Membrane material appearance detection device and use method thereof

Abstract

The invention discloses a membrane material appearance detection device and a use method thereof, and belongs to the technical field of membrane material appearance detection. Comprising a rack, a first transition assembly and a second transition assembly. A first detection assembly is arranged right above the first transition assembly, a second detection assembly is arranged right above the second transition assembly, and the first detection assembly and the second detection assembly respectively execute initial detection and redetection of the membrane material; a leveling mechanism is arranged in the middle of the rack and is used for directionally eliminating wrinkles of the membrane material after suspected cracks are initially detected and identified; supporting mechanisms are arranged on the two sides of the outer surface of the rack. After the cracks are initially detected and recognized through the first detection assembly, the supporting mechanism is used for driving the leveling mechanism to ascend to tighten the membrane material, wrinkles are removed through rotation of the roller, then redetection is conducted through the second detection assembly, real cracks are marked, and wrinkles pseudo defects are marked, so that the effect of accurately distinguishing the cracks from the wrinkles is achieved; the problems that according to existing equipment, local wrinkles are misjudged as cracks, so that raw materials are wasted, and the percent of pass is reduced are solved.

Description

Technical Field

[0001] This invention relates to the field of membrane material appearance inspection technology, and more specifically, to a device for membrane material appearance inspection and its usage method. Background Technology

[0002] In the production and quality inspection of thin film materials, the automatic identification of appearance defects has become an important part of ensuring product quality. At present, common film material inspection devices mainly use image acquisition systems to conduct online inspection of thin films in operation, and combine image processing algorithms to identify and classify defects such as cracks, perforations, impurities, and discoloration spots on the surface of the film material.

[0003] However, in practical applications, it has been found that existing detection equipment has certain misjudgments when identifying defects on the membrane surface, especially local wrinkles caused by uneven tension, misalignment of the transfer rollers, or improper winding during membrane operation. Since wrinkles and cracks both exhibit linear gray-scale abrupt changes in 2D images, traditional algorithms, which rely on edge gradient features, cannot distinguish between three-dimensional wrinkles (local undulations) and real cracks (through-breaks). These wrinkles are easily misidentified by image recognition systems as cracks or fractures. This misjudgment leads the control system to incorrectly mark normal areas as defective areas, resulting in unnecessary cutting and rejection in subsequent processes, causing waste of raw materials, a decrease in product qualification rate, and an increase in production costs. Summary of the Invention

[0004] In view of the problems existing in the prior art, the purpose of the present invention is to provide a device for inspecting the appearance of membrane materials and a method for using it, so as to solve the above-mentioned technical problems.

[0005] To solve the above problems, the present invention adopts the following technical solution.

[0006] A device for inspecting the appearance of film materials and its method of use include a frame, with a feeding roller and a take-up roller respectively arranged at both ends inside the frame, and a guiding mechanism inside the frame for conveying the film material and guiding it through the inspection station; the guiding mechanism includes a transition roller and a first transition component and a second transition component arranged sequentially along the film material conveying direction. A first detection component is positioned directly above the first transition component, and a second detection component is positioned directly above the second transition component. The two components respectively perform initial inspection and re-inspection of the membrane material. A leveling mechanism is provided in the middle of the frame to eliminate membrane material wrinkles after identifying suspected cracks during the initial inspection. Support mechanisms are provided on both sides of the outer surface of the frame to drive the leveling mechanism to move up and down. The support mechanism includes a first pad fixed to both sides of the frame, a first hydraulic rod fixedly connected to the upper surface of the first pad, and a second pad fixedly connected to the top of the first hydraulic rod. The leveling mechanism includes a first limiting seat fixedly connected to one side of the second pad. The first limiting seat has a first driving rod and a second driving rod rotatably connected to its two ends. One end of the first driving rod passes through the first limiting seat and is fixedly connected to a third servo motor. The outer surfaces of the first driving rod and the second driving rod are fixedly connected to a first roller and a second roller, respectively. A first belt drive assembly is provided between the first driving rod and the second driving rod.

[0007] As a further aspect of the present invention: the first transition component and the second transition component have the same structure and function, but their positions are different; both the first transition component and the second transition component include a first guide roller and a second guide roller rotatably connected inside the frame, and a transmission component is provided between the first guide roller and the second guide roller, and a first servo motor fixedly connected to the frame is provided at the output end of the second guide roller, so as to make the first guide roller and the second guide roller rotate synchronously through the first servo motor and the transmission component to complete the film material conveying; multiple sets of transition rollers are provided inside the frame, which work together with the first guide roller and the second guide roller to complete the film material conveying.

[0008] As a further aspect of the present invention: the first guide roller and the second guide roller of the first transition component are jointly provided with an illumination lamp for providing preliminary inspection illumination at their middle positions; and the first guide roller and the second guide roller of the first transition component are jointly provided with a UV irradiation lamp for providing secondary inspection illumination at their middle positions; the first inspection component and the second inspection component have the same structure and function, but their positions are different; both the first inspection component and the second inspection component include brackets fixedly connected to both sides of the frame, the top of the brackets is bolted to a fixing frame, and the bottom of the fixing frame is fixedly connected to inspection cameras arranged in a linear pattern. The inspection cameras are used in conjunction with the illumination lamp and the UV irradiation lamp to complete the preliminary inspection and secondary inspection of the film material.

[0009] As a further aspect of the present invention: a marking mechanism for marking defective film material is provided directly above the second guide roller. The marking mechanism includes a slide rod rotatably connected inside the frame. A linear motor is fixedly connected to one end of the slide rod. A sliding seat is slidably connected to the outer surface of the slide rod. An electric telescopic rod is fixedly connected to the bottom of the sliding seat. A UV inkjet printer is fixedly connected to the sliding seat through the electric telescopic rod. A first storage box, a second storage box, and a third storage box are fixedly connected to one side of the outer surface of the frame. The output ends of the first storage box, the second storage box, and the third storage box are connected to a three-way electric valve. The three-way electric valve and the UV inkjet printer are fixedly connected to a conveying pipe to facilitate material conveying.

[0010] As a further aspect of the present invention: the marking mechanism further includes: The defect analysis module is used to receive the original image of the membrane surface acquired by the detection camera at the first detection component, separate potential defect areas through image noise reduction and segmentation processing, perform contour extraction on the segmentation results, generate closed defect polygons and calculate their geometric features, including length and width characteristics, area fill rate and contour curvature complexity, and output structured feature vectors. The feature vectors are compared with the pre-stored defect template library: if they meet the characteristics of a slender through-type defect with a high aspect ratio, low area fill rate, and gentle curvature, they are classified as through-type linear defects; if they meet the characteristics of a local linear defect with a medium aspect ratio and a relatively high area fill rate, they are classified as local linear defects; if they meet the characteristics of an irregular blocky defect with a low aspect ratio and high curvature complexity, they are classified as irregular blocky defects. Based on the classification results and defect size threshold, the defect type is determined. That is, a through-line defect exceeding the width threshold is determined as an obvious crack; a local linear defect below the width threshold is determined as a suspected crack; and an irregular block defect is directly determined as a surface contaminant. According to the real-time conveying speed of the membrane material and the camera acquisition timestamp, the position of the defect contour center point in the image coordinate system is converted into a three-dimensional spatial coordinate with the starting end of the feeding roller as the origin. The X-axis is the length direction of the membrane material, the Y-axis is the width direction, and the Z-axis is the thickness direction.

[0011] As a further aspect of the present invention: the marking mechanism further includes: The control module is used to automatically select the corresponding ink storage box based on the defect type judgment result output by the defect analysis module. Specifically, when the defect is judged to be an obvious crack, the control module controls the three-way electric valve to connect to the first storage box; when the defect is judged to be a suspected crack, the control module controls the three-way electric valve to connect to the second storage box; and when the defect is judged to be a surface contaminant, the control module controls the three-way electric valve to connect to the third storage box. Based on the Y-axis coordinates output by the defect analysis module, the linear motor is driven to move the sliding seat laterally, so that the UV inkjet printer is aligned with the target position in the width direction of the film material; the electric telescopic rod is controlled to press down the UV inkjet printer, so that the nozzle maintains a set vertical distance from the surface of the film material, and the spraying mode is triggered according to the defect type, that is, for obvious cracks, the spraying is controlled to spray continuous solid lines, for suspected cracks, the spraying is controlled to spray intermittent dashed lines, and for surface contaminants, the spraying is controlled to spray circular marks.

[0012] As a further aspect of the present invention: the leveling mechanism performs directional wrinkle removal operation based on the received coordinates of the suspected crack location. The first hydraulic rod is extended to drive the second pad and leveling mechanism to be raised to a predetermined height, so that the membrane material is in a taut and stretched state; the third servo motor is started at the same time, and the first roller and the second roller are driven to rotate in opposite directions through the first belt drive assembly, so that the surface wrinkles are eliminated under the action of membrane material tension; After wrinkle removal, the membrane material undergoes closed-loop verification via the second testing component: The combined working mode of the UV irradiation lamp is activated, with the main light source providing imaging ultraviolet light and the auxiliary light source emitting activation wavelengths to excite the development of the marking ink; Based on secondary image analysis of defect morphology, if a continuous indentation with a depth exceeding a preset threshold is detected, it is determined to be a real defect and the mark is retained; if there is no structural deformation and only color residue remains, it is determined to be a wrinkle pseudo defect, and the UV irradiation lamp is switched to degradation mode, that is, the main light source is turned off, the auxiliary light source is enhanced to the degradation intensity and continuously irradiated, so that the marking ink is completely degraded to an invisible state.

[0013] As a further aspect of the present invention: a receiver is fixedly connected to one side of the outer surface of the frame; a coating mechanism is provided between the guiding mechanism and the leveling mechanism, the coating mechanism including a rotating rod rotatably connected to the middle of the frame, one end of the rotating rod passing through the frame and fixedly connected to a second servo motor, a cooling pipe and a pulsed UV lamp are fixedly connected to the upper and lower sides of the outer surface of the rotating rod respectively, one end of the cooling pipe and the pulsed UV lamp are jointly fitted with a collar bracket, the collar bracket and the rotating rod are at a 45-degree angle, a coating spray plate is fixedly connected to one side of the collar bracket, a storage tank is fixedly connected to one side of the outer surface of the frame, and a connecting pipe is fixedly connected between the storage tanks; an infrared humidity sensor is fixedly connected to one end of the top of the coating spray plate.

[0014] As a further aspect of the present invention: the support mechanism further includes a second hydraulic rod fixedly connected to the upper surface of the second pad, and a load-bearing plate fixedly connected to the top of the second hydraulic rod; a cleaning mechanism for cleaning dirt from the surface of the membrane material is provided directly above the first roller, the cleaning mechanism including a first limiting rod and a second limiting rod respectively provided above the first roller and the second roller, and both ends of the first limiting rod and the second limiting rod are provided with a second limiting seat fixedly connected to the load-bearing plate; slots are provided on both sides of the outer circular surface of the first limiting rod, and the outer circular surface of the first limiting rod... Both sides of the first limiting rod are fitted with semi-circular sleeves, and the inner wall of the semi-circular sleeve is fixedly connected with a locking strip that matches the slot. The outer surface of the semi-circular sleeve is fixedly connected with absorbent cotton. The upper and lower sides of the outer circular surface of the second limiting rod are respectively provided with a grinding plate and a semi-circular cotton cylinder, and the semi-circular cotton cylinder and the grinding plate together form a processing cylinder to facilitate the processing of the film plate. One end of the second limiting rod passes through the second limiting seat and is fixedly connected to a fourth servo motor. Both ends of the first limiting rod and the second limiting rod are provided with a second belt drive assembly. The outer side of the first pad is provided with a protective cover that is fixedly connected to the frame.

[0015] A method of using a membrane material appearance inspection device includes the following steps: S1: The film material to be tested is wound up and placed on the feeding roller. The feeding roller, winding roller and guiding mechanism in the frame are started so that the film material passes through the transition roller, the first guide roller and the second guide roller of the first transition component in sequence and enters the first detection area. S2: When the membrane material reaches the first detection area, the lighting lamp in the middle of the first transition component is lit, and the detection camera of the first detection component takes continuous pictures of the membrane material surface and transmits the original images to the defect analysis module of the marking mechanism. S3: The control module of the marking mechanism selects the ink in the corresponding storage tank through a three-way electric valve according to the defect type, drives the linear motor to move the UV inkjet printer to the target position, and sprays the corresponding mark according to the defect type; S4: For membrane materials marked as suspected cracks, after receiving the position coordinates, the first hydraulic rod drives the leveling mechanism to rise and tighten the membrane material. The third servo motor drives the first roller and the second roller to rotate in opposite directions to eliminate wrinkles. For membrane materials marked as surface contaminants, the cleaning mechanism moves down under the drive of the second hydraulic rod. The fourth servo motor drives the first limit rod and the second limit rod to rotate. The dirt is removed by wiping with absorbent cotton and polishing with a grinding plate. S5: The leveled or cleaned membrane material enters the second inspection area. The UV irradiation lamp at the second transition component starts the composite mode, and the inspection camera of the second inspection component acquires a secondary image. If it is determined to be a real defect, the mark is retained for subsequent cutting. If it is determined to be a wrinkle or a false defect or a contaminant that has been removed, the UV irradiation lamp switches to the degradation mode to remove the mark, and the membrane material is normally wound onto the winding roller.

[0016] Compared with the prior art, the technical solution provided by the present invention has at least the following beneficial effects: This solution establishes a first detection component, a second detection component, a support mechanism, and a leveling mechanism. After the first detection component initially identifies cracks, the support mechanism drives the leveling mechanism to rise and tighten the film material, and the film is wrinkled by rotating rollers. The second detection component then performs a second inspection, marking genuine cracks and removing marks from false defects such as wrinkles. This approach accurately distinguishes between cracks and wrinkles, solving the problem of existing equipment misjudging local wrinkles as cracks, leading to material waste, decreased yield, and increased costs.

[0017] By setting up a marking mechanism, a leveling mechanism, and a second inspection component, the defect type is marked with different inks after the initial inspection. Suspected cracked membrane materials are wrinkled by the leveling mechanism and then re-inspected by the second inspection component. The marking of real defects is retained and the marking of false defects is eliminated. This method achieves the effect of accurately identifying defects and reducing misjudgment, and solves the problem of membrane material wrinkles being misjudged as cracks, which leads to waste of raw materials and a decrease in the pass rate.

[0018] By setting up a coating mechanism, an infrared humidity sensor, and a receiver, the infrared humidity sensor identifies the marked film material after marking, triggers the coating spray plate to spray a protective coating, and then cures it with a pulsed UV lamp. The unmarked areas are treated by cooling pipes. This method achieves the effect of protecting the TiO2 ink markings from wear and solves the problem of marking wear affecting the accuracy of secondary detection. Attached Figure Description

[0019] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments of the invention and, together with the specification, further serve to explain the principles of the invention and enable those skilled in the art to practice and use the invention.

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the connection of the first detection component of the present invention; Figure 3 This is a schematic diagram of the marking mechanism of the present invention; Figure 4 This is a schematic diagram of the connection of the coating mechanism of the present invention; Figure 5 This is a schematic diagram showing the connection between the leveling mechanism and the cleaning mechanism of the present invention; Figure 6 This is a schematic diagram showing the connection between the support mechanism and the leveling mechanism of the present invention; Figure 7 This is a schematic diagram showing the disassembled connection of the cleaning mechanism of the present invention; Figure 8 This is a split left view of the cleaning mechanism of the present invention.

[0021] Figure label: 1. Frame; 2. Feed roller; 3. Take-up roller; 4. Guiding mechanism; 41. First servo motor; 42. First guide roller; 43. Second guide roller; 44. Second transition assembly; 45. Transition roller; 46. Lighting lamp; 5. UV irradiation lamp; 6. First detection component; 61. Bracket; 62. Mounting bracket; 63. Detection camera; 7. Marking mechanism; 71. Linear motor; 72. Slide bar; 73. Sliding seat; 74. UV inkjet printer; 75. Delivery pipe; 76. Three-way electric valve; 77. First storage box; 78. Second storage box; 79. Third storage box; 8. Coating mechanism; 81. Second servo motor; 82. Rotating rod; 83. Pulse UV lamp; 84. Cooling pipe; 85. Collar bracket; 86. Coating spray plate; 87. Storage tank; 88. Connecting pipe; 89. Infrared humidity sensor; 9. Receiver; 10. Support mechanism; 101. Protective cover; 102. First pad; 103. First hydraulic rod; 104. Second pad; 105. Second hydraulic rod; 106. Load-bearing plate; 11. Leveling mechanism; 111. First limiting seat; 112. First drive rod; 113. First roller; 114. Second drive rod; 115. Second roller; 116. Third servo motor; 117. First belt drive assembly; 12. Cleaning mechanism; 121. Second limit seat; 122. First limit rod; 123. Slot; 124. Semi-circular sleeve; 125. Locking strip; 126. Absorbent cotton; 127. Second limit rod; 128. Fourth servo motor; 129. Second belt drive assembly; 1210. Semi-circular cotton cylinder; 1211. Grinding plate; 13. Second detection component.

[0022] As shown in the figure, specific structures and devices are marked in the figure to clearly illustrate the structure of the embodiments of the present invention. However, this is only for illustrative purposes and is not intended to limit the present invention to this specific structure, device and environment. Those skilled in the art can adjust or modify these devices and environments according to specific needs. Detailed Implementation

[0023] The following is a detailed description of a membrane material appearance inspection device and its usage method provided by the present invention, with reference to the accompanying drawings and specific embodiments. It should be noted that, to make the embodiments more detailed, the following embodiments are the best and preferred embodiments; those skilled in the art can also use other alternative methods to implement some known technologies; and the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0024] like Figures 1 to 8 As shown, this embodiment of the invention provides a device for inspecting the appearance of film materials and its usage method, including a frame 1, with a feeding roller 2 and a winding roller 3 respectively arranged at both ends inside the frame 1, and a guiding mechanism 4 provided inside the frame 1 for conveying the film material and guiding it through the inspection station; the guiding mechanism 4 includes a transition roller 45 and a first transition component and a second transition component 44 arranged sequentially along the film material conveying direction; The first detection component 6 is set directly above the first transition component, and the second detection component 13 is set directly above the second transition component 44. The two components perform the initial inspection and re-inspection of the membrane material, respectively. A leveling mechanism 11 is provided in the middle of the frame 1, which is used to eliminate membrane material wrinkles after identifying suspected cracks in the initial inspection. Supporting mechanisms 10 are provided on both sides of the outer surface of the frame 1, which are used to drive the leveling mechanism 11 to rise and fall. The support mechanism 10 includes a first pad 102 fixed to both sides of the frame 1, a first hydraulic rod 103 fixedly connected to the upper surface of the first pad 102, and a second pad 104 fixedly connected to the top of the first hydraulic rod 103. The leveling mechanism 11 includes a first limiting seat 111 fixedly connected to one side of the second pad 104. The two ends inside the first limiting seat 111 are respectively rotatably connected to a first driving rod 112 and a second driving rod 114. One end of the first driving rod 112 passes through the first limiting seat 111 and is fixedly connected to a third servo motor 116. The outer circular surfaces of the first driving rod 112 and the second driving rod 114 are respectively fixedly connected to a first roller 113 and a second roller 115. A first belt drive assembly 117 is provided between the first driving rod 112 and the second driving rod 114.

[0025] To address the misjudgment problems existing in current membrane material appearance inspection equipment, particularly the issue of localized wrinkles being incorrectly identified as cracks due to uneven membrane tension, conveyor roller misalignment, or improper winding, the above-mentioned technical solution is adopted. This solution mainly consists of a first inspection component 6, a second inspection component 13, a support mechanism 10, and a leveling mechanism 11. During membrane material appearance inspection, the membrane material to be inspected is first wound and placed on the feed roller 2. Then, by activating the feed roller 2 and the winding roller 3 within the frame 1, they rotate, and simultaneously, the guide mechanism 4 is activated, allowing the membrane material to pass through the transition roller 45 and enter the first inspection area. In the field, the first detection component 6 performs visual inspection on the membrane material during the conveying process. When the first detection component 6 detects cracks on the surface of the membrane material, to avoid false detections, during the continued conveying of the defective membrane material, the first hydraulic rod 103 is automatically activated by a signal sensor to extend it. This allows the second pad 104 to drive the entire leveling mechanism 11 to rise synchronously to a certain height, thereby tightening and stretching the membrane material during the winding process. At the same time, the third servo motor 116 is activated, causing the first drive rod 112 to rotate clockwise. The first belt drive component 117 (in the prior art, two pulleys are respectively fixed to the first drive rod 112 and the second drive rod 11) is used to drive the membrane material. 14. The two pulleys are connected via belt drive, causing the first drive rod 112 and the second drive rod 114 to rotate clockwise within the first limit seat 111. This causes the first roller 113 to rotate, thereby removing wrinkles from the surface of the taut membrane material under the rotation of the first roller 113, thus eliminating the error caused by wrinkles. After the wrinkle removal process, the marked membrane material re-enters the secondary inspection area and is re-inspected by the second inspection component 13. At this time, two situations may occur: First, if the membrane material after the wrinkle removal step is still found to have cracks on its surface after the secondary inspection by the second inspection component 13, then... Directly feeding the marked defective film material onto the take-up roller 3 does not remove the markings, facilitating subsequent cutting of the marked defective film material. Alternatively, after the wrinkle removal step, the film material undergoes a second inspection by the second inspection component 13. If the inspection result shows that the film material surface is normal, the markings on the film material surface are removed using appropriate inspection tools, allowing for normal feeding and winding of the film material. Through the above operations, it is possible to avoid situations where local wrinkles caused by uneven tension during film material operation, conveyor roller misalignment, or improper winding are mistakenly identified as cracks, leading to unnecessary cutting and rejection in subsequent processes, resulting in waste of raw materials, decreased product qualification rate, and increased production costs.

[0026] like Figure 1 , Figure 2As shown, the first transition component and the second transition component 44 have the same structure and function, but their positions are different. Both the first transition component and the second transition component 44 include a first guide roller 42 and a second guide roller 43 rotatably connected inside the frame 1. A transmission component is provided between the first guide roller 42 and the second guide roller 43, and a first servo motor 41 fixedly connected to the frame 1 is provided at the output end of the second guide roller 43. The first guide roller 42 and the second guide roller 43 are rotated synchronously through the first servo motor 41 and the transmission component to complete the film material conveying. Multiple sets of transition rollers 45 are provided inside the frame 1, which work together with the first guide roller 42 and the second guide roller 43 to complete the film material conveying.

[0027] like Figure 1 , Figure 2 , Figure 3 As shown, the first guide roller 42 and the second guide roller 43 of the first transition assembly are jointly provided with an illumination lamp 46 for providing preliminary inspection illumination; and the first transition assembly is jointly provided with a UV irradiation lamp 5 for providing secondary inspection illumination; the first inspection assembly 6 and the second inspection assembly 13 have the same structure and function, but their positions are different; the first inspection assembly 6 and the second inspection assembly 13 both include a bracket 61 fixedly connected to both sides of the frame 1, the top of the bracket 61 is bolted to a fixing frame 62, and the bottom of the fixing frame 62 is fixedly connected to an inspection camera 63 arranged in a linear pattern. The inspection camera 63 is used in conjunction with the illumination lamp 46 and the UV irradiation lamp 5 to complete the preliminary inspection and secondary inspection of the film material.

[0028] like Figure 1 , Figure 2 , Figure 3 As shown, a marking mechanism 7 for marking defective film is provided directly above the second guide roller 43. The marking mechanism 7 includes a slide rod 72 rotatably connected inside the frame 1. A linear motor 71 is fixedly connected to one end of the slide rod 72. A sliding seat 73 is slidably connected to the outer surface of the slide rod 72. An electric telescopic rod is fixedly connected to the bottom of the sliding seat 73. A UV inkjet printer 74 is fixedly connected to the sliding seat 73 through the electric telescopic rod. A first storage box 77, a second storage box 78, and a third storage box 79 are fixedly connected to one side of the outer surface of the frame 1. The output ends of the first storage box 77, the second storage box 78, and the third storage box 79 are connected to a three-way electric valve 76. The three-way electric valve 76 and the UV inkjet printer 74 are fixedly connected to a conveying pipe 75 to facilitate the conveying of the inkjet material.

[0029] like Figure 1 , Figure 2 , Figure 3As shown, the marking mechanism 7 also includes a defect analysis module, which is used to receive the original image of the membrane surface acquired by the detection camera 63 at the first detection component 6, separate the potential defect area through image noise reduction and segmentation processing, perform contour extraction on the segmentation result, generate a closed defect polygon and calculate its geometric morphological features, including length and width characteristics, area fill rate and contour curvature complexity, and output a structured feature vector. The feature vectors are compared with the pre-stored defect template library: if they meet the characteristics of a slender through-type defect with a high aspect ratio, low area fill rate, and gentle curvature, they are classified as through-type linear defects; if they meet the characteristics of a local linear defect with a medium aspect ratio and a relatively high area fill rate, they are classified as local linear defects; if they meet the characteristics of an irregular blocky defect with a low aspect ratio and high curvature complexity, they are classified as irregular blocky defects. Based on the classification results and defect size threshold, the defect type is determined. That is, a through-line defect exceeding the width threshold is determined as an obvious crack; a local linear defect below the width threshold is determined as a suspected crack; and an irregular block defect is directly determined as a surface contaminant. According to the real-time conveying speed of the membrane material and the camera acquisition timestamp, the position of the defect contour center point in the image coordinate system is converted into a three-dimensional spatial coordinate with the starting end of the feeding roller 2 as the origin. The X-axis is the length direction of the membrane material, the Y-axis is the width direction, and the Z-axis is the thickness direction.

[0030] like Figure 1 , Figure 2 , Figure 3 As shown, the marking mechanism 7 also includes a control module, which is used to automatically select the corresponding ink storage box according to the defect type judgment result output by the defect analysis module. That is, when it is judged to be an obvious crack, the three-way electric valve 76 is controlled to connect to the first storage box 77; when it is judged to be a suspected crack, the three-way electric valve 76 is controlled to connect to the second storage box 78; when it is judged to be a surface contaminant, the three-way electric valve 76 is controlled to connect to the third storage box 79. Based on the Y-axis coordinates output by the defect analysis module, the linear motor 71 is driven to move the sliding seat 73 laterally, so that the UV inkjet printer 74 is aligned with the target position in the width direction of the film material; the electric telescopic rod is controlled to press down the UV inkjet printer 74, so that the nozzle maintains a set vertical distance from the surface of the film material, and the spraying mode is triggered according to the defect type, that is, for obvious cracks, continuous solid lines are sprayed, for suspected cracks, intermittent dashed lines are sprayed, and for surface contaminants, circular marks are sprayed.

[0031] The leveling mechanism 11 performs directional wrinkle removal based on the received coordinates of the suspected crack location: The first hydraulic rod 103 is extended to drive the second pad 104 and the leveling mechanism 11 to be raised to a predetermined height, so that the membrane material is in a taut and stretched state; the third servo motor 116 is started at the same time, and the first roller 113 and the second roller 115 are driven to rotate in opposite directions through the first belt drive assembly 117, so that the surface wrinkles are eliminated under the action of membrane material tension. After wrinkle removal, the membrane material undergoes closed-loop verification via the second testing component 13: Activate the composite working mode of UV lamp 5, where the main light source provides imaging ultraviolet light and the auxiliary light source emits activation wavelengths to excite the development of the marking ink; Based on secondary image analysis of defect morphology, if a continuous indentation with a depth exceeding a preset threshold is detected, it is determined to be a real defect and the mark is retained; if there is no structural deformation and only color residue remains, it is determined to be a wrinkle pseudo defect, and the UV irradiation lamp 5 is switched to degradation mode, that is, the main light source is turned off, the auxiliary light source is enhanced to the degradation intensity and continuously irradiated, so that the marking ink is completely degraded to an invisible state.

[0032] During membrane material appearance inspection, the membrane material to be inspected, wound by the feeding roller 2, enters the first inspection area via the transition roller 45. When it reaches the first guide roller 42 and the second guide roller 43 of the first transition assembly, the lighting lamp 46 provides illumination for the inspection. At this time, the inspection camera 63 located on the first inspection assembly 6 takes pictures of the membrane material on the first guide roller 42 and the second guide roller 43 and performs image recognition to analyze the actual condition of the membrane material surface. Once the inspection camera 63 detects a defect on the membrane material surface, it immediately transmits its signal to the marking mechanism 7 and simultaneously starts the linear motor 71. Based on the location of the defect on the membrane material surface, it... The sliding seat 73 moves to the designated position along the guide of the slide bar 72. Depending on the defects of the membrane material, the three-way electric valve 76 opens the ink delivery port of different concentrations to mark the defective membrane material in different ways. For example, when obvious cracks appear on the surface of the membrane material, the delivery port of the first storage box 77 is opened, so that the TiO2 ink with a concentration of 8% in the first storage box 77 enters the UV inkjet printer 74 through the delivery pipe 75. The printhead of the UV inkjet printer 74 marks the crack position on the surface of the membrane material with ink, so that the subsequent staff can cut the membrane material in that area to ensure the quality of the product.

[0033] When a suspected crack appears on the surface of the film material, the delivery port of the second storage tank 78 is opened through the three-way electric valve 76, so that the TiO2 ink with a concentration of 5% in the second storage tank 78 enters the UV inkjet printer 74 through the delivery pipe 75. The nozzle of the UV inkjet printer 74 sprays ink on the suspected crack position on the surface of the film material for inkjet marking, so that according to this marking, secondary detection can be carried out subsequently to determine the true situation of the film material defect; for the film material initially marked as a suspected crack, it first passes through the leveling mechanism 11 to extend the film material and eliminate the influencing factor of wrinkles on the surface of the film material, and then enters the secondary detection area, that is, enters the roller area of the second detection component 13. At this time, a UV irradiation lamp 5 is arranged between the two rollers of the second detection component 13, which not only provides a light source for the detection camera 63 in the second detection area, so that the detection camera 63 in the second detection area can perform secondary detection and analysis on the marked film material. At this time, once it is determined to be a crack, it is directly output, and there is still residual inkjet marking on the surface of the film material, so as to facilitate subsequent cutting of the crack area; when it is determined to be qualified during secondary detection after removing wrinkles, at this time, the conveying speed of the entire film material is adjusted, and the UV irradiation lamp 5 is used to provide a light heat source. The 5% TiO2 ink marking on the surface of the film material undergoes a UV-triggered nano-catalytic reaction, with an almost instantaneous fading ability and non-destructive processing characteristics, perfectly removing the marking on the surface of the film material. For the convenience of removing this marking, compared with traditional chemical markings, there are no residue and diffusion problems.

[0034] When performing the appearance inspection of the film material, the film material to be inspected wound by the feeding roller 2 enters the first detection area through the transition roller 45. When the film material reaches the first guide roller 42 and the second guide roller 43 of the first transition component, the lighting lamp 46 at the middle of the first guide roller 42 and the second guide roller 43 of the first transition component is immediately lit to provide a stable and uniform light source for the inspection, ensuring that the detection camera 63 on the first detection component 6 can clearly capture the image of the film material surface. At this time, the detection camera 63 continuously takes pictures of the film material on the first guide roller 42 and the second guide roller 43, and transmits the original image of the film material surface collected in real time to the defect analysis module of the marking mechanism 7.

[0035] After receiving the original image, the defect analysis module immediately starts a multi-dimensional image processing process. Considering problems such as dust interference that may exist at the film material production site and image blurring caused by equipment operation vibration, first, image noise reduction processing is carried out through adaptive median filtering technology. This method can dynamically adjust the filtering range according to the gray distribution around the pixel points, and retain the edge details of the defect to the greatest extent while removing noise. Subsequently, an automatic threshold segmentation technology based on the Otsu algorithm is adopted. Taking the gray distribution of the normal area on the surface of the film material as a reference, the potential defect area with abnormal gray values and the uniform background area are accurately divided, and even tiny defects with low contrast can be effectively separated.

[0036] When performing contour extraction on the segmented binarized image, an eight-neighbor chain code tracing algorithm is used to scan the image point by point, recording the coordinate information of all pixels on the boundary of the defect region, thereby generating a closed defect contour polygon. To comprehensively characterize the geometry of the defect, feature parameters are calculated from three key dimensions: First, length and width characteristics, which are determined by using the minimum bounding rectangle algorithm to determine the longest and shortest axes of the defect and calculating their ratio to determine the extension direction and slenderness of the defect; second, area fill rate, which is the ratio of the number of pixels actually occupied by the defect to the total number of pixels contained in the bounding rectangle, and this parameter can effectively distinguish whether the defect is linearly distributed or blocky; third, contour curvature complexity, which is determined by calculating the curvature value of each point on the contour line and statistically analyzing its standard deviation to reflect the irregularity of the defect edge. These parameters are integrated into a structured feature vector to provide accurate quantitative basis for subsequent defect classification.

[0037] When structured feature vectors are input into a pre-stored defect template library for similarity comparison, the library contains a massive amount of manually calibrated typical defect feature data, including feature vector samples of different types and sizes of defects. Accurate matching of defect types is achieved by calculating the Euclidean distance between the feature vector of the defect to be detected and the feature vectors of various templates. If the feature vector of the defect to be detected satisfies the characteristics of a slender, through-thick defect, specifically exhibiting a high aspect ratio (usually not less than 5:1), a low area fill rate (generally not exceeding 30%), and a smooth change in contour curvature (curvature standard deviation within a preset low range), it is determined to be a through-thick linear defect. These types of defects often extend along the membrane. The extension of the material along its length may seriously affect the overall structural integrity of the membrane material. If the feature vector shows local linear features, that is, a medium aspect ratio (mostly between 3:1 and 5:1) and a high area fill rate (usually exceeding 30%), it is classified as a local linear defect. Such defects are mostly concentrated in specific areas on the surface of the membrane material and may be caused by uneven local stress. If the feature vector shows irregular block features, that is, a low aspect ratio (usually less than 2:1) and high curvature complexity (curvature standard deviation is in the preset high range), it is judged as an irregular block defect. Its shape is mostly scattered and irregular, which may be impurities attached during the production process.

[0038] After completing the initial classification of defects (i.e., dividing them into through-line defects, localized line defects, and irregular block defects), the defect type needs to be further clarified by combining the preset defect size threshold. The specific judgment process is as follows: For areas classified as through-line defects (characterized by high aspect ratio, low area fill rate, and gentle curvature changes), their actual width needs to be measured (converted to physical size through image pixel size). For example, when the width exceeds the preset width threshold, it is directly judged as an "obvious crack." These defects are large in size and through-line, significantly affecting the structural integrity of the membrane material, and need to be marked to ensure subsequent processing. For areas classified as localized line defects (characterized by medium aspect ratio and high area fill rate), their actual width is also measured. When the width is lower than the above width threshold, it is judged as a "suspected crack." These defects may be real micro-cracks or pseudo-defects caused by membrane material wrinkles, uneven local tension, etc., so subsequent secondary testing is required to verify their authenticity. For areas classified as irregular blocky defects (characterized by low aspect ratio and high curvature complexity), no additional size threshold judgment is required; they are directly identified as "surface contaminants." These defects are mostly impurities such as dust and fibers that adhere during the production process. Their morphology differs significantly from the structural defects of the membrane material itself (such as cracks), and they can be treated through cleaning processes.

[0039] After determining the defect type, based on the real-time conveying speed of the membrane material and the timestamp of image acquisition, the two-dimensional coordinates of the defect contour center point in the image coordinate system are accurately mapped to a three-dimensional spatial coordinate system with the starting end of the feeding roller 2 as the origin. The X-axis is parallel to the conveying direction of the membrane material and represents the length direction of the membrane material. Its coordinate value is calculated by multiplying the conveying speed of the membrane material by the image acquisition time. The Y-axis is perpendicular to the X-axis and extends laterally along the membrane material, representing the width direction. Its coordinate value is calculated by converting the lateral pixel position in the image coordinate system. The Z-axis is perpendicular to the plane where the membrane material surface is located and represents the thickness direction, which is used for possible depth detection in the future. Through this coordinate transformation process, the spatial position of the defect on the membrane material can be accurately recorded, providing an accurate positional reference for subsequent marking, re-inspection and processing procedures.

[0040] Once the inspection camera 63 detects a defect on the film surface through the defect analysis module, it immediately transmits the signal to the control module of the marking mechanism 7 and simultaneously starts the linear motor 71. The control module, as the core control unit of the marking mechanism 7, is responsible for automatically executing a series of marking operations based on the defect type determination result output by the defect analysis module. First, it automatically selects the corresponding ink storage box according to the defect type: when a significant crack is determined, it controls the three-way electric valve 76 to switch to a state connected to the first storage box 77. The first storage box 77 stores TiO2 ink with a concentration of 8%, which has… The high adhesion and high contrast characteristics ensure that obvious crack markings are clearly visible in subsequent processing. When a suspected crack is detected, the three-way electric valve 76 is controlled to connect to the second storage tank 78, which contains 5% TiO2 ink. This ink has special photosensitive properties and will exhibit obvious fluorescence under ultraviolet light of a specific wavelength, making it easy to identify during secondary inspection. When a surface contaminant is detected, the three-way electric valve 76 is controlled to connect to the third storage tank 79, which contains quick-drying pigment that can quickly form a stable mark at the contaminant location.

[0041] After determining the ink storage bin, the control module sends precise drive commands to the linear motor 71 based on the Y-axis coordinates output by the defect analysis module. The linear motor 71 drives the sliding seat 73 on the slide bar 72 to move laterally along the guide of the slide bar 72, so that the UV inkjet printer 74 is precisely aligned with the defect target position in the width direction of the film material. Subsequently, the control electric telescopic rod extends downward, adjusting the nozzle of the UV inkjet printer 74 to maintain a set vertical distance from the surface of the film material. This distance ensures that the ejected ink forms clear and uniform marks. Finally, the corresponding inkjet pattern is triggered based on the defect type: for obvious cracks, continuous solid lines are sprayed, with the width and length of the lines dynamically adjusted according to the actual size of the crack to ensure complete coverage of the crack area. For example, when obvious cracks appear on the film surface, 8% TiO2 ink enters the UV inkjet printer 74 through the delivery pipe 75. The printhead of the UV inkjet printer 74 marks the crack location on the film surface with inkjet ink, facilitating subsequent cutting of the film in that area by subsequent workers and ensuring product quality; for suspected cracks, intermittent dashed lines are sprayed, with the spacing between the dashed lines and... The line segment length is optimized to clearly mark the location and distinguish it from the markings of obvious cracks. When a suspected crack appears on the membrane surface, 5% TiO2 ink enters the UV inkjet printer 74 through the delivery pipe 75. The printhead of the UV inkjet printer 74 marks the suspected crack location on the membrane surface with ink, so that a secondary inspection can be carried out based on the mark to determine the true extent of the membrane defect. Circular marks are sprayed to control the surface contaminants. The diameter of the circle is set according to the size of the contaminant, usually slightly larger than the actual size of the contaminant, to ensure the accuracy of the marking.

[0042] The membrane material initially marked as potentially cracked continues to be conveyed, first passing through the leveling mechanism 11. Upon receiving the location coordinates of the suspected crack, the leveling mechanism 11 immediately initiates a directional wrinkle removal operation to eliminate membrane wrinkles that might lead to misjudgment. First, the control module sends an extension command to the first hydraulic rod 103, which pushes the top second pad 104 upwards, thereby raising the leveling mechanism 11, fixed to the second pad 104, to a predetermined height. This height is precisely calibrated to ensure the membrane material is under appropriate tension under the action of the leveling mechanism 11, effectively eliminating local wrinkles caused by uneven tension, conveyor roller misalignment, or improper winding, thus stretching the membrane material and eliminating the influencing factors of wrinkles on the membrane surface. Simultaneously, the third servo motor 116 is activated. The output shaft of the third servo motor 116 transmits power to the first drive rod 112 and the second drive rod 114 via the first belt drive assembly 117, causing them to rotate in opposite directions at a set speed within the first limit seat 111. This, in turn, drives the first roller 113 and the second roller 115 to rotate synchronously. With the membrane material under tension, the opposite rotation of the two rollers generates uniform friction on the membrane surface, causing wrinkles on the membrane surface to gradually smooth out and disappear. In particular, targeted wrinkle removal treatment can be performed on areas suspected of having cracks, ensuring that subsequent secondary inspections are not affected by wrinkles.

[0043] After wrinkle removal, the membrane material continues to be conveyed to the secondary inspection area where the second inspection component 13 is located, that is, into the roller area of ​​the second inspection component 13. The second inspection component 13 performs closed-loop verification to determine the authenticity of the suspected cracks. A UV irradiation lamp 5 is set between the two rollers of the second transition component 44. At this time, the composite working mode of the UV irradiation lamp 5 is activated: the main light source emits ultraviolet light with a wavelength of 365nm to provide stable imaging illumination for the inspection camera 63 in the second inspection area, ensuring that the image of the membrane material surface can be clearly captured; the auxiliary light source emits ultraviolet light with a peak wavelength of 395nm. This wavelength can effectively activate the photosensitizer in the 5% TiO2 ink used for the suspected crack marking, so that the intermittent dashed line markings exhibit a strong fluorescence effect, which makes it easy for the inspection camera 63 to accurately identify the marking position, so that the inspection camera 63 in the second inspection area can perform secondary inspection and analysis on the marked membrane material.

[0044] Based on the secondary images acquired by the detection cameras 63 at the 13 locations of the second detection component, the system performs a detailed analysis of the defect morphology: If a continuous indentation with a depth exceeding a preset threshold (e.g., 0.1 mm) is detected at the marked location, and the shape of the indentation matches the characteristics of the initially detected suspected crack, it is determined to be a real crack. In this case, the system will retain the mark at that location, meaning that the inkjet marking on the membrane surface still remains, so that subsequent processes can accurately cut the defect area and directly output the membrane. If no obvious structural deformation is detected at the marked location, and only the color of the marking ink remains, it is determined to be a wrinkle false defect, meaning that the initially detected suspected crack was a misjudgment caused by membrane wrinkles. In this case, the system adjusts the overall membrane conveying speed and immediately switches the UV irradiation lamp 5 to degradation mode, i.e., turning off the main light source and increasing the power of the auxiliary light source to 150% of the rated power. The marked area is continuously irradiated with high-intensity 395nm ultraviolet light for 2-3 seconds, and 5% of the TiO2 ink marking on the membrane surface undergoes chemical decomposition through ultraviolet-triggered nanocatalytic reaction, completely degrading to an invisible state. Compared to traditional chemical marking, this method of removing markings has near-instantaneous fading ability and non-destructive processing characteristics, with no residue or diffusion issues. It can perfectly remove markings from the surface of the membrane material, preserving the normal conveying and winding of the membrane material, avoiding unnecessary cutting of normal membrane material in subsequent processes, thereby reducing raw material waste and improving product qualification rate.

[0045] like Figure 1 , Figure 2 , Figure 4 As shown, a receiver 9 is fixedly connected to one side of the outer surface of the frame 1; a coating mechanism 8 is provided between the guide mechanism 4 and the leveling mechanism 11. The coating mechanism 8 includes a rotating rod 82 rotatably connected to the middle of the inside of the frame 1. One end of the rotating rod 82 passes through the frame 1 and is fixedly connected to a second servo motor 81. Cooling pipes 84 and pulse UV lamps 83 are fixedly connected to the upper and lower sides of the outer surface of the rotating rod 82, respectively. A collar bracket 85 is fitted together at one end of the cooling pipes 84 and the pulse UV lamps 83. The collar bracket 85 forms a 45-degree angle with the rotating rod 82. A coating spray plate 86 is fixedly connected to one side of the collar bracket 85. A storage tank 87 is fixedly connected to one side of the outer surface of the frame 1. A connecting pipe 88 is fixedly connected between the storage tanks 87. An infrared humidity sensor 89 is fixedly connected to one end of the top of the coating spray plate 86.

[0046] To prevent the TiO2 ink on the marked film surface from wearing away and affecting the accuracy of secondary inspection and analysis, after the defective film is marked using the UV inkjet printer 74, it continues to be conveyed. Then, the infrared humidity sensor 89 automatically identifies the marked film and transmits its signal to the second servo motor 81 through the receiver 9. This causes the rotating rod 82 to drive the cooling pipe 84 and the pulse UV lamp 83 to rotate, thus positioning the pulse UV lamp 83 at the bottom. At the same time, the collar bracket 85 aligns the coating spray plate 86 with the marked film, and the delivery pump in the storage tank 87 is activated simultaneously, so that the protective coating pigment in the storage tank 87 is delivered to the coating through the connecting pipe 88. In the spray plate 86, the nozzle of the coating spray plate 86 applies a coating to the marked area of ​​the film material, forming a protective coating on the surface of the marked area. The coated film material is then irradiated by the pulse UV lamp 83 to cure the coating area, so as to prevent the TiO2 ink marked area from being damaged and to ensure the accuracy of subsequent secondary inspection. For the unmarked area, the infrared humidity sensor 89 is used to automatically monitor the humidity of the film material. When the surface is dry, the receiver 9 transmits the signal to the second servo motor 81, so that the rotating rod 82 rotates clockwise, so that the cooling pipe 84 is on the surface of the conveying film material. During this process, the cooling pipe 84 will not cause any wear to the surface of the film material.

[0047] like Figure 6 , Figure 7 , Figure 8 As shown, the support mechanism 10 also includes a second hydraulic rod 105 fixedly connected to the upper surface of the second pad 104, and a load-bearing plate 106 fixedly connected to the top of the second hydraulic rod 105; a cleaning mechanism 12 for cleaning dirt from the surface of the membrane material is provided directly above the first roller 113. The cleaning mechanism 12 includes a first limiting rod 122 and a second limiting rod 127 respectively located directly above the first roller 113 and the second roller 115. Both ends of the first limiting rod 122 and the second limiting rod 127 are provided with a second limiting seat 121 fixedly connected to the load-bearing plate 106; slots 123 are provided on both sides of the outer circular surface of the first limiting rod 122, and half-slots are fitted on both sides of the outer circular surface of the first limiting rod 122. The inner wall of the round sleeve 124 is fixedly connected with a retaining strip 125 that matches the retaining groove 123, and the outer surface of the semi-circular sleeve 124 is fixedly connected with an absorbent cotton 126; the upper and lower sides of the outer circular surface of the second limiting rod 127 are respectively provided with a grinding plate 1211 and a semi-circular cotton cylinder 1210, and the semi-circular cotton cylinder 1210 and the grinding plate 1211 together form a processing cylinder to facilitate the processing of the film plate; one end of the second limiting rod 127 passes through the second limiting seat 121 and is fixedly connected with a fourth servo motor 128; both ends of the first limiting rod 122 and the second limiting rod 127 are provided with a second belt drive assembly 129; a protective cover 101 fixedly connected to the frame 1 is provided on the outer side of the first pad 102.

[0048] After analysis by the first detection component 6, if the membrane surface is determined to have residual contaminants, the conveying port of the second storage tank 78 is opened via the three-way electric valve 76. This allows 2% TiO2 ink from the third storage tank 79 to enter the UV inkjet printer 74 via the conveying pipe 75. The printhead of the UV inkjet printer 74 marks the location of the contaminants on the membrane surface. The marked membrane then passes through the first roller 113 and the second roller 115. Based on the membrane thickness, the second hydraulic rod 105 moves the entire cleaning mechanism 12 downwards, causing the absorbent cotton 126 and the corresponding polishing components to contact the membrane surface. Simultaneously, the fourth servo motor 128 is activated, causing the first limit rod 122 to rotate. At the same time, the second belt drive component 129 (the existing belt drive) drives the second limit rod 127 to rotate, placing the polishing plate 1211 on the membrane surface. This allows the absorbent cotton 126 to wipe away surface dirt and remove water stains, preventing water stains from affecting the test results. If an error occurs, the wiped membrane material is then polished by the grinding plate 1211, further polishing the dirt on the membrane surface. The wear particle size of the grinding plate 1211 meets the polishing requirements of the membrane material and will not cause the membrane material to break. After cleaning, the membrane material is then transported to the secondary inspection area for secondary inspection. At this time, the inspection camera 63 in the second inspection area performs secondary inspection and analysis on the marked membrane material. After the UV irradiation lamp 5 decomposes the marked area with 2% TiO2 ink, and the analysis results show that there is no dirt on the membrane material surface, it is normally transported and wound onto the winding roller 3. If the analysis results show that there are defects on the membrane material surface, it is subsequently marked and the area is cut to ensure the normal use of the membrane material. In addition, during the entire cleaning process, due to the long-term use of the absorbent cotton 126, the wiping effect decreases. The machine can be stopped periodically, and the semi-circular cotton cylinder 1210 can be removed from the first limit rod 122 to replace the new absorbent cotton 126 and ensure the normal operation of the cleaning work.

[0049] A method of using a membrane material appearance inspection device includes the following steps: S1: The film material to be tested is wound up and placed on the feeding roller 2. The feeding roller 2, winding roller 3 and guiding mechanism 4 in the frame 1 are started so that the film material passes through the transition roller 45, the first guide roller 42 and the second guide roller 43 of the first transition component in sequence and enters the first detection area. S2: When the membrane material reaches the first detection area, the lighting lamp 46 in the middle of the first transition component is lit, and the detection camera 63 of the first detection component 6 takes continuous pictures of the membrane material surface and transmits the original images to the defect analysis module of the marking mechanism 7. S3: The control module of the marking mechanism 7 selects the ink in the corresponding storage tank through the three-way electric valve 76 according to the defect type, drives the linear motor 71 to move the UV inkjet printer 74 to the target position, and sprays the corresponding mark according to the defect type; S4: For membrane materials marked as suspected cracks, after receiving the position coordinates, the first hydraulic rod 103 drives the leveling mechanism 11 to rise and tighten the membrane material. The third servo motor 116 drives the first roller 113 and the second roller 115 to rotate in opposite directions to eliminate wrinkles. For membrane materials marked as surface contaminants, the cleaning mechanism 12 moves down under the drive of the second hydraulic rod 105. The fourth servo motor 128 drives the first limit rod 122 and the second limit rod 127 to rotate. The dirt is removed by wiping with absorbent cotton 126 and polishing with grinding plate 1211. S5: The leveled or cleaned membrane material enters the second inspection area. The UV irradiation lamp 5 at the second transition component 44 starts the composite mode, and the inspection camera 63 of the second inspection component 13 acquires a secondary image. If it is determined to be a real defect, the mark is retained for subsequent cutting. If it is determined to be a wrinkle or a false defect or a contaminant that has been removed, the UV irradiation lamp switches to the degradation mode to remove the mark, and the membrane material is normally wound onto the winding roller 3.

[0050] When using this invention, the first step is to prepare for testing by placing the film material to be tested on the feeding roller 2 of the frame 1, ensuring that the starting end of the film material is flat and drawn out. The film material passes through the transition roller 45 of the guide mechanism 4, the first guide roller 42 and the second guide roller 43 of the first transition component in sequence, and is finally fixed on the take-up roller 3, thus completing the path laying of the film material. After the device is started, the feeding roller 2 and the take-up roller 3 rotate synchronously under the drive mechanism. The first servo motor 41 drives the first guide roller 42 and the second guide roller 43 to operate in coordination through the transmission component, and the film material enters the first testing area at a stable speed. At this time, the lighting lamp 46 in the middle of the first transition component is lit, providing uniform illumination for the detection camera 63 of the first detection component 6. The detection camera 63 continuously captures images of the membrane surface, acquiring raw images in real time and transmitting them to the defect analysis module of the marking mechanism 7. The defect analysis module performs multi-dimensional processing on the images. First, it removes interference noise such as dust and vibration through adaptive median filtering, and then uses the Otsu algorithm to segment potential defect areas. Subsequently, it extracts features such as the length and width characteristics, area fill rate, and contour curvature complexity of the defect contour, generates a structured feature vector, and compares it with a pre-stored template library to classify defects into through-line defects, local linear defects, or irregular block defects. Based on the defect size threshold, further judgment is made. If the width of a through-line defect exceeds the threshold, it is considered an obvious crack; if the width of a local linear defect is below the threshold, it is considered a suspected crack; and irregular block defects are directly judged as surface contaminants. The defect position is converted into three-dimensional spatial coordinates. At the same time, the control module of the marking mechanism 7 performs a marking operation according to the judgment result, that is, it controls the three-way electric valve 76 to connect the corresponding storage box (obvious cracks correspond to 8% of the first storage box 77). TiO2 ink (5% TiO2 ink in the second storage tank 78 for suspected cracks, and quick-drying pigment or 2% TiO2 ink in the third storage tank 79 for surface contaminants); drive linear motor 71 to move sliding seat 73 along slide bar 72, so that UV inkjet printer 74 is aligned with the Y-axis coordinate position of the defect; electric telescopic rod adjusts the distance between nozzle and film to 5-10mm, spraying continuous solid lines, intermittent dashed lines or circular marks according to the defect type; the marked film enters the processing stage, and after the infrared humidity sensor 89 of coating mechanism 8 identifies the marked area, the receiver 9 triggers the second servo motor 81 to rotate the rotating rod 82, so that the pulse UV lamp 83 faces downward and the coating spray plate 86 is aligned with the marked area; the protective coating of storage tank 87 is transported to coating spray plate 86 through connecting pipe 88, the protective coating is sprayed on the marked area and cured by pulse UV lamp 83; the unmarked area is treated by cooling pipe 84 to keep the surface dry.When the suspected cracked membrane material is conveyed to the leveling mechanism 11, the first hydraulic rod 103 extends, causing the leveling mechanism 11 to rise and tighten the membrane material. The third servo motor 116 drives the first roller 113 and the second roller 115 to rotate in opposite directions through the first belt drive assembly 117, eliminating surface wrinkles. When surface contaminants pass over the membrane material, the second hydraulic rod 105 drives the cleaning mechanism 12 to move downward, so that the absorbent cotton 126 contacts the polishing plate 1211. The fourth servo motor 128 drives the first limit rod 122 and the second limit rod 127 to rotate through the second belt drive assembly 129, completing the wiping and polishing of dirt. The semi-circular sleeve 124 can be replaced periodically to ensure the effectiveness of the absorbent cotton 126. After processing, the membrane material enters the second inspection area. The UV irradiation lamp 5 of the second transition component 44 starts the composite mode. The main light source provides imaging illumination, and the auxiliary light source excites the marking ink to develop. The inspection camera 63 of the second inspection component 13 acquires secondary images. If it is determined to be a real defect (obvious crack or unremoved contaminants), the mark is retained for subsequent cutting. If it is a false defect of wrinkles or the contaminants have been removed, the UV irradiation lamp 5 switches to the degradation mode. High-intensity 395nm ultraviolet light is irradiated for 2-3 seconds to degrade and disappear the marking ink. Finally, the qualified membrane material is normally wound up by the winding roller 3, and the membrane material with real defect marks is cut according to the marked position in the subsequent process, completing the entire inspection process.

[0051] This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the following preferred embodiments; however, those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0052] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A device for inspecting the appearance of film materials, comprising a frame, wherein a feeding roller and a take-up roller are respectively arranged at both ends inside the frame; characterized in that: The frame is equipped with a guiding mechanism for conveying the film material and guiding it through the inspection station; the guiding mechanism includes a transition roller and a first transition component and a second transition component arranged sequentially along the film material conveying direction; The first detection component is located directly above the first transition component, and the second detection component is located directly above the second transition component. The two components perform the initial inspection and re-inspection of the membrane material, respectively. A leveling mechanism is provided in the middle of the frame to eliminate membrane wrinkles after identifying suspected cracks in the initial inspection. Support mechanisms are provided on both sides of the outer surface of the frame to drive the leveling mechanism to rise and fall. The support mechanism includes a first pad fixed to both sides of the frame, a first hydraulic rod fixedly connected to the upper surface of the first pad, and a second pad fixedly connected to the top of the first hydraulic rod; The leveling mechanism includes a first limiting seat fixedly connected to one side of the second pad. The first limiting seat has a first driving rod and a second driving rod rotatably connected to its two ends. One end of the first driving rod passes through the first limiting seat and is fixedly connected to a third servo motor. The outer surfaces of the first driving rod and the second driving rod are fixedly connected to a first roller and a second roller, respectively. A first belt drive assembly is provided between the first driving rod and the second driving rod.

2. The device for inspecting the appearance of membrane materials according to claim 1, characterized in that, The first transition assembly and the second transition assembly have the same structure and function, but their positions are different. Both the first transition assembly and the second transition assembly include a first guide roller and a second guide roller rotatably connected inside the frame. A transmission assembly is provided between the first guide roller and the second guide roller, and a first servo motor fixedly connected to the frame is provided at the output end of the second guide roller. The first servo motor and the transmission assembly enable the first guide roller and the second guide roller to rotate synchronously to complete the film material conveying. Multiple sets of transition rollers are provided inside the frame to work together with the first guide roller and the second guide roller to complete the film material conveying.

3. The device for inspecting the appearance of membrane materials according to claim 2, characterized in that, The first transition assembly has a common lighting lamp at the middle of the first guide roller and the second guide roller for providing preliminary inspection illumination; and the first transition assembly also has a common UV irradiation lamp at the middle of the first guide roller and the second guide roller for providing secondary inspection illumination; the first inspection assembly and the second inspection assembly have the same structure and function, but their positions are different; both the first inspection assembly and the second inspection assembly include brackets fixedly connected to both sides of the frame, with a fixing frame bolted to the top of the brackets, and inspection cameras arranged in a linear pattern fixedly connected to the bottom of the fixing frames. The inspection cameras are used in conjunction with the lighting lamp and the UV irradiation lamp to complete the preliminary inspection and secondary inspection of the film material.

4. The device for inspecting the appearance of membrane materials according to claim 3, characterized in that, A marking mechanism for marking defective film is provided directly above the second guide roller. The marking mechanism includes a slide rod rotatably connected inside the frame. One end of the slide rod is fixedly connected to a linear motor. A sliding seat is slidably connected to the outer surface of the slide rod. An electric telescopic rod is fixedly connected to the bottom of the sliding seat. A UV inkjet printer is fixedly connected to the sliding seat through the electric telescopic rod. A first storage box, a second storage box, and a third storage box are fixedly connected to one side of the outer surface of the frame. The output ends of the first storage box, the second storage box, and the third storage box are all connected to a three-way electric valve. The three-way electric valve and the UV inkjet printer are fixedly connected to a conveying pipe to facilitate the conveying of the inkjet material.

5. The device for inspecting the appearance of membrane materials according to claim 4, characterized in that, The marking mechanism also includes: The defect analysis module is used to receive the original image of the membrane surface acquired by the detection camera at the first detection component, separate potential defect areas through image noise reduction and segmentation processing, perform contour extraction on the segmentation results, generate closed defect polygons and calculate their geometric features, including length and width characteristics, area fill rate and contour curvature complexity, and output structured feature vectors. The feature vectors are compared with the pre-stored defect template library: if they meet the characteristics of a slender through-type defect with a high aspect ratio, low area fill rate, and gentle curvature, they are classified as through-type linear defects; if they meet the characteristics of a local linear defect with a medium aspect ratio and a relatively high area fill rate, they are classified as local linear defects; if they meet the characteristics of an irregular blocky defect with a low aspect ratio and high curvature complexity, they are classified as irregular blocky defects. Based on the classification results and defect size threshold, the defect type is determined. That is, a through-line defect exceeding the width threshold is determined as an obvious crack; a local linear defect below the width threshold is determined as a suspected crack; and an irregular block defect is directly determined as a surface contaminant. According to the real-time conveying speed of the membrane material and the camera acquisition timestamp, the position of the defect contour center point in the image coordinate system is converted into a three-dimensional spatial coordinate with the starting end of the feeding roller as the origin. The X-axis is the length direction of the membrane material, the Y-axis is the width direction, and the Z-axis is the thickness direction.

6. The device for inspecting the appearance of membrane materials according to claim 5, characterized in that, The marking mechanism also includes: The control module is used to automatically select the corresponding ink storage box based on the defect type judgment result output by the defect analysis module. Specifically, when the defect is judged to be an obvious crack, the control module controls the three-way electric valve to connect to the first storage box; when the defect is judged to be a suspected crack, the control module controls the three-way electric valve to connect to the second storage box; and when the defect is judged to be a surface contaminant, the control module controls the three-way electric valve to connect to the third storage box. Based on the Y-axis coordinates output by the defect analysis module, the linear motor is driven to move the sliding seat laterally, so that the UV inkjet printer is aligned with the target position in the width direction of the film material; the electric telescopic rod is controlled to press down the UV inkjet printer, so that the nozzle maintains a set vertical distance from the surface of the film material, and the spraying mode is triggered according to the defect type, that is, for obvious cracks, the spraying is controlled to spray continuous solid lines, for suspected cracks, the spraying is controlled to spray intermittent dashed lines, and for surface contaminants, the spraying is controlled to spray circular marks.

7. The device for inspecting the appearance of membrane materials according to claim 6, characterized in that, The leveling mechanism performs targeted wrinkle removal based on the received coordinates of the suspected crack location: The first hydraulic rod is extended to drive the second pad and leveling mechanism to be raised to a predetermined height, so that the membrane material is in a taut and stretched state; the third servo motor is started at the same time, and the first roller and the second roller are driven to rotate in opposite directions through the first belt drive assembly, so that the surface wrinkles are eliminated under the action of membrane material tension; After wrinkle removal, the membrane material undergoes closed-loop verification via the second testing component: The combined working mode of the UV irradiation lamp is activated, with the main light source providing imaging ultraviolet light and the auxiliary light source emitting activation wavelengths to excite the development of the marking ink; Based on secondary image analysis of defect morphology, if a continuous dent with a depth exceeding a preset threshold is detected, it is determined to be a real defect and the mark is retained. If there is no structural deformation and only color residue, it is judged as a false defect of wrinkles. Switch the UV irradiation lamp to degradation mode, that is, turn off the main light source, increase the auxiliary light source to the degradation intensity and continue to irradiate, so that the marking ink is completely degraded to an invisible state.

8. The device for inspecting the appearance of membrane materials according to claim 7, characterized in that, A receiver is fixedly connected to one side of the outer surface of the frame; a coating mechanism is set between the guiding mechanism and the leveling mechanism. The coating mechanism includes a rotating rod rotatably connected to the middle of the frame. One end of the rotating rod passes through the frame and is fixedly connected to a second servo motor. Cooling pipes and pulsed UV lamps are fixedly connected to the upper and lower sides of the outer surface of the rotating rod, respectively. One end of the cooling pipes and the pulsed UV lamps are fitted with a collar bracket. The collar bracket is at a 45-degree angle to the rotating rod. A coating spray plate is fixedly connected to one side of the collar bracket. A storage tank is fixedly connected to one side of the outer surface of the frame. A connecting pipe is fixedly connected between the storage tanks. An infrared humidity sensor is fixedly connected to one end of the top of the coating spray plate.

9. A device for inspecting the appearance of membrane materials according to claim 8, characterized in that, The support mechanism also includes a second hydraulic rod fixedly connected to the upper surface of the second pad, with a load-bearing plate fixedly connected to the top of the second hydraulic rod; a cleaning mechanism for cleaning dirt from the membrane surface is provided directly above the first roller, the cleaning mechanism including a first limiting rod and a second limiting rod respectively located directly above the first roller and the second roller, with a second limiting seat fixedly connected to the load-bearing plate at both ends of the first limiting rod and the second limiting rod; slots are provided on both sides of the outer circular surface of the first limiting rod, and slots are fitted on both sides of the outer circular surface of the first limiting rod. A semi-circular sleeve is provided, with a retaining strip that matches the slot fixedly connected to the inner wall of the semi-circular sleeve, and absorbent cotton fixedly connected to the outer surface of the semi-circular sleeve; a grinding plate and a semi-circular cotton cylinder are respectively provided on the upper and lower sides of the outer circular surface of the second limiting rod, and the semi-circular cotton cylinder and the grinding plate together form a processing cylinder to facilitate the processing of the film plate; a fourth servo motor is fixedly connected to one end of the second limiting rod through the second limiting seat, and a second belt drive assembly is provided at both ends of the first limiting rod and the second limiting rod; a protective cover fixedly connected to the frame is provided on the outer side of the first pad.

10. A method of using the membrane appearance inspection device as described in claim 9, characterized in that, The method of use includes the following steps: S1: The film material to be tested is wound up and placed on the feeding roller. The feeding roller, winding roller and guiding mechanism in the frame are started so that the film material passes through the transition roller, the first guide roller and the second guide roller of the first transition component in sequence and enters the first detection area. S2: When the membrane material reaches the first detection area, the lighting lamp in the middle of the first transition component is lit, and the detection camera of the first detection component takes continuous pictures of the membrane material surface and transmits the original images to the defect analysis module of the marking mechanism. S3: The control module of the marking mechanism selects the ink in the corresponding storage tank through a three-way electric valve according to the defect type, drives the linear motor to move the UV inkjet printer to the target position, and sprays the corresponding mark according to the defect type; S4: For membrane materials marked as suspected cracks, after receiving the position coordinates, the first hydraulic rod drives the leveling mechanism to rise and tighten the membrane material. The third servo motor drives the first roller and the second roller to rotate in opposite directions to eliminate wrinkles. For membrane materials marked as surface contaminants, the cleaning mechanism moves down under the drive of the second hydraulic rod. The fourth servo motor drives the first limit rod and the second limit rod to rotate. The dirt is removed by wiping with absorbent cotton and polishing with a grinding plate. S5: The leveled or cleaned membrane material enters the second inspection area. The UV irradiation lamp at the second transition component starts the composite mode, and the inspection camera of the second inspection component acquires a secondary image. If it is determined to be a real defect, the mark is retained for subsequent cutting. If it is determined to be a wrinkle or a false defect or a contaminant that has been removed, the UV irradiation lamp switches to the degradation mode to remove the mark, and the membrane material is normally wound onto the winding roller.

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