Information processing system, information processing method, and information processing program

Abstract

An information processing system, an information processing method, and an information processing program capable of grasping the state of defects between manufacturing processes are provided. The information processing system includes: an acquisition section (511) that acquires first feature point information related to feature points present in a first web and second feature point information related to feature points present in a second web obtained by performing a prescribed process on the first web; a classification section (513) that classifies the feature points present in the first web and the feature points present in the second web into: first feature points present in the first web and not present in the second web, second feature points not present in the first web and present in the second web, and third feature points present in both the first web and the second web, based on the acquired first feature point information and second feature point information; and a display control section (514) that causes at least either the feature points present in the first web and the feature points present in the second web, and at least any one of the first feature points, the second feature points, and the third feature points to be displayed on one screen.

Description

Technical Field

[0001] This invention relates to information processing systems, information processing methods, and information processing programs. Background Technology

[0002] Optical thin films are used on the display surfaces of liquid crystal display devices and the like. High quality is required for such optical thin film rolls. Therefore, strict management of defects generated in the roll material is necessary during the manufacturing process. For example, Patent Document 1 discloses a technique for detecting defects generated during the manufacturing of optical thin films.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2013-024868

[0004] In roll materials such as optical films that are manufactured through multiple processes, it is desirable to be able to monitor the status of defects between manufacturing processes. Summary of the Invention

[0005] The present invention was made in view of the above circumstances, and its object is to provide an information processing system, information processing method and information processing program that can grasp the status of defects between manufacturing processes.

[0006] The above-mentioned objectives of the present invention are achieved through the following solutions.

[0007] (1) An information processing system comprising: an acquisition unit for acquiring first feature point information related to feature points existing in a first roll and second feature point information related to feature points existing in a second roll obtained by performing a predetermined processing on the first roll; a classification unit for classifying the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll and not existing in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll, based on the acquired first feature point information and the second feature point information; and a display control unit for displaying at least one of the feature points existing in the first roll and the feature points existing in the second roll, and at least any one of the first type of feature point, the second type of feature point, and the third type of feature point on a screen.

[0008] (2) According to the information processing system described in (1) above, the information processing system further includes a position alignment unit, which establishes a correspondence between the specified feature points existing in the first roll and the specified feature points existing in the second roll based on their mutual positions, and the classification unit uses the correspondence result to classify the feature points existing in the first roll and the feature points existing in the second roll into a first type of feature point, a second type of feature point and a third type of feature point.

[0009] (3) According to the information processing system described in (1) above, on the above-mentioned screen, at least one of the feature points existing in the first roll and the feature points existing in the second roll, and a third feature point are displayed.

[0010] (4) According to the information processing system described in (3) above, on the above one screen, at least one of the feature points existing in the first inspection area of ​​the first roll and the feature points existing in the second inspection area of ​​the second roll, and a third feature point existing in the first inspection area or the second inspection area, wherein the second inspection area is the area in the second roll that corresponds to the first inspection area.

[0011] (5) According to the information processing system described in (4) above, the display control unit displays feature points existing in the first inspection area, feature points existing in the second inspection area, and third feature points existing in the first inspection area and the second inspection area on the screen, wherein the length and width of the first inspection area and the second inspection area are the same.

[0012] (6) According to the information processing system described in (1) above, the specified processing includes at least winding processing and unwinding processing.

[0013] (7) According to the information processing system described in (1) above, the information processing system further includes a first receiving unit, which receives the selection of a region of interest, wherein the region of interest is a part of an original image representing at least one of feature points existing in the first roll and feature points existing in the second roll, or a part of a classification image representing at least any one of a first feature point, a second feature point and a third feature point, and when the display control unit receives the selection of the region of interest, it causes the region of interest and the part of the original image or the classification image corresponding to the region of interest to be magnified or reduced in a coordinated manner.

[0014] (8) According to the information processing system described in (1) above, in the above one screen, at least one of the feature points existing in the first roll and the feature points existing in the second roll, and at least any one of the first feature point, the second feature point and the third feature point are displayed in an overlapping manner.

[0015] (9) According to the information processing system described in (1) above, in the above-mentioned one screen, at least one of the feature points existing in the first roll and the feature points existing in the second roll, and at least any one of the first feature point, the second feature point and the third feature point are displayed in an arranged manner.

[0016] (10) According to the information processing system described in (1) above, the display control unit causes the screen to display information related to the position and size of at least one of the feature points present in the first roll and the feature points present in the second roll, and information related to the position and size of at least any one of the first feature point, the second feature point and the third feature point.

[0017] (11) According to the information processing system described in (1) above, the information processing system further includes a second receiving unit that receives a switching instruction for displaying an image on the screen.

[0018] (12) According to the information processing system described in (1) above, the information processing system further includes a third receiving unit, which receives a non-display instruction for a feature point existing in the first roll, a feature point existing in the second roll, a first feature point, a second feature point, or a third feature point displayed on the screen.

[0019] (13) According to the information processing system described in (1) above, at least one of the length and width of the first roll and the second roll is different.

[0020] (14) An information processing system comprising: an acquisition unit for acquiring first feature point information related to feature points existing in a first roll and second feature point information related to feature points existing in a second roll obtained by performing a predetermined processing on the first roll; a classification unit for classifying, based on the acquired first feature point information and second feature point information, the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll but not in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll; and a display control unit for enabling the display unit to display, in a switchable manner, a screen displaying feature points existing in the first roll, a screen displaying feature points existing in the second roll, a screen displaying the first type of feature point, a screen displaying the second type of feature point, and a screen displaying the third type of feature point.

[0021] (15) An information processing method, comprising: acquiring first feature point information related to feature points existing in a first roll, and second feature point information related to feature points existing in a second roll obtained by performing a predetermined processing on the first roll; classifying the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll but not in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll; and displaying at least one of the feature points existing in the first roll and the feature points existing in the second roll, and at least any one of the first feature point, the second type of feature point, and the third type of feature point on a screen.

[0022] (16) An information processing method, comprising: acquiring first feature point information related to feature points existing in a first roll, and second feature point information related to feature points existing in a second roll obtained by performing a predetermined processing on the first roll; classifying the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll but not in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll based on the acquired first feature point information and the second feature point information; and causing a display unit to display, in a switchable manner, a screen displaying feature points existing in the first roll, a screen displaying feature points existing in the second roll, a screen displaying the first type of feature point, a screen displaying the second type of feature point, and a screen displaying the third type of feature point.

[0023] (17) An information processing program, wherein a computer is caused to perform the information processing method described in (15) or (16) above.

[0024] In the information processing system, information processing method, and information processing program involved in this invention, feature points existing in the first roll and feature points existing in the second roll are classified into first type feature points, second type feature points, and third type feature points. Furthermore, at least one of the feature points existing in the first roll and the feature points existing in the second roll, as well as at least any one of the first type, second type, and third type feature points, are displayed on a single screen. Therefore, roll manufacturing managers can easily grasp the disappearance of feature points, the generation of feature points, and the remaining feature points when manufacturing the second roll from the first roll. Thus, the status of defects can be grasped between manufacturing processes. Attached Figure Description

[0025] The advantages and features provided by one or more embodiments of the present invention will be more fully understood through the following detailed description and accompanying drawings, but these are for illustrative purposes only and are not intended to limit the invention.

[0026] Figure 1 This is a schematic diagram illustrating an application example of the information processing system according to the first embodiment.

[0027] Figure 2 It means Figure 1 A block diagram showing the schematic structure of the terminal device.

[0028] Figure 3 It is used to explain the existence of Figure 1The table shows the classification of feature points in the first and second rolls, respectively.

[0029] Figure 4 It means Figure 1 The diagram shows a schematic outline of the information processing system.

[0030] Figure 5A yes Figure 4 The example shown is a list of users stored in the storage section.

[0031] Figure 5B yes Figure 4 The example shown is a list of batches stored in the storage section.

[0032] Figure 6A yes Figure 4 The image shows an example of a database (DB) containing inspection data stored in the storage section.

[0033] Figure 6B yes Figure 4 Other examples of inspection data DBs stored in the storage section are shown.

[0034] Figure 6C yes Figure 4 Other examples of inspection data DBs stored in the storage section are shown.

[0035] Figure 7 It means Figure 6B The flowchart shown illustrates the generation and processing of the first inspection data.

[0036] Figure 8A It means Figure 1 A schematic diagram of an example of the structure of the inspection device shown.

[0037] Figure 8B It means Figure 8A Other schematic diagrams of the structure of the inspection device shown.

[0038] Figure 8C It means Figure 8A A schematic diagram of other structures of the inspection device shown.

[0039] Figure 9 It means Figure 6C The flowchart shown illustrates the generation and processing of the second inspection data.

[0040] Figure 10 It means by Figure 4 The figure shows an example of the determination results of feature points obtained by the classification department.

[0041] Figure 11 It means by Figure 4 The diagram shows an example of a screen displayed by the display control unit.

[0042] Figure 12 It means by Figure 4 The diagram shows other examples of screens displayed by the display control unit.

[0043] Figure 13 It means Figure 11 The flowchart shows the generation process of the screen shown.

[0044] Figure 14 It is used for explanation Figure 13 The diagram shows steps S32, S33, and S34.

[0045] Figure 15 yes Figure 13 The flowchart of the subroutine for step S34 is shown.

[0046] Figure 16 This is a flowchart of the subroutine executed by the information processing system involved in the second embodiment.

[0047] Figure 17 It means through Figure 16 The figure shows an example of the probability density function calculated from the kernel density estimation.

[0048] Figure 18 This is a schematic diagram illustrating an application example of the information processing system involved in the third embodiment.

[0049] Figure 19 It means Figure 18 A table showing details of each of the various inspection devices.

[0050] Figure 20 It means from Figure 19 The table shows an example of the first and second inspection data selected from the inspection data.

[0051] Figure 21 It means Figure 1 A schematic diagram of an example of the first roll material manufacturing apparatus shown.

[0052] Figure 22 yes Figure 21 An enlarged schematic diagram of the area surrounding the winding device.

[0053] Figure 23 It means Figure 1 A schematic diagram of an example of a second roll material manufacturing apparatus. Detailed Implementation

[0054] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. However, the scope of the present invention is not limited to the disclosed embodiments. Furthermore, in the description of the drawings, the same reference numerals are used for the same elements, and repeated descriptions are omitted. Additionally, the dimensions of the drawings are sometimes exaggerated for ease of explanation and differ from the actual proportions.

[0055] <First Implementation>

[0056] Figure 1 This is a schematic diagram illustrating an application example of the information processing system 50 according to the first embodiment. The information processing system 50 is, for example, composed of a server. This information processing system 50 communicates with terminal devices 70A at factory A and 70B at factory B via a network. The network is a data communication network or similar communication line. In some networks, wired LANs or wireless LANs may also be used. A wireless LAN is, for example, a LAN conforming to the IEEE 802.11 standard. The information processing system 50 may also connect to multiple factories via the network. These multiple factories include, for example, factory C and factory N.

[0057] [Structure of terminal devices 70A and 70B]

[0058] Terminal devices 70A and 70B are, for example, computers such as PCs, smartphones, and tablets. PC is an abbreviation for Personal Computer. Terminal devices 70A and 70B are configured to connect to information processing system 50, and each of terminal devices 70A and 70B sends and receives various types of information with information processing system 50. Terminal devices 70A and 70B are, for example, PCs used by employees of a manufacturing company operating factories A and B. Factories A and B are, for example, operated by a single manufacturer.

[0059] Figure 2 This is a block diagram showing the general structure of terminal devices 70A and 70B. Each terminal device 70A and 70B has a CPU 71, ROM 72, RAM 73, memory 74, communication interface 75, display unit 76, and operation receiving unit 77. All components are communicatively connected to each other via a bus 78. CPU is an abbreviation for Central Processing Unit. ROM is an abbreviation for Read-Only Memory. RAM is an abbreviation for Random Access Memory.

[0060] CPU 71 performs control and various arithmetic operations on the above-mentioned structures according to the program recorded in ROM 72 or memory 74.

[0061] ROM72 stores various programs and data.

[0062] RAM73 is used as temporary storage for programs and data in the working area.

[0063] The memory 74 stores various programs and data, including those of the operating system. For example, an application program for displaying various information sent from the information processing system 50 is installed in the memory 74.

[0064] The communication interface 75 is an interface used for communicating with other devices. As the communication interface 75, various communication interfaces based on wired or wireless standards are used. The communication interface 75 is used, for example, when sending the first feature point information and the second feature point information (described later) to the information processing system 50, and when receiving the screen data (described later) from the information processing system 50.

[0065] The display unit 76 may include, for example, a liquid crystal display or an organic EL display, to display various information. The display unit 76 may also be composed of browser software or a printer.

[0066] The operation receiving unit 77 includes a touch sensor, a pointing device such as a mouse, or a keyboard, and accepts various operations from the user. Alternatively, the display unit 160 and the operation receiving unit 77 can be combined to form a touch panel by overlapping the touch sensor, which serves as the operation receiving unit 77, on the display surface of the display unit 76.

[0067] [Factory A, Factory B]

[0068] like Figure 1 As shown, a first roll material manufacturing apparatus 1000 is provided in factory A. A first manufacturing process for manufacturing a first roll material 80A is performed in factory A. The surface of the first roll material 80A is inspected by an inspection device 90A. The inspection device 90A includes, for example, a camera. The first roll material 80A is, for example, a raw film. The width of the first roll material 80A is, for example, in the range of 1000 mm to 5000 mm. Considering quality and operation, the thickness of the first roll material 80A is set to be in the range of 15 μm to 500 μm. When the first roll material 80A contains metal such as steel, the thickness of the first roll material 80A can also be 1 mm or more. The first roll material 80A is manufactured in factory A, for example. The length of the first roll material 80A is, for example, in the range of 2000 m to 10000 m. The first roll material 80A is wound in factory A, for example.

[0069] A second roll material manufacturing apparatus 2000 is provided at factory B. At factory B, a second roll material 80B is manufactured using a first roll material 80A transported from factory A. That is, a second manufacturing process for manufacturing the second roll material 80B is performed at factory B. At factory B, the second roll material 80B is manufactured by performing a prescribed treatment on the first roll material 80A. The prescribed treatment includes, for example, winding, unwinding, stretching, slitting, surface finishing, coating, laminating, cleaning, and drying. The prescribed treatment is the process from the inspection of the first roll material 80A until the inspection of the second roll material 80B, and can also be performed at factory A. The prescribed treatment may also include, for example, winding. The prescribed treatment includes, for example, at least winding and unwinding. For example, at factory B, after unwinding the first roll material 80A in its wound state, a coating process is performed to impart a functional layer to the surface of the first roll material 80A. Thus, the second roll material 80B is manufactured from the first roll material 80A. At least one of the length and width of the first roll material 80A and the second roll material 80B is different. The difference in at least one of their length and width includes the following situations: after a portion of the first roll 80A is cut off, it is stretched so that the length and width of the first roll 80A and the second roll 80B become the same in appearance. The thickness of the first roll 80A and the second roll 80B may also be different. The surface of the second roll 80B is inspected by an inspection device 90B. The inspection device 90B includes, for example, a camera. In addition to factory B, the first roll 80A may also be transported to factory C and factory N, etc. At least one of the first roll 80A and the second roll 80B is, for example, a resin film.

[0070] In the first manufacturing process at factory A, first inspection data for the first roll 80A is generated through optical inspection performed by inspection device 90A. This first inspection data includes first feature point information related to feature points present in the first roll 80A.

[0071] In the second manufacturing process at factory B, second inspection data for the second roll 80B is generated through optical inspection performed by inspection device 90B. This second inspection data includes second feature point information related to feature points present in the second roll 80B.

[0072] Here, the feature points present in the first roll 80A and the second roll 80B respectively refer to optical feature points present in the roll, specifically, spots that have optical differences from their surroundings. Furthermore, when determining optical differences from their surroundings, a predetermined threshold can be set, and spots exceeding this threshold can be considered feature points. Feature points present in the roll are sometimes also referred to as defects, flaws, or faults of the roll. Feature points include, for example, defects caused by poor adhesion when bonding multiple rolls, and defects caused by uneven axial distribution. Bonding multiple rolls may be done, for example, using ultrasonic welding. For example, dozens to hundreds of feature points can be detected from image data obtained by photographing one first roll 80A or second roll 80B. The total length of the first roll 80A or second roll 80B is, for example, several kilometers. Alternatively, multiple defects, flaws, and faults within a defined area can be considered as a single feature point. The defined area is, for example, a 10mm square area.

[0073] For example, the terminal device 70A generates first feature point information by performing image analysis on the image data of the first roll 80A captured by the inspection device 90A. Alternatively, the inspection device 90A may also generate the first feature point information.

[0074] For example, the terminal device 70B generates second feature point information by performing image analysis on the image data of the second roll 80B captured by the inspection device 90B. Alternatively, the inspection device 90B may also generate the second feature point information.

[0075] Image analysis can be performed using known techniques. Specifically, pixels whose values ​​deviate from the surrounding average by a specified amount are extracted as feature points. Alternatively, the methods described later can also be used to extract feature points.

[0076] The first feature point information includes, for example, information related to the position, size, shape, brightness, and defect severity of multiple feature points present in the first roll 80A. The second feature point information includes, for example, information related to the position, size, shape, brightness, and defect severity of multiple feature points present in the second roll 80B. The position of the feature points can be represented using XY coordinates, for example. Neighboring feature points can also be clustered within the first and second feature point information.

[0077] Terminal device 70A of factory A, for example, sends first inspection data containing the first feature point information to information processing system 50. Terminal device 70B of factory B, for example, sends second inspection data containing the second feature point information to information processing system 50.

[0078] Information processing system 50, for example, classifies feature points existing in first roll 80A and second roll 80B into three types: first feature points, second feature points, and third feature points, based on first inspection data and second inspection data received from terminal devices 70A and 70B.

[0079] Figure 3 This is a table used to describe the first to third type of feature points. Multiple feature points present in the first roll 80A can be classified as, for example, the first type of feature point and the third type of feature point. Multiple feature points present in the second roll 80B can be classified as, for example, the second type of feature point and the third type of feature point.

[0080] The first type of feature point is a feature point that exists only in the first roll 80A and not in the second roll 80B. That is, the first type of feature point is a feature point that disappears during the second manufacturing process. This first type of feature point is a feature point that, even if it exists in the first roll 80A, has a low probability of affecting the second manufacturing process and subsequent processes. Furthermore, in this specification, the term "feature point not existing in the roll or disappearing" does not necessarily mean that it has completely disappeared; rather, it also includes the concept of feature points that, although present as feature points, have a low probability of causing problems as defects.

[0081] The second type of feature point is a feature point that does not exist in the first roll 80A but exists in the second roll 80B. That is, the second type of feature point is a feature point newly generated in the second manufacturing process. This second type of feature point is a feature point caused by the second manufacturing process.

[0082] The third type of feature point exists in both the first roll 80A and the second roll 80B. That is, the third type of feature point is one that is generated in the first manufacturing process and remains in the second manufacturing process. This third type of feature point is highly likely to affect the second manufacturing process and subsequent processes. Furthermore, due to the second manufacturing process, the shape and size of the third type of feature point may sometimes change compared to when it exists in the first roll 80A. Depending on the manufacturing process, additional defects may occur. For example, in the second manufacturing process of extending the first roll 80A, bubbles called cavities may be generated around a small foreign object from the first manufacturing process.

[0083] The information processing system 50 classifies the feature points existing in the first roll 80A and the second roll 80B into a first type of feature point, a second type of feature point, and a third type of feature point, and stores them.

[0084] [Structure of Information Processing System 50]

[0085] Figure 4This is a block diagram showing the general structure of the information processing system 50. The information processing system 50 includes, for example, a control unit 51, a storage unit 52, and a communication unit 53.

[0086] The control unit 51 includes, for example, a CPU, and memories such as RAM and ROM. The CPU is composed of a multi-core processor that executes control and various arithmetic operations of the aforementioned units according to a program. The various functions of the information processing system 50 are performed by the CPU executing its corresponding program. The specific functions of the control unit 51 will be described later.

[0087] Storage unit 52 is a large-capacity auxiliary storage device that stores various programs, including the operating system, and various types of data. The storage medium may be a hard disk, solid-state drive, flash memory, or ROM. Storage unit 52 may store, for example, user lists, batch lists, and inspection data databases. For example, the user lists and batch lists are managed by the manager of factory A. The manager of factory A may be, for example, an employee of the manufacturer operating factory A.

[0088] Figure 5A An example of a user list is shown. The user list may include information such as each user's user ID, username, and contact address. Access permissions to the database (DB) can also be set for each user; for example, each user may be able to access various data related to a specified first volume 80A.

[0089] Figure 5B An example of a batch list is shown. The batch list contains information such as batch ID, product name, delivery location user ID, manufacturing conditions, dimensions, and manufacturing date for each batch.

[0090] Figures 6A-6C Each example of an inspection data database is shown. An inspection data database may contain, for example, a list of processes in each of factories A and B, inspection data for each inspection performed in each of factories A and B, and feature point classification data, etc.

[0091] Figure 6A An example of a process list is shown. The process list contains information related to the batch ID, the width and length of the roll material in each process, the process name, the elongation of the roll material, the number of layers in the roll material, the orientation of the short side, and the orientation of the long side. The process list further includes, for example, information related to each inspection performed in factories A and B. Information related to each inspection includes, for example, the inspection ID of each inspection, the inspection device ID of the inspection device used in each inspection, the inspection data, and the inspection date and time. Information related to the orientation of the short side and the long side of the roll material is indicated, for example, by whether the orientation of the short side and the long side of the roll material is the same as or reversed from that of the roll material in the previous process.

[0092] Figure 6B as well as Figure 6C Each example shows an inspection data set for each inspection included in the process list. Figure 6B An example of inspection data with inspection ID i0101 is shown. This inspection data, for example, is the first inspection data of the first roll 80A, containing first feature point information. Figure 6C An example of inspection data with inspection ID i0102 is shown. This inspection data, for example, is the second inspection data of the second roll 80B, containing second feature point information. Both the first and second inspection data contain, for example, information related to the feature point ID, position, area, length, width, maximum brightness, minimum brightness, differentiation, and presence or absence of clustered dots for each of the multiple feature points present in the first roll 80A or the second roll 80B.

[0093] The location of the feature point is represented, for example, by XY coordinates based on a predetermined position of the first roll 80A or the second roll 80B. The X coordinate is, for example, the coordinate in the width direction of the first roll 80A or the second roll 80B, and can be in the range of 0 to 3000 mm. The Y coordinate is, for example, the coordinate in the long side direction of the first roll 80A or the second roll 80B, and can be in the range of 0 to 10000 mm.

[0094] The distinction of feature points can be represented by factors such as their shape and brightness distribution. Each feature point can be classified into approximately 5 to 20 categories based on its shape and brightness distribution. The presence or absence of clustered points indicates, for example, whether multiple feature points exist around a given feature point.

[0095] The communication section 53 is an interface for network connection with external devices such as terminal devices 70A and 70B.

[0096] [Inspect the generation and processing of the database]

[0097] Here, an example of a method for generating inspection data DB by information processing system 50 is described. For example, first inspection data is generated by terminal device 70A and inspection device 90A, and second inspection data is generated by terminal device 70B and inspection device 90B.

[0098] Figure 7 This is a flowchart illustrating an example of a method for generating the first inspection data.

[0099] (Step S11)

[0100] The terminal device 70A, for example, instructs the first roll manufacturing device 1000 to manufacture a first roll 80A. For example, at this time, the first roll 80A is manufactured in roll form according to the shipping specification z.

[0101] (Step S12)

[0102] Next, the terminal device 70A causes the inspection device 90A to acquire image data.

[0103] The inspection device 90A is either a transmissive or reflective inspection device. A transmissive inspection device 90A illuminates the first roll 80A with light and receives the light that has passed through the first roll 80A. This allows it to detect feature points present in the first roll 80A. A reflective inspection device 90A illuminates the first roll 80A with light and receives the light reflected from the first roll 80A. This also allows it to detect feature points present in the first roll 80A. Both the transmissive and reflective inspection devices include bright-field and dark-field inspection devices, respectively.

[0104] Figure 8A as well as Figure 8B An example of the structure of a reflective inspection device 90A is shown. Figure 8A The structure of the inspection device 90A is shown when viewed from the width direction of the first roll 80A. Figure 8B The structure of the inspection device 90A as viewed from the transport direction of the first roll 80A is shown. The inspection device 90A includes, for example, a light source 91, a camera 92, a resolution unit 93, and a storage unit 94.

[0105] In the inspection apparatus 90A, camera 92 captures images of the surface of the first roll 80A, thereby generating image data. The number of cameras 92, the field of view, and the distance to the surface of the first roll 80A are appropriately set to capture the entire area of ​​the first roll 80A in its width direction. Figure 8B The image shows an inspection device 90A with two cameras 92 in the width direction.

[0106] Light source 91 illuminates the inspection area of ​​the first roll 80A. Light source 91 illuminates the first roll 80A uniformly along its width. Here, uniform illumination means that the illuminance of the illuminated light is approximately the same.

[0107] Camera 92 is an optical sensor that optically reads the inspection area of ​​the first roll 80A. Camera 92 includes imaging elements such as a CCD and a CMOS sensor, as well as a lens. CCD is an abbreviation for Charge Coupled Device. CMOS is an abbreviation for Complementary Metal Oxide Semiconductor. Camera 92 generates two-dimensional image data based on the output signals of each imaging element. Camera 92 detects diffuse light in the light emitted by the light source 91 and reflected from the surface of the first roll 80A. Camera 92 can be a color camera or a monochrome camera. Camera 92 can be a camera that detects light in the visible light region or a camera that detects light in the infrared region.

[0108] Camera 92, for example, is capable of reading the entire width direction of the first roll 80A at once. The contrast of the image data captured by camera 92 is expected to be above a predetermined value. In other words, the illuminated area and unilluminated area of ​​the light source 91 in the first roll 80A are expected to have a contrast value above a predetermined value. To generate image data with a contrast value above a predetermined value, it is desirable to use a powerful light source 91 with high linearity.

[0109] Here, "powerful" means, for example, that when the illuminance at an illumination distance of 50mm is set to E50, the illuminance E50 is 50,000 lx or more. Furthermore, "high direct penetration" means, for example, that when the illuminance at an illumination distance of 50mm is set to E50 and the illuminance at an illumination distance of 100mm is set to E100, (E50 - E100) / E50 < 0.5.

[0110] Camera 92 is configured, for example, to receive orthogonal reflected light from light source 91. Camera 92 may also be configured to avoid orthogonal reflected light from light source 91, i.e., to receive diffused light at the first roll 80A.

[0111] The analysis unit 93 comprises a CPU and RAM, etc. The analysis unit 93 reads various processing programs stored in the storage unit 94 and expands them in RAM, performing various processing tasks in cooperation with these programs. The analysis unit 93 processes image data captured by the camera 92 to detect feature points present in the first roll 80A. For example, after performing prescribed image processing on the image data, the analysis unit 93 detects feature points and performs quantitative evaluation on each detected feature point.

[0112] The analysis unit 93 can, for example, combine multiple images obtained by continuous shooting from a single camera 92. The analysis unit 93 can, for example, generate an image of the entire surface of the first roll 80A and store it in the storage unit 94. Alternatively, the analysis unit 93 can generate multiple image data corresponding to the shooting time and store them in the storage unit 94. The analysis unit 93 can also combine multiple image data obtained by multiple cameras 92 arranged along the width direction. The analysis unit 93 can, for example, determine the position of the first roll 80A along its long side by referring to the stored transport speed and based on the shooting time. Hereinafter, the analysis unit 93 will be described as generating multiple image data corresponding to the shooting time and storing them in the storage unit 94.

[0113] The storage unit 94 is composed of HDDs and SSDs, etc. SSD is an abbreviation for Solid State Drive. The storage unit 94 stores various processing programs and the data required to execute those programs. For example, the storage unit 94 stores image data captured by the camera 92 in association with the time of capture. The storage unit 94 stores, for example, manufacturing conditions such as the winding speed in the first roll material manufacturing apparatus 1000. The manufacturing conditions in the first manufacturing process may also be included in the process list for checking the DB.

[0114] Figure 8C An example of a transmissive inspection device 90A is shown. In this inspection device 90A, a light source 91 is positioned opposite a camera 92, separated by a first roll of material 80A.

[0115] The inspection device 90A may also have multiple inspection sections. For example, the camera 92 may include a camera for detecting scratches on the surface of the first roll 80A and a camera for detecting foreign objects inside the first roll 80A. In the first inspection data, a portion of the data from multiple inspection sections may be used, or a combination of the results from multiple inspection sections may be used.

[0116] (Step S13)

[0117] Terminal device 70A, for example, causes inspection device 90A to detect multiple feature points from image data and generate first inspection data. Inspection device 90A generates the first inspection data, for example, through the following process.

[0118] The analysis unit 93 of the inspection device 90A first acquires image data captured by the camera 92. Then, the analysis unit 93 divides the image data into multiple regions. For example, the analysis unit 93 divides the image data into n regions in the width direction. n can be, for example, several to dozens of regions. Hereinafter, the n regions will be referred to as region a1 to region an.

[0119] Next, the analysis unit 93 acquires image data for region a1 and performs mathematical processing on the image data for region a1. This mathematical processing includes, for example, preprocessing, enhancement processing, signal processing, and image feature extraction.

[0120] Preprocessing includes image cropping, low-pass filtering, high-pass filtering, Gaussian filtering, median filtering, bilateral filtering, morphological transformation, color conversion, contrast adjustment, noise removal, restoration of blurred / jittery images, masking, Hough transform, and projective transform. Color conversion includes, for example, L*a*b*, sRGB, HSV, and HSL.

[0121] Enhancement processing methods include, for example, the Sobel filter, the Scharr filter, the Laplacian filter, the Gabor filter, and the Canny method.

[0122] Signal processing includes, for example, basic statistics, square and square root analysis, differences, sums, products, ratios, distance matrix calculations, calculus, thresholding, Fourier transform, wavelet transform, and peak detection. Basic statistics include, for example, maximum, minimum, mean, median, standard deviation, variance, and quartiles. Thresholding includes, for example, binarization and adaptive binarization. Peak detection includes, for example, the detection of peak value, number of peaks, or full width at half maximum (FWHM).

[0123] Image feature extraction includes template matching and SIFT features.

[0124] After performing mathematical processing on the image data of region a1, the analysis unit 93 performs thresholding on the values ​​obtained through this processing. Thresholding is a process that determines whether a point is a feature point based on a predetermined threshold, and determines the size of the feature point, etc.

[0125] The analysis unit 93 also processes regions other than region a1 in the same way.

[0126] After processing each region a1 to an, the analysis unit 93 integrates the results for each region a1 to an, and the data processing ends. Specifically, the analysis unit 93 generates data that corresponds to the position and size of the feature points detected in each region.

[0127] After this, the analysis unit 93 stores the processing results of the data processing in the storage unit 94. The analysis unit 93 performs such data processing on each of the multiple image data obtained during the inspection of one first roll 80A and obtains the processing result. By summarizing these processing results, the first inspection data is generated.

[0128] (Step S14)

[0129] The terminal device 70A sends the first inspection data generated by the inspection device 90A to the information processing system 50 and saves it in the inspection data DB of the storage unit 52.

[0130] Figure 9 This is a flowchart illustrating an example of a method for generating the second inspection data.

[0131] (Step S21)

[0132] The terminal device 70B may instruct the second roll manufacturing apparatus 2000 to manufacture a second roll 80B. For example, at this time, the second roll 80B is manufactured by coating a specified material onto the first roll 80A by the second roll manufacturing apparatus 2000.

[0133] (Step S22)

[0134] Next, the terminal device 70A causes the inspection device 90B to acquire image data. The inspection device 90B, for example, similar to the inspection device 90A described above, includes a light source 91, a camera 92, a resolution unit 93, and a storage unit 94. The inspection device 90B uses, for example, the same measurement system as the inspection device 90A. For example, when the inspection device 90A is a reflective inspection device, the inspection device 90B is also a reflective inspection device. By making the inspection method of the inspection device 90B the same as that of the inspection device 90A, it is easier to compare the inspection results. The inspection devices 90A and 90B can also use inspection devices with different measurement systems depending on the required performance, quality, and product specifications of the roll material, and can also inspect the first roll material 80A or the second roll material 80B under different measurement conditions.

[0135] (Step S23)

[0136] The analysis unit 93 detects feature points from the image data and generates second inspection data through the same process as in step S13.

[0137] (Step S24)

[0138] The terminal device 70B sends the second inspection data generated by the inspection device 90B to the information processing system 50 and saves it in the inspection data DB of the storage unit 52.

[0139] After receiving the first inspection data and the second inspection data, the information processing system 50 classifies the feature points of the first roll 80A and the second roll 80B into any one of the first feature point, the second feature point, and the third feature point.

[0140] [Functions of Information Processing System 50]

[0141] like Figure 4 As shown, the information processing system 50 reads and executes the program stored in the storage unit 52 through the control unit 51, thereby functioning as the acquisition unit 511, the position alignment unit 512, the classification unit 513, the display control unit 514, and the receiving unit 515. Here, the receiving unit 515 corresponds to a specific example of the first receiving unit, the second receiving unit, and the third receiving unit of the present invention.

[0142] The acquisition unit 511 acquires first feature point information and second feature point information. For example, the first inspection data contains the first feature point information. For example, the second inspection data contains the second feature point information.

[0143] The first feature point information and the second feature point information preferably include at least information related to the position of each feature point. The position of the feature point is represented, for example, by XY coordinates based on a specified position of each roll.

[0144] The position alignment unit 512 integrates the XY coordinates of the first roll 80A and the second roll 80B. For example, the position alignment unit 512 establishes a correspondence between predetermined feature points present in the first roll 80A and predetermined feature points present in the second roll 80B based on their relative positions. This correspondence is based on first feature point information and second feature point information acquired by the acquisition unit 511. Through this correspondence of feature points, the XY coordinates are integrated between the first roll 80A and the second roll 80B. The position alignment unit 512 can also correct the length and width of at least one of the first roll 80A and the second roll 80B to integrate the XY coordinates between them. Therefore, the display control unit 514 can ensure that the length and width of the first roll 80A and the second roll 80B are consistent and displayed on the screen.

[0145] The classification unit 513 uses the corresponding result from the position alignment unit 512 to classify the feature points present in the first roll 80A and the feature points present in the second roll 80B into first type feature points, second type feature points, and third type feature points. The classification unit 513 classifies the feature points of the first roll 80A and the second roll 80B, after the position alignment unit 512 has integrated the XY coordinates, into first type feature points, second type feature points, and third type feature points.

[0146] Figure 10An example of the classification results for the first, second, and third feature points is shown. For example, the classification unit 513 first integrates the feature points present in the first roll 80A with the feature points present in the second roll 80B. The classification unit 513, for example, assigns a new feature point ID to all the integrated feature points. Then, for each feature point ID, the classification unit 513 classifies the feature point as a first, second, or third feature point. The classification results may also include information related to the accuracy of the classified first, second, and third feature points.

[0147] The display control unit 514 displays at least one of the feature points present in the first roll 80A and the feature points present in the second roll 80B, as well as at least any one of the first type of feature point, the second type of feature point, and the third type of feature point classified by the classification unit 513, on a single screen. For example, the display control unit 514 may display at least one of the feature points present in a first inspection area of ​​the first roll 80A and the feature points present in a second inspection area of ​​the second roll 80B, as well as a third type of feature point present in either the first or second inspection area, on a single screen. The first or second inspection area may be selected, for example, by a manager of the first or second manufacturing process. The first inspection area may be, for example, a portion of the first roll 80A. The second inspection area may be, for example, a portion of the second roll 80B. The display control unit 514 may display this screen, for example, on the display unit 76 of the terminal device 70A or the terminal device 70B. The display control unit 514 may also display this screen on an external display device.

[0148] Figure 11 This represents an example of a screen displayed on the display unit 76. For example, a first image 761, a second image 762, and a third image 763 may be arranged in this screen.

[0149] The first image 761 is an image representing feature points present in the first inspection area of ​​the first roll 80A. For example, the first image 761 represents the XY coordinates of each of the multiple feature points detected by the inspection device 90A. The first image 761 represents the position and size of each of the multiple feature points present in the first inspection area of ​​the first roll 80A.

[0150] The second image 762 is an image showing feature points present in the second inspection area of ​​the second roll 80B. The second image 762, for example, shows the XY coordinates of each of the multiple feature points detected by the inspection device 90B. The second inspection area shown in the second image 762 is, for example, an area in the second roll 80B corresponding to the first inspection area of ​​the first roll 80A. For example, the first and second inspection areas have their XY coordinates integrated by a position alignment portion 512. Furthermore, the length and width of the first and second inspection areas are the same. The second image 762 shows the position and size of each of the multiple feature points present in the second inspection area of ​​the second roll 80B. In the second image 762, compared to the first image 761, there are more feature points per unit area.

[0151] The third image 763 is an image representing a third type of feature point present in the first inspection area and the second inspection area. For example, the third image 763 shows the XY coordinates of each of the multiple third type of feature points determined by the classification unit 513. The third image 763 shows the position and size of each of the multiple third type of feature points present in the first inspection area and the second inspection area. In the XY coordinates of the first image 761, the second image 762, and the third image 763, for example, markers corresponding to the size of the feature point or the third type of feature point are used to represent the feature point or the third type of feature point. Different colors may also be used for each size of the feature point or the third type of feature point in the first image 761, the second image 762, and the third image 763. The size of the feature point or the third type of feature point may also be displayed using numerical values ​​in the first image 761, the second image 762, and the third image 763. The concentration of feature points or the probability of them remaining in the downstream process may also be displayed in the first image 761, the second image 762, and the third image 763.

[0152] The display control unit 514 can also cause the display unit 76 to display a screen composed of one of the first image 761 and the second image 762 and the third image 763.

[0153] Figure 12 Another example of a screen displayed by display unit 76. In this screen, for example, a fourth image 764 is configured. In the fourth image 764, feature points present in a first inspection area of ​​the first roll 80A and a second inspection area of ​​the second roll 80B, and third feature points present in the first and second inspection areas, are shown in an overlapping manner. The feature points present in the first roll 80A and the feature points present in the second roll 80B are displayed, for example, in different colors. The third feature point is, for example, accompanied by an arrow.

[0154] In the fourth image 764, a first type of feature point and a second type of feature point existing in the first inspection area of ​​the first roll 80A and the second inspection area of ​​the second roll 80B can also be displayed. At this time, the first type of feature point, the second type of feature point, and the third type of feature point are shown with different colors or different line types.

[0155] The receiving unit 515, for example, accepts the selection of a region of interest that is part of any one of the first image 761, the second image 762, and the third image 763. The region of interest may be selected, for example, by a manager of the first or second manufacturing process. The receiving unit 515 may accept the selection of the region of interest from the manager of the first or second manufacturing process, for example, via the operation receiving unit 77.

[0156] When the receiving unit 515 receives a selection of a region of interest, the display control unit 514, for example, causes the region of interest to be magnified or reduced in conjunction with corresponding portions of other images. For instance, when a region of interest is selected from the first image 761, the display control unit 514 causes portions of the second image 762 and the third image 763 corresponding to that region of interest to be magnified or reduced together with the region of interest in the first image 761. This allows managers of the first or second manufacturing process to easily confirm the generation, disappearance, and retention of feature points located in the region of interest. Here, the first image 761 or the second image 762 corresponds to a specific example of the original image of the present invention, and the third image 763 corresponds to a specific example of the classification image of the present invention.

[0157] The receiving unit 515 may also receive, for example, a switching instruction for displaying an image on a screen. For example, when a first image 761 and a third image 763 are displayed on a screen, the receiving unit 515 may receive an instruction to switch from the first image 761 to the second image 762. For example, when a first image 761 and a third image 763 are displayed on a screen, the receiving unit 515 may also receive an instruction to switch from the first image 761, the second image 762, and the third image 763 to the fourth image 764.

[0158] The receiving unit 515 may also receive, for example, a non-display instruction for feature points present in the first roll 80A, feature points present in the second roll 80B, a first type of feature point, a second type of feature point, or a third type of feature point displayed on a screen. For example, when a fourth image 764 is displayed on a screen, the receiving unit 515 receives a non-display instruction for feature points present in the second roll 80B.

[0159] Figure 13 This is a flowchart illustrating an example of the sequence of display control processes performed in the information processing system 50. Figure 13 The processing of the information processing system 50 shown in the flowchart is stored as a program in the storage unit 52 of the information processing system 50 and is executed by the CPU controlling each unit.

[0160] (Step S31)

[0161] Information processing system 50 may acquire, for example, a pair of first and second inspection data in the same batch, based on instructions from a user via terminal device 70A or terminal device 70B. Information processing system 50 may also acquire the pair of first and second inspection data when both are available. For example, the first inspection data may contain first feature point information, and the second inspection data may contain second feature point information.

[0162] (Steps S32, S32 and S34)

[0163] In order to align the coordinate systems of the first roll 80A and the second roll 80B, the information processing system 50 performs preprocessing on the first inspection data according to a first condition and preprocessing on the second inspection data according to a second condition. For example, the information processing system 50 integrates the XY coordinate system of the second roll 80B into the XY coordinate system of the first roll 80A.

[0164] Figure 14 This is a schematic diagram illustrating an example of the processing steps S32, S33, and S34. For example, the information processing system 50 reverses the Y-coordinate of the second roll 80B as a preprocessing step for the second inspection data. This integrates the differences in the Y-coordinate caused by the winding in the first manufacturing process and the unwinding in the second manufacturing process. The information processing system 50 may also reverse the X-coordinate of the second roll 80B based on factors such as the placement of the camera 92 in the first and second manufacturing processes. The information processing system 50 may also transform the XY coordinates of the second roll 80B based on factors such as its elongation. The information processing system 50 may also integrate the XY coordinate system of the first roll 80A into the XY coordinate system of the second roll 80B.

[0165] The information processing system 50 further performs noise removal processing as preprocessing for both the first and second inspection data. Noise removal processing includes, for example, at least one of the removal of low-intensity feature points, removal of extremely small feature points, and removal of continuous dots. Noise removal processing may also include the removal of concentrated dots along the short side. Concentrated dots along the short side may occur, for example, at the head or tail of the first roll 80A or the second roll 80B.

[0166] After preprocessing the first inspection data and the second inspection data, the information processing system 50 performs coordinate system alignment processing.

[0167] Figure 15 This is a flowchart of the subroutine for the position alignment process in step S34.

[0168] (Coarse adjustment: steps S401~S403)

[0169] The information processing system 50 first performs a coarse adjustment of the XY coordinates of the feature points of the first roll 80A and the second roll 80B as follows. For example, the information processing system 50 first shifts the coordinate position of a specified feature point of the second roll 80B by a specified amount. Next, the information processing system 50 calculates the distances L1 to Lm between the specified feature point of the second roll 80B and the corresponding feature point of the first roll 80A, and selects the shift amount (x1, y1) with the smallest sum. The information processing system 50 may also use an average value instead of the sum. For example, the information processing system 50 determines the feature point of the first roll 80A that has the coordinate position closest to the specified feature point of the second roll 80B as the feature point of the first roll 80A corresponding to the specified feature point of the second roll 80B. When it is impossible to determine the feature point of the first roll 80A corresponding to the specified feature point of the second roll 80B, that is, when the specified feature point is a second type of feature point, the information processing system 50 may also exclude that feature point when calculating the sum of the distances L1 to Lm.

[0170] Information processing system 50, for example, uses a fixed coarse adjustment shift step size 'a', with the center shift (0,0) as the center, and sequentially shifts the coordinate positions of the specified feature points of the second roll 80B up to (-shift_x, -shift_y) to (+shift_x, +shift_y). It calculates the distances L1 to Lm from the coordinate positions of the specified feature points of the second roll 80B to the feature points 1 to m of the first roll 80A. Then, it selects the shift amount (x1, y1) with the smallest sum of distances L1 to Lm from (-shift_x, -shift_y) to (+shift_x, +shift_y).

[0171] For example, with a coarse adjustment shift a = 1.0 mm, (-shift_x,-shift_y) = (-10 mm,-10 mm) and (+shift_x,+shift_y) = (+10 mm,+10 mm). The information processing system 50 can also make the units for the X and Y directions different in the coarse adjustment shift a. For example, the X direction can be in millimeters and the Y direction in meters, set as (-shift_x,-shift_y) = (-10 mm,-10 m) and (+shift_x,+shift_y) = (+10 mm,+10 m).

[0172] (Minor adjustments: steps S404~S406)

[0173] Next, the information processing system 50 performs fine adjustments to the XY coordinates of the feature points of the first roll 80A and the second roll 80B, and selects a shift amount (x2, y2). The information processing system 50 selects the shift amount (x2, y2) in almost the same way as in steps S401 to S403. Steps S404 to S406 differ from steps S401 to S403, for example, in the following aspects: The fine adjustment shift amount b in step S404 is smaller than the coarse adjustment shift amount a. In addition, the center shift amount in step S405 uses the shift amount (x1, y1) selected in step S403. For example, the fine adjustment shift amount b is sufficiently small than the coarse adjustment shift amount a, for example, 0.1 mm, which is one order of magnitude smaller.

[0174] (Step S407)

[0175] The information processing system 50 uses the shift amount (x2, y2) selected in step S406 to perform coordinate transformation processing on all feature points of the second roll 80B.

[0176] (Step S408)

[0177] The information processing system 50 calculates the coordinate transformation distances L1~Lm after step S407 and confirms whether the sum of distances L1~Lm is less than a specified threshold. If it is above the specified threshold, the information processing system 50 can also determine that the coordinate transformation process in step S407 is inappropriate.

[0178] (Step S409)

[0179] If the alignment is incorrect (YES), the information processing system 50 terminates processing. In this case, the information processing system 50 may display an error message on the display unit 76 or record the inability to calculate in the check data database. Conversely, if the alignment is correct (NO), the information processing system 50 terminates processing. Figure 15The processing was returned to Figure 13 The processing will proceed, and the subsequent processing will be executed after step S35.

[0180] (Step S35)

[0181] The information processing system 50 compares each feature point of the first roll 80A with each feature point of the second roll 80B. The coordinates of each feature point of the second roll 80B are transformed through the processing in step S34. As a result, the feature points of the first roll 80A and the second roll 80B are classified into any one of a first type of feature point, a second type of feature point, and a third type of feature point. In other words, the information processing system 50 determines the third type of feature point from the feature points of the first roll 80A and the second roll 80B. The information processing system 50, for example, stores the classification result of the feature points in the inspection data DB of the storage unit 52.

[0182] (Step S36)

[0183] The information processing system 50 displays at least one of the feature points present in the first roll 80A and the feature points present in the second roll 80B, as well as the third type of feature point determined in step S35, on a single screen. The information processing system 50, for example, causes the display unit 76 to display this screen.

[0184] (Step S37)

[0185] Information processing system 50 determines whether it has received a selection of a region of interest. If no selection of a region of interest has been received, i.e., in the case of no (NO), information processing system 50 terminates processing.

[0186] (Step S38)

[0187] When a region of interest is selected (i.e., in the case of "YES"), the information processing system 50 zooms in or out of the region of interest and the corresponding portion thereof in a coordinated manner. After this, the information processing system 50 terminates the processing.

[0188] [The effects and benefits of information processing system 50]

[0189] In the information processing system 50 according to the present invention, feature points present in the first roll 80A and feature points present in the second roll 80B are classified as first feature points, second feature points, and third feature points. Furthermore, at least one of the feature points present in the first roll 80A and the feature points present in the second roll 80B, and at least any one of the first, second, and third feature points, are displayed on a single screen. Therefore, when the manager of the first or second manufacturing process manufactures the second roll 80B from the first roll 80A, they can easily grasp the disappearance of feature points, the generation of feature points, and the remaining feature points. Thus, the defect status can be grasped between manufacturing processes. The effects of this operation will be explained below.

[0190] In the production of roll-to-roll materials such as optical films, stringent quality management is required. This includes rigorously controlling the generation of defects, such as foreign objects, scratches, and dents. These roll-to-roll materials undergo multiple manufacturing processes, with quality checks performed at each stage. When defects are detected in roll-to-roll materials that have passed through multiple manufacturing processes, it can be difficult for managers to determine which process caused the defect. This is especially true in downstream manufacturing processes, where the number of defects present is higher than in upstream processes, making defect analysis more complex. Consequently, defect analysis may be impossible, leading to reduced manufacturing efficiency and output.

[0191] In contrast, the information processing system 50 classifies the feature points present in the first roll 80A and the feature points present in the second roll 80B, and displays at least one of the first, second, and third feature points. Thus, for example, managers of each manufacturing process can easily grasp the residual status of defects between the first and second manufacturing processes by confirming the third feature point. That is, managers of each manufacturing process can easily analyze defects between manufacturing processes. Therefore, it is possible to suppress the reduction in roll manufacturing efficiency and output caused by defects.

[0192] In particular, the information processing system 50 classifies feature points after integrating the coordinate systems of the first roll 80A and the second roll 80B. Therefore, even if the lengths or widths of the first roll 80A and the second roll 80B differ, feature points can be classified with high accuracy. Furthermore, the information processing system 50 classifies feature points without marking the rolls. Therefore, even in processes unsuitable for marking, such as when marking becomes blurred, feature points can be classified. Moreover, it can suppress the generation of new defects in the rolls caused by marking. The information processing system 50 eliminates the need for new marking equipment and the need to provide marking areas at the short-side ends of the rolls. Therefore, the information processing system 50 also prevents the final marking areas from being discarded, thereby improving productivity.

[0193] Hereinafter, variations and other embodiments of the information processing system described in the first embodiment will be described. Furthermore, in the following description, to avoid repetition, detailed descriptions of structures identical to those of the information processing system described in the first embodiment will be omitted.

[0194] <Variation Example>

[0195] The information processing system 50 can also use tags or the like to switch screens. For example, the information processing system 50 causes the display unit 76 to display, in a switchable manner, a screen showing feature points present in the first roll 80A, a screen showing feature points present in the second roll 80B, a screen showing a first type of feature point, a screen showing a second type of feature point, and a screen showing a third type of feature point. The information processing system 50 receives screen switching instructions, for example, from a manager of the first or second manufacturing process via an operation receiving unit 77. Thus, the screen displayed on the display unit 76 is switched.

[0196] <Second Implementation>

[0197] Figure 16 This is a flowchart illustrating the subroutine process for position alignment in the information processing system 50 according to the second embodiment. Figure 16 Corresponding to the description in the first embodiment above Figure 15 The information processing system 50 uses kernel density estimation to align the XY coordinates of the first roll 80A and the second roll 80B. In this respect, the information processing system 50 of the second embodiment differs from the information processing system 50 of the first embodiment. Apart from this, the information processing system 50 of the second embodiment has the same structure as the information processing system 50 of the first embodiment described above and performs the same functions.

[0198] (Step S451)

[0199] The information processing system 50 obtains a probability density function by performing kernel density estimation on the feature points of the first roll 80A. The kernel density estimation is performed in two dimensions, using a Gaussian kernel as the kernel function. For bandwidth, a predetermined value is used, for example. For instance, a table linking the roll's product name to its bandwidth is stored in the storage unit 52. The information processing system 50 may also use a bandwidth value corresponding to the roll's product name, or it may use different bandwidth values ​​depending on the number of feature points present in the first roll 80A. When estimating the kernel density of a specified feature point, the information processing system 50 also considers the data surrounding that feature point. Then, the information processing system 50 sums the densities of each feature point to obtain the probability density function.

[0200] Figure 17 This represents an example of a probability density function calculated using kernel density estimation. Figure 17 The vertical and horizontal axes represent the XY coordinates, and the color intensity represents the density level.

[0201] (Step S452)

[0202] The information processing system 50 obtains the probability density function of each feature point of the second roll 80B in the same way as the processing in step S451.

[0203] (Steps S453~S455)

[0204] The information processing system 50 compares the two obtained probability density functions and establishes a correspondence based on the density distribution. Then, the information processing system 50 calculates the transformation matrix based on the correspondence result and performs XY coordinate transformation on the feature points of the second roll 80B.

[0205] (Steps S456~S457)

[0206] Information processing system 50 and Figure 15 Steps S406 to S407 are performed in the same way as steps S456 to S457.

[0207] The information processing system 50 involved in this second embodiment, like that described in the first embodiment, displays at least one of the feature points present in the first roll 80A and the feature points present in the second roll 80B, as well as at least any one of the first type of feature point, the second type of feature point, and the third type of feature point, on a single screen. Therefore, when the manager of the first or second manufacturing process manufactures the second roll 80B from the first roll 80A, they can easily grasp the disappearing feature points, the generated feature points, and the remaining feature points. Thus, the defect status can be grasped between manufacturing processes.

[0208] The information processing system 50 can also align the positions of the feature points of the first roll 80A and the second roll 80B using other methods. For example, the information processing system 50 can perform kernel density estimation on the feature points of one of the first roll 80A and the second roll 80B. In this case, the information processing system 50 compares the obtained probability density function with the feature points of the other roll. Thus, the information processing system 50 can align the positions of the feature points of the first roll 80A and the second roll 80B.

[0209] <Third Implementation Method>

[0210] Figure 18 This is a schematic diagram illustrating an application example of the information processing system 50 according to the third embodiment. Figure 18 It corresponds to the first embodiment described above. Figure 1 The image, but Figure 18 The description of some structures such as terminal devices 70A and 70B is omitted here. The second manufacturing process includes a first sub-process, a second sub-process, and a third sub-process. In factory B where the second manufacturing process is performed, for example, roll 80ba becomes roll 80bb after the first sub-process. This roll 80bb becomes roll 80bc after the second sub-process. This roll 80bc becomes second roll 80B after the third sub-process. Roll 80ba is, for example, the first roll 80A transported from factory A. The first, second, and third sub-processes are, for example, coating processes. That is, the second roll 80B is a laminate including the first roll 80A. The first, second, and third sub-processes may also include auxiliary processes such as drying processes. The first, second, and third sub-processes may also include bonding processes such as lamination processes, slit processes for cutting off the film ends, lamination processes for conveying protective films, and peeling processes for conveying protective films.

[0211] In factory B, for example, multiple inspection devices are provided. For example, inspection device 90B0 is located before the first sub-process. For example, inspection device 90B1 is located between the first and second sub-processes. For example, inspection device 90B2 is located between the second and third sub-processes. For example, inspection device 90B3 is located after the third sub-process. The first manufacturing process may also include multiple sub-processes, and multiple inspection devices may be provided in factory A. Multiple inspection devices may also be provided in both factory A and factory B.

[0212] Figure 19This indicates the details of each of the inspection devices 90A, 90B0, 90B1, 90B2, and 90B3. Data A is obtained from inspection device 90A, data B0 from inspection device 90B0, data B1 from inspection device 90B1, data B2 from inspection device 90B2, and data B3 from inspection device 90B3, respectively.

[0213] Figure 20 This represents an example of a combination of first and second inspection data. For example, the first inspection data is data A, and the second inspection data is data B0. For example, the first inspection data is data B0, and the second inspection data is data B1. For example, the first inspection data is data B1, and the second inspection data is data B2. For example, the first inspection data is data B2, and the second inspection data is data B3. For example, the first inspection data is data A, and the second inspection data is data B3. The first and second inspection data can be combinations of inspection data obtained in different processes, or combinations other than those described above.

[0214] The information processing system 50 involved in this third embodiment, like that described in the first embodiment, displays at least one of the feature points present in the first roll 80A and the feature points present in the second roll 80B, as well as at least any one of the first type of feature point, the second type of feature point, and the third type of feature point, on a single screen. Therefore, when the manager of the first or second manufacturing process manufactures the second roll 80B from the first roll 80A, they can easily grasp the disappearing feature points, the generated feature points, and the remaining feature points. Thus, the defect status can be grasped between manufacturing processes.

[0215] (First roll material manufacturing device 1000)

[0216] Figure 21 This is an example illustrating the schematic structure of a first roll material manufacturing apparatus 1000. The first roll material manufacturing apparatus 1000 manufactures, for example, a first roll material 80A by solution casting. The first roll material manufacturing apparatus 1000 includes, for example, a casting section 01, a first drying section 02, an stretching section 03, a second drying section 04, an embossing section 05, and a winding and recovery section 06. For example, an inspection device 90A is disposed in the winding and recovery section 06.

[0217] The casting section 01 includes, for example, a belt 01a, a die 01b, and a peeling roller 01d. In the casting section 01, a stock solution of resin dissolved in a solvent is cast from the die 01b onto the belt 01a. A cast film 01c is formed on the belt 01a. The peeling roller 01d peels off the cast film 01c.

[0218] The first drying section 02 includes, for example, a drying chamber 02a and a conveying roller 02d. A drying air inlet 02b and an outlet 02c are provided in the drying chamber 02a. The amount of solvent included in the cast film 01c can also be adjusted in the first drying section 02.

[0219] The extension section 03 includes an MD extension section 03a and a TD extension section 03b. The extension section 03 extends the cast film 01c conveyed from the first drying section 02.

[0220] The second drying section 04 has, for example, almost the same structure as the first drying section 02.

[0221] Embossing forming section 05 embosses both ends of the cast film 01c conveyed from second drying section 04.

[0222] The winding and recovery unit 06 includes a winding machine 06a and an accompanying air volume control device 06b. The winding and recovery unit 06 further includes a linear encoder 06c, a winding shaft speed measuring machine 06d, a tension control device 06e, and a thickness measuring device 6f. The linear encoder 06c can be either a contact type or a non-contact type.

[0223] Figure 22 Will Figure 21 The embossing forming section 05 and the winding and rewinding section 06 shown are shown in enlarged form.

[0224] In the embossing forming apparatus 05a, an embossing forming roller 501a and a receiving roller 501b form a pair. A pressing unit 501c is connected to the embossing forming roller 501a. The embossing forming roller 501a has concave and convex surfaces. A cast film 01c is held between the embossing forming roller 501a and the receiving roller 501b to form an embossing. The embossing forming roller 501a moves vertically via the pressing unit 501c. The amount of movement of the pressing unit 501c is controlled, for example, by a control device 07.

[0225] The control device 07 includes a memory, a CPU, and input / output I / O. For example, the control device 07 uses information input to the CPU and information pre-input to the memory to determine the amount of movement of the pressing unit 501c, i.e., the amount of movement of the embossing roller 501a. If the amount of movement of the embossing roller 501a increases, the height of the formed embossing increases. If the amount of movement of the embossing roller 501a decreases, the height of the formed embossing decreases.

[0226] Embossing apparatus 05a can also be an embossing apparatus using inkjet or laser methods, etc.

[0227] The accompanying air volume control device 06b includes, for example, a pressure roller 602a and a pressure volume control device 602b for controlling the pressure amount of the pressure roller 602a. The pressure volume control device 602b is disposed at both ends of the pressure roller 602a.

[0228] The relationship between the pressure roller and tension control is described, for example, in the literature (JK Good Modeling NipInduced Tension in Wound Rolls Proceedings of Fourth International Conference on Web Handling, 1997).

[0229] The tension control device 06e includes a tension controller 605a and a moving unit 605b for the tension controller 605a. The tension control device 06e works in conjunction with the first roll 80A wound by the winding shaft 82 to move the position of the tension controller 605a.

[0230] (Second roll material manufacturing unit 2000)

[0231] Figure 23 This is an example illustrating the schematic structure of a second roll-to-roll manufacturing apparatus 2000. For example, the second roll-to-roll manufacturing apparatus 2000 laminates a first protective film 12 and a second protective film 13 onto both sides of the polarizer 1c. Thus, for example, a laminated polarizing film 1 having a layer structure of first protective film 12 / adhesive layer 31 / polarizer 11 / adhesive layer 32 / second protective film 13 is obtained. The second protective film 13 is formed from a first roll-to-roll 80A manufactured in the first roll-to-roll manufacturing apparatus 1000.

[0232] The second roll material manufacturing apparatus 2000 includes, for example, a wet processing apparatus 204, a drying apparatus 205, and a laminating apparatus 206 sequentially from the upstream side. The second roll material manufacturing apparatus 2000 further includes an unwinding section 202. For example, a first roll material 80A is loaded onto the third roller section 63 of the unwinding section 202.

[0233] The wet processing apparatus 204 includes a first roller section 41, a conveying section 42, and a processing section. A strip of untreated hydrophilic polymer film 1a is wound around the first roller section 41. The conveying section 42 conveys the hydrophilic polymer film 1a. In the processing section, the hydrophilic polymer film 1a is transformed into a polarizer 1b.

[0234] The conveying section 42 has multiple guide rollers, etc. The conveying section 42 draws out the hydrophilic polymer film 1a wound on the first roller section 41 and conveys it to the processing section.

[0235] The processing unit, for example, includes, from the upstream side, a swelling treatment tank 4A, a dyeing treatment tank 4B, a crosslinking treatment tank 4C, a stretching treatment tank 4D, and a cleaning treatment tank 4E.

[0236] Swelling treatment tank 4A is a treatment tank containing a swelling treatment solution. The swelling treatment solution swells the hydrophilic polymer film 1a. Dyeing treatment tank 4B is a treatment tank containing a dyeing treatment solution. The dyeing treatment solution dyes the hydrophilic polymer film 1a. Crosslinking treatment tank 4C is a treatment tank containing a crosslinking treatment solution. The crosslinking treatment solution crosslinks the dyed hydrophilic polymer film 1a. Stretching treatment tank 4D is a treatment tank containing a stretching treatment solution. The stretching treatment solution is not particularly limited; for example, a solution containing a boron compound as an active ingredient can be used. Cleaning treatment tank 4E is a treatment tank containing a cleaning treatment solution. The cleaning treatment solution cleans the stretched hydrophilic polymer film 1a. The cleaning treatment solution is a treatment solution used to clean the dyeing treatment solution or crosslinking treatment solution, etc., adhering to the hydrophilic polymer film 1a. Water such as ion-exchanged water, distilled water, and pure water are representative examples of cleaning treatment solutions used.

[0237] The drying apparatus 205 includes a conveying section 501 and a heating section. There may be one drying apparatus 205, or two or more may be arranged in the conveying direction of the polarizer. In the example shown, for example, one drying apparatus 205 is provided in the conveying path of the polarizer. The conveying section 501 conveys a strip-shaped polarizer 1b. The heating section applies heat to the polarizer 1b to dry it.

[0238] The heating section of the drying apparatus 205 includes, for example, a chamber 502 and a heat source. The chamber 502 has a space 503 inside which a polarizer can be transported.

[0239] The laminating apparatus 206 includes a conveying section 61, an adhesive coating section 64, a bonding section 67, and a chamber 69. The conveying section 61 conveys the dried polarizer 1c and the first protective film 12. The chamber 69 surrounds the adhesive coating section 64 and the bonding section 67.

[0240] The conveying section 61 includes guide rollers, etc. The conveying section 61 conveys the elongated strip-shaped polarizer 1c, dried by the drying device 205, to the laminating section 67. In addition, the conveying section 61 conveys the elongated strip-shaped first protective film 12, etc., to the laminating section 67.

[0241] The adhesive coating section 64 includes a gravure roller 641. The gravure roller 641 is a coating roller for applying adhesive to the film. The adhesive coating section 64 is disposed upstream of the bonding section 67. The adhesive coating section 64 may be disposed, for example, on one side of the first protective film 12 and one side of the second protective film 13. The adhesive coating section 64 may also be disposed on one side of the polarizer 1c and the other side of the polarizer 1c.

[0242] The adhesive coating section 64 includes, for example, a gravure roller 641 serving as a coating roller, a container 642 for storing adhesive, and a doctor blade 643. Furthermore, the adhesive coating section 64 may also include a support roller if needed. The support roller is arranged opposite the gravure roller 641 in a manner that clamps the film.

[0243] Multiple cavities are formed on the surface of the gravure roller 641. These cavities are recesses for the adhesive to enter. The gravure roller 641 rotates so that its surface comes into contact with the adhesive 65 stored in the container 642. With rotation, the adhesive 65 adheres to the surface including the cavities of the gravure roller 641. Excess adhesive 65 is scraped off into the container 642 by a doctor blade 643. Through contact with the film by the gravure roller 641, the adhesive 65 in the cavities is transferred to one side of the first protective film 12 and the second protective film 13. In this way, the adhesive 65 is solidly applied from the gravure roller 641 to one side of the first protective film 12 and the second protective film 13, respectively.

[0244] The adhesive used to bond the polarizer 1c to the first protective film 12 and the second protective film 13 is not particularly limited, but as described above, an active energy radiation-curable adhesive is preferred. Conventionally known adhesives can be used as active energy radiation-curable adhesives. Active energy radiation-curable adhesives generally contain active energy radiation-curable components and polymerization initiators, and may contain various additives as needed.

[0245] The unwinding section 202 includes an easy-bonding treatment tank 21, a cleaning treatment tank 22, and a heat treatment tank 23. The easy-bonding treatment tank 21 performs easy-bonding treatment on the surface of the bonding polarizer 11 in the second protective film 13. For example, the easy-bonding treatment tank 21 performs corona discharge treatment or plasma treatment. In corona discharge treatment, a high voltage is applied to the linear or sawtooth electrodes within the chamber. The cleaning treatment tank 22 has the same structure as the cleaning treatment tank 4E described above. A cleaning solution is contained within the cleaning treatment tank 22. The second protective film 13 is cleaned using the cleaning solution. The heat treatment tank 23 has the same structure as the drying apparatus 205. The heat treatment tank 23 heats and dries the second protective film 13. The drying temperature of the heat treatment tank 23 is changed, for example, by the manufacturing management system 3000.

[0246] The second roll material manufacturing apparatus 2000 further includes a second roller section 62 and a third roller section 63. A first protective film 12 in the form of an elongated strip is wound on the second roller section 62. A second protective film 13 in the form of an elongated strip is wound on the third roller section 63. The first protective film 12 and the second protective film 13 are conveyed from the second roller section 62 and the third roller section 63 to the bonding section 67, respectively.

[0247] The structure of the information processing system 50 described above is a main structure illustrated to illustrate the features of the above embodiments, and is not limited to the above structure. Various modifications can be made within the scope of the claims. Furthermore, this does not exclude the structure possessed by general information processing apparatuses or information processing systems. For example, the information processing system 50 may also include inspection devices 90A and 90B. In addition, the control unit 51 of the information processing system 50 may also perform the function of generating feature points of the analysis unit 93 of the inspection device 90.

[0248] Furthermore, in the above embodiment, an example was described in which the sizes of the first roll 80A and the second roll 80B are made consistent by integrating their respective XY coordinates. The sizes of the first roll 80A and the second roll 80B can also be made consistent using other methods, such as based on the elongation rate in each process.

[0249] Furthermore, the means and methods for performing the various processes in the information processing system 50 described above can be implemented either by dedicated hardware circuitry or by a programmed computer. The aforementioned program can be provided, for example, via a computer-readable recording medium such as a USB memory or DVD-ROM, or online via a network such as the Internet. In this case, the program recorded on the computer-readable recording medium is typically transferred to a storage unit such as a hard disk and stored. Furthermore, the aforementioned program can be provided as standalone application software or integrated into the software of the device as a functional component.

[0250] While embodiments of the invention have been described and illustrated in detail, the disclosed embodiments are for illustrative and exemplary purposes only and are not intended to be limiting. The scope of the invention should be interpreted according to the literal meaning of the appended claims.

[0251] This application is based on Japanese Patent Application No. 2024-52963, filed on March 28, 2024, the disclosure of which is incorporated herein by reference in its entirety.

[0252] Explanation of reference numerals in the attached drawings: 50…Information processing system; 51…Control unit; 511…Acquisition unit; 512…Position alignment unit; 513…Classification unit; 514…Display control unit; 515…Receiving unit; 52…Storage unit; 90, 90A, 90B…Inspection device; 1000…First roll material manufacturing device; 2000…Second roll material manufacturing device.

Claims

1. An information processing system, wherein, have: The acquisition unit acquires first feature point information related to feature points existing in the first roll, and second feature point information related to feature points existing in the second roll obtained by performing a specified process on the first roll; The classification department, based on the acquired first feature point information and second feature point information, classifies the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll and not existing in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll. as well as The display control unit displays at least one of the feature points existing in the first roll and the feature points existing in the second roll, as well as at least any one of the first feature point, the second feature point, and the third feature point on a single screen.

2. The information processing system according to claim 1, wherein, The information processing system further includes a position alignment unit, which establishes a correspondence between specified feature points existing in the first roll and specified feature points existing in the second roll based on their mutual positions. The classification department uses the corresponding results to classify the feature points existing in the first roll and the feature points existing in the second roll into a first type of feature point, a second type of feature point, and a third type of feature point.

3. The information processing system according to claim 1, wherein, On the screen, feature points existing in the first roll and at least one of feature points existing in the second roll, as well as a third type of feature point, are displayed.

4. The information processing system according to claim 3, wherein, On the screen, at least one of the feature points present in the first inspection area of ​​the first roll and the feature points present in the second inspection area of ​​the second roll, as well as a third type of feature point present in either the first inspection area or the second inspection area, is displayed. The second inspection area is the area in the second roll material that corresponds to the first inspection area.

5. The information processing system according to claim 4, wherein, The display control unit displays feature points existing in the first inspection area, feature points existing in the second inspection area, and a third type of feature point existing in both the first and second inspection areas on the same screen. The length and width of the first inspection area and the second inspection area are the same.

6. The information processing system according to claim 1, wherein, The specified processing includes at least winding and unwinding.

7. The information processing system according to claim 1, wherein, The information processing system further includes a first receiving unit, which receives a selected region of interest. The region of interest is either a portion of an original image representing at least one of feature points present in the first roll and feature points present in the second roll, or a portion of a classified image representing at least any one of a first feature point, a second feature point, and a third feature point. When the display control unit receives the selection of the region of interest, it causes the region of interest and the corresponding portion of the original image or the classified image to be magnified or reduced in a coordinated manner.

8. The information processing system according to claim 1, wherein, In the aforementioned image, feature points existing in the first roll and feature points existing in the second roll are displayed in an overlapping manner, as well as at least one of the first feature point, the second feature point, and the third feature point.

9. The information processing system according to claim 1, wherein, In the aforementioned image, feature points present in the first roll and feature points present in the second roll are displayed in an arranged manner, including at least one of the first feature point, the second feature point, and the third feature point.

10. The information processing system according to claim 1, wherein, The display control unit causes the screen to display information related to the position and size of at least one of the feature points present in the first roll and the feature points present in the second roll, as well as information related to the position and size of at least any one of the first feature point, the second feature point, and the third feature point.

11. The information processing system according to claim 1, wherein, The information processing system also has a second receiving unit, which receives a switching instruction for the image displayed on the screen.

12. The information processing system according to claim 1, wherein, The information processing system also has a third receiving unit, which receives non-display indications of feature points existing in the first roll, feature points existing in the second roll, a first type of feature point, a second type of feature point, or a third type of feature point displayed on the screen.

13. The information processing system according to claim 1, wherein, The length and width of the first roll and the second roll are different.

14. An information processing system, wherein, have: The acquisition unit acquires first feature point information related to feature points existing in the first roll, and second feature point information related to feature points existing in the second roll obtained by performing a specified process on the first roll; The classification department, based on the acquired first feature point information and second feature point information, classifies the feature points existing in the first roll and the feature points existing in the second roll into: a first type of feature point existing in the first roll and not existing in the second roll, a second type of feature point not existing in the first roll but existing in the second roll, and a third type of feature point existing in both the first roll and the second roll. as well as The display control unit enables the display unit to display in a switchable manner: displaying a screen showing feature points present in the first roll, displaying a screen showing feature points present in the second roll, displaying a screen showing a first type of feature point, displaying a screen showing a second type of feature point, and displaying a screen showing a third type of feature point.

15. An information processing method, wherein, include: Acquire first feature point information related to feature points existing in the first roll, and second feature point information related to feature points existing in the second roll obtained by performing a specified process on the first roll; Based on the obtained first feature point information and second feature point information, the feature points existing in the first roll and the feature points existing in the second roll are classified as: a first type of feature point that exists in the first roll but not in the second roll, a second type of feature point that does not exist in the first roll but exists in the second roll, and a third type of feature point that exists in both the first roll and the second roll. as well as The feature points existing in the first roll and at least one of the feature points existing in the second roll, as well as at least any one of the first feature point, the second feature point and the third feature point, are displayed on a single screen.

16. An information processing method, wherein, include: Acquire first feature point information related to feature points existing in the first roll, and second feature point information related to feature points existing in the second roll obtained by performing a specified process on the first roll; Based on the obtained first feature point information and second feature point information, the feature points existing in the first roll and the feature points existing in the second roll are classified as: a first type of feature point that exists in the first roll but not in the second roll, a second type of feature point that does not exist in the first roll but exists in the second roll, and a third type of feature point that exists in both the first roll and the second roll. as well as The display unit can display in a switchable manner: a screen displaying feature points present in the first roll, a screen displaying feature points present in the second roll, a screen displaying a first type of feature point, a screen displaying a second type of feature point, and a screen displaying a third type of feature point.

17. An information processing program, wherein, To enable the computer to perform the information processing method as described in claim 15 or 16.

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