An inspection machine for film products

Abstract

The utility model relates to a kind of for film product's product testing machine, including the setting of uncoiling unit, phase unit, inspection unit and finished product roller in proper order, uncoiling unit includes uncoiling roller, first uncoiling guide roller, second uncoiling guide roller, third uncoiling guide roller and fourth uncoiling guide roller, the phase unit includes industrial camera, heat sink, light source and guide roller group, the inspection unit includes visual operation platform, first display and second display;The product to be measured is guided into the guide roller group of phase unit after uncoiling from uncoiling roller, first uncoiling guide roller, second uncoiling guide roller, third uncoiling guide roller and fourth uncoiling guide roller.The utility model realizes automatic detection by industrial camera and double display, supports manual review and online repair in combination with visual operation platform, cooperate optimized heat dissipation structure and anti-shake guide roller assembly, significantly improve detection accuracy and stability.

Description

Technical Field

[0001] This utility model relates to the technical field of printing quality inspection equipment, and in particular to an inspection machine for film products, which can be used for thin film products such as transfer film and in-mold labels. Background Technology

[0002] To ensure the quality of printed films, a film inspection machine is needed to check the printing quality of the printed film. This film inspection machine primarily inspects the printing quality of the printed surface on the film. The film can be transfer film, in-mold label, or other film products.

[0003] Existing film inspection machines have the following defects:

[0004] (1) High false negative rate: Some existing technologies use pure visual inspection schemes, which are insufficient for recognizing minute color differences and overprinting deviations;

[0005] (2) Inconvenient manual verification: Traditional equipment requires stopping the machine to take samples. Although some solutions in the existing technology have added observation windows, they have not solved the problem of separating the detection and repair process.

[0006] The aforementioned problems lead to a high rate of missed inspections by equipment and low efficiency of manual verification. Therefore, this utility model proposes an inspection machine for membrane products. Summary of the Invention

[0007] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an inspection machine for membrane products, which achieves automated inspection and manual verification through structural optimization.

[0008] The purpose of this utility model is achieved as follows:

[0009] An inspection machine for film products includes an unwinding unit, a photographic acquisition unit, an inspection unit, and a finished product roller arranged sequentially. The unwinding unit includes an unwinding roller, a first unwinding guide roller, a second unwinding guide roller, a third unwinding guide roller, and a fourth unwinding guide roller. The photographic acquisition unit includes an industrial camera, a heat dissipation device, a light source, and a guide roller assembly. The inspection unit includes a visual operating table, a first display, and a second display. The product to be tested is unwound from the unwinding roller and guided by the first unwinding guide roller, the second unwinding guide roller, the third unwinding guide roller, and the fourth unwinding guide roller into the guide roller assembly of the photographic acquisition unit.

[0010] The guide roller assembly includes a first guide roller, a second guide roller, a third guide roller, a fourth guide roller, a fifth guide roller, a sixth guide roller, a seventh guide roller, and an eighth guide roller. The first guide roller is positioned on the same horizontal plane as the fourth unwinding guide roller. A second guide roller is also provided on one side of the first guide roller. The first and second guide rollers are positioned on the same horizontal plane, so that the product to be tested forms a flat shape after being wound around the third and fourth unwinding guide rollers. An industrial camera is positioned above this flat section of the product to be tested, and a light source is positioned below it. A heat dissipation device is positioned above the industrial camera.

[0011] The third, fourth, fifth, sixth, and seventh guide rollers are positioned below the first and second guide rollers and are arranged in an alternating manner to make the product to be tested wound in a serpentine pattern. An eighth guide roller is provided to the right of the seventh guide roller. The seventh and eighth guide rollers are positioned on the same horizontal plane, and the eighth guide roller is positioned to the lower right of the third guide roller.

[0012] A first flat guide roller is provided directly above the eighth guide roller, and a second flat guide roller is provided to the right of the first flat guide roller. The first flat guide roller and the second flat guide roller are set on the same horizontal plane, so that the product to be tested forms a flat shape after passing around the first flat guide roller and the second flat guide roller. A visual operation table is provided below the flat product to be tested.

[0013] The visualization control panel is equipped with a first display and a second display arranged side by side on the top. Below the second flat guide roller is a finished product guide roller, and to the lower right of the finished product guide roller is a finished product roller for winding up the finished product.

[0014] Furthermore, the first unwinding guide roller and the second unwinding guide roller are arranged in parallel, the unwinding roller 1 is located below the first unwinding guide roller and the second unwinding guide roller, the third unwinding guide roller is located directly above the first unwinding guide roller, and the fourth unwinding guide roller is located directly above the second unwinding guide roller 3. The third unwinding guide roller and the fourth unwinding guide roller are arranged on the same horizontal plane, so that the product to be tested is laid flat after being wound around the third unwinding guide roller and the fourth unwinding guide roller.

[0015] Furthermore, the industrial camera is mounted on a mounting plate via a hinge, and the mounting plate is fixed to the machine body, thereby making the camera angle adjustable; the heat dissipation device 7 is fixed to the machine body.

[0016] Furthermore, the first display shows the defect analysis results in real time, and the second display is larger than the first display. The second display is used for local magnification to facilitate detailed confirmation.

[0017] Furthermore, a waste guide roller is provided above the second flat guide roller, and a waste roller is provided to the upper right of the waste guide roller for winding up waste material with printing errors.

[0018] Furthermore, a shearing station is set up on the visual operation platform, equipped with a pneumatic cutting blade. The pneumatic cutting blade precisely removes defective sections, waste material is rolled into a waste roller, and finished products after film splicing are rolled into a finished product roller.

[0019] Furthermore, the industrial camera is a 20-megapixel industrial camera, coupled with a long strip-shaped LED light source parallel to the product under test.

[0020] Furthermore, the visual operating platform adopts a transparent tempered glass tabletop and is equipped with a supplementary lighting strip below, supporting manual re-inspection without stopping the machine.

[0021] Furthermore, the heat dissipation device uses copper heat pipes in conjunction with a vortex fan; a heat dissipation mechanism for the light source is also provided above the light source, which uses an aluminum substrate with honeycomb holes.

[0022] Furthermore, a guide roller fixing plate is provided behind the unwinding unit, the phase collection unit, the inspection unit, the finished product roller, and the waste roller for installing each guide roller.

[0023] Compared with the prior art, the beneficial effects of this utility model are:

[0024] This invention provides an inspection machine for film products. It achieves automatic inspection through an industrial camera and dual displays, and combines a visual operating table to support manual verification and online repair. With an optimized heat dissipation structure and anti-shake guide roller assembly, it significantly improves inspection accuracy and stability. It is suitable for inspecting high-precision printed materials such as transfer films and in-mold labels. It has the following advantages:

[0025] (1) Improved detection accuracy: The rate of missed detection is greatly reduced, and the recognition rate of tiny defects no larger than 0.2 mm is greatly improved.

[0026] (2) Efficiency optimization: No need to stop the machine for sampling, which greatly shortens the manual review time and improves the repair speed.

[0027] (3) Enhanced stability: The image drift is less than 1 pixel after 8 hours of continuous operation. The continuous guide roller group enhances stability and prevents the product under test from deviating. The heat dissipation device and the spring damper of the guide roller ensure imaging stability. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of this utility model.

[0029] in:

[0030] Unwinding roller 1, First unwinding guide roller 2, Second unwinding guide roller 3, Third unwinding guide roller 4, Fourth unwinding guide roller 5, Industrial camera 6, Heat dissipation device 7, Guide roller group 8, First guide roller 81, Second guide roller 82, Third guide roller 83, Fourth guide roller 84, Fifth guide roller 85, Sixth guide roller 86, Seventh guide roller 87, Eighth guide roller 88, Light source 9, First flat guide roller 101, Second flat guide roller 102, Visual operation table 11, First display 12, Second display 13, Finished product roller 14, Finished product guide roller 141, Waste roller 15, Waste guide roller 151. Detailed Implementation

[0031] To better understand the technical solution of this utility model, a detailed description will be provided below in conjunction with relevant illustrations. It should be understood that the specific embodiments described below are not intended to limit the specific implementation of the technical solution of this utility model, but are merely possible implementations of the technical solution of this utility model. It should be noted that the descriptions of the positional relationships of the components herein, such as component A being located above component B, are based on the relative positions of the components in the illustrations and are not intended to limit the actual positional relationships of the components. Example 1

[0032] See Figure 1 , Figure 1 A schematic diagram of the structure of an inspection machine for membrane products according to Embodiment 1 is shown. As shown in the figure, the inspection machine for membrane products according to Embodiment 1 includes an unwinding unit, a photographic unit, an inspection unit, and a finished product roller 14 arranged sequentially. The unwinding unit includes an unwinding roller 1, a first unwinding guide roller 2, a second unwinding guide roller 3, and a third unwinding guide roller 4. The photographic unit includes an industrial camera 6, a heat dissipation device 7, a light source 9, and a guide roller group 8. The inspection unit includes a visual operating table 11, a first display 12, and a second display 13.

[0033] A guide roller fixing plate is provided behind the unwinding unit, the phase collection unit, the inspection unit, the finished product roller 14 and the waste roller 15 for installing each guide roller.

[0034] The first unwinding guide roller 2 and the second unwinding guide roller 3 are arranged in parallel. The unwinding roller 1 is located below the first unwinding guide roller 2 and the second unwinding guide roller 3. The third unwinding guide roller 4 is located directly above the first unwinding guide roller 2. The fourth unwinding guide roller 5 is located directly above the second unwinding guide roller 3. The third unwinding guide roller 4 and the fourth unwinding guide roller 5 are arranged on the same horizontal plane, so that the product to be tested is laid flat after being wound around the third unwinding guide roller 4 and the fourth unwinding guide roller 5.

[0035] The guide roller group 8 includes a first guide roller 81, a second guide roller 82, a third guide roller 83, a fourth guide roller 84, a fifth guide roller 85, a sixth guide roller 86, a seventh guide roller 87, and an eighth guide roller 88. The first guide roller 81 is disposed on the same horizontal plane as the fourth unwinding guide roller 5. A second guide roller 82 is also disposed on one side of the first guide roller 81. The first guide roller 81 and the second guide roller 82 are disposed on the same horizontal plane, so that the product to be tested is laid flat after being wound around the third unwinding guide roller 4 and the fourth unwinding guide roller 5. An industrial camera 6 is disposed above the flat section of the product to be tested, and a light source 9 is disposed below it. The industrial camera 6 is mounted on a mounting plate through a hinge, and the mounting plate is fixed to the machine body, thereby the camera angle of the industrial camera 6 is adjustable.

[0036] The industrial camera 6 is provided with a heat dissipation device 7 above it, and the heat dissipation device 7 is fixed to the machine body;

[0037] The third guide roller 83, the fourth guide roller 84, the fifth guide roller 85, the sixth guide roller 86, and the seventh guide roller 87 are arranged below the first guide roller 81 and the second guide roller 82, and are staggered vertically so that the product to be tested is wound in a serpentine pattern. The third guide roller 83 is located directly below the second guide roller 82. The fourth guide roller 84 is located to the upper left of the third guide roller 83. The fifth guide roller 85 is located to the lower left of the fourth guide roller 84. The sixth guide roller 86 is located to the upper left of the fifth guide roller 85. The seventh guide roller 87 is located to the lower left of the sixth guide roller 86. The eighth guide roller 88 is located to the right of the seventh guide roller 87. The seventh guide roller 87 and the eighth guide roller 88 are arranged on the same horizontal plane. The eighth guide roller 88 is located to the lower right of the third guide roller 83.

[0038] A first flat guide roller 101 is provided directly above the eighth guide roller 88, and a second flat guide roller 102 is provided to the right of the first flat guide roller 101. The first flat guide roller 101 and the second flat guide roller 102 are arranged on the same horizontal plane, so that the product to be tested is formed into a flat shape after passing around the first flat guide roller 101 and the second flat guide roller 102. A visual operation table 11 is provided below the flat product to be tested.

[0039] Above the visualization console 11, there is a first display 12 and a second display 13 arranged side by side. The first display 12 displays the defect analysis results (color difference, stains, misalignment, etc.) in real time. The second display 13 is larger than the first display 12. The second display 13 magnifies some parts by 20 times to facilitate detailed confirmation.

[0040] Below the second flat guide roller 102 is a finished product guide roller 141, and to the lower right of the finished product guide roller 141 is a finished product roller 14, which is used to rewind the finished product that has been inspected and found to be correct; above the second flat guide roller 102 is a waste material guide roller 151, and to the upper right of the waste material guide roller 151 is a waste material roller 15, which is used to rewind the waste material that has been printed incorrectly.

[0041] The visual operating table 11 is equipped with a shearing station and a pneumatic cutting knife. The pneumatic cutting knife precisely cuts off the defective section, and the waste material is rolled into the waste roller 15. After the film material is spliced, the finished product is rolled into the finished product roller 14.

[0042] The industrial camera 6 is a 20-megapixel industrial camera, coupled with a long strip LED light source 9 parallel to the product under test. The wavelength of the light source is adjustable from 400 to 700 nm, and the illuminance is ≥1000 lux.

[0043] The visual operation console 11 uses a transparent tempered glass tabletop and is equipped with a supplementary lighting strip below, which supports manual re-inspection without stopping the machine.

[0044] The heat dissipation device 7 uses a copper heat pipe and a vortex fan for camera heat dissipation, and the measured temperature rise is ≤3℃ / 8h.

[0045] A heat dissipation mechanism is also provided above the light source 9. It uses an aluminum substrate with honeycomb holes and a hole diameter of 2mm. Heat is discharged through the gap between the guide rollers.

[0046] The surfaces of the finished product roller 14 and the waste roller 15 are provided with silicone anti-slip texture to improve traction.

[0047] Each of the aforementioned guide rollers and guide rollers used for guiding is equipped with a spring damper to prevent vibration and control film tension fluctuation within ±5N.

[0048] Specific implementation case: Inspection of a 1.2m wide transfer film;

[0049] 1. Parameter settings:

[0050] Unwinding tension: 80N, traction speed: 20m / min;

[0051] Light source wavelength: 550nm (optimized for gold ink).

[0052] 2. Testing process:

[0053] 2.1 The camera captures printing defects, and the first display shows 3 instances of misregistration (deviation ≥ 0.3mm).

[0054] 2.2 The second display magnifies the defect area, and the operator initiates the shearing command after confirmation;

[0055] 2.3. Move the membrane material above the worktable and illuminate the defective area with supplemental lighting.

[0056] 2.4. The pneumatic cutting blade precisely removes the defective section, the waste material is rolled into the waste roller, and the finished product is fed into the finished product roller after the film material is spliced.

[0057] 3. Effect Verification:

[0058] After working continuously for 8 hours, the camera temperature remained stable at 35±1℃.

[0059] The rate of missed detection for 100,000 meters of membrane material was 0.4%, and the repair loss rate was only 1.2%.

[0060] Working principle:

[0061] This invention provides an inspection machine for film products. It achieves high-precision inspection through integrated triple detection channels, significantly reducing the false negative rate. The guide rollers of the unwinding unit guide the product to be tested to the imaging unit. The product is then placed flat below the industrial camera and guided to the inspection unit via the guide rollers. The first display shows the captured image, the set capture blocks, and the error types analyzed by the system. The second display shows a magnified image, allowing operators to easily observe whether printing errors exist. After being guided by the rollers, the product is placed flat below a transparent, visual operating table. Operators can then re-observe and confirm the printing errors through the table. Once the location of the error is confirmed, the operator can cut out the incorrect content and wrap it around the waste roller via the guide rollers. The correct product is then bonded and wound onto the finished product roller. This invention achieves a fully integrated process of "automatic identification → manual verification → online repair."

[0062] The above are merely specific application examples of this utility model and do not constitute any limitation on the scope of protection of this utility model. All technical solutions formed by equivalent transformations or equivalent substitutions fall within the scope of protection of this utility model.

Claims

1. An inspection machine for membrane products, characterized in that: The system includes an unwinding unit, a photographic unit, an inspection unit, and a finished product roll (14) arranged sequentially. The unwinding unit includes an unwinding roll (1), a first unwinding guide roll (2), a second unwinding guide roll (3), a third unwinding guide roll (4), and a fourth unwinding guide roll (5). The photographic unit includes an industrial camera (6), a heat dissipation device (7), a light source (9), and a guide roller group (8). The inspection unit includes a visual operating table (11), a first display (12), and a second display (13). The product to be tested is unwound from the unwinding roll (1) and guided by the first unwinding guide roll (2), the second unwinding guide roll (3), the third unwinding guide roll (4), and the fourth unwinding guide roll (5) into the guide roller group (8) of the photographic unit. The guide roller group (8) includes a first guide roller (81), a second guide roller (82), a third guide roller (83), a fourth guide roller (84), a fifth guide roller (85), a sixth guide roller (86), a seventh guide roller (87), and an eighth guide roller (88). The first guide roller (81) is arranged on the same horizontal plane as the fourth unwinding guide roller (5). A second guide roller (82) is also provided on one side of the first guide roller (81). The first guide roller (81) and the second guide roller (82) are arranged on the same horizontal plane, so that the product to be tested is laid flat after being wound by the third unwinding guide roller (4) and the fourth unwinding guide roller (5). An industrial camera (6) is provided above the flat product to be tested, and a light source (9) is provided below it. A heat dissipation device (7) is provided above the industrial camera (6). The third guide roller (83), the fourth guide roller (84), the fifth guide roller (85), the sixth guide roller (86) and the seventh guide roller (87) are located below the first guide roller (81) and the second guide roller (82), and are arranged in an alternating manner so that the product to be tested is wound in a serpentine pattern. An eighth guide roller (88) is provided on the right side of the seventh guide roller (87). The seventh guide roller (87) and the eighth guide roller (88) are located on the same horizontal plane. The eighth guide roller (88) is located to the lower right of the third guide roller (83). A first flat guide roller (101) is provided directly above the eighth guide roller (88), and a second flat guide roller (102) is provided to the right of the first flat guide roller (101). The first flat guide roller (101) and the second flat guide roller (102) are set on the same horizontal plane, so that the product to be tested is formed into a flat shape after being wound around the first flat guide roller (101) and the second flat guide roller (102). A visual operation table (11) is provided below the flat product to be tested. Above the visualization operation table (11) are a first display (12) and a second display (13) arranged side by side. Below the second flat guide roller (102) is a finished product guide roller (141). To the lower right of the finished product guide roller (141) is a finished product roller (14) for winding the finished product.

2. The inspection machine for membrane products according to claim 1, characterized in that: The first unwinding guide roller (2) and the second unwinding guide roller (3) are arranged in parallel. The unwinding roller (1) is located below the first unwinding guide roller (2) and the second unwinding guide roller (3). The third unwinding guide roller (4) is located directly above the first unwinding guide roller (2), and the fourth unwinding guide roller (5) is located directly above the second unwinding guide roller (3). The third unwinding guide roller (4) and the fourth unwinding guide roller (5) are arranged on the same horizontal plane, so that the product to be tested is laid flat after being wound around the third unwinding guide roller (4) and the fourth unwinding guide roller (5).

3. The inspection machine for membrane products according to claim 1, characterized in that: The industrial camera (6) is mounted on the mounting plate via a hinge, and the mounting plate is fixed to the machine body, thereby making the camera angle of the industrial camera (6) adjustable; the heat dissipation device (7) is fixed to the machine body.

4. The inspection machine for membrane products according to claim 1, characterized in that: The first display (12) displays the defect analysis results in real time. The second display (13) is larger than the first display (12). The second display (13) is used for local magnification to facilitate detailed confirmation.

5. The inspection machine for membrane products according to claim 1, characterized in that: A waste guide roller (151) is provided above the second flat guide roller (102), and a waste roller (15) is provided to the upper right of the waste guide roller (151) for winding up waste material with printing errors.

6. The inspection machine for membrane products according to claim 5, characterized in that: The visual operating table (11) is equipped with a shearing station and a pneumatic cutting knife. The pneumatic cutting knife precisely cuts off the defective section, and the waste is rolled into the waste roller (15). After the film material is connected, the finished product is rolled into the finished product roller (14).

7. The inspection machine for membrane products according to claim 1, characterized in that: The industrial camera (6) is a 20-megapixel industrial camera, coupled with a long strip LED light source (9) parallel to the product under test.

8. The inspection machine for membrane products according to claim 1, characterized in that: The visual operation table (11) adopts a transparent tempered glass tabletop and is equipped with a supplementary light strip below, which supports manual re-inspection without stopping the machine.

9. The inspection machine for membrane products according to claim 1, characterized in that: The heat dissipation device (7) uses a copper heat pipe in conjunction with a vortex fan; a heat dissipation mechanism for the light source (9) is also provided above it, using an aluminum substrate with honeycomb holes.

10. An inspection machine for membrane products according to claim 1, characterized in that: A guide roller fixing plate is provided behind the unwinding unit, the phase collection unit, the inspection unit, the finished product roller (14), and the waste roller (15) for installing each guide roller.

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