Glass plate manufacturing method and manufacturing device

Abstract

The invention provides a method and an apparatus for manufacturing a glass plate. When a glass plate (3) cut from a glass ribbon (2) is subjected to an inspection step (P3) for inspecting attachments and damages on a main surface (3a) of the glass plate (3) as surface defects (4), the inspection step (P3) is performed before a cleaning step (P8) for cleaning the glass plate (3). In other words, the inspection step (P3) is performed at a time before removing the attachments from the glass plate (3) with the cleaning and at a time when there is no risk of new damage to the glass plate (3) with the cleaning. As a result, the distribution of surface defects (4) resulting from the cutting of the glass plate (3) on the main surface (3a) can be monitored, and the occurrence of defects during the cutting of the glass plate (3) can be ascertained on the basis of the excess of the surface defects (4) and the presence of the concentration of the surface defects (4).

Description

Technical Field

[0001] This invention relates to a method and apparatus for manufacturing glass plates. Background Technology

[0002] The glass manufacturing process typically includes a step to check for defects in the glass to determine its quality.

[0003] Patent Document 1 discloses a method for identifying foreign objects as defects contained within the glass plate, bubbles as defects also contained within the glass plate, and dust adhering to the surface of the glass plate when inspecting for defects in the glass plate.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2018-112411 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] The aforementioned dust, glass powder, and other contaminants adhering to the glass plate can be removed by cleaning the glass plate before it is shipped as a product. Therefore, these contaminants, unlike the aforementioned foreign matter and bubbles, will not be a factor in determining the quality of the glass plate.

[0009] However, excessive glass powder on the main surfaces of the glass sheet (the two opposing surfaces of the glass sheet in the thickness direction) or areas where glass powder is concentrated on the main surfaces indicate potential defects in the glass sheet manufacturing process. For example, if there are areas of concentrated glass powder near the ends of the glass sheet, it suggests poor cutting during the cutting of the glass sheet. Therefore, it is necessary to monitor the distribution of deposits on the main surfaces of the glass sheet.

[0010] Similar to the aforementioned attachments, it is also necessary to monitor the distribution of damage on the main surface of the glass plate. This is because excessive damage on the main surface of the glass plate, or the presence of areas of concentrated damage on the main surface, indicates potential defects, primarily glass breakage, during the glass plate manufacturing process.

[0011] In view of the above, the problem that needs to be solved is to be able to monitor the distribution of deposits and damage on the main surface of the glass plate during the manufacturing process, and to be able to control the occurrence of defects in the glass plate manufacturing process.

[0012] Solution for solving the problem

[0013] A method for manufacturing a first glass plate to solve the aforementioned problem includes: a processing step in which a glass plate is subjected to a prescribed processing using a processing device; and an inspection step in which adhering substances and damage to the main surface of the glass plate after the processing step are inspected as surface defects. The inspection step includes: a setting step in which an inspection area is set on the main surface; a defining step in which a reference dimension having an area below the inspection area is defined; and a notification step in which, if the number of surface defects present in each reference dimension within the inspection area exceeds a threshold, a notification is sent to a control device controlling the processing device. The method for manufacturing the glass plate is characterized in that it further includes a cleaning step for cleaning the glass plate, and the inspection step is performed before the cleaning step. Here, "main surface of the glass plate" refers to two opposing surfaces in the thickness direction of the glass plate. Furthermore, "notifying the control device" means not only notification to the control device itself, but also notification to the operator in the presence of an operator who operates the control device.

[0014] In the manufacturing method of the first glass plate, during the execution of the inspection process, if the number of surface defects (attachments and damage) existing per reference size within the inspection area set on the main surface of the glass plate exceeds a threshold, a notification is sent to the control device of the control processing device. Here, based on setting the area of ​​the inspection area to be the same as the area of ​​the reference size through the setting and specifying processes, when the control device receives the notification during the notification process, it is determined that the distribution of surface defects is excessive in the inspection area. Furthermore, based on setting the area of ​​the reference size to be smaller than the area of ​​the inspection area through the setting and specifying processes, when the control device receives the notification during the notification process, it is determined that the distribution of surface defects is concentrated in certain areas within the inspection area. Thus, in this manufacturing method, by performing the inspection process, the distribution of attachments and damage on the main surface of the glass plate can be monitored. Moreover, in this manufacturing method, the inspection process is performed before the cleaning process of cleaning the glass plate. That is, the inspection process is performed at a time before the attachments are removed from the glass plate during cleaning, and at a time when there is no risk of new damage being generated to the glass plate during cleaning. Therefore, the surface defects present on the main surface of the glass plate at the time of inspection originate from surface defects in the processing steps performed prior to inspection. Furthermore, an excessive number of surface defects on the main surface of the glass plate, or areas where surface defects are concentrated, indicate that defects occurred during the processing steps. As a result, in this manufacturing method, it is possible to control the occurrence of defects in the glass plate manufacturing process (processing steps).

[0015] The manufacturing method of the second glass plate is based on the manufacturing method of the first glass plate described above, and is configured in such a way that the processing conditions of the specified processing in the processing step are changed by a control device that receives a notification through the notification process.

[0016] In the manufacturing method of the second glass plate, the control device that receives the notification changes the processing conditions, and thus the adverse conditions generated in the processing step can be eliminated along with the change.

[0017] The manufacturing method of the third glass plate is based on the manufacturing method of the first or second glass plate described above, wherein the control device is equipped with a display device, and the display device displays the intention of receiving a notification.

[0018] In the manufacturing method of the third glass plate, the display device displays the intention to receive notification, which is advantageous, for example, in the presence of an operator with an operation control device. That is, the operator can reliably identify areas on the main surface of the glass plate where there are excessive surface defects or concentrated areas of surface defects by means of the display.

[0019] The fourth glass plate manufacturing method is based on any one of the first to third glass plate manufacturing methods described above, wherein in the inspection process, the upper end of the glass plate, which is in a longitudinal orientation, is supported by a support member, and in the setting process, an inspection area is set on the main surface at a position lower than the position where the support member is located.

[0020] In the manufacturing method of the fourth glass plate, an inspection area is set on the main surface of the glass plate at a position lower than where the support member is located. Therefore, since there is no support member in the inspection area, the risk of mistaking the support member for a surface defect can be reliably eliminated. As a result, it is advantageous in accurately monitoring the distribution of deposits and damage on the main surface of the glass plate.

[0021] The manufacturing method of the fifth glass plate is based on the manufacturing method of the fourth glass plate described above, and is configured such that, in the setting process, at least the entire area of ​​the effective surface of the glass plate is included in the inspection area.

[0022] In the case of excessive surface defects or concentrated areas of surface defects on the effective surface (the portion that later becomes the product glass sheet) of the main surface of the glass sheet, the risk of defects degrading the quality of the product glass sheet increases during the processing steps. In the fifth glass sheet manufacturing method, at least the entire area of ​​the effective surface is included in the inspection area, thus enabling accurate identification of defects in the processing steps that could degrade the quality of the product glass sheet.

[0023] The manufacturing method of the sixth glass plate is based on any one of the manufacturing methods of the first to fifth glass plates described above, and is configured as follows: the manufacturing method of the glass plate further includes a quality determination process for determining the quality of the glass plate. The quality determination process includes: an internal defect detection process, which takes the effective surface of the glass plate as the object and detects foreign objects and bubbles existing inside the glass plate as internal defects; and a pass / fail determination process, which determines whether the quality of the glass plate is pass / fail based on the result of the internal defect detection process.

[0024] Internal defects (foreign matter and bubbles) present within the glass sheet cannot be removed even by cleaning. In the sixth glass sheet manufacturing method, along with the quality assessment process, an internal defect detection process is performed to inspect for these defects. In the pass / fail determination process, the quality of the glass sheet is determined based on the results of the internal defect detection process. This prevents defective glass sheets containing unacceptable internal defects from being shipped as finished products.

[0025] The manufacturing method of the seventh glass plate is based on the manufacturing method of the sixth glass plate described above, and is configured in the following manner, using a single inspection device to simultaneously perform the inspection process and the quality judgment process.

[0026] In the seventh method for manufacturing glass sheets, by simultaneously performing the inspection process and the quality judgment process, the manufacturing efficiency of the glass sheets can be improved compared to performing the two processes separately. Furthermore, by utilizing a single inspection device to perform both the inspection process and the quality judgment process, space-saving can be achieved in the glass sheet production line.

[0027] The manufacturing method of the eighth glass plate is based on the manufacturing method of the sixth or seventh glass plate described above, and is configured as follows: In the inspection process and the quality judgment process, a first imaging system and a second imaging system are used. The first imaging system has a first light source, a first imaging part that captures the first transmitted light that is irradiated by the first light source and passes through the glass plate, and a blocking member that blocks a portion of the first transmitted light to form a bright part and a dark part in the field of view of the first imaging part. The second imaging system has a second light source and a third light source, and a second imaging part that captures the second transmitted light that is irradiated by the second light source and passes through the glass plate in the bright field of view, and captures the third transmitted light that is irradiated by the third light source and passes through the glass plate in the dark field of view. Surface defects and internal defects are identified based on the images obtained by the first imaging system and the images obtained by the second imaging system.

[0028] In the manufacturing method of the eighth glass plate, a first imaging system and a second imaging system are used in the inspection and quality judgment processes. The features extracted from the images obtained by the first imaging system and the second imaging system (image shape, color, presence or absence, etc.) differ between surface defects existing on the main surface of the glass plate and internal defects existing inside the glass plate. Therefore, surface defects and internal defects can be accurately identified.

[0029] The manufacturing method of the ninth glass plate is based on any one of the manufacturing methods of the first to eighth glass plates described above, and is configured as follows: the manufacturing method of the glass plate further includes a storage process for storing the glass plate or a conveying process for conveying the glass plate, and an inspection process is performed before the storage process or the conveying process is performed.

[0030] In the ninth glass plate manufacturing method, an inspection process is performed before the storage or conveying process, thereby enabling timely detection of defects in the glass plate manufacturing process (processing process).

[0031] The manufacturing method of the tenth glass plate is based on any one of the manufacturing methods of the first to ninth glass plates described above, and is configured as follows: the manufacturing method of the glass plate further includes a forming process of forming a glass ribbon from molten glass and a cutting process as a processing process of cutting the glass plate from the glass ribbon, and an inspection process is performed after the cutting process.

[0032] In the manufacturing method of the tenth glass plate, by performing an inspection process after the cutting process, it is possible to inspect for any adhering substances or damage that occur on the main surface of the glass plate during the cutting process. Therefore, it is possible to identify any defects that may occur during the cutting process.

[0033] A glass plate manufacturing apparatus for solving the above-mentioned problems includes: a processing device that performs a prescribed processing on the glass plate; and an inspection device that inspects the adhering substances and damage to the main surface of the processed glass plate as surface defects. The inspection device includes: a setting mechanism that sets an inspection area on the main surface; a specifying mechanism that specifies a reference size having an area below the inspection area; and a notification mechanism that notifies a control device controlling the processing device when the number of surface defects per reference size in the inspection area exceeds a threshold. The glass plate manufacturing apparatus is characterized in that it further includes a cleaning device for cleaning the glass plate, and the inspection device is positioned upstream of the cleaning device on the production line.

[0034] In this glass plate manufacturing apparatus, the same function and effect as the first glass plate manufacturing method described above can be obtained.

[0035] Invention Effects

[0036] According to the glass plate manufacturing method and manufacturing apparatus of the present invention, during the manufacturing of the glass plate, it is possible to monitor the distribution of deposits and damage on the main surface of the glass plate, and to grasp the occurrence of defects in the glass plate manufacturing process. Attached Figure Description

[0037] Figure 1 This is a flowchart of the glass plate manufacturing process.

[0038] Figure 2 This diagram illustrates the forming process, cutting process, inspection process, and quality judgment process in the manufacturing method of glass plates, as well as a part of the glass plate manufacturing apparatus.

[0039] Figure 3 This diagram illustrates the inspection and quality assessment processes in the manufacturing method of glass plates.

[0040] Figure 4 This diagram illustrates the inspection and quality assessment processes in the glass plate manufacturing method, as well as the inspection equipment included in the glass plate manufacturing apparatus.

[0041] Figure 5 This is a diagram showing the light source unit included in the inspection device.

[0042] Figure 6 This is a diagram illustrating the inspection process in the manufacturing method of a glass plate.

[0043] Figure 7 This is a diagram illustrating the inspection process in the manufacturing method of a glass plate.

[0044] Figure 8 This is a flowchart of the glass plate manufacturing process.

[0045] Explanation of reference numerals in the attached figures

[0046] 1. Molten glass

[0047] 2. Glass ribbon

[0048] 3. Glass plate

[0049] 3a Main face

[0050] 3b effective surface

[0051] 3s reference size

[0052] 3x Inspection Area

[0053] 4 Surface defects

[0054] 7. Cutting device

[0055] 8. Control device

[0056] 9. Internal defects

[0057] 10. Glass plate manufacturing apparatus

[0058] 12 Inspection device

[0059] 16 First Cutting Device

[0060] 17 Second Cutting Device

[0061] 32. Clamp (support component)

[0062] 33 Display devices

[0063] 34 First Shooting System

[0064] 35 Second shooting system

[0065] 37 First Light Source

[0066] 38 First Filming Department

[0067] 39. Shelter (shielding component)

[0068] 40 Second Shooting Department

[0069] 41 Second Light Source

[0070] 42 Third Light Source

[0071] L1 First light transmission

[0072] L2 Second Transmitted Light

[0073] L3 Third Transmitted Light

[0074] P1 Forming Process

[0075] P2 Cutting process

[0076] P2a First Cutting Process

[0077] P2b Second Cutting Process

[0078] P3 Inspection Procedure

[0079] P3a Setting Process

[0080] P3b specifies the process

[0081] P3c Notification Process

[0082] P4 Quality Judgment Process

[0083] P4a Internal Defect Inspection Process

[0084] P4b Pass / Fail Judgment Process

[0085] P6 Storage Procedure

[0086] P7 Conveying Process

[0087] P8 Cleaning process. Detailed Implementation

[0088] Hereinafter, embodiments of the glass plate manufacturing method and manufacturing apparatus will be described with reference to the accompanying drawings. In the description of the embodiments, the X, Y, and Z directions shown in a portion of the accompanying drawings are mutually orthogonal.

[0089] <First Implementation>

[0090] like Figure 1 As shown in the flowchart, the glass plate manufacturing method includes the following main processes sequentially, starting from the upstream process: forming process P1 ( Figure 2 ), forming glass strip 2 from molten glass 1; cutting process P2 ( Figure 2 ), cut glass plate 3 from glass strip 2; inspect process P3 ( Figure 2 , Figure 3 as well as Figure 4 ), and inspect the attachments and damage on the main surface 3a of the glass plate 3 as surface defects 4; quality judgment process P4 ( Figure 2 , Figure 3 as well as Figure 4 The quality of glass plate 3 is determined simultaneously with inspection process P3; rejection process P5 discards unqualified glass plate 3 in quality determination process P4; storage process P6 or conveying process P7 stores or conveys qualified glass plate 3 in quality determination process P4; and cleaning process P8 cleans glass plate 3 after storage or conveying.

[0091] The cutting process P2, inspection process P3, and quality judgment process P4 in the above-mentioned processes P1 to P8 are composed of multiple processes they include.

[0092] The cutting process P2 includes, in chronological order: the first cutting process P2a ( Figure 2 ), cut the eared glass plate 5 from the glass strip 2; and the second cutting process P2b ( Figure 2 Glass plate 3 is obtained by cutting the glass plate 5 with lugs and removing the unwanted parts 6 and 6. Cutting process P2 is an example of a processing process that performs a prescribed treatment on the glass plate.

[0093] The inspection process P3, in chronological order, includes: setting up process P3a (… Figure 3 ), an inspection area 3x is set on the main surface 3a of glass plate 3; the specified process P3b ( Figure 3The reference size 3s is defined as having an area of ​​less than 3x within the inspection area; and the notification process P3c is notified that if the number of surface defects 4 present in each reference size 3s within the inspection area 3x exceeds a threshold, the control device 8, which controls the cutting device 7 described later, is notified.

[0094] The quality assessment process P4, in chronological order, includes: internal defect inspection process P4a (… Figure 3 as well as Figure 4 The effective surface 3b of the glass plate 3 (which later becomes the product glass plate) is taken as the object, and foreign objects and bubbles existing inside the glass plate 3 are detected as internal defects 9; and the pass / fail determination process P4b, based on the result of the internal defect detection process P4a, determines whether the quality of the glass plate 3 is pass / fail.

[0095] Each of the above-mentioned processes P1 to P8 is performed using the devices included in the glass plate manufacturing apparatus 10 (hereinafter referred to as manufacturing apparatus 10). The devices included in the manufacturing apparatus 10, starting from the upstream side of the glass plate 3 production line, sequentially include: a forming device 11 (… Figure 2 ), which is used in forming process P1; cutting device 7 ( Figure 2 ), which is used for cutting process P2; inspection device 12 ( Figure 2 as well as Figure 4 The equipment is used for inspection process P3 and quality judgment process P4; the loading device (not shown) is used for storage process P6 or conveying process P7; and the cleaning device (not shown) is used for cleaning process P8.

[0096] Figure 2 The forming apparatus 11 shown is used to form the glass strip 2 by the overflow pull method. It should be noted that, as a variation of this embodiment, the forming apparatus 11 may also be used to form the glass strip 2 by the slit pull method, the re-pulling method, the float glass method, etc., instead of the overflow pull method.

[0097] The forming apparatus 11 includes: a forming body 13, the cross-section of which is wedge-shaped and orthogonal to the X direction; and rollers (not shown) arranged in multiple layers below the forming body 13. A groove 14 extending in the X direction is formed on the top of the forming body 13.

[0098] In forming process P1 using forming apparatus 11, firstly, molten glass 1 is continuously supplied to the groove 14 of the forming body 13, and the molten glass 1 overflows from the groove 14 to both sides (Z direction). Next, the molten glass 1 overflowing from the groove 14 flows down along both sides of the forming body 13 and then fuses at the lower end 15 of the forming body 13. This generates a plate-shaped molten glass 1 that becomes the raw material for glass strip 2. Then, the plate-shaped molten glass 1 is annealed while being pulled downwards from the surface using rollers arranged in a multi-stage configuration. This forms glass strip 2. At both ends of the formed glass strip 2 in the width direction (X direction), there are unwanted portions 6, including ears with a greater thickness than other portions.

[0099] Figure 2 The cutting device 7 shown includes: a first cutting device 16 for a first cutting process P2a; and a second cutting device 17 for a second cutting process P2b. The cutting device 7 is an example of a processing device for performing a prescribed process on a glass plate.

[0100] The first cutting device 16 is a device for cutting out the portion below the scribed line 18 as the lug glass plate 5 by breaking the glass strip 2 along the scribed line 18.

[0101] The first cutting device 16 includes: a scribing wheel 19 that forms scribing lines 18 while traveling on the surface of the glass strip 2; a breaking rod 20 that contacts the glass strip 2 at the time of breaking from the back side and becomes a fulcrum for bending the periphery of the scribing lines 18; a holding member 21 that changes its posture while holding the glass strip 2 at the time of breaking; and a first dust collector (not shown) that has a suction port for attracting glass powder generated by the breaking.

[0102] The break bar 20 is formed extending in the X direction. The break bar 20 is movable along the thickness direction (Z direction) of the glass strip 2. Therefore, the break bar 20 can move between a contact position where it contacts the glass strip 2 and a standby position where it separates from the glass strip 2. The break bar 20 is present in the contact position when the glass strip 2 breaks, and is present in the standby position otherwise. When in the contact position, the break bar 20 contacts the portion of the back surface of the glass strip 2 directly behind or slightly above the scribe line 18.

[0103] The retaining member 21 has a pair of arms 22, 22 that respectively retain the two ends of the glass strip 2 in the width direction. The retaining member 21 can rotate about an axis extending in the X direction (not shown) as indicated by arrow T, and its posture changes with the rotation. Thus, the retaining member 21 can take a vertical posture in which the arms 22 extend in the vertical direction (Y direction) and an inclined posture in which the arms 22 are tilted at a predetermined angle relative to the vertical posture.

[0104] The first dust collector has an opening with its suction port being longer in the X direction. The suction port just before it breaks is positioned opposite to the scribe line 18 formed on the glass strip 2. On the other hand, the suction port immediately after it breaks is positioned opposite to the lower end of the glass strip 2 (the end newly formed with the break) and the upper end of the lug glass plate 5.

[0105] In the first cutting device 16, at least one of the following conditions can be changed by the control device 8 described later: (A) the angular velocity of the rotational motion of the holding member 21 when it is transferred from a vertical posture to an inclined posture, (B) the size of the specified angle, (C) the speed at which the breaking rod 20 contacts the glass strip 2 (the speed at which the breaking rod 20 moves from the standby position to the contact position), and (D) the location of the contact position in the Z direction (the distance by which the breaking rod 20 at the contact position presses the glass strip 2 from the back side to the surface side).

[0106] In the first cutting process P2a using the first cutting device 16, firstly, a scribe line 18 is formed along the width direction of the glass strip 2 using the scribe wheel 19. Next, the posture of the holding member 21 holding the glass strip 2 is changed from a vertical posture to an inclined posture, and the breaking rod 20 is brought into contact with the glass strip 2. As a result, the periphery of the scribe line 18 of the glass strip 2 bends so that the surface side becomes convex with the breaking rod 20 as the fulcrum, and the glass strip 2 is broken along the scribe line 18. Then, a glass plate 5 with ears is cut from the glass strip 2. The cut glass plate 5 with ears is held by the holding member 21. The glass powder generated by the breakage is attracted and recovered by the suction port of the first dust collector.

[0107] The second cutting device 17 is a device for breaking off and removing two unwanted parts 6, 6 from the glass plate 5 by breaking the glass plate 5 with ears along the two scribed lines 23, 23 to obtain the glass plate 3.

[0108] The second cutting device 17 includes: a conveying mechanism 24 that conveys the lug-covered glass plate 5 received from the holding member 21 in a longitudinal orientation along the X direction; two scribing wheels 25, 25 that form scribing lines 23 while traveling on the surface of the lug-covered glass plate 5; two breaking rods 26, 26 that become fulcrums for bending the peripheries of the two scribing lines 23, 23 by contacting the lug-covered glass plate 5 from the back side when it is broken; two pressing rods 27, 27 that press the two unwanted parts 6, 6 from the surface side to the back side when it is broken; and two second dust collectors (not shown), each having a suction port for attracting glass powder generated by the breakage.

[0109] The transport mechanism 24 has a clamp assembly 29 consisting of multiple (two in the example) clamps 28 that hold the upper end of the lug-covered glass plate 5. The lug-covered glass plate 5 is suspended by the clamp assembly 29 during transport. The transport path of the transport mechanism 24 for transporting the lug-covered glass plate 5 is divided into multiple sections, each of which is equipped with a clamp assembly 29. The clamp assembly 29 in each section can reciprocate within that section. While the lug-covered glass plate 5 is transferred between the clamp assemblies 29 in adjacent sections, it is sequentially moved into the scribing area A1 for forming the scribing lines 23 and the breaking area A2 for breaking.

[0110] Two breakable rods 26, 26 are each formed extending along the Y direction. Each breakable rod 26 is movable along the thickness direction (Z direction) of the lug glass plate 5. Thus, each breakable rod 26 can move between a contact position in contact with the lug glass plate 5 and a standby position separated from the lug glass plate 5. Each breakable rod 26 is in the contact position when the lug glass plate 5 breaks, and is in the standby position otherwise. When in the contact position, each breakable rod 26 contacts the portion on the back of the lug glass plate 5 directly behind the scribe line 23 or slightly inside the width direction.

[0111] Two press-in rods 27, 27 are each formed extending along the Y direction. Each press-in rod 27 can move along the thickness direction of the lug glass plate 5 when it breaks.

[0112] Each of the two second dust collectors has its suction port opening longer in the Y direction. The suction port just before breakage is positioned opposite the scribed line 23 formed on the lug-type glass plate 5. Conversely, the suction port immediately after breakage is positioned opposite the width-direction end of the glass plate 3 and the width-direction end of the unwanted portion 6.

[0113] In the second cutting device 17, at least one of the following conditions can be changed by the control device 8 described later: (E) the moving speed of the pressing rod 27 when pressing in the unwanted part 6, (F) the distance that the pressing rod 27 presses in the unwanted part 6, (G) the speed of the breaking rod 26 when it contacts the eared glass plate 5 (the moving speed of the breaking rod 26 when it moves from the standby position to the contact position), and (H) the position of the contact position in the Z direction (the distance that the breaking rod 26 at the contact position presses in the eared glass plate 5 from the back side to the surface side).

[0114] In the second cutting process P2b using the second cutting device 17, firstly, in the scribing area A1, two scribing lines 23, 23 are formed along the vertical direction of the eared glass plate 5 using two scribing wheels 25, 25. Next, in the breaking area A2, two unwanted parts 6, 6 are pressed in from the surface side to the back side using two pressing rods 27, 27, and the two breaking rods 26, 26 are brought into contact with the eared glass plate 5. As a result, the periphery of each of the two scribing lines 23, 23 is bent so that the surface side becomes convex with each breaking rod 26 as a fulcrum, and the eared glass plate 5 is broken along the two scribing lines 23, 23. Furthermore, the two unwanted parts 6, 6 are broken off from the eared glass plate 5 and removed. The glass powder generated by the breaking is attracted and recovered by the suction ports of the two second dust collectors.

[0115] Figure 2 The inspection device 12 shown is capable of performing the inspection process P3 and the quality judgment process P4 independently.

[0116] The inspection device 12 includes a line sensor camera 30. In this embodiment, the line sensor camera 30 is positioned at a fixed location, and the glass plate 3 is transported longitudinally by the transport mechanism 31 to scan the main surface 3a (surface and back surface) of the glass plate 3. It should be noted that, as a variation of this embodiment, the main surface 3a of the glass plate 3 can also be scanned by moving the inspection device 12 relative to the glass plate 3, which is supported longitudinally at a fixed position relative to the transport mechanism 31. The transport mechanism 31 includes multiple grippers 32 that can move along the X-direction while respectively gripping the upper and lower ends of the glass plate 3. Each gripper 32 functions as a support member supporting the upper or lower end of the glass plate 3. It should be noted that, as a variation of this embodiment, the upper or lower end of the glass plate 3 can also be supported by an adsorption pad or the like.

[0117] The inspection device 12, accompanied by scanning by the line sensor camera 30, can detect defects simultaneously by identifying the type of defects (surface defects 4 or internal defects 9) contained in the glass plate 3 and determining the location of defects on the main surface 3a of the glass plate 3. Figure 3In the inspection device 12, triangles are used to represent surface defects 4 (attachments and damage), and × marks are used to represent internal defects 9 (foreign objects and bubbles). Furthermore, the inspection device 12 can also identify whether internal defects 9 are foreign objects or bubbles. Foreign objects include, for example, unmelted material from the glass raw material that becomes the raw material for molten glass 1, precipitated crystals, etc. Bubbles include, for example, air mixed in during the manufacturing process of glass plate 3, volatile glass raw material, etc. Damage, which is a surface defect 4, is damage caused to the main surface 3a during the manufacturing process of glass plate 3. Attachments, which are surface defects 4, include glass powder, dust, dirt, etc. The specific mechanism for the inspection device 12 to identify the type of defect and determine the location of the defect will be described later.

[0118] In addition to the line sensor camera 30 described above, the inspection device 12 also includes a setting mechanism for setting process P3a, a specifying mechanism for specifying process P3b, and a notification mechanism for notifying process P3c. For example, the setting mechanism and specifying mechanism could be an operation panel, operation buttons, etc., for setting the inspection area 3x and specifying the reference size 3s. For example, the notification mechanism could be an alarm that emits an alarm sound to notify the control device 8 (the operator of the control device 8), which will be described later. Alternatively, it could be a line, cable, etc., that transmits a signal to notify the control device 8, which will be described later.

[0119] In inspection process P3 using inspection device 12, firstly, along with the execution of setting process P3a and specified process P3b, the setting mechanism is used to set the... Figure 3 The inspection area is a rectangle of 3x, indicated by a double-dotted line, and is specified using a prescribed mechanism. Figure 3 The reference dimension 3s is shown by a quadrilateral with an applied diagonal line.

[0120] In this embodiment, only the effective surface 3b of the glass plate 3 is designated as the inspection area 3x. However, this is not a limitation; the inspection area 3x can be larger than the effective surface 3b. But to prevent the clamp 32 from being mistakenly detected as surface defect 4 or internal defect 9, it is preferable to designate the inspection area 3x such that it is positioned below the clamp 32 holding the upper end of the glass plate 3 and above the clamp 32 holding the lower end. The reference size 3s can be, for example, set to 500mm square (500mm × 500mm), 250mm square (250mm × 250mm), etc.

[0121] When setting up process P3a and specifying process P3b, the aforementioned threshold values ​​are also set in conjunction with processes P3a and P3b. The threshold value is set as the maximum allowable number of surface defects 4 present per reference dimension 3s within the inspection area 3x. For example, the threshold value is set to 10 per 500mm square, 10 per 250mm square, and so on.

[0122] After setting the process P3a, specifying the process P3b, and setting the threshold, the main surface 3a of the glass plate 3 is scanned using the line sensor camera 30. If the scanning result shows that the number of surface defects 4 per reference dimension 3s at any location within the inspection area 3x exceeds the threshold, a notification process P3c is executed to notify the control device 8, which will be described later. On the other hand, if the number of surface defects 4 per reference dimension 3s at any location within the inspection area 3x is below the threshold, the notification process P3c is not executed.

[0123] In the quality judgment process P4 using the inspection device 12, firstly, the main surface 3a of the glass plate 3 is scanned by the line sensor camera 30, thereby performing the internal defect detection process P4a. Then, by performing the pass / fail judgment process P4b, it is determined whether there are internal defects 9 exceeding the allowable range in quantity and size within the inspection area 3x (effective surface 3b). If there are no internal defects 9 exceeding the allowable range in quantity and size, the glass plate 3 is judged to be of acceptable quality; if there are internal defects 9 exceeding the allowable range in quantity and size, the glass plate 3 is judged to be of unacceptable quality.

[0124] In the waste disposal process P5, where defective glass plates 3 are discarded, as an example, the defective glass plates 3 are discarded by falling from the upper layer, which is equipped with the second cutting device 17 and the inspection device 12, toward the lower layer where the waste area is set.

[0125] Figure 2 The control device 8 shown can change the conditions of (A) to (D) in the first cutting device 16 and the conditions of (E) to (H) in the second cutting device 17.

[0126] The control device 8 includes a display device 33 (e.g., a monitor). When the notification process P3c is performed in the inspection process P3, the display device 33 displays the meaning of the notification received by the control device 8 (e.g., an alarm sound). This display includes a distribution map of surface defects 4 within the inspection area 3x (within the effective surface 3b) of the glass plate 3. The distribution map allows the identification of concentrated areas of surface defects 4 within the inspection area 3x. These concentrated areas are those where the number of surface defects 4 present per reference dimension 3s exceeds a threshold. Furthermore, by operating the control device 8 after verifying the distribution map, the operator can change the conditions (A) to (H) using the control device 8. Alternatively, the control device 8 can automatically change the conditions (A) to (H) upon receiving a notification, without relying on the operator.

[0127] Here, an example is given of a scheme in which the conditions (A) to (H) are changed using the control device 8. As a first example, based on the distribution diagram displayed on the display device 33, it is determined that surface defects 4 are concentrated near the upper and lower edges of the effective surface 3b of the glass plate 3. In this case, it indicates that a defect has occurred in the first cutting process P2a. Therefore, at least one of the conditions (A) to (D) is changed using the control device 8. It should be noted that, in addition to changing at least one of the conditions (A) to (D) using the control device 8, the scribing wheel 19 may also be replaced, or the scribing wheel 19 may be replaced instead of changing at least one of the conditions (A) to (D) using the control device 8.

[0128] Next, as a second example, based on the distribution diagram displayed on the display device 33, it is determined that surface defects 4 are concentrated near the two sides (the two sides extending along the Y direction) of the effective surface 3b of the glass plate 3. In this case, it indicates that a defect has occurred in the second cutting process P2b. Therefore, at least one of the conditions (E) to (H) is changed using the control device 8. It should be noted that, in addition to changing at least one of the conditions (E) to (H) using the control device 8, it is also possible to replace both scribing wheels 25, 25, or replace both scribing wheels 25, 25 instead of changing at least one of the conditions (E) to (H) using the control device 8.

[0129] The loading device is a device that continuously loads the glass plates 3 determined to be qualified in the quality determination process P4 (the pass / fail determination process P4b) onto a tray. The loading device loads multiple glass plates 3 onto the tray. The tray loaded with multiple glass plates is bundled to form a glass bundle. After that, when storing multiple glass plates 3 in the state of the glass bundle, the storage process P6 is executed, and when transporting without storage, the transportation process P7 is executed. It should be noted that as a modification example of the present embodiment, the transportation process P7 may be executed after the storage process P6, or the storage process P6 may be executed after the transportation process P7. It should be noted that in the present embodiment, before the storage process P6 and the transportation process P7 are executed after the cutting process P2, the inspection process P3 is executed. Thus, it is possible to grasp the defective conditions generated in the cutting process P2 as early as possible and take appropriate measures.

[0130] The cleaning device is a device that continuously cleans multiple glass plates 3 taken out from the glass bundle that has undergone the storage process P6 or the transportation process P7. The cleaning device can supply cleaning liquid to the glass plates 3 and clean the main surfaces 3a of the glass plates 3 with a rotating brush. In the cleaning process P8 using the cleaning device, as the glass plates 3 are cleaned, the attachments on the main surfaces 3a of the glass plates 3 are removed as much as possible.

[0131] It should be noted that sometimes a end face processing process (grinding process, polishing process) for processing the end faces of multiple glass plates 3 is executed after the execution of the storage process P6 or the transportation process P7 and before the execution of the cleaning process P8.

[0132] Hereinafter, a mechanism for identifying the types of defects and determining the positions of defects in the inspection device 12 will be described.

[0133] As Figure 4 shown, the inspection device 12 includes a first imaging system 34, a second imaging system 35, and an identification mechanism 36. These are the components of the above-mentioned line sensor camera 30.

[0134] The first imaging system 34 has: a first light source 37; a first imaging unit 38 that images the first transmitted light L (1) that is irradiated from the first light source 37 and transmitted through the glass plate 3; and a light shielding plate 39 that serves as a shielding member that shields a part (for example, half) of the first transmitted light L (1) to form a bright part and a dark part in the field of view of the first imaging unit 38. Here, when transmitted light is used as the measurement light imaged by the first imaging unit 38 and the second imaging unit 40 described later, the term "transmitted light" also includes scattered light.

[0135] A first light source 37 is disposed on the surface side of the glass plate 3, and a first imaging unit 38 is disposed on the back side of the glass plate 3. The optical axis of the first light source 37 extends in such a way that the light is incident approximately perpendicularly to the surface of the glass plate 3. The optical axis of the first imaging unit 38 is aligned with the optical axis of the first light source 37, so that the first transmitted light L1 can be substantially supplemented by the first imaging unit 38. Thus, for the first imaging unit 38, if there is no obstruction plate 39, it is in a state of photographing the first transmitted light L1 in bright field of view; however, in reality, a portion of the first transmitted light L1 is blocked by the obstruction plate 39, so it is in a state of photographing the first transmitted light L1 in half bright field of view.

[0136] On the other hand, the second imaging system 35 includes a second light source 41, a third light source 42, and a second imaging unit 40. The second imaging unit 40 captures second transmitted light L2, which is emitted from the second light source 41 and passes through the glass plate 3, in the bright field, and captures third transmitted light L3, which is emitted from the third light source 42 and passes through the glass plate 3, in the dark field.

[0137] The second light source 41 is disposed on the surface side of the glass plate 3, and the second imaging unit 40 is disposed on the back side of the glass plate 3. The optical axis of the second light source 41 extends in such a way that the light is incident approximately perpendicularly to the surface of the glass plate 3. The light-receiving portion of the second imaging unit 40 is located on the optical path of the second transmitted light L2, which is separated by the beam splitter 43 described later, so that the second transmitted light L2 can be substantially supplemented by the second imaging unit 40. Thus, the second imaging unit 40 is in a state of imaging the second transmitted light L2 in a bright field of view.

[0138] The third light source 42 is disposed on the surface side of the glass plate 3. The optical axis of the third light source 42 extends such that the light is incident obliquely relative to the surface of the glass plate 3. In this embodiment, a pair of third light sources 42 are provided. The light-receiving portion of the second imaging unit 40 is disposed in a manner detached from the optical axis of the third light source 42, so as to substantially prevent the third transmitted light L3 from entering the second imaging unit 40. Thus, the second imaging unit 40 is in a state of imaging the third transmitted light L3 in a dark field. The third transmitted light L3 is only received by the second imaging unit 40 under specific conditions, such as when the glass plate 3 causes scattering. It should be noted that, in Figure 4 The tilt angle of the third transmitted light L3 is exaggerated, but the third transmitted light L3 is also basically incident on the beam splitter 43 described later.

[0139] In the second imaging unit 40, the light obtained by combining the second transmitted light L2 and the third transmitted light L3 is captured.

[0140] In this embodiment, such as Figure 4 as well as Figure 5As shown, the first light source 37, the second light source 41, and the third light source 42 are assembled into a single light source unit 44. Thus, the first light source 37, the second light source 41, and the third light source 42 are arranged close together, and the first transmitted light L1, the second transmitted light L2, and the third transmitted light L3 pass through substantially the same location on the glass plate 3. In this embodiment, the light source unit 44 simultaneously illuminates the first light source 37, the second light source 41, and the third light source 42. It should be noted that the light source unit 44 can also illuminate and extinguish the first light source 37, the second light source 41, and the third light source 42 at different times.

[0141] like Figure 4 As shown, beam splitters 43 are arranged on the optical axis of the first imaging unit 38 and the optical axis of the second imaging unit 40. A baffle plate 39 is disposed between the beam splitter 43 and the first imaging unit 38. The beam splitter 43 separates the transmitted light irradiated from the light source unit 44 and transmitted through the glass plate 3 into two components: a first component containing first transmitted light L1 and a second component containing second transmitted light L2 and third transmitted light L3. Specifically, the beam splitter 43 is a beam splitter that transmits a specific wavelength and reflects other wavelengths. Furthermore, the first light source 37 uses, for example, a blue LED, and the second light source 41 and the third light source 42 use LEDs of a different color than the first light source 37, such as red LEDs. Thus, the beam splitter 43 separates the light into two colors: the first transmitted light L1 from the first light source 37 and the second transmitted light L2 and the third transmitted light L3 from the second light source 41 and the third light source 42. In the example shown, the first component containing the first transmitted light L1 is captured by the first imaging unit 38 through the beam splitter 43, and the second component containing the second transmitted light L2 and the third transmitted light L3 is reflected by the beam splitter 43 and captured by the second imaging unit 40. It should be noted that the first light source 37, the second light source 41, and the third light source 42 are not limited to LEDs, and may also be metal halide lamps, laser light sources, etc.

[0142] Furthermore, although the illustration is omitted, multiple light source units 44 are arranged along the Y direction, forming a line light source. Similarly, multiple first imaging units 38 and second imaging units 40 are also arranged along the Y direction, forming a line camera. Thus, when the glass plate 3 is transported along the X direction, the inspection area 3x (effective surface 3b) of the glass plate 3 is inspected.

[0143] The identification mechanism 36 is connected to the first imaging unit 38 and the second imaging unit 40 via wired or wireless means, and is input with the imaging results captured by the two imaging units 38 and 40. The two imaging units 38 and 40 output an image composed of black and white information, where bright parts are set to white and dark parts to black. Here, "image" refers to a candidate defect in the glass plate 3. The identification mechanism 36 is, for example, composed of a PC CPU. Based on the shape, color, and presence or absence of the image itself in the image obtained by the first imaging system 34 and the image obtained by the second imaging system 35, the identification mechanism 36 identifies the type of defect in the glass plate 3 as surface defect 4 and internal defect 9. Although not shown in the figure, the identification mechanism 36 stores the identified type of defect in the glass plate 3 and its position on the main surface 3a in a storage mechanism (e.g., a PC memory).

[0144] <Second Implementation>

[0145] The following is for reference Figure 6 The second embodiment will be described. In the second embodiment, the notification process P3c included in the inspection process P3 is performed according to the following scheme.

[0146] In this embodiment, the region having the same area as the reference size 3s (in) Figure 6 The area shown by the quadrilateral with diagonal lines is designated as the scanning area 45. One of the four corners of the inspection area 3x is designated as the starting point SP, and the diagonal position opposite the starting point SP is designated as the ending point EP. While continuously moving the position of the scanning area 45 within the inspection area 3x, the number of surface defects 4 within the scanning area 45 is counted at each position. If the number of surface defects 4 present in the scanning area 45 at any position within the inspection area 3x exceeds a threshold, a notification process P3c is executed. It should be noted that the method for continuously moving the scanning area 45 may differ from this embodiment; for example, the trajectory of the continuously moving scanning area 45 may be vortex-shaped. Furthermore, the positions of the starting point SP and the ending point EP may also differ from this embodiment.

[0147] <Third Implementation Method>

[0148] The following is for reference Figure 7 The third embodiment will be described. In the third embodiment, the notification process P3c included in the inspection process P3 is performed according to the following scheme.

[0149] In this embodiment, once a surface defect 4 is detected within the inspection area 3x, the area centered on the surface defect 4 (in...) Figure 7The area shown by the quadrilateral with diagonal lines is designated as the scanning area 45. The scanning area 45 has the same area as the reference size 3s. The number of surface defects 4 present within the scanning area 45 is counted. The above process is repeated whenever a new surface defect 4 is detected within the inspection area 3x. If, at any point during the repetition, the number of surface defects 4 present within the scanning area 45 exceeds a threshold, a notification step P3c is executed. The order in which new surface defects 4 are detected within the inspection area 3x can be based on their position within the inspection area 3x or on the size of the surface defect 4.

[0150] <Other variations>

[0151] Here, variations of the above-described embodiments can also be applied.

[0152] In the above-described embodiments, when the notification process P3c is executed in inspection process P3, the conditions of (A) to (H) are changed using the control device 8, but this is not a limitation. Alternatively, based on the control device 8 controlling the attractive force drawn by the suction ports of the first and second dust collectors, when the notification process P3c is executed in inspection process P3, the attractive force drawn by the suction ports of the first and second dust collectors may be increased. Alternatively, based on the attractive force being variable at each position in the X direction of the suction port of the first dust collector and each position in the Y direction of the suction port of the second dust collector, the attractive force at the position corresponding to the concentration of surface defects 4 may be increased. Furthermore, based on the control device 8 controlling the air circulation volume in the glass plate 3 production line, when the notification process P3c is executed in inspection process P3, the air circulation volume may be increased. Furthermore, it is also possible to change the supply of cleaning fluid to the glass plate 3 and the angular velocity (circumferential velocity) of the rotating brush by increasing the amount of cleaning fluid supplied to the glass plate 3 and increasing the amount of cleaning fluid supplied to the glass plate 3, based on the control device 8 controlling the cleaning device and the notification process P3c being performed in the inspection process P3.

[0153] In the above embodiment, the glass plate 3 that was deemed unqualified in the quality judgment process P4 (pass / fail judgment process P4b) is discarded through the discarding process P5. However, it is not limited to this, and other methods may also be used as follows: Figure 8 As shown in the flowchart, if the notification process P3c is performed in the inspection process P3, the glass plate 3 is also discarded through the discard process P5.

Claims

1. A method for manufacturing a glass plate, comprising: The processing procedure involves using a processing device to perform a prescribed treatment on the glass plate; The process also includes an inspection step, in which the deposits on the main surface of the glass plate after the processing step, as well as any damage to the main surface, are inspected as surface defects. The inspection process includes: The process is set up, and an inspection area is set on the main surface; The specified process specifies the reference dimensions for the area below the inspection area; and In the notification process, if the number of surface defects existing at each reference size within the inspection area exceeds a threshold, a notification is sent to the control device controlling the processing apparatus. The method for manufacturing the glass plate is characterized in that, The method for manufacturing the glass plate also includes a cleaning step for cleaning the glass plate. The inspection process is performed before the cleaning process.

2. The method for manufacturing a glass plate according to claim 1, characterized in that, The control device that receives the notification through the notification process changes the processing conditions of the specified processing in the processing process.

3. The method for manufacturing a glass plate according to claim 1 or 2, characterized in that, The control device includes a display device. The display device displays the intention of receiving the notification.

4. The method for manufacturing a glass plate according to claim 1 or 2, characterized in that, In the inspection process, the upper end of the glass plate, which is positioned vertically, is supported by a support member. In the setting process, the inspection area is set on the main surface at a position lower than the position where the support member exists.

5. The method for manufacturing a glass plate according to claim 4, characterized in that, In the setting process, at least the entire area of ​​the effective surface of the glass plate is included in the inspection area.

6. The method for manufacturing a glass plate according to claim 5, characterized in that, The manufacturing method of the glass plate also includes a quality determination process for judging the quality of the glass plate. The quality assessment process includes: The internal defect detection process takes the effective surface of the glass plate as the object and detects foreign objects and bubbles existing inside the glass plate as internal defects; and The pass / fail determination process, based on the results of the internal defect detection process, determines whether the quality of the glass plate is qualified or not.

7. The method for manufacturing a glass plate according to claim 6, characterized in that, Both the inspection process and the quality judgment process are performed simultaneously using a single inspection device.

8. The method for manufacturing a glass plate according to claim 6, characterized in that, In the inspection process and the quality judgment process, a first imaging system and a second imaging system are used. The first imaging system includes a first light source, a first imaging part for capturing first transmitted light that is irradiated by the first light source and passes through the glass plate, and a blocking member for blocking a portion of the first transmitted light to form bright and dark areas within the field of view of the first imaging part. The second imaging system includes a second light source and a third light source, and a second imaging unit that simultaneously captures second transmitted light illuminating the glass plate from the second light source in the bright field and captures third transmitted light illuminating the glass plate from the third light source in the dark field. The surface defects and the internal defects are identified based on the images obtained by the first imaging system and the second imaging system.

9. The method for manufacturing a glass plate according to claim 1 or 2, characterized in that, The method for manufacturing the glass plate also includes a storage step for storing the glass plate or a conveying step for transporting the glass plate. The inspection process is performed before the storage process or the transport process.

10. The method for manufacturing a glass plate according to claim 1 or 2, characterized in that, The method for manufacturing the glass plate further includes a forming step of forming a glass ribbon from molten glass and a cutting step, which is a processing step, of cutting the glass plate from the glass ribbon. The inspection process is performed after the cutting process.

11. A glass plate manufacturing apparatus comprising: a processing device for performing a predetermined processing on the glass plate; and an inspection device for inspecting deposits on the main surface of the processed glass plate and damage to the main surface as surface defects. The inspection device has: A setting mechanism is provided, which sets an inspection area on the main surface; The designating body specifies the reference dimensions for the area below the inspection area; as well as The notification agency notifies the control device controlling the processing apparatus when the number of surface defects present at each reference size within the inspection area exceeds a threshold. The glass plate manufacturing apparatus is characterized in that, The glass plate manufacturing apparatus also includes a cleaning device for cleaning the glass plate. The inspection device is positioned on the production line upstream of the cleaning device.

Images