A device for detecting the appearance of a film material and a method of using the same

Abstract

The application discloses a kind of for film appearance detection device and its use method, belong to film appearance detection technical field;Including rack, first transition component and second transition component;First detection component is arranged in first transition component directly above, second detection component is arranged in second transition component directly above, and the preliminary inspection and reinspection of film are executed respectively by two;The middle of rack is equipped with leveling mechanism, for in preliminary inspection identification suspected crack after directional elimination film wrinkle;The outer surface of rack both sides are equipped with support mechanism;After the crack is identified by first detection component preliminary inspection in the application, leveling mechanism is driven to rise by support mechanism, and film is taut, and wrinkle is removed by roller rotation, and then reinspection is carried out by second detection component, the mode that real crack is kept mark and wrinkle false defect is removed mark is kept, the effect that crack and wrinkle are accurately distinguished is realized, the problem that raw material is wasted and the problem of the decline of qualified rate due to local wrinkle misjudgment as crack in existing equipment is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of film appearance detection, and more particularly to a film appearance detection device and a method thereof. BACKGROUND

[0002] In the production and quality detection process of thin film materials, automatic identification of film appearance defects has become an important link to ensure product quality. Currently, common film detection devices mainly use image acquisition systems to conduct online detection on running thin films, and combine image processing algorithms to identify and classify defects such as cracks, perforations, impurities, and color points on the film surface.

[0003] However, in actual application, it is found that the existing detection equipment has certain misjudgment when identifying film surface defects, especially local wrinkles caused by uneven tension, transmission roller deviation, or improper winding during film running. Since wrinkles and cracks both show linear gray level changes in 2D images, traditional algorithms rely on edge gradient features and cannot distinguish between three-dimensional wrinkles (local undulations) and real cracks (through cracks), which are easily mistaken by image recognition systems as crack or break defects. This misjudgment causes the control system to incorrectly mark normal areas as defect areas and perform unnecessary cutting and rejection in subsequent processes, resulting in waste of raw materials, reduction of product qualification rate, and increased production cost. SUMMARY

[0004] To solve the problems in the prior art, the present application provides a film appearance detection device and a method thereof, aiming to solve the above technical problems.

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

[0006] A film appearance detection device and a method thereof, including a rack, two ends of the rack are provided with a feeding roller and a winding roller inside the rack, a guide mechanism is arranged inside the rack for conveying the film and guiding it through the detection station; the guide mechanism includes a transition roller and a first transition assembly and a second transition assembly arranged in sequence along the film conveying direction;

[0007] A first detection assembly is arranged above the first transition assembly, and a second detection assembly is arranged above the second transition assembly, which respectively performs preliminary inspection and re-inspection of the film; a leveling mechanism is arranged at the middle of the rack for directional elimination of film wrinkles after preliminary inspection of suspected cracks; support mechanisms are arranged on both sides of the outer surface of the rack for driving the leveling mechanism to rise and fall;

[0008] The support mechanism comprises first base plates fixed on both sides of the frame, the upper surfaces of the first base plates are fixedly connected with first hydraulic rods, the top of the first hydraulic rods is fixedly connected with second base plates;

[0009] The leveling mechanism comprises a first limiting seat fixedly connected to one side of the second base plate, both ends in the first limiting seat are rotatably connected with a first drive rod and a second drive rod, one end of the first drive rod penetrates through the first limiting seat and is fixedly connected with a third servo motor, the outer cylindrical surfaces of the first drive rod and the second drive rod are fixedly connected with a first roller and a second roller respectively, and a first belt transmission assembly is arranged between the first drive rod and the second drive rod.

[0010] As a further scheme of the present application: the first transition assembly and the second transition assembly are the same in structure and function but different in position; the first transition assembly and the second transition assembly both comprise first guide rollers and second guide rollers rotatably connected to the inside of the frame, a transmission assembly is arranged between the first guide rollers and the second guide rollers, and the output end of the second guide roller is provided with a first servo motor fixedly connected with the frame, so that the first guide roller and the second guide roller are synchronously rotated by the first servo motor and the transmission assembly to complete the film material conveying; a plurality of transition rollers are arranged in the inside of the frame to cooperatively complete the film material conveying with the first guide rollers and the second guide rollers.

[0011] As a further scheme of the present application: the middle of the first guide roller and the second guide roller of the first transition assembly is provided with an illuminating lamp for providing preliminary detection illumination; the middle of the first guide roller and the second guide roller of the first transition assembly is provided with a UV irradiation lamp for providing secondary detection illumination; the first detection assembly and the second detection assembly are the same in structure and function but different in position; the first detection assembly and the second detection assembly both comprise brackets fixedly connected to both sides of the frame, the top of the bracket is bolted with a fixing frame, and the bottom of the fixing frame is fixedly connected with detection cameras arranged in a linear array, so that the detection cameras are used in cooperation with the illuminating lamp and the UV irradiation lamp to complete the preliminary detection and the secondary detection of the film material.

[0012] As a further scheme of the present application: a marking mechanism for marking defective film material is arranged directly above the second guide roller, the marking mechanism comprises a slide rod rotatably connected to the inside of the frame, one end of the slide rod is fixedly connected with a linear motor, the outer cylindrical surface of the slide rod is slidably connected with a sliding seat, the bottom of the sliding seat is fixedly connected with an electric telescopic rod, and the sliding seat is fixedly connected with a UV inkjet machine 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 commonly connected with a three-way electric valve, the three-way electric valve and the UV inkjet machine are commonly fixedly connected with a conveying pipe to facilitate the conveying of the sprayed material.

[0013] As a further scheme of the present application: the marking mechanism further comprises:

[0014] a defect analysis module, configured to receive the original image of the film surface collected by the camera at the first detection assembly, separate the potential defect area through image denoising and segmentation processing, perform contour extraction on the segmentation result, generate a closed defect polygon and calculate its geometric shape features, including length-width characteristics, area filling rate and contour curvature complexity, and output a structured feature vector;

[0015] compare the feature vector with a pre-stored defect template library: if it meets the elongated penetrating feature with high length-width ratio, low area filling rate and gentle curvature change, it is classified as a penetrating linear defect; if it meets the local linear feature with medium length-width ratio and relatively high area filling rate, it is classified as a local linear defect; if it meets the irregular block feature with low length-width ratio and high curvature complexity, it is classified as an irregular block defect;

[0016] determine the defect type based on the classification result and the defect size threshold, i.e. determine it as an obvious crack when the penetrating linear defect exceeds the width threshold; determine it as a suspected crack when the local linear defect is below the width threshold; determine it as a surface contaminant when the irregular block defect is directly determined; convert the position of the defect contour center point in the image coordinate system to a three-dimensional space coordinate with the starting end of the feeding roller as the origin, according to the real-time conveying speed of the film and the camera collection timestamp, wherein the X-axis is the length direction of the film, the Y-axis is the width direction, and the Z-axis is the thickness direction.

[0017] As a further scheme of the present application: the marking mechanism further comprises:

[0018] a control module, configured to automatically select the corresponding ink storage tank according to the defect type determination result output by the defect analysis module, i.e. when it is determined as an obvious crack, control the three-way electric valve to connect the first storage tank; when it is determined as a suspected crack, control the three-way electric valve to connect the second storage tank; when it is determined as a surface contaminant, control the three-way electric valve to connect the third storage tank;

[0019] drive the linear motor to move the sliding seat horizontally based on the Y-axis coordinate output by the defect analysis module, so that the UV inkjet machine is aligned with the target position in the width direction of the film; control the electric telescopic rod to press down the UV inkjet machine, so that the nozzle maintains a set vertical distance from the film surface, and trigger the spraying mode according to the defect type, i.e. control the spraying of continuous solid lines for obvious cracks, control the spraying of intermittent dotted lines for suspected cracks, and control the spraying of circular marks for surface contaminants.

[0020] As a further scheme of the present application: the flattening mechanism performs directional wrinkle removal operation based on the received suspected crack position coordinate:

[0021] The first hydraulic rod is controlled to be elongated, the second base plate and the leveling mechanism are driven to be lifted to a predetermined height as a whole, and the film material is in a taut and stretched state; the third servo motor is started synchronously, the first roller and the second roller are driven to rotate towards each other through the first belt transmission assembly, and surface wrinkles are eliminated under the action of the film material tension;

[0022] The film material after wrinkle removal is subjected to closed-loop verification by the second detection assembly:

[0023] The composite working mode of the UV irradiation lamp is started, the main light source provides imaging ultraviolet light, and the auxiliary light source emits an activation wavelength to excite the marker ink to develop;

[0024] Based on secondary image analysis of defect morphology, if continuous dents with a depth exceeding a preset threshold are detected, it is determined that the defect is real and the marker is retained; if only color residues exist without structural deformation, it is determined that the defect is a wrinkle false defect, and the UV irradiation lamp is switched to a degradation mode, i.e., the main light source is turned off, the auxiliary light source is enhanced to a degradation intensity and continuously irradiated, so that the marker ink is completely degraded to an invisible state.

[0025] As a further scheme of the application, the outer surface of the rack is fixedly connected with a receiver; a coating mechanism is arranged between the guide mechanism and the leveling mechanism, the coating mechanism comprises a rotating rod rotatably connected to the middle part of the inside of the rack, one end of the rotating rod penetrates through the rack and is fixedly connected with a second servo motor, the outer circumferential surface of the rotating rod is fixedly connected with a cooling pipe and a pulse UV lamp on the upper side and the lower side respectively, one end of the cooling pipe and the pulse UV lamp is jointly sleeved with a sleeve bracket, the sleeve bracket and the rotating rod are at a 45-degree angle, one side of the sleeve bracket is fixedly connected with a coating spray plate, one side of the outer surface of the rack is fixedly connected with a storage barrel, the storage barrel and the storage barrel are fixedly and continuously connected with a communication pipe; an infrared humidity sensor is fixedly connected to one end of the top of the coating spray plate.

[0026] 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.

[0027] A method of using a membrane material appearance inspection device includes the following steps:

[0028] 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.

[0029] 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.

[0030] 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;

[0031] 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.

[0032] S5: The flattened or cleaned film material enters the second detection area, the UV irradiation lamp at the second transition assembly starts the composite mode, the detection camera of the second detection assembly collects the secondary image; if it is judged as a real defect, the mark is retained for subsequent cutting; if it is judged as a false defect of wrinkle or a cleared contaminant, the UV irradiation lamp switches to the degradation mode to eliminate the mark, and the film material is normally wound on the winding roller.

[0033] The above technical solutions provided by the present application have at least the following beneficial effects compared with the prior art:

[0034] The first detection assembly, the second detection assembly, the supporting mechanism and the flattening mechanism are provided, after the first detection assembly initially detects and identifies the crack, the supporting mechanism drives the flattening mechanism to rise and tighten the film material, and the wrinkles are removed through the rotation of the roller, and then the second detection assembly re-inspects, the real crack is marked, and the false defect of wrinkle is removed, which realizes the effect of accurately distinguishing the crack from the wrinkle, and solves the problems of waste of raw materials, decrease of qualified rate and increase of cost caused by misjudgment of local wrinkles as cracks in the prior art.

[0035] The marking mechanism, the flattening mechanism and the second detection assembly are provided, different inks are used for marking according to the defect type after initial detection, the suspected crack film material is re-inspected by the second detection assembly after removing wrinkles by the flattening mechanism, the real defect is marked, and the false defect is removed, which realizes the effect of accurately identifying the defect and reducing misjudgment, and solves the problems of waste of raw materials and decrease of qualified rate caused by misjudgment of wrinkles as cracks.

[0036] The coating mechanism, the infrared humidity sensor and the receiver are provided, the infrared humidity sensor identifies the marked film material after marking, triggers the coating spray plate to spray the protective coating and solidifies by the pulse UV lamp, and the unmarked area is treated by the cooling pipe, which realizes the effect of protecting the TiO2 ink mark from being worn, and solves the problem of affecting the accuracy of secondary detection caused by mark wear. BRIEF DESCRIPTION OF DRAWINGS

[0037] The accompanying drawings, which are incorporated herein and constitute part of the specification, illustrate embodiments of the present application and, together with the description, further serve to explain the principles of the present application and to enable a person skilled in the relevant art to implement and use the present application.

[0038] Figure 1 is a schematic diagram of the overall structure of the present application;

[0039] Figure 2 is a connection diagram of the first detection assembly of the present application;

[0040] Figure 3 is a structure diagram of the marking mechanism of the present application;

[0041] Figure 4Connection diagram of the coating mechanism of the present application;

[0042] Figure 5 Connection diagram of the leveling mechanism and the cleaning mechanism of the present application;

[0043] Figure 6 Connection diagram of the support mechanism and the leveling mechanism of the present application;

[0044] Figure 7 Split connection diagram of the cleaning mechanism of the present application;

[0045] Figure 8 Split left view of the cleaning mechanism of the present application.

[0046] Reference signs:

[0047] 1, rack; 2, feeding roller; 3, winding roller;

[0048] 4, guide mechanism; 41, first servo motor; 42, first guide roller; 43, second guide roller; 44, second transition assembly; 45, transition roller; 46, illuminating lamp;

[0049] 5, UV irradiation lamp; 6, first detection assembly; 61, bracket; 62, fixed frame; 63, detection camera;

[0050] 7, marking mechanism; 71, linear motor; 72, sliding rod; 73, sliding seat; 74, UV inkjet machine; 75, conveying pipe; 76, three-way electric valve; 77, first storage box; 78, second storage box; 79, third storage box;

[0051] 8, coating mechanism; 81, second servo motor; 82, rotating rod; 83, pulse UV lamp; 84, cooling pipe; 85, sleeve bracket; 86, coating spray plate; 87, storage barrel; 88, communication pipe; 89, infrared humidity sensor;

[0052] 9, receiver;

[0053] 10, support mechanism; 101, protective cover; 102, first pad plate; 103, first hydraulic rod; 104, second pad plate; 105, second hydraulic rod; 106, bearing plate;

[0054] 11, leveling mechanism; 111, first limiting seat; 112, first driving rod; 113, first roller; 114, second driving rod; 115, second roller; 116, third servo motor; 117, first belt transmission assembly;

[0055] 12, cleaning mechanism; 121, second limiting seat; 122, first limiting rod; 123, clamping groove; 124, semicircular sleeve; 125, clamping strip; 126, adsorbing cotton; 127, second limiting rod; 128, fourth servo motor; 129, second belt transmission assembly; 1210, semicircular cotton tube; 1211, polishing plate;

[0056] 13, second detection assembly.

[0057] As shown in the drawings, in order to clearly realize the structure of the embodiments of the present application, specific structures and devices are marked in the drawings, but this is only for the need of illustration, and is not intended to limit the present application in this specific structure, device and environment, and those skilled in the art can adjust or modify these devices and environment according to specific needs. DETAILED DESCRIPTION

[0058] A film appearance detection device and a method thereof provided by the present application are described in detail below in combination with the drawings and specific embodiments. It should be noted that the following embodiments are the best, preferred embodiments, and other alternative ways can also be used by those skilled in the art to implement some known technologies; and the drawings are only used to more specifically describe the embodiments, and are not intended to specifically limit the present application.

[0059] As shown in the drawings, in order to clearly realize the structure of the embodiments of the present application, specific structures and devices are marked in the drawings, but this is only for the need of illustration, and is not intended to limit the present application in this specific structure, device and environment, and those skilled in the art can adjust or modify these devices and environment according to specific needs. Figures 1 to 8 The present application provides a film appearance detection device and a method thereof, which comprises a rack 1, a feeding roller 2 and a winding roller 3 are arranged at both ends of the inside of the rack 1, a guide mechanism 4 is arranged in the inside of the rack 1, which is used to transport the film and guide it through the detection station; the guide mechanism 4 comprises a transition roller 45 and a first transition assembly and a second transition assembly 44 arranged in sequence along the film transport direction;

[0060] A first detection assembly 6 is arranged directly above the first transition assembly, and a second detection assembly 13 is arranged directly above the second transition assembly 44, which respectively performs preliminary inspection and re-inspection of the film; a flattening mechanism 11 is arranged at the middle of the rack 1, which is used to eliminate the wrinkles of the film after identifying suspected cracks in the preliminary inspection; a supporting mechanism 10 is arranged on both sides of the outer surface of the rack 1, which is used to drive the flattening mechanism 11 to rise and fall;

[0061] The supporting mechanism 10 comprises a first base plate 102 fixed on both sides of the rack 1, a first hydraulic rod 103 fixedly connected to the upper surface of the first base plate 102, and a second base plate 104 fixedly connected to the top of the first hydraulic rod 103;

[0062] The flattening mechanism 11 comprises a first limiting seat 111 fixedly connected to one side of the second pad plate 104, two ends in the first limiting seat 111 are respectively rotationally connected with a first driving rod 112 and a second driving rod 114, one end of the first driving rod 112 penetrates through the first limiting seat 111 and is fixedly connected with a third servo motor 116, the outer cylindrical surfaces of the first driving rod 112 and the second driving rod 114 are respectively fixedly connected with a first roller 113 and a second roller 115, and a first belt transmission assembly 117 is arranged between the first driving rod 112 and the second driving rod 114.

[0063] To solve the misjudgment problem in the identification process of the existing film appearance detection equipment, especially the problem of local wrinkles being incorrectly identified as cracks due to uneven tension during film running, transmission roller deviation or improper winding, etc., the above technical solution is used to solve the problem. The above technical solution mainly consists of a first detection component 6, a second detection component 13, a support mechanism 10, and a flattening mechanism 11. When detecting the appearance of the film, the film to be detected is first wound and placed on the feeding roller 2. Then, the feeding roller 2 and the winding roller 3 in the rack 1 are started to make the feeding roller 2 and the winding roller 3 rotate, and the guide mechanism 4 is started at the same time to make the film to be detected pass through the transition roller 45 into the first detection area, and the first detection component 6 is used to detect the appearance of the film during transportation. When the first detection component 6 detects that the film surface presents cracks, in order to avoid misjudgment, the defective film is continuously transported, and the first hydraulic rod 103 is automatically started by the signal sensor to make it elongate, so that the second pad 104 drives the entire flattening mechanism 11 to rise to a certain height synchronously, and then the film during winding is stretched tightly. At the same time, the third servo motor 116 is started to make the first drive rod 112 rotate clockwise, and the first belt drive assembly 117 (prior art, two pulleys are fixedly arranged on the first drive rod 112 and the second drive rod 114 respectively, and the two pulleys are connected by a belt) makes the first drive rod 112 and the second drive rod 114 rotate clockwise in the first limiting seat 111, so that the first roller 113 and the first roller 113 rotate, and then the film that is stretched tightly is removed from the surface wrinkles under the action of the rotation of the first roller 113 and the first roller 113, to eliminate the error of wrinkles. After the wrinkle removal process, the marked film enters the secondary detection area again and is detected again by the second detection component 13. At this time, there are two situations: first, after the film that has passed through the wrinkle removal step is detected again by the second detection component 13, the film surface still presents a crack state, then the defective film with the mark is directly transported to the winding roller 3, and the mark on the defective film will not be removed, so as to facilitate subsequent cutting of the marked defective film; second, after the film that has passed through the wrinkle removal step is detected again by the second detection component 13, the detection result shows that the film surface is normal, then the mark on the film surface is removed by the corresponding detection tool, and the normal transportation and winding of the film are retained. Through the above operation, the local wrinkles caused by uneven tension during film running, transmission roller deviation or improper winding, etc. can be avoided to be incorrectly identified as cracks, unnecessary cutting and rejection in subsequent processes are avoided, raw material waste, product qualification rate is reduced, and production cost is increased.

[0064] As Figure 1 , Figure 2As shown, the first transition assembly, the structure and function of the second transition assembly 44 are the same, but its position is different; the first transition assembly, the second transition assembly 44 both include the first guide roller 42, the second guide roller 43 rotatably connected to the inside of the rack 1, the first guide roller 42, the second guide roller 43 are provided with a transmission assembly, and the output end of the second guide roller 43 is provided with a first servo motor 41 fixedly connected with the rack 1, the first guide roller 42, the second guide roller 43 are synchronously rotated through the first servo motor 41 and the transmission assembly, to complete the film material conveying; the inside of the rack 1 is provided with a plurality of transition rollers 45, which cooperates with the first guide roller 42 and the second guide roller 43 to complete the film material conveying.

[0065] As shown in Figure 1 , Figure 2 , Figure 3 As shown, the first guide roller 42, the second guide roller 43 of the first transition assembly are provided with an illuminating lamp 46 for providing preliminary detection illumination at the middle thereof; and the first is provided with a UV irradiation lamp 5 for providing secondary detection illumination; the structure and function of the first detection assembly 6 and the second detection assembly 13 are the same, but their positions are different; the first detection assembly 6 and the second detection assembly 13 both include a bracket 61 fixedly connected to both sides of the rack 1, the top of the bracket 61 is bolted with a fixed frame 62, the bottom of the fixed frame 62 is fixedly connected with a detection camera 63 arranged in a line, the detection camera 63 is used in cooperation with the illuminating lamp 46 and the UV irradiation lamp 5 respectively to complete the preliminary inspection and secondary detection of the film material.

[0066] As shown in Figure 1 , Figure 2 , Figure 3 As shown, a marking mechanism 7 for marking defective film material is provided above the second guide roller 43, the marking mechanism 7 includes a slide rod 72 rotatably connected to the inside of the rack 1, one end of the slide rod 72 is fixedly connected with a linear motor 71, the outer circular surface of the slide rod 72 is slidably connected with a sliding seat 73, the bottom of the sliding seat 73 is fixedly connected with an electric telescopic rod, the sliding seat 73 is fixedly connected with a UV inkjet machine 74 through the electric telescopic rod; a first storage box 77, a second storage box 78, a third storage box 79 are fixedly connected to one side of the outer surface of the rack 1, the output ends of the first storage box 77, the second storage box 78, the third storage box 79 are commonly connected with a three-way electric valve 76, the three-way electric valve 76 is commonly fixedly connected with a conveying pipe 75 with the UV inkjet machine 74 to facilitate the spraying of the material.

[0067] As shown in Figure 1 , Figure 2 , Figure 3As shown in the figure, the marking mechanism 7 also includes a defect analysis module for receiving the original image of the film surface collected by the detection camera 63 at the first detection assembly 6, separating the potential defect area through image denoising and segmentation processing; performing contour extraction on the segmentation result, generating a closed defect polygon and calculating its geometric shape features, including length-width characteristics, area filling rate and contour curvature complexity, and outputting a structured feature vector;

[0068] Compare the feature vector with the pre-stored defect template library: if it meets the high length-width ratio, low area filling rate and gentle curvature change of the elongated penetrating feature, it is classified as a penetrating linear defect; if it meets the medium length-width ratio and higher area filling rate of the local linear feature, it is classified as a local linear defect; if it meets the low length-width ratio and high curvature complexity of the irregular block feature, it is classified as an irregular block defect;

[0069] Based on the classification result and the defect size threshold, the defect type is determined, i.e. when the penetrating linear defect exceeds the width threshold, it is determined as an obvious crack; when the local linear defect is below the width threshold, it is determined as a suspected crack; the irregular block defect is directly determined as a surface contaminant; according to the real-time conveying speed of the film and the camera acquisition timestamp, the position of the defect contour center point in the image coordinate system is converted into a three-dimensional space coordinate with the starting end of the feeding roller 2 as the origin, wherein the X axis is the length direction of the film, the Y axis is the width direction, and the Z axis is the thickness direction.

[0070] As shown in Figure 1 , Figure 2 , Figure 3 The marking mechanism 7 also includes a control module for automatically selecting the corresponding ink storage tank according to the defect type determination result output by the defect analysis module, i.e. when it is determined as an obvious crack, the three-way electric valve 76 is controlled to connect the first storage tank 77; when it is determined as a suspected crack, the three-way electric valve 76 is controlled to connect the second storage tank 78; when it is determined as a surface contaminant, the three-way electric valve 76 is controlled to connect the third storage tank 79.

[0071] Based on the Y-axis coordinate output by the defect analysis module, the linear motor 71 drives the sliding seat 73 to move laterally, so that the UV inkjet machine 74 is aligned with the target position in the width direction of the film; the electric telescopic rod is controlled to press down the UV inkjet machine 74, so that the nozzle maintains a set vertical distance from the film surface, and the spraying mode is triggered according to the defect type, i.e. for obvious cracks, continuous solid lines are controlled to be sprayed; for suspected cracks, intermittent dotted lines are controlled to be sprayed; for surface contaminants, circular marks are controlled to be sprayed.

[0072] The flattening mechanism 11 performs directional wrinkle removal operation based on the received suspected crack position coordinates:

[0073] The first hydraulic rod 103 is controlled to extend, the second base plate 104 and the leveling mechanism 11 are driven to lift to a predetermined height as a whole, so that the film material is in a taut and stretched state; the third servo motor 116 is started synchronously, the first roller 113 and the second roller 115 are driven to rotate towards each other through the first belt transmission assembly 117, and surface wrinkles are eliminated under the action of the film material tension;

[0074] After wrinkle removal, the film material is subjected to closed-loop verification by the second detection assembly 13:

[0075] The compound working mode of the UV irradiation lamp 5 is started, the main light source provides imaging ultraviolet light, and the auxiliary light source emits an excitation wavelength to excite the marker ink to develop;

[0076] Based on secondary image analysis of defect morphology, if continuous dents deeper than a preset threshold are detected, it is determined that the defect is real and the marker is retained; if only color residues are left without structural deformation, it is determined that the defect is a wrinkle false defect, and the UV irradiation lamp 5 is switched to a degradation mode, i.e., the main light source is turned off, the auxiliary light source is enhanced to a degradation intensity and continuously irradiated, so that the marker ink is completely degraded to an invisible state.

[0077] During the appearance detection of the film material, the film material to be detected wound by the feeding roller 2 passes through the transition roller 45 into the first detection area. When the film material reaches the first guide roller 42 and the second guide roller 43 of the first transition assembly, the illuminating lamp 46 provides a light source for detection. At this time, the detection camera 63 located on the first detection assembly 6 takes a photo of the film material on the first guide roller 42 and the second guide roller 43 and performs image recognition to analyze the actual situation of the film material surface. Once the detection camera 63 detects a defect on the film material surface, it immediately transmits a signal to the marking mechanism 7 and synchronously starts the linear motor 71. According to the position of the defect on the film material surface, the sliding seat 73 is guided along the slide rod 72 to move to the specified position. According to the defect condition of the film material, different concentrations of ink marking delivery ports are opened through the three-way electric valve 76 to mark the defective film material. For example, when there is a obvious crack on the film material surface, the first storage tank 77 delivery port is opened, so that the TiO2 ink with a concentration of 8% in the first storage tank 77 enters the UV inkjet printer 74 through the delivery pipe 75, and the nozzle of the UV inkjet printer 74 marks the crack position on the film material surface, so as to facilitate the subsequent workers to cut the film material in this area and ensure the qualification of the product.

[0078] 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 machine 74 through the delivery pipe 75, and the suspected crack position on the surface of the film material is marked by the nozzle of the UV inkjet machine 74, so that the real situation of the film material defect can be determined by subsequent secondary detection according to the mark. The film material preliminarily marked as a suspected crack is first stretched by the flattening mechanism 11 to eliminate the influence factors of wrinkles on the surface of the film material, and then enters the secondary detection area, i.e. the roller area of the second detection assembly 13. At this time, the UV irradiation lamp 5 is arranged between the two rollers of the second detection assembly 13, which not only provides a light source for the detection camera 63 of the second detection area, but also facilitates the secondary detection and analysis of the marked film material by the detection camera 63 of the second detection area. At this time, if it is determined to be a crack, it is directly output, and the ink mark on the surface of the film material is still left, so that the crack area can be cut in the subsequent process. When the wrinkles are removed and the secondary detection is qualified, the conveying speed of the entire film material is adjusted at this time, and the UV irradiation lamp 5 provides a light source. The 5% TiO2 ink mark on the surface of the film material triggers a nano-catalytic reaction through ultraviolet, which has almost instantaneous fading ability and lossless processing characteristics, and perfectly removes the mark on the surface of the film material. Compared with traditional chemical marking, there is no residue and diffusion problem.

[0079] When the film material is detected, the film material to be detected is wound by the feeding roller 2 and 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 assembly, the illumination lamp 46 between the first guide roller 42 and the second guide roller 43 of the first transition assembly is immediately turned on to provide a stable and uniform light source for detection, ensuring that the detection camera 63 located on the first detection assembly 6 can clearly capture the image of the film material surface. At this time, the detection camera 63 continuously photographs the film material on the first guide roller 42 and the second guide roller 43, and transmits the collected original image of the film material surface to the defect analysis module of the marking mechanism 7 in real time.

[0080] After receiving the original image, the defect analysis module immediately starts a multi-dimensional image processing flow. Considering the possible dust interference in the film material production site and the image blur caused by equipment operation vibration, the image noise reduction processing is first carried out through the adaptive median filtering technology. This method can dynamically adjust the filtering range according to the gray distribution around the pixel point, and can remove noise while retaining the edge details of the defect to the greatest extent. Subsequently, the automatic threshold segmentation technology based on Otsu algorithm is adopted, and the gray distribution of the normal area on the film material surface is taken as a reference to accurately divide the potential defect area with abnormal gray value and the uniform background area. Even small defects with low contrast can be effectively separated.

[0081] When performing contour extraction on the segmented binary image, the eight-neighbor chain code tracking algorithm is used to scan the image point by point, record the coordinate information of all pixels on the boundary of the defect area, and then generate a closed defect contour polygon; in order to fully depict the geometric shape of the defect, three key dimensions are calculated to obtain characteristic parameters: first, the length-width characteristic, that is, the longest axis and the shortest axis of the defect are determined by the minimum circumscribed rectangle algorithm, and the ratio of the two is calculated to determine the extension direction and elongation degree of the defect; second, the area filling rate, that is, the ratio of the number of pixels actually occupied by the defect to the total number of pixels contained in the circumscribed rectangle, which can effectively distinguish whether the defect is linearly distributed or blockily distributed; third, the contour curvature complexity, by calculating the curvature value of each point on the contour line and calculating the standard deviation, reflecting the irregularity of the defect edge. These parameters are integrated into a structured feature vector, which provides accurate quantitative basis for subsequent defect classification.

[0082] When the structured feature vector is input into the pre-stored defect template library for similarity comparison, the template library stores a large amount of typical defect feature data calibrated by artificial, including feature vector samples of different types and different sizes of defects; by calculating the Euclidean distance between the feature vector of the defect to be detected and the feature vector of each type of template, the accurate matching of the defect type is realized; if the feature vector of the defect to be detected satisfies the elongated penetrating feature, specifically represented by high length-width ratio (usually not less than 5:1), low area filling rate (generally not more than 30%) and smooth contour curvature change (curvature standard deviation in a pre-set low interval), it is determined as a penetrating linear defect, which often extends along the length direction of the film material and may cause serious impact on the overall structural integrity of the film material; if the feature vector presents local linear feature, that is, medium length-width ratio (usually between 3:1 and 5:1), high area filling rate (usually more than 30%), it is classified as a local linear defect, which is mostly concentrated in a specific area of the film surface and may be caused by uneven local stress; if the feature vector shows irregular block feature, that is, low length-width ratio (usually less than 2:1) and high curvature complexity (curvature standard deviation in a pre-set high interval), it is determined as an irregular block defect, which is mostly in a scattered irregular shape and may be impurities attached in the production process.

[0083] After the preliminary classification of defects (i.e. divided into penetrating linear defects, local linear defects, irregular block defects), the type of defect needs to be further clarified in combination with the preset defect size threshold, and the specific determination process is as follows: for the area classified as penetrating linear defects (characterized by high aspect ratio, low area fill rate, and gentle curvature change), the actual width needs to be measured (converted to physical size by image pixel size); for example, when the width exceeds the preset width threshold, it is directly determined as "obvious crack", this kind of defect is significantly affected on the structural integrity of the film material due to its large size and penetrating, and needs to be marked for emphasis to ensure subsequent processing. For the area classified as local linear defects (characterized by medium aspect ratio and high area fill rate), the actual width is also measured, and when the width is lower than the above-mentioned width threshold, it is determined as "suspected crack", this kind of defect may be a real fine crack, or a false defect caused by film material wrinkles, local uneven tension and other factors, therefore, subsequent secondary detection is needed to verify its authenticity. For the area classified as irregular block defects (characterized by low aspect ratio and high curvature complexity), no additional size threshold is needed, and it is directly determined as "surface contaminant", this kind of defect is mostly dust, fibers and other impurities attached in the production process, its form is significantly different from the structural defects (such as cracks) of the film material itself, and it can be handled by cleaning process.

[0084] After the defect type is determined, according to the real-time conveying speed of the film material and the time stamp of image acquisition, the two-dimensional coordinates of the center point of the defect profile in the image coordinate system are accurately mapped to the three-dimensional space coordinate system with the starting end of the feeding roller 2 as the origin; wherein the X axis is parallel to the conveying direction of the film material, representing the length direction of the film material, and its coordinate value is calculated by the product of the film material conveying speed and the image acquisition time; the Y axis is perpendicular to the X axis and extends along the width direction of the film material, representing the width direction, and its coordinate value is calculated by the transverse pixel position in the image coordinate system; the Z axis is perpendicular to the plane where the film material is located, representing the thickness direction, which is used for possible depth detection in the subsequent process. Through this coordinate conversion process, the spatial position of the defect on the film material can be accurately recorded, providing accurate position reference for subsequent marking, re-inspection and processing procedures.

[0085] Once the detection camera 63 detects defects 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 according to the defect type judgment result output by the defect analysis module; first, automatically select the corresponding ink storage tank according to the defect type: when it is judged as obvious crack, control the three-way electric valve 76 to switch to the state of communicating with the first storage tank 77, the first storage tank 77 stores TiO2 ink with a concentration of 8%, this ink has the characteristics of high adhesion and high contrast, which can ensure that the obvious crack mark is clearly visible in the subsequent processing process; when it is judged as suspected crack, control the three-way electric valve 76 to communicate with the second storage tank 78, the second storage tank 78 stores TiO2 ink with a concentration of 5%, this ink has special photosensitive properties, it will show obvious fluorescence effect under the irradiation of specific wavelength ultraviolet light, which is convenient for identification in secondary detection; when it is judged as surface contamination, control the three-way electric valve 76 to communicate with the third storage tank 79, the ink in the third storage tank 79 is quick-drying pigment, which can quickly form a stable mark at the position of the contamination.

[0086] After determining the ink storage tank, the control module sends precise driving instructions 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 rod 72 to move horizontally along the guide of the slide rod 72, so that the UV inkjet machine 74 accurately aligns with the defect target position in the width direction of the film. Subsequently, the control electric telescopic rod is extended downward to adjust the nozzle of the UV inkjet machine 74 to maintain a set vertical distance from the film surface, which can ensure that the sprayed ink forms a clear and uniform mark. Finally, trigger the corresponding spraying mode according to the defect type: control the continuous solid line for obvious crack, the width and length of the solid line are dynamically adjusted according to the actual size of the crack to ensure that it can completely cover the crack area, for example, when there is an obvious crack on the film surface, 8% TiO2 ink enters the UV inkjet machine 74 through the delivery pipe 75, and the nozzle of the UV inkjet machine 74 sprays ink on the crack position on the film surface for subsequent workers to cut the film in this area, ensuring product quality; control the intermittent dashed line for suspected crack, the interval distance and line segment length of the dashed line are optimized in design, which can clearly mark the position and also distinguish it from the mark of obvious crack, that is, when there is a suspected crack on the film surface, 5% TiO2 ink enters the UV inkjet machine 74 through the delivery pipe 75, and the nozzle of the UV inkjet machine 74 sprays ink on the suspected crack position on the film surface, so that subsequent secondary detection can be carried out according to the mark to determine the true situation of the film defect; control the circular mark for surface contamination, the diameter of the circle is set according to the size of the contamination, usually slightly larger than the actual size of the contamination, to ensure the accuracy of the mark.

[0087] The film material preliminarily marked as suspected crack continues to be conveyed, first passing through the flattening mechanism 11, which immediately starts the directional wrinkle removal operation after receiving the coordinates of the suspected crack position to eliminate the film material wrinkles that may cause misjudgment. First, the control module sends an elongation instruction to the first hydraulic rod 103, which pushes the second pad plate 104 at the top to move upwards, thereby driving the flattening mechanism 11 fixed on the second pad plate 104 to lift as a whole to a predetermined height. This height is accurately calibrated to enable the film material to be in a moderate tension state under the action of the flattening mechanism 11, effectively eliminating local wrinkles caused by uneven tension, transmission roller deviation or improper winding, and extending the film material to eliminate the influencing factors of wrinkles on the surface of the film material. At the same time, the third servo motor 116 is started, and the output shaft of the third servo motor 116 transmits power to the first drive rod 112 and the second drive rod 114 through the first belt transmission assembly 117, so that the two rotate in opposite directions at a set speed in the first limiting seat 111, thereby driving the first roller 113 and the second roller 115 to rotate synchronously. Under the premise that the film material is in a tension state, the opposite rotation of the two rollers will generate uniform friction on the surface of the film material, promoting the gradual stretching and elimination of wrinkles on the surface of the film material, especially in the area where the suspected crack is located, which can be targeted for wrinkle removal to ensure that the subsequent secondary detection is not affected by wrinkles.

[0088] The film material after wrinkle removal continues to be conveyed to the secondary detection area where the second detection assembly 13 is located, i.e., enters the roller area of the second detection assembly 13, which performs closed-loop verification to determine the authenticity of the suspected crack; the two rollers of the second transition assembly 44 are provided with a UV irradiation lamp 5, and at this time the compound working mode of the UV irradiation lamp 5 is started: the main light source emits ultraviolet light with a wavelength of 365 nm to provide stable imaging illumination for the detection camera 63 of the second detection area, ensuring that the image of the film material surface can be clearly captured; the auxiliary light source emits ultraviolet light with a peak wavelength of 395 nm, which can effectively activate the photosensitizer in 5% TiO2 ink used for suspected crack marking, making the intermittent dotted line mark present a strong fluorescent effect, facilitating the detection camera 63 to accurately identify the mark position, so as to facilitate the second detection camera 63 of the second detection area to perform secondary detection analysis on the marked film material.

[0089] Based on the secondary image captured by the detection camera 63 at the second detection assembly 13, the system conducts a detailed analysis of the defect morphology: if a continuous indentation with a depth exceeding a preset threshold (such as 0.1 mm) is detected at the marked position, and the indentation morphology is consistent with the suspected crack feature detected in the primary detection, it is determined to be a real crack. At this time, the system will retain the mark at this position, i.e. the ink mark on the surface of the film material still remains, so that the subsequent process can accurately cut the defect area and directly output the film material; if no obvious structural deformation is detected at the marked position, only the color residue of the mark ink exists, it is determined to be a false defect of wrinkle, i.e. the suspected crack detected in the primary detection is a false judgment caused by the film material wrinkle. For this case, the conveying speed of the entire film material is adjusted, the system immediately switches the UV irradiation lamp 5 to the degradation mode, i.e. the main light source is turned off, and the power of the auxiliary light source is increased to 150% of the rated power. By continuously irradiating the marked area with high-intensity 395 nm ultraviolet light for 2-3 seconds, 5% of the TiO2 ink mark on the surface of the film material is chemically decomposed by the ultraviolet triggered nano-catalytic reaction, and completely degraded to an invisible state. This mark removal method has almost instantaneous fading ability and non-destructive processing characteristics compared to traditional chemical marking, and has no residue and diffusion problems, can perfectly remove the mark on the surface of the film material, and can keep the normal conveying and winding of the film material, avoiding unnecessary cutting of the normal film material in the subsequent process, thereby reducing the waste of raw materials and improving the product qualification rate.

[0090] As shown in Figure 1 、 Figure 2 、 Figure 3 The outer surface of the rack 1 is fixedly connected with a receiver 9. A coating mechanism 8 is arranged between the guide mechanism 4 and the leveling mechanism 11. The coating mechanism 8 comprises a rotating rod 82 rotatably connected to the middle part of the inside of the rack 1. One end of the rotating rod 82 penetrates through the rack 1 and is fixedly connected with a second servo motor 81. The outer circumferential surface of the rotating rod 82 is fixedly connected with a cooling pipe 84 and a pulse UV lamp 83 on the upper side and the lower side, respectively. One end of the cooling pipe 84 and the pulse UV lamp 83 is jointly sleeved with a sleeve bracket 85, and the sleeve bracket 85 is at a 45-degree angle with the rotating rod 82. One side of the sleeve bracket 85 is fixedly connected with a coating spray plate 86. The outer surface of the rack 1 is fixedly connected with a storage barrel 87. The storage barrel 87 and the storage barrel 87 are fixedly and continuously connected with a connecting pipe 88. The top end of the coating spray plate 86 is fixedly connected with an infrared humidity sensor 89.

[0091] In order to ensure that the TiO2 ink on the marked surface of the film material does not wear off and affect the accuracy of the secondary detection analysis, after the film material with defects is marked by the UV inkjet machine 74, it continues to be conveyed, and then the marked film material is automatically identified by the infrared humidity sensor 89, and the signal thereof is transmitted to the second servo motor 81 through the receiver 9, so that the rotating rod 82 drives the cooling pipe 84 and the pulse UV lamp 83 to rotate, so that the pulse UV lamp 83 is below, at the same time, the coating spray plate 86 is aligned with the marked film material by the sleeve bracket 85, and the conveying pump in the storage barrel 87 is started at the same time, so that the protective coating pigment in the storage barrel 87 is conveyed into the coating spray plate 86 through the communication pipe 88, and the film material marking area is coated by the spray head of the coating spray plate 86, so that a layer of protective coating is formed on the surface of the marked area; the film material after being sprayed is irradiated by the pulse UV lamp 83, so that the coating area is solidified to avoid the TiO2 ink marked area from being damaged, so as to ensure the accuracy of the subsequent secondary detection; for the unmarked area, the infrared humidity sensor 89 is also used to automatically monitor the humidity of the film material, when the surface is dry, the signal thereof is transmitted to the second servo motor 81 through the receiver 9, so that the rotating rod 82 rotates clockwise, so that the cooling pipe 84 is on the surface of the conveying film material, and in this process, the cooling pipe 84 will not cause any wear to the surface of the film material.

[0092] As shown in Figure 1 , Figure 2 , Figure 4 Figure 6 Figure 7 Figure 8 The support mechanism 10 further comprises a second hydraulic rod 105 fixedly connected to the upper surface of the second base plate 104, and a bearing plate 106 fixedly connected to the top of the second hydraulic rod 105; a cleaning mechanism 12 for cleaning the dirt on the surface of the film material is arranged above the first roller 113, and the cleaning mechanism 12 comprises a first limiting rod 122 and a second limiting rod 127 arranged above the first roller 113 and the second roller 115 respectively, and the two ends of the first limiting rod 122 and the second limiting rod 127 are both provided with a second limiting seat 121 fixedly connected with the bearing plate 106; the two sides of the outer surface of the first limiting rod 122 are provided with clamping grooves 123, and the two sides of the outer surface of the first limiting rod 122 are provided with semicircular sleeves 124, the inner wall of the semicircular sleeve 124 is fixedly connected with clamping strips 125 matched with the clamping grooves 123, and the outer surface of the semicircular sleeve 124 is fixedly connected with adsorbing cotton 126; the upper and lower sides of the outer surface of the second limiting rod 127 are provided with a polishing plate 1211 and a semicircular cotton barrel 1210 respectively, and the semicircular cotton barrel 1210 and the polishing plate 1211 jointly form a processing barrel for facilitating film processing; one end of the second limiting rod 127 penetrates through the second limiting seat 121 and is fixedly connected with a fourth servo motor 128, and the two ends of the first limiting rod 122 and the second limiting rod 127 are both provided with a second belt drive assembly 129; the outer side of the first base plate 102 is provided with a protective cover 101 fixedly connected with the rack 1.

[0093] After the analysis of the first detection assembly 6, if the film surface is determined to have residual contaminants on its surface, the delivery port of the second storage tank 78 is opened by the three-way electric valve 76, so that the TiO2 ink with a concentration of 2% in the third storage tank 79 enters the UV inkjet printer 74 through the delivery pipe 75. The position of the contaminants on the film surface is marked by the nozzle of the UV inkjet printer 74, and then the marked film passes through the first roller 113 and the second roller 115. According to the thickness of the film, the second hydraulic rod 105 drives the entire cleaning mechanism 12 to move downward, so that the adsorbing cotton 126 and the corresponding polishing assembly contact the film surface, and at the same time, the fourth servo motor 128 is started to make the first limiting rod 122 rotate. At the same time, the second belt transmission assembly 129 (the existing belt transmission) drives the second limiting rod 127 to rotate, so that the polishing plate 1211 is on the film surface, so that the adsorbing cotton 126 wipes the film surface dirt and removes the water stains on the surface to avoid errors in the detection results caused by water stains. The polished film passes through the polishing plate 1211, so that the contaminants on the film surface are further polished. The abrasion particle size of the polishing plate 1211 here meets the polishing requirements of the film and will not cause the film to break. Then the cleaned film is transported to the secondary detection area for secondary detection. After the second detection camera 63 of the second detection area detects and analyzes the marked film, the TiO2 ink with a concentration of 2% in the marked area is decomposed by the UV irradiation lamp 5, and the analysis result shows that there is no dirt on the film surface. The film is normally transported and wound on the winding roller 3. When the analysis result shows that the film surface has defects, the area is subsequently marked and cut to ensure normal use of the film. Due to the long-term use of the adsorbing cotton 126, the wiping effect is reduced, so the machine can be stopped regularly, the semi-circular cotton cylinder 1210 is removed from the first limiting rod 122, and the new adsorbing cotton 126 is replaced to ensure the normal operation of the cleaning work.

[0094] A method for using a film appearance detection device, comprising the following steps:

[0095] S1: Place the film to be detected on the feeding roller 2, start the feeding roller 2, winding roller 3 and guide mechanism 4 in the rack 1, so that the film passes through the transition roller 45, the first guide roller 42 and the second guide roller 43 of the first transition assembly in turn, and enters the first detection area;

[0096] S2: When the film reaches the first detection area, the lighting lamp 46 in the middle of the first transition assembly is turned on, and the detection camera 63 of the first detection assembly 6 continuously takes pictures of the film surface and transmits the original image to the defect analysis module of the marking mechanism 7;

[0097] S3: The control module of the marking mechanism 7 selects the corresponding ink storage tank according to the defect type through the three-way electric valve 76, drives the linear motor 71 to move the UV inkjet machine 74 to the target position, and sprays the corresponding mark according to the defect type;

[0098] S4: For the film material marked as suspected cracks, the leveling mechanism 11 rises after receiving the position coordinates, the first hydraulic rod 103 drives the leveling mechanism 11 to rise to tighten the film material, and the third servo motor 116 drives the first roller 113 and the second roller 115 to rotate towards each other to eliminate wrinkles. For the film material marked as surface contaminants, the cleaning mechanism 12 is lowered under the action of the second hydraulic rod 105, the fourth servo motor 128 drives the first limiting rod 122 and the second limiting rod 127 to rotate, and the dirt is removed by wiping with the adsorbing cotton 126 and polishing with the polishing plate 1211.

[0099] S5: The leveled or cleaned film material enters the second detection area, the UV irradiation lamp 5 at the second transition assembly 44 starts the composite mode, and the detection camera 63 of the second detection assembly 13 collects the second 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 false defect or a removed contaminant, the UV irradiation lamp switches to the degradation mode to eliminate the mark, and the film material is normally wound on the winding roller 3.

[0100] In use, first, the preparation before detection is carried out, the film material to be detected is wound and placed on the feeding roller 2 of the rack 1, the starting end of the film material is ensured to be flat and led out, and the film material is sequentially wound around the transition roller 45 of the guide mechanism 4, the first guide roller 42 and the second guide roller 43 of the first transition assembly, and finally fixed on the winding roller 3, so that the path laying of the film material is completed; after the device is started, the feeding roller 2 and the winding roller 3 are synchronously rotated under the driving of the driving mechanism, the first servo motor 41 drives the first guide roller 42 and the second guide roller 43 to cooperatively rotate through the transmission assembly, and the film material enters the first detection area at a stable speed. At this time, the illuminating lamp 46 in the middle of the first transition assembly is lighted, providing uniform illumination for the detection camera 63 of the first detection assembly 6, the detection camera 63 continuously photographs the surface of the film material, collects original images in real time and transmits them to the defect analysis module of the marking mechanism 7; the images are processed in multiple dimensions by using the defect analysis module, first, dust, vibration and other interference noises are removed through adaptive median filtering, and then potential defect areas are segmented by using the Otsu algorithm; subsequently, the length-width characteristics, area filling rate, profile curvature complexity and other characteristics of the defect profile are extracted, a structured feature vector is generated, and a comparison is made with a pre-stored template library, so that the defect is divided into a penetrating linear defect, a local linear defect or an irregular block defect; and based on the defect size threshold, further determination is made, if the width of the penetrating linear defect exceeds the threshold, it is an obvious crack, if the width of the local linear defect is below the threshold, it is a suspected crack, and the irregular block defect is directly determined as a surface contaminant, and the defect position is converted into a three-dimensional space coordinate; at the same time, the control module of the marking mechanism 7 executes a marking operation according to the determination result, that is, by controlling the three-way electric valve 76 to communicate the corresponding storage tank (8% TiO2 ink of the first storage tank 77 for obvious cracks, 5% TiO2 ink of the second storage tank 78 for suspected cracks, and quick-drying pigment or 2% TiO2 ink of the third storage tank 79 for surface contaminants); the linear motor 71 drives the sliding seat 73 to move along the slide rod 72, so that the UV inkjet machine 74 is aligned with the Y-axis coordinate position of the defect, the electric telescopic rod adjusts the distance between the nozzle and the film material to 5-10 mm, and continuous solid lines, intermittent dotted lines or circular marks are sprayed according to the defect type; the marked film material enters the processing link, after the marking area is recognized by the infrared humidity sensor 89 of the coating mechanism 8, 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 marking area, the protective coating in the storage barrel 87 is delivered to the coating spray plate 86 through the communication pipe 88, the protective coating is sprayed on the marking area and solidified by the pulse UV lamp 83; the unmarked area is processed by the 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.

[0101] 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.

[0102] 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; A first inspection component is positioned directly above the first transition component, and a second inspection component is positioned directly above the second transition component. These components perform initial and re-inspections of the membrane material, respectively. A leveling mechanism is located in the middle of the frame to eliminate membrane wrinkles after identifying suspected cracks during the initial inspection. Support mechanisms are located on both sides of the outer surface of the frame to drive the leveling mechanism to move up and down. An illumination lamp for providing initial inspection lighting is located between the first and second guide rollers of the first transition component. A UV irradiation lamp for providing secondary inspection lighting is located between the first and second guide rollers of the second transition component. A marking mechanism for marking defective membrane material is located directly above the second guide roller of the first transition component. 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 via the electric telescopic rod. 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. 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.

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 and second inspection components have the same structure and function, but their positions are different. Both the first and second inspection components include brackets fixedly connected to both sides of the frame. The top of the bracket 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 lighting lamps and UV irradiation lamps to complete the initial inspection and secondary inspection of the membrane material.

4. The device for inspecting the appearance of membrane materials according to claim 3, characterized in that, The first storage box, the second storage box, and the 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 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, 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 pipe and the pulsed UV lamp 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 tank and the coating spray plate. An infrared humidity sensor is fixedly connected to one end of the top of the coating spray plate.

8. The device for inspecting the appearance of membrane materials according to claim 7, 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 locking 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 film processing; 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.

9. A method of using the membrane appearance inspection device as described in claim 8, 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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