Online quality detection device for synthetic quartz manufacturing

Abstract

The invention relates to the technical field of quartz synthesis quality detection, and particularly discloses an on-line quality detection device and detection system for synthetic quartz manufacturing, the device comprises an imaging detection device, the imaging detection device is arranged on one side of a quartz weight, the imaging detection device comprises a high-definition CCD area-array camera, a high-precision lens, a mounting bracket and a cooling device, the high-definition CCD area-array camera is connected with the computer image processing equipment, and the computer image processing equipment is respectively connected with the remote signal transmission device and the alarm. According to the device, the detection precision and reliability are improved, the production efficiency is enhanced, automatic monitoring is achieved, the requirement for manual intervention is reduced, the labor cost is reduced, quality control instability and potential errors caused by human factors (such as vision conditions and personal judgment differences) are reduced, quality management is optimized, and intelligent manufacturing transformation is promoted.

Description

Technical Field

[0001] The invention relates to the technical field of quartz synthesis quality detection, in particular to an online quality detection device for synthetic quartz manufacturing. Background Art

[0002] The chemical vapor deposition (CVD) process is also called hydrogen-oxygen flame hydrolysis deposition. Its principle is to allow volatile liquid SiCl4 to enter a hydrogen / oxygen combustion burner driven by a carrier gas, react with water vapor to generate amorphous silicon dioxide, and deposit on a high-temperature rotating target to form quartz glass. The CVD process has the advantage of preparing large-size high-purity quartz glass, and can produce high-quality, high-transparency, and low-bubble quartz glass.

[0003] For the deposition of quartz materials, especially when using CVD methods, it is very important to ensure quality control during the deposition process. This includes monitoring deposition rate, uniformity, thickness, and any other parameters that may affect the performance of the final product.

[0004] The laser positioning device is mainly used for real-time monitoring of the growth height of quartz columns on the production line. The device obtains real-time results of the growth height of the measured quartz columns through laser height scanning and computer real-time sampling and processing. Figure 2 As shown, the whole device consists of a scanning transmitter 9, a scanning receiver 10, a display host 5, a remote signal transmission device 6, an alarm 7 and other parts. In the scanning transmitter, the He-Ne laser beam is transformed by the optical system and reflected by the high-speed rotating multi-faceted prism to form a parallel, uniform scanning fine light beam, which performs a high-speed scan of the standard window and the quartz column to be measured hundreds of times per second. The photoelectric conversion signal obtained by the scanning receiver is sent to the display host after standardized processing, and the height of the quartz column to be measured is obtained through real-time processing and calculation by the single-chip computer and its peripheral digital circuits. The display host displays the height of the quartz column in real time, and the data results are synchronously transmitted to the remote signal output device.

[0005] In the past, the quality defects of quartz crystals were often observed by human eyes during the CVD deposition process, such as abnormal bubbles in quartz glass and surface nodules, but real-time observation and recording were not possible. Usually, the stable deposition rate of quartz crystals was judged based on manual experience, or the growth rate was adjusted to maintain balance by real-time monitoring of the production height of quartz columns through a laser positioning device. However, the accuracy of naked eye recognition is not high, and problems such as lag in regulation have a greater impact on product quality; laser positioning can only realize position monitoring and control, and cannot control the online quality of the ingot.

[0006] In the current production environment, existing technologies face many challenges: cost control is difficult, bubble and nodule phenomena rely on manual visual assessment, and production rates are limited by laser positioning systems, resulting in low overall integration efficiency and high labor costs.

[0007] Traditional manual inspection methods have many shortcomings: low production efficiency, each operator can only monitor one or two devices at the same time; quality control lacks consistency and is easily affected by the operator's vision conditions and personal subjective judgment; long-term work can easily cause visual fatigue, thus affecting the consistency and stability of product quality, making it difficult to ensure that the products produced meet the expected standards.

[0008] In addition, although detection methods such as laser positioning can improve detection efficiency to a certain extent, they still have limitations. For example, the laser positioning method can only measure the real-time results of the growth height of the quartz column, and cannot provide specific data on the size or number of bubbles; for this purpose, an online quality detection device for synthetic quartz manufacturing is provided. Summary of the invention

[0009] The purpose of the present invention is to provide an online quality detection device for synthetic quartz manufacturing in view of the defects of the prior art, so as to solve the problems raised by the above background technology.

[0010] To achieve the above-mentioned object, the present invention provides the following technical solutions: an online quality detection device for synthetic quartz manufacturing, comprising an imaging detection device, the imaging detection device is arranged on one side of a quartz ingot, the imaging detection device comprises a high-definition CCD area array camera, a high-precision lens, a mounting bracket and a cooling device, the high-precision lens is mounted on the high-definition CCD area array camera, the high-definition CCD area array camera is mounted on the mounting bracket, and the cooling device is arranged on one side of the mounting bracket to prevent the lens from being damaged by high temperature generated by the production reaction;

[0011] The high-definition CCD area array camera is connected to a computer image processing device, and the computer image processing device is respectively connected to a remote signal transmission device and an alarm.

[0012] As a preferred technical solution of the present invention, the computer image processing device includes a computer host, a display, a keyboard and a mouse.

[0013] As a preferred technical solution of the present invention, the cooling device is a fan.

[0014] As a preferred technical solution of the present invention, the high-definition CCD area array camera is mounted on a mounting bracket by bolts, and the cooling device is mounted on a side close to the high-precision lens.

[0015] A detection system for an online quality detection device for synthetic quartz manufacturing comprises an image acquisition module, an image processing module, a data judgment module and a data display module; the image acquisition module is connected to the image processing module, the image processing module is connected to the data judgment module, and the data judgment module is connected to the data display module.

[0016] As a preferred technical solution of the present invention,

[0017] The image acquisition module is used to acquire images taken by a high-definition CCD area array camera;

[0018] The image processing module is used to continuously collect the serial image data of the quartz ingot, and perform comprehensive analysis, processing and calculation to accurately extract the geometric profile and height information of the quartz ingot, and at the same time identify and quantify the specific position and size of abnormal bubbles and nodules inside the quartz ingot;

[0019] The data judgment module is used to judge the data processed by the image processing module, and if the data deviates, it is recorded and an alarm is triggered through the interface controller;

[0020] The data display module displays the data processed by the image processing module through a display.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1: Improve detection accuracy and reliability: By introducing a machine vision detection system to replace traditional manual visual inspection, the present invention can provide more accurate, objective and immediate quality assessment; high-definition CCD array cameras and high-precision lenses ensure high quality image acquisition, and computer image processing equipment ensures efficient analysis and processing of image data. The system can automatically identify and quantify bubbles and nodules in quartz crystals, and the specific information of their location and size, thereby greatly improving the accuracy of defect detection.

[0023] 2: Enhanced production efficiency: Automated monitoring is achieved, reducing the need for manual intervention, allowing each operator to manage more equipment at the same time, improving the overall efficiency of the production line. The system can monitor and feedback any deviations in the production process in real time, quickly respond and adjust production parameters, avoiding material waste or product quality degradation caused by delayed response.

[0024] 3. Reduce labor costs: The improvement of automation reduces the number of professional inspectors required, reduces the high labor cost problem caused by long-term reliance on manual inspection, and reduces the instability and potential errors in quality control caused by human factors (such as vision conditions, personal judgment differences, etc.).

[0025] 4: Optimize quality management: Provides a complete data recording and storage mechanism, supports historical data analysis and report generation, and provides a scientific basis for continuous improvement of production processes. Dynamically display the height change and defect trend curve of the lump, which helps to discover process problems in time and promote the improvement of the quality management system.

[0026] 5: Promote the transformation of intelligent manufacturing: The application of this system marks an important step in the transformation from traditional manufacturing to intelligent manufacturing, reflecting the development trend of modern industry in pursuit of high efficiency, precision and intelligence. It has promoted the improvement of production automation level and laid the foundation for enterprises to maintain their leading position in the fierce market competition. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the structure of the detection device of the present invention;

[0028] In the figure: 1. High-definition CCD area array camera; 2. High-precision lens; 3. Mounting bracket; 4. Cooling device; 5. Computer image processing equipment; 6. Remote signal transmission device; 7. Alarm; 8. Quartz ingot.

[0029] Figure 2 It is a structural schematic diagram of a laser positioning device in the background technology of the present invention;

[0030] In the figure: 9, scanning transmitter, 10, scanning receiver.

[0031] Figure 3 It is a detection flow chart of the present invention. DETAILED DESCRIPTION

[0032] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0033] Example: See Figure 1 and 3 The present invention provides a technical solution: an online quality detection device for synthetic quartz manufacturing, comprising an imaging detection device, the imaging detection device is arranged on one side of a quartz ingot 8, the imaging detection device comprises a high-definition CCD area array camera 1, a high-precision lens 2, a mounting bracket 3 and a cooling device 4, the high-precision lens 2 is mounted on the high-definition CCD area array camera 1, the high-definition CCD area array camera 1 is mounted on the mounting bracket 3, the cooling device 4 is arranged on one side of the mounting bracket 3, and is used to prevent the high temperature generated by the production reaction from damaging the lens;

[0034] The high-definition CCD area array camera 1 is connected to a computer image processing device 5 , and the computer image processing device 5 is connected to a remote signal transmission device 6 and an alarm 7 respectively.

[0035] The computer image processing device 5 includes a computer host, a display, a keyboard and a mouse.

[0036] The cooling device 4 is a fan.

[0037] The high-definition CCD area array camera 1 is mounted on the mounting bracket 3 by means of bolts, and the cooling device 4 is mounted on a side close to the high-precision lens 2 .

[0038] A detection system for an online quality detection device for synthetic quartz manufacturing includes an image acquisition module, an image processing module, a data judgment module and a data display module; the image acquisition module is connected to the image processing module, the image processing module is connected to the data judgment module, and the data judgment module is connected to the data display module.

[0039] The image acquisition module is used to acquire images taken by a high-definition CCD area array camera;

[0040] The image processing module is used to continuously collect the serial image data of the quartz ingot, and conduct comprehensive analysis, processing and calculation to accurately extract the geometric profile and height information of the quartz ingot, and at the same time identify and quantify the specific location and size of abnormal bubbles and nodules inside the quartz ingot;

[0041] The data judgment module is used to judge the data processed by the image processing module, and if the data deviates, it is recorded and the alarm 7 is triggered through the interface controller;

[0042] The data display module displays the data processed by the image processing module through a display.

[0043] Working principle: An online quality inspection device for synthetic quartz manufacturing. After the equipment is started, the imaging inspection device implements continuous real-time imaging monitoring of the preparation process of the quartz ingot 8 in the kiln; the image processing module continuously collects the sequence image data of the quartz ingot 8, and performs comprehensive analysis, processing and calculation to accurately extract the geometric contour and height information of the quartz ingot 8, and at the same time identify and quantify the specific position and size of abnormal bubbles and nodules inside the quartz ingot 8. All data are displayed in real time and visually. For any production deviation found during the inspection process, the system can trigger the corresponding alarm 7 to send an alarm signal through the interface controller.

[0044] The system can also present the on-site situation of quartz ingot 8 preparation in real time, dynamically displaying the height change of the ingot, the deviation trend curve of the bubble and the nodule position. The system design includes a complete data recording and storage mechanism, which supports users to query historical data and generate detailed report output, providing solid data support for quality control and process optimization.

[0045] By introducing a machine vision inspection system, the traditional manual visual inspection method has been replaced, achieving a more accurate, objective, reliable and immediate assessment of product quality. This effectively solves the problem of insufficient accuracy and possible omissions caused by manual inspection in the production process, significantly reduces manpower input, and greatly improves the overall efficiency of the production line. In addition, the application of this system ensures the consistency and high standards of product quality, providing solid technical support for the company's quality control.

[0046] This transformation not only optimizes the inspection process, but also promotes the improvement of production automation level, laying the foundation for enterprises to maintain their leading position in the fierce market competition. The application of machine vision technology marks an important step in the transformation from traditional manufacturing to intelligent manufacturing, reflecting the development trend of modern industry in pursuit of efficiency, precision and intelligence.

[0047] Practical application of quartz crystal online quality detection device;

[0048] Equipment installation and commissioning: Install an imaging detection device next to the existing vertical CVD synthetic quartz glass lump production line to ensure that the high-definition CCD area array camera can cover the entire working area inside the kiln. The mounting bracket needs to be fixed in an appropriate position to ensure that the camera will not be affected by vibration or other external factors during operation. The selection of high-precision lenses should take into account the requirements of the high temperature environment in the kiln, and be equipped with appropriate cooling devices (fans or blowers) to maintain the normal operating temperature of the lens. The interface controller is connected to the production line control system to receive and send signals.

[0049] Image acquisition and processing: After starting the system, the imaging detection device begins to continuously monitor the quartz crystal deposition process in the kiln in real time. The collected sequence image data is pre-processed by computer image processing equipment, such as denoising, contrast enhancement, etc., to better identify the surface features of the quartz crystal. Then the software is used to accurately measure the geometric contours, height information, abnormal bubbles and nodules in the image. All of these data are displayed and viewed in real time, so that the current production status can be quickly understood.

[0050] Alarm mechanism and feedback control: When any non-standard conditions are detected, such as exceeding the set bubble size or number, the system will sound an alarm prompt and the operator can view the alarm record on the display.

[0051] Data analysis and report generation: The system's built-in data recording and storage function allows users to query historical data and generate detailed reports as needed. This not only helps track product quality trends, but also provides an important basis for subsequent quality management and process optimization. In addition, the dynamically displayed quartz ingot height change and defect trend curves provide an intuitive reference for operators, making it easier to find problems in a timely manner and take corresponding measures.

[0052] The above embodiments only express the implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention.

Claims

1. An online quality detection device for synthetic quartz manufacturing, comprising an imaging detection device, characterized in that: The imaging detection device is arranged on one side of the quartz ingot (8), and comprises a high-definition CCD area array camera (1), a high-precision lens (2), a mounting bracket (3) and a cooling device (4); the high-precision lens (2) is mounted on the high-definition CCD area array camera (1), the high-definition CCD area array camera (1) is mounted on the mounting bracket (3), and the cooling device (4) is arranged on one side of the mounting bracket (3) to prevent the lens from being damaged by high temperature generated by the production reaction; The high-definition CCD area array camera (1) is connected to a computer image processing device (5), and the computer image processing device (5) is respectively connected to a remote signal transmission device (6) and an alarm (7).

2. The online quality inspection device for synthetic quartz manufacturing according to claim 1, characterized in that: The computer image processing device (5) comprises a computer host, a display, a keyboard and a mouse.

3. The online quality inspection device for synthetic quartz manufacturing according to claim 1, characterized in that: The cooling device (4) is a fan.

4. The online quality inspection device for synthetic quartz manufacturing according to claim 1, characterized in that: The high-definition CCD area array camera (1) is mounted on a mounting bracket (3) by means of bolts, and the cooling device (4) is mounted on a side close to the high-precision lens (2).

5. A detection system for an online quality detection device for synthetic quartz manufacturing as claimed in claim 1, characterized in that: It includes an image acquisition module, an image processing module, a data judgment module and a data display module; the image acquisition module is connected to the image processing module, the image processing module is connected to the data judgment module, and the data judgment module is connected to the data display module.

6. The detection system of the online quality detection device for synthetic quartz manufacturing according to claim 5, characterized in that: The image acquisition module is used to acquire images taken by a high-definition CCD area array camera; The image processing module is used to continuously collect sequential image data of the quartz ingot (8), and to perform comprehensive analysis, processing and calculation to accurately extract the geometric profile and height information of the quartz ingot (8), and to simultaneously identify and quantify the specific position and size of abnormal bubbles and nodules inside the quartz ingot (8); The data judgment module is used to judge the data processed by the image processing module, and if the data deviates, it is recorded and an alarm is triggered through an interface controller (7); The data display module displays the data processed by the image processing module through a display.

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