Overflow method substrate glass indentation detection device and real-time monitoring method thereof

Abstract

The application discloses an overflow method substrate glass indentation detection device and a real-time monitoring method thereof, and belongs to the technical field of overflow down-draw method substrate glass manufacturing. The device is composed of a real-time monitoring device, a fixing and position adjusting device and a cooling shell. The device realizes real-time monitoring of the indentation width change of the substrate glass at the furnace mouth through image analysis, and realizes automatic data processing and early warning in combination with a DCS system. The device is light in design, anti-interference, adaptive to high-temperature environment, and stable in operation due to the cooling shell. The application provides a safe and efficient detection method, solves the pollution risk and safety problems caused by manual detection, improves production yield and efficiency, reduces cost, is suitable for TFT-LCD substrate glass production lines, and has important application value and broad prospects.

Description

Technical Field

[0001] This application belongs to the field of overflow-pull-down method for manufacturing substrate glass, and specifically relates to an overflow-pull-down method substrate glass indentation detection device and its real-time monitoring method. Background Technology

[0002] In the production process of modern TFT-LCD substrate glass, the changes in the substrate glass indentation are a key factor in ensuring the stability of production quality. In the later stages of muffle furnace production, wear and tear and lifespan instability of equipment such as edge-pulling machines and superheaters can easily lead to unstable material flow. Therefore, it is necessary to monitor the changes in the substrate glass indentation in real time.

[0003] However, existing technologies mainly rely on visual measurements by on-site staff, which has obvious drawbacks: on the one hand, staff need to be close to high-temperature boards, making it difficult to guarantee safety; on the other hand, manual measurement is difficult to meet the requirements of production efficiency, product quality and standardization, and is prone to inaccurate test results due to human factors, thus failing to detect abnormalities in the production process in a timely manner, hiding production risks, and increasing production time and costs.

[0004] Therefore, how to achieve effective, real-time, and safe monitoring of edge plate indentations during the glass substrate production process has become a technical challenge that urgently needs to be solved in this field. Summary of the Invention

[0005] The purpose of this application is to provide an overflow-method substrate glass indentation detection device and its real-time monitoring method. This addresses the contamination risks and safety issues associated with manual inspection mentioned in the background art, thereby improving production yield and efficiency.

[0006] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, an overflow-method substrate glass indentation detection device is provided, comprising: The real-time monitoring device has a built-in image acquisition module for continuously capturing images of the edge of the substrate glass flowing out of the annealing furnace. The steering shaft is mechanically connected to the real-time monitoring device, and the image acquisition module is aligned with the indentation area of ​​the substrate glass by angle adjustment; A cooling housing covers the real-time monitoring device, and a cooling duct is connected to the outside of the housing to maintain the operating temperature of the real-time monitoring device. The fixing device anchors the steering shaft to the center position of surface A of the transverse wall; A signal transmission module is used to transmit the image data acquired by the image acquisition module to the image analysis device; The image analysis device is configured as follows: Based on a preset ratio conversion model, the image pixel values ​​are converted into the actual width of the indentation; The system correlates indentation width changes with traction speed data and outputs anomaly warning signals to the DCS system.

[0007] In one possible implementation, the cooling housing is equipped with a temperature sensor that automatically activates the air-cooling system of the cooling duct when the ambient temperature in the cross section exceeds 150°C.

[0008] In one possible implementation, the adjustment range of the steering axis is: ±30° in the horizontal direction and ±15° in the pitch direction to adapt to the limited space between cross sections and adjust the shooting angle.

[0009] In one possible implementation, the fixing device employs a dual-mode fixing structure of a magnetic base and a mechanical locking mechanism. The magnetic base is attached to the transverse wall, and the mechanical locking mechanism is used to lock the position of the steering shaft.

[0010] In one possible implementation, the real-time monitoring device is a CCD camera, the lens of which is coated with a high-temperature resistant anti-reflective film to adapt to the high-temperature environment between cross sections.

[0011] In one possible implementation, the signal transmission module is connected to the OPC protocol interface of the DCS system via a terminal block to achieve real-time transmission of image data.

[0012] In one possible implementation, the image analysis device is integrated into a microcontroller, and its output interface is simultaneously displayed on the DCS operator station and the LCD monitoring screen.

[0013] Secondly, a method for real-time monitoring of substrate glass indentation is provided, employing the overflow method substrate glass indentation detection device of the first aspect, including the following steps: Step 1: Adjust the angle of the steering shaft so that the image acquisition module of the real-time monitoring device is aligned with the indentation area of ​​the substrate glass flowing out of the annealing furnace. Step 2: Cool the real-time monitoring device through the cooling duct connected to the cooling shell to maintain its operating temperature; Step 3: The image acquisition module continuously acquires images of the indentation on the edge of the substrate glass, and transmits the image data to the image analysis device through the signal transmission module; Step 4: The image analysis device converts the image pixel values ​​into the actual width of the indentation based on a preset ratio conversion model, and correlates the change in the indentation width with the traction speed data; Step 5: When the change in indentation width meets the preset abnormal conditions, the image analysis device outputs an abnormal warning signal to the DCS system.

[0014] In one possible implementation, the image processing procedure of the image analysis device in step 4 includes: reading the image and performing noise reduction processing, converting it to a grayscale image and enhancing the contrast, then performing adaptive thresholding processing, edge detection and creating an edge mask, then detecting straight lines through Hough transform, taking the longest straight line as the main edge of the substrate, then performing contour detection and morphological operations, converting it to integer coordinates and obtaining the minimum bounding rectangle, calculating the actual width, and finally recording the results and outputting the information.

[0015] In one possible implementation, the warning signal triggering condition in step 5 is: the indentation width fluctuation value is greater than ±5% of the standard value and lasts for ≥10 seconds.

[0016] Compared with the prior art, this application has the following beneficial effects: The overflow-method substrate glass indentation detection device and its real-time monitoring method provided in this application significantly improve the accuracy and efficiency of substrate glass indentation detection through real-time monitoring and intelligent analysis. Automatic temperature control of the cooling housing and flexible adjustment of the steering shaft ensure stable operation and optimal acquisition angle of the equipment in high-temperature environments, while the integrated image analysis device and efficient processing flow enable accurate measurement of indentation width and abnormality warning. In practical applications, this solution effectively reduces the defect rate in production, improves product quality control, and provides strong support for the safe operation and process optimization of overflow-method substrate glass production lines. Attached Figure Description

[0017] Figure 1 The control logic diagram provided in this application; Figure 2 The distance measurement principle diagram provided for this application; Figure 3 A schematic diagram of the overall structure of an overflow method substrate glass indentation detection device provided in this application; Figure 4 This is a schematic diagram of the device fixed inside the transverse section for the purposes of this application.

[0018] The attached diagram is labeled as follows: 1. Cross-section wall; 2. Steering shaft; 3. Wiring terminal; 4. Real-time monitoring device; 5. Substrate glass; 6. Cooling housing. Detailed Implementation

[0019] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0020] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0022] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0023] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, this application discloses an overflow method substrate glass indentation detection device, which may include a real-time monitoring device 4 with a built-in image acquisition module for continuously capturing images of the edge of the substrate glass 5 flowing out of the annealing furnace.

[0026] The steering shaft 2 is mechanically connected to the real-time monitoring device 4, and the image acquisition module is aligned with the indentation area of ​​the substrate glass 5 by angle adjustment; the cooling housing 6 covers the real-time monitoring device 4, and is externally connected to a cooling duct to maintain the operating temperature of the real-time monitoring device 4.

[0027] The fixing device anchors the steering shaft 2 to the center of surface A of the transverse wall 1.

[0028] This signal transmission module is used to transmit image data acquired by the image acquisition module to the image analysis device.

[0029] The image analysis device is configured to convert image pixel values ​​into the actual width of the indentation based on a preset ratio conversion model; correlate the changes in the indentation width with the traction speed data; and output an abnormal warning signal to the DCS system.

[0030] Technically, the real-time monitoring device 4 uses a high-definition CCD camera to ensure the accuracy and clarity of image acquisition, while the design of the steering shaft 2 allows the device to flexibly adjust the shooting angle within a limited space to ensure accurate capture of the target area.

[0031] In principle, this image analysis device is based on computer vision technology. It uses algorithms to convert pixel values ​​in an image into actual physical dimensions, enabling non-contact measurement of indentation width. At the same time, it combines the traction speed data of the substrate glass 5 to analyze the trend of indentation changes.

[0032] In terms of effectiveness, the technology in this embodiment can monitor the indentation changes of the substrate glass 5 in real time, provide timely warnings of abnormal situations, effectively prevent production accidents, and improve production yield.

[0033] In other embodiments, a stereo vision system can be constructed by adding multi-angle cameras to solve the occlusion problem that may exist in a single viewpoint in complex environments.

[0034] Furthermore, the cooling housing 6 is equipped with a temperature sensor, which automatically activates the air-cooling system of the cooling duct when the ambient temperature in the cross section exceeds 150°C.

[0035] Technically, a combination of temperature sensors and cooling ducts is used to ensure the stable operation of the real-time monitoring device 4 in high-temperature environments.

[0036] In principle, the temperature sensor monitors the ambient temperature in real time. Once the set threshold is exceeded, the cooling system is activated immediately to prevent the equipment from overheating and being damaged.

[0037] In terms of effectiveness, the technology in this embodiment ensures the long-term reliability of the real-time monitoring device 4, extends the service life of the equipment, and reduces maintenance costs.

[0038] In other embodiments, a water-cooling system can be used instead of air cooling to solve the noise and dust problems that air cooling may cause.

[0039] Furthermore, the adjustment range of the steering shaft 2 is: ±30° in the horizontal direction and ±15° in the pitch direction to adapt to the limited space between cross sections and adjust the shooting angle.

[0040] Technically, the precision mechanical design of the steering shaft 2 allows for multi-dimensional adjustments within a confined space, ensuring the best shooting angle.

[0041] In principle, the steering shaft 2 is rotated by a motor to achieve precise positioning of the real-time monitoring device 4.

[0042] In terms of effectiveness, the technology in this embodiment improves the adaptability and flexibility of the device, enabling it to meet the needs of indentation detection on substrate glass 5 at different production stages.

[0043] In other embodiments, a wider range of free rotation can be achieved by adding a motorized gimbal, thus solving the problem of limited shooting at specific angles.

[0044] Furthermore, the fixing device adopts a dual-mode fixing structure of magnetic base and mechanical locking. The magnetic base is attached to the transverse wall 1, and the mechanical locking structure is used to lock the position of the steering shaft 2.

[0045] Technically, the combination of the magnetic base and the mechanical locking structure ensures the stability of the device while also enabling quick assembly and disassembly.

[0046] In principle, the magnetic base is fixed by magnetic attraction, while the mechanical locking structure is locked by bolts, providing double protection to ensure the stability of the steering shaft 2 in the working state.

[0047] In terms of effectiveness, the technology in this embodiment simplifies the installation and adjustment process of the device, improves the ease of operation, and enhances safety.

[0048] In other embodiments, a vacuum suction cup can be used for fixation, which is suitable for non-metallic walls and solves the problem of the limited applicability of magnetic bases.

[0049] Furthermore, the real-time monitoring device 4 is a CCD camera, and the CCD camera lens is coated with a high-temperature resistant anti-reflective film to adapt to the high-temperature environment between cross sections.

[0050] Technically, the CCD camera was chosen as the core component of the image acquisition module due to its high sensitivity and stable imaging quality, while the high-temperature resistant anti-reflective coating ensures the optical performance of the lens under high-temperature conditions.

[0051] In principle, this CCD camera converts light into electrical signals through the photoelectric effect, while the anti-reflection coating reduces reflection loss and improves light transmittance.

[0052] In terms of effectiveness, the technology in this embodiment ensures the accuracy and continuity of image acquisition, and can provide high-quality image data even under extreme conditions.

[0053] In other embodiments, a CMOS sensor can be used instead of a CCD to achieve lower power consumption and faster frame rates, thus addressing the energy consumption issues that may arise during long-term operation.

[0054] Furthermore, the signal transmission module is connected to the OPC protocol interface of the DCS system via terminal block 3 to achieve real-time transmission of image data.

[0055] Technically, this terminal block 3 and the OPC protocol interface of the DCS system form a high-efficiency data transmission channel.

[0056] In principle, this signal transmission module encodes image data into a format that conforms to the OPC protocol and sends it to the DCS system via the network to achieve remote monitoring and data analysis.

[0057] In terms of effectiveness, the technology in this embodiment ensures the real-time nature and accuracy of image data, making it convenient for technicians to grasp the production status in real time.

[0058] In other embodiments, wireless transmission technology can also be used to reduce wiring complexity and solve the installation inconvenience and maintenance difficulties that may be caused by wired transmission.

[0059] Furthermore, the image analysis device is integrated into a microcontroller, and its output interface is simultaneously displayed on the DCS operator station and the LCD monitoring screen.

[0060] Technically, this microcontroller integrates image processing algorithms and data communication functions, achieving tight coupling between hardware and software.

[0061] In principle, the microcontroller executes an image analysis program to convert image pixel values ​​into actual physical dimensions and sends the results to the DCS operator station and LCD monitoring screen via the network.

[0062] In terms of effectiveness, the technology in this embodiment simplifies the system architecture, reduces costs, and ensures the real-time nature and visualization of data.

[0063] In other embodiments, the image analysis device can also be deployed on a cloud server to leverage the powerful processing capabilities of cloud computing and solve the problem of insufficient local computing resources.

[0064] One aspect of this application provides a real-time monitoring method for indentation on substrate glass 5, employing an overflow method substrate glass indentation detection device, comprising the following steps: by adjusting the angle of the steering shaft 2, the image acquisition module of the real-time monitoring device 4 is aligned with the indentation area of ​​the substrate glass 5 flowing out of the annealing furnace opening. The real-time monitoring device 4 is cooled by the cooling duct connected to the cooling housing 6 to maintain its operating temperature; the image acquisition module continuously acquires images of the indentation on the edge of the substrate glass 5 and transmits the image data to the image analysis device through the signal transmission module. The image analysis device converts image pixel values ​​into the actual width of the indentation based on a preset ratio conversion model, and correlates the changes in the indentation width with the traction speed data. When the change in indentation width meets the preset abnormal conditions, the image analysis device outputs an abnormal warning signal to the DCS system.

[0065] Technically, this method integrates multiple technical means to achieve automated real-time monitoring of the indentation on the substrate glass 5.

[0066] In principle, this image analysis device uses computer vision algorithms to convert pixel information in an image into actual physical dimensions, and combines traction speed data to evaluate the trend of indentation changes.

[0067] In terms of effectiveness, the technology in this embodiment can provide early warning of equipment malfunctions, reduce production risks, and improve production efficiency.

[0068] In other embodiments, machine learning algorithms can be introduced to train models to identify abnormal indentation patterns, thereby improving the accuracy and intelligence of early warnings.

[0069] Furthermore, the image processing procedure of the image analysis device in step 4 includes: after reading the image, performing noise reduction processing, converting it into a grayscale image and enhancing the contrast, then performing adaptive threshold processing, edge detection and creating an edge mask, then detecting straight lines through Hough transform, taking the longest straight line as the main edge of the substrate, then performing contour detection and morphological operations, converting it into integer coordinates to obtain the minimum bounding rectangle, calculating the actual width, and finally recording the results and outputting the information.

[0070] Technically, this image processing workflow employs advanced computer vision technology, ensuring both accuracy and speed in image analysis.

[0071] In principle, steps such as noise reduction, grayscale conversion, and edge detection are used to gradually extract key features from the image, while Hough transform and minimum bounding rectangle calculation are used to accurately measure the indentation width.

[0072] In terms of effectiveness, the technology in this embodiment can quickly and accurately obtain indentation width data from complex images, providing a solid foundation for subsequent anomaly warning.

[0073] In other embodiments, a neural network model can be constructed using deep learning technology to directly predict the indentation width from the original image, simplifying the image processing workflow and improving efficiency.

[0074] Furthermore, the warning signal triggering condition in step 5 is: the indentation width fluctuation value is greater than ±5% of the standard value, and lasts for ≥10 seconds.

[0075] Technically, the setting of the warning signal triggering conditions is based on statistical principles, ensuring the sensitivity and accuracy of the warning.

[0076] In principle, by continuously monitoring changes in the indentation width, an early warning signal is triggered once fluctuations are found to exceed the normal range and last for an extended period.

[0077] In terms of effectiveness, the technology in this embodiment can promptly detect potential production problems, prevent major accidents, and improve the safety and reliability of production.

[0078] In other embodiments, the warning threshold can be dynamically adjusted based on historical data to adapt to changes in different production batches and environmental conditions, thereby improving the adaptability and robustness of the warning system.

[0079] The technical solution of this application involves the working process and the usage process.

[0080] The work process is described as follows: First, the operator installs the overflow method substrate glass indentation detection device at the center of surface A of the transverse cutting wall 1, ensuring that the real-time monitoring device 4 can cover the indentation area of ​​the substrate glass 5 flowing out of the annealing furnace. Then, the cooling duct is turned on to maintain the operating temperature of the real-time monitoring device 4 within a safe range.

[0081] Real-time monitoring device 4 begins continuously acquiring images, and the image data is sent to the image analysis device via the signal transmission module. The image analysis device executes a preset image processing procedure, converting the image pixel values ​​into actual physical dimensions, while simultaneously correlating the indentation width change with the traction speed data. Once the indentation width change exceeds the preset abnormal conditions, the image analysis device immediately outputs a warning signal to the DCS system. Based on this, operators take corresponding measures, adjusting production parameters or checking equipment status to prevent equipment malfunctions and ensure the smooth operation of the production process.

[0082] Throughout the entire process, the various technical modules work together to form a complete closed-loop monitoring system, which effectively improves production efficiency and product quality, and reduces production costs and safety risks.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them; although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions for some or all of the technical features, do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. An overflow method substrate glass indentation detection device, characterized in that, include: The real-time monitoring device (4) has a built-in image acquisition module for continuously capturing images of the edge of the substrate glass (5) flowing out of the annealing furnace opening; The steering shaft (2) is mechanically connected to the real-time monitoring device (4), and the image acquisition module is aligned with the indentation area of ​​the substrate glass (5) by angle adjustment; A cooling housing (6) covers the real-time monitoring device (4), and a cooling duct is connected to the outside of the housing to maintain the operating temperature of the real-time monitoring device (4); The fixing device anchors the steering shaft (2) to the center position of surface A of the transverse wall (1); A signal transmission module is used to transmit the image data acquired by the image acquisition module to the image analysis device; The image analysis device is configured as follows: Based on a preset ratio conversion model, the image pixel values ​​are converted into the actual width of the indentation; Correlate indentation width changes with traction speed data, and output abnormal warning signals to the DCS system; A method for real-time monitoring of substrate glass indentation using the overflow method substrate glass indentation detection device includes the following steps: Step 1: By adjusting the angle of the steering shaft (2), the image acquisition module of the real-time monitoring device (4) is aligned with the indentation area of ​​the substrate glass (5) flowing out of the annealing furnace. Step 2: Cool the real-time monitoring device (4) through the cooling air duct connected to the cooling shell (6) to maintain its working temperature; Step 3: The image acquisition module continuously acquires indentation images of the edge of the substrate glass (5), and transmits the image data to the image analysis device through the signal transmission module; Step 4: The image analysis device converts the image pixel values ​​into the actual width of the indentation based on a preset ratio conversion model, and correlates the change in the indentation width with the traction speed data; Step 5: When the change in indentation width meets the preset abnormal conditions, the image analysis device outputs an abnormal warning signal to the DCS system; The image processing procedure of the image analysis device in step 4 includes: After reading the image, noise reduction is performed, the image is converted to grayscale and the contrast is enhanced. Then, adaptive thresholding, edge detection and edge masking are performed. Then, straight lines are detected by Hough transform, and the longest straight line is taken as the main edge of the substrate. Next, contour detection and morphological operations are performed. After converting to integer coordinates, the minimum bounding rectangle is obtained, the actual width is calculated, and finally the results are recorded and the information is output.

2. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The cooling housing (6) is equipped with a temperature sensor. When the ambient temperature in the cross section exceeds 150°C, the air cooling system of the cooling duct is automatically activated.

3. The overflow method substrate glass (5) indentation detection device according to claim 1, characterized in that, The adjustment range of the steering shaft (2) is: ±30° in the horizontal direction and ±15° in the pitch direction to adapt to the limited space between cross sections and adjust the shooting angle.

4. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The fixing device adopts a dual-mode fixing structure of magnetic base and mechanical locking. The magnetic base is adsorbed onto the transverse wall (1), and the mechanical locking is used to lock the position of the steering shaft (2).

5. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The real-time monitoring device (4) is a CCD camera, and the CCD camera lens is coated with a high-temperature resistant anti-reflective film to adapt to the high-temperature environment between cross sections.

6. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The signal transmission module is connected to the OPC protocol interface of the DCS system via a terminal block (3) to realize real-time transmission of image data.

7. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The image analysis device is integrated into a microcontroller, and its output interface is simultaneously displayed on the DCS operator station and the LCD monitoring screen.

8. The overflow method substrate glass indentation detection device according to claim 1, characterized in that, The triggering condition for the warning signal in step 5 is: The indentation width fluctuation value is greater than ±5% of the standard value and lasts for ≥10 seconds.

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