through the exclusive code of the barcode to obtain the specific position and type of the defect. These information will be used for accurate marking operation.

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

[0289] Module installation: The line scan detection module is installed at a fixed position of the rear-end process station and does not need to move with the change of the width of the material. It can cover the width range from the edge to the center of the material and is suitable for a maximum width change of 750 mm.

[0290] Detection technology: A 4K resolution CCD line scan camera is adopted, which has a shooting range of 375 mm and a resolution of 90 microns, can capture clear images on a high-speed production line, and ensures the identification accuracy of the two-dimensional barcode.

[0291] Light source configuration: A high-intensity LED line light source is provided to ensure that the two-dimensional barcode on the edge of the material has sufficient contrast under different environmental light conditions, facilitating the reading of the line scan camera.

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

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

[0294] Software support: The built-in decoding algorithm supports fast decoding of two-dimensional barcodes in Data Matrix format and can handle various complex barcode deformation cases to ensure high reading rate.

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

[0296] Maintenance convenience: The modular design makes maintenance more convenient, only the lens and light source need to be cleaned regularly, and the cable connection needs to be checked, which reduces the maintenance cost and downtime.

[0297] Through the above configuration, the line scan detection module can efficiently and accurately read the edge two-dimensional barcode to provide reliable position reference for subsequent defect marking.

[0298] The present application uses a line scanning detection module to replace a conventional bar code scanner to read a two-dimensional bar code mark on the side, the line scanning system uses a 4K CCD, the shooting range is 375mm, the resolution is 90 microns, the change of the width of the roll material is less than 750mm, the fixed detection unit position can be used for large range transverse detection, the two-dimensional bar code mark and the edge position are read at the same time, the motor is not needed to drive the edge searching, and the moving scanning detection unit is not needed to change with the width, the structure is simple, and the construction cost is low; the conventional bar code scanner has a small shooting range at a fast scanning speed, and has a large shooting range at a slow scanning speed, under the condition of high-speed operation of an online continuous production line, the scanner can only maintain a small range shooting structure, and the position of the moving scanner is assisted to change with the width of the roll material, the structure is complex, and a front-end auxiliary searching roll material edge device is needed to provide an accurate moving shooting position of the conventional scanner, so that the construction cost is high. The biggest innovation method is to spray a two-dimensional bar code on the side of a product per meter in a first process station, the content of the two-dimensional bar code is not information such as a defect type and a coordinate, but records the position length of the bar code in the whole roll continuous roll product and a specific code belonging to the bar code, the code content is a production batch number of the roll material, the length information is combined to generate a unique combination content, and the combination content is presented by a Data Matrix, the high information density allows a small size to be printed. When a defect is detected by a station AOI, the relative distance between the defect and the closest bar code is calculated, the specific code of the bar code is captured, and the defect type is written into a database (DataBase) together, so that strict correlation data between the two-dimensional bar code and the defect are established. The data chain structure of a multi-station AOI data correlation platform Figure 1

[0299] In the process in the rear end, an operator inputs a to-be-operated roll number on a system, the roll correlation file data in the previous station are called from a database, a line scanning detection module reads a fixed-pitch two-dimensional bar code on the side of a product, the length and the specific code in the bar code are analyzed, the code is searched in the database to obtain all defect data related to the code, all defects and coordinate positions of the defects and defect types in the relative distance of the two-dimensional bar code are obtained, the data are transmitted to a rear-end spraying mark system, the defects needing to be marked are screened after type comparison, and accurate position spraying is performed by using the coordinate positions provided by the correlation data.

[0300] ​The present application is a cross-process station transmission AOI detection defect data mode, creates the advantage of larger capacity data flow transmission, two-dimensional bar code mark information record is complete, through record tracking, supports multi-station process before and after, product defect data is still accurately associated, analyzes the accurate defect coordinate position, when implementing the inkjet marking operation in the rear-end process station, can more accurately and not miss, mark the defect accurately. On reading two-dimensional bar code mode, use line scanning detection system, instead of traditional bar code scanner, can define two-dimensional bar code mark longitudinal position coordinate with high precision, greatly improve the data association accuracy, and fixed position wide range of transverse detection, two-dimensional bar code mark and film edge position are read at the same time, without motor driven edge finding, simple structure.

[0301] The technical scheme of the present application has high integration and intelligence, improves the operation reliability of the high-voltage high-power stabilized power supply, greatly enhances the maintainability and operation convenience of the system, provides an efficient, stable and easy-to-maintain solution for the related field, and has important practical value and technical innovation significance.

Claims

1. A multi-site AOI data correlation defect detection method, characterized in that, The steps include: The first process station step: The production starts, and the operator manually inputs the roll number; The detection system receives the AOI encoder signal and sets the delay distance; A Data Matrix two-dimensional barcode containing the production batch number of the roll and the length of the position in meters is printed every meter; The correctness and recognizability of the two-dimensional barcode are confirmed; When a roll change signal is received, the printing is stopped, and the defect data of the current roll is saved to the database; The defect detection and two-dimensional barcode marking of the first process station are completed; The back-end process station step: The production starts, and the pre-arranged roll number is input using a handheld code reader; The defect association data of the roll at the previous process station is obtained from the database; The detection system receives the AOI encoder signal and reads the two-dimensional barcode at each meter using the line scan detection module; The information in the two-dimensional barcode is parsed and matched with the defect information in the database; According to the matching result, the defect coordinate position is filtered, corrected, and output; When a roll change signal is received, the defect association information in the database is updated; At the last process station, accurate printing marking is performed according to the defect coordinate position; At the first process station, a two-dimensional barcode is printed every meter on the side of the product, which records the position length in meters of the barcode in the entire continuous roll product and the specific code belonging to the barcode, and the code content is the production batch number of the roll. The length of the meter information is combined to generate a unique combination content presented in Data Matrix. The AOI encoder records the position information of the roll on the production line to associate with the defect information. When the defect is detected by the station AOI, the relative distance between the closest barcode and the defect is calculated, and the defect type is also written into the database to establish the association data between the two-dimensional barcode and the defect.

2. The method of claim 1, wherein the method is performed on a plurality of sites. In the back-end process station, the information in the two-dimensional barcode is parsed and matched with the defect information in the database. According to the matching result, the defect coordinate position is filtered, corrected, and output. Specifically, the steps include: Data transmission: After the line scan detection module reads the two-dimensional barcode on the side, the barcode information is sent to the database management unit through the communication module; The database management unit searches for the related defect information, including the defect type and relative distance, based on the received two-dimensional barcode information, and arranges these information into a format suitable for the second printing module; Category comparison: After receiving the defect information from the database management unit, the control module of the second printing module compares the categories of the defects to determine which defects need to be marked; Screening of defects for marking: The control module screens the defects that need to be marked based on the results of the category 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, position coordinate, and other necessary information; Precise position printing using the coordinate position provided by the association data: According to the screened defects and their coordinate position information, the control module instructs the second printing module to perform precise printing on the roll; 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. The method of claim 2, wherein the method further comprises: The control module of the second printing module will compare the types of the defects, to determine which defects need to be marked. Specifically, the database management unit predefines a set of quality standards, which define the maximum allowed number and severity of various defect types. On this basis, the threshold of the manually input quality standard is configured. The database management unit sets the screening rules based on the pre-defined quality standards and the threshold of the manually input quality standard. The control module compares the types based on the screening rules, and screens out the defects that need to be marked according to the comparison results. The printing instructions are generated to guide the second printing module to print and mark at specific positions on the web.

4. The method of claim 3, wherein, The screening rules include: Defect size: defects larger than the threshold size need to be marked; Defect position: defects appearing in specific areas need to be marked; Defect severity: defects with an impact exceeding the threshold need to be marked; Defect type: defects of a certain type always need to be marked.

5. A multi-site AOI data correlation defect detection system employing the method of claim 1, characterized in that, The system includes: A defect detection unit: It includes an AOI module equipped at each process station, which detects product surface defects in real time at each process station of the continuous web process, and records the specific information of the defects. It includes an AOI encoder for recording the position information of the web running. It includes a control module for controlling the operation of the AOI module, receiving the position signal from the encoder, and transmitting the defect information to the defect information transmission unit after synchronizing with the position signal. A position division unit: It includes a first printing module configured on the side of the product at the first process station, which prints a two-dimensional barcode containing position information and production batch number on the side of the web at certain intervals. It includes a control module for controlling the work of the first printing module and ensuring the accuracy of the printed barcode position. It includes an encoder for recording the position information of the web to ensure the accurate printing of the barcode. A defect information transmission unit: It includes a data processing module for processing the defect information detected by the AOI module and calculating the relative distance between the defect and the nearest two-dimensional barcode. It includes a communication module for transmitting the defect information and the corresponding two-dimensional barcode association data to the database management unit. It includes a control module for controlling the workflow of the data processing module and the communication module to ensure accurate information transmission. A 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 web. It includes a control module for controlling the work of the line scanning detection module and ensuring the accuracy of the read barcode information. It includes a communication module for transmitting the read barcode information to the database management unit to obtain the corresponding defect information. A defect marking unit: It includes a second printing module configured at the back-end process station for accurately printing defect marks on the web according to the defect information obtained from the database. It includes a control module for controlling the work of the second printing module and ensuring the accuracy of the printing position. The communication module is configured to obtain the defect information from the database management unit and transmit the defect information to the control module; The database management unit comprises a data storage module configured to store the defect information uploaded by all process stations and the associated data of the two-dimensional bar code; The data processing module is configured to process and update the data in the database, and ensure the consistency and integrity of the data; The communication module is configured to exchange data with other units. The two-dimensional bar code adopts a Data Matrix encoding format. The two-dimensional bar code comprises a position length in meters and a production batch number. The position length in meters records the specific position of the bar code in the whole continuous roll-shaped product, and the production batch number identifies the production batch to which the roll belongs, so that the specific production time and production line can be traced.

6. The multi-site AOI data correlation defect detection system of claim 5, wherein, The line scanning detection module comprises a line scanning camera fixedly installed at the rear-end process station. The line scanning camera adopts a CCD line scanning camera with a 4K resolution.

7. The multi-site AOI data correlation defect detection system of claim 5, wherein, ​

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