A film defect detection device with code spraying marking function

Abstract

The utility model provides a film defect detection device with code spraying marking function. The existing film production line conveying device does not have the defect detection function. The upper support and lower support of the utility model are hinged; the top of lower support is equipped with conveying track, and the film production line conveying device is arranged on the conveying track; the outer side of conveying track is equipped with speed sensor; the lower support is equipped with defect detection host computer, code sprayer and lifting device; the upper support is equipped with first industrial camera, light source and second industrial camera; the column of lifting device is vertically installed on the box cover of the top of case, and the clamping block is slidably arranged on the column; the lifting motor is arranged on the box cover, and the output end of lifting motor is equipped with top block; the utility model installs each part on the existing film production line conveying device, does not need other reform, is convenient to install and is low in cost, and can avoid the pollution of detection equipment to the film to be detected.

Description

Technical Field

[0001] This utility model relates to a coding and marking device, and more particularly to a film defect detection device with coding and marking function. Background Technology

[0002] Thin films are prone to defects such as crystal points, voids, wrinkles, and uneven thickness during forming, cooling, stretching, and winding processes. Traditional production lines rely on manual sampling or offline inspection, which suffers from low inspection frequency (typically ≤2 times / hour) and slow response (average lag time >30 minutes). Failure to detect tiny crystal points on the film surface in a timely manner may lead to the degradation of the entire batch of products, resulting in direct economic losses. More seriously, the lack of an online inspection system makes it impossible to accurately locate defects. When quality problems are found in subsequent processes, it is necessary to trace back a conveyor path of 50-100 meters, involving the coordinated shutdown and inspection of multiple devices, which extends the average fault handling time to 4-6 hours and reduces the overall equipment efficiency (OEE) by 12%-18%. At the process optimization level, the lack of defect detection function creates a "quality black box." Changes in key parameters such as film thickness fluctuations (±3μm) and abnormal tension (±5N) cannot be correlated with defect characteristics, resulting in a process improvement cycle of 3-6 months. A lithium battery separator manufacturer successfully reduced its pinhole rate from 0.3% to 0.05% by introducing a machine vision inspection system and establishing a defect database, achieving a product yield of over 98% and improving process efficiency by 60%.

[0003] Existing technologies for thin film defect detection are becoming increasingly diversified, including optical inspection, ultrasonic testing, capacitive sensors, and machine vision systems. These technologies necessitate the development of intelligent conveyor devices integrating multimodal detection technologies, defect localization algorithms suitable for high-speed motion scenarios (linear speed ≥ 500 m / min), or the construction of defect data analysis platforms based on the Industrial Internet. Ultimately, this will enable a quality management upgrade from "post-production inspection" to "real-time control." Current thin film production line conveyor systems lack defect detection capabilities, making it impossible to accurately locate defects and trace their root causes. Therefore, modifications to the production line are necessary, resulting in substantial engineering work and high costs.

[0004] To facilitate the intelligent upgrading of the film manufacturing industry, this utility model designs and improves a film defect detection device for the conveying equipment of a film production line. Summary of the Invention

[0005] The purpose of this invention is to solve the problem that existing film production line conveying devices do not have defect detection functions, and to provide a film defect detection device with inkjet marking function.

[0006] The above objectives are achieved through the following technical solutions:

[0007] A film defect detection device with inkjet marking function includes an upper support and a lower support. The upper support is located above the lower support, and the bottom of one side of the upper support is hinged to the top of the corresponding side of the lower support.

[0008] The lower support is a square frame. A conveyor track is installed on each of the two opposite sides of the top of the lower support. The conveyor track is equipped with a film production line conveyor device. A speed sensor is installed on the outer side of one of the conveyor tracks. The chassis is installed inside the frame of the lower support. The defect detection host is installed inside the chassis. The space between the top of the chassis and the conveyor track is the inkjet printing operation space. The inkjet printer and lifting device are installed in the inkjet printing operation space.

[0009] The upper support is a square frame, and the first industrial camera is slidably mounted on the first crossbeam at the top of the upper support; on two opposite sides that are aligned with the length direction of the conveyor track, a light source is slidably mounted on the third crossbeam of one side, and a second industrial camera is slidably mounted on the second crossbeam of the other side.

[0010] The film production line conveying device includes a set of supports and a set of long shaft rollers; the supports are evenly arranged on each conveying track, and the supports on the two conveying tracks are set correspondingly, with a long shaft roller installed between two corresponding supports;

[0011] The top of the chassis is equipped with a cover that covers half of the top of the chassis, making the chassis a semi-open cuboid; a door is hinged to one side of the chassis.

[0012] The lifting device includes a lifting motor, a top block, a column, and a clamping block. The column is vertically mounted on the top cover of the chassis. The clamping block is slidably mounted on the column. The lifting motor is mounted on the cover, and the top block is mounted on the output end of the lifting motor. The force-bearing end of the clamping block is located above the top cover of the chassis, and the clamping end of the clamping block is located above the semi-opening of the top of the chassis. The top block is located below the force-bearing end of the clamping block. The top block includes a rotating block and a protrusion. The protrusion is provided on the side of the rotating block. The top block is mounted on the output shaft of the lifting motor through the rotating block. The cross-section of the protrusion is arc-shaped, and the radius of the arc of the lifting surface is smaller than the radius of the arc of the buffer surface. The clamping end is used to clamp the inkjet printer.

[0013] The defect detection host is electrically connected to a speed sensor, an inkjet printer, and a lifting motor for the lifting device.

[0014] Furthermore, the rotating block is disc-shaped, with protrusions disposed on the outer circumferential side.

[0015] Furthermore, the first crossbeam at the top of the upper support slides up and down on the upper support, and the sliding direction of the first camera on the first crossbeam is consistent with the width direction of the conveying track; the second crossbeam on the side of the upper support slides up and down on the upper support, and the sliding direction of the second camera on the second crossbeam is consistent with the width direction of the conveying track; the third crossbeam can slide up and down inside the upper support, and the light source can slide on the third crossbeam in a direction consistent with the width direction of the conveying track.

[0016] Threaded holes are provided at both ends of the first, second, and third crossbeams for detachably mounting the first, second, and third crossbeams onto the upper bracket using screws. Slides are provided in the horizontal direction of the first, second, and third crossbeams, and the first camera, second camera, and light source are mounted on the first, second, and third crossbeams respectively via the slides.

[0017] Furthermore, the bottom of the chassis is provided with two sliding tracks, through which the chassis is slidably mounted on the inner bottom layer of the lower bracket. Universal casters are also provided on the outer side of the bottom of the chassis. Beneficial effects

[0018] 1. This utility model primarily centers on a defect detection host, connecting and transmitting information to a first industrial camera, a second industrial camera, a light source, a speed sensor, a lifting device, and an inkjet printer via wiring. This utility model utilizes a linear array of the first and second industrial cameras to detect surface defects on the film conveyor on a film production line. The inkjet printer then marks the corresponding defect location on the back of the film. After production, the manufacturer can locate the defect based on this mark, providing a reference for troubleshooting product quality issues. Furthermore, to prevent the film from sinking under its own weight and coming into contact with the inkjet printer through the gap between the long-shaft rollers of the film production line conveyor during the marking process, this utility model also includes a lifting device. This lifting device ensures that the inkjet printer moves from a distance to a position close to the film only when marking is needed, and remains at a distance when not marking.

[0019] 2. This utility model integrates the defect detection host, speed sensor, two industrial cameras, and inkjet printer into a single bracket, making it easy to install onto existing film production line conveying devices without requiring any other modifications. It is convenient to install and has low cost.

[0020] 3. The defect detection host of this utility model uses the built-in program of the existing image defect recognition method to calculate the timing of marking based on the speed value collected by the speed sensor. It does not require a lot of parameter changes, the program is simple to modify, and it can adapt to automated thin film production lines with different conveying speeds. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model;

[0022] Figure 2 This is a schematic diagram of the structure of this utility model;

[0023] Figure 3 This is a top view structural diagram of the present invention;

[0024] Figure 4 This is a schematic diagram of the structure of the lower support involved in this utility model;

[0025] Figure 5 This is a schematic diagram of the upper support structure involved in this utility model;

[0026] Figure 6 This is a structural schematic diagram of the lifting device involved in this utility model;

[0027] Figure 7 This is a schematic diagram of the structure of the top block involved in this utility model;

[0028] Figure 8 This is a block diagram illustrating the working principle of the defect detection host involved in this utility model.

[0029] 1 is the upper support, 2 is the lower support, 3 is the conveyor rail, 4 is the speed sensor, 5 is the chassis, 6 is the defect detection host, 7 is the inkjet printer, 8 is the first industrial camera, 9 is the light source, 10 is the second industrial camera, 11 is the support, 12 is the long shaft roller, 13 is the lifting motor, 14 is the top block, 15 is the column, 16 is the clamping block, and 17 is the box cover. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model. Specific implementation method one:

[0032] This embodiment provides a film defect detection device with inkjet marking function. The device comprises an upper support 1 and a lower support 2. The upper support 1 is located above the lower support 2. The bottom of one side of the upper support 1 is hinged to the top of the corresponding side of the lower support 2. The two opposite sides are connected by a pin. By opening the pin and flipping the upper support 1 with the bottom edge of the hinged side as the axis, the structure set on the lower support 2 can be inspected, which facilitates various operations.

[0033] The lower support 2 is a square frame for easy manufacturing and installation. A conveyor rail 3 is installed on each of the two opposite sides of the top of the lower support 2. The conveyor rail 3 is equipped with a film production line conveying device. A speed sensor 4 is installed on the outer side of one of the conveyor rails 3. A chassis 5 is installed inside the frame of the lower support 2. The defect detection host 6 is installed inside the chassis 5. The space between the top of the chassis 5 and the conveyor rail 3 is the inkjet printing operation space. The inkjet printing operation space is equipped with an inkjet printer 7 and a lifting device. The inkjet printer 7 is a small or handheld inkjet printer sold on the market. The defect detection host 6 is a PC.

[0034] The upper bracket 1 is square to facilitate manufacturing and installation. The first industrial camera 8 is slidably mounted on the first crossbeam at the top of the upper bracket 1. On the two opposite sides of the upper bracket 1 that are aligned with the length direction of the conveyor track 3, the light source 9 is slidably mounted on the third crossbeam of one side, and the second industrial camera 10 is slidably mounted on the second crossbeam of the other side.

[0035] After the upper support 1 is installed on the lower support 2, the film production line conveying device is located in the lower part of the frame of the upper support 1; the film production line conveying device includes a set of supports 11 and a set of long shaft rollers 12; the supports 11 are evenly arranged on each conveying track 3, and the supports 11 on the two conveying tracks 3 are set correspondingly, and a long shaft roller 12 is installed between two corresponding supports 11.

[0036] The top of the chassis 5 is provided with a cover 17, which covers half of the top of the chassis 5, making the chassis 5 a semi-open cuboid, which facilitates wiring when the defect detection host 6 installed inside the chassis 5 is connected to other structural components; one side of the chassis 5 is hinged to a door.

[0037] To prevent the film being inspected from sinking under its own weight and coming into contact with the inkjet printer 7 through the gap between the long-shaft rollers 12 of the film production line conveyor, this invention also includes a lifting device. This device ensures that the inkjet printer 7 only moves from a distance to a position close to the film when coding is required, and remains at a distance when not coding. The lifting device includes a lifting motor 13, a top block 14, a column 15, and a clamping block 16. The column 15 is vertically mounted on the top cover of the housing 5, near the edge of the cover. The clamping block 16 is slidably mounted on the column 15. The lifting motor 13 is mounted on the top cover of the housing 5, and the top block 14 is mounted on the output end of the lifting motor 13. The force-bearing end of the clamping block 16 is located above the top cover of the housing 5, and the clamping end of the clamping block 16 is located above the semi-opening at the top of the housing 5. The top block 14 is located below the force-bearing end of the clamping block 16. The top block 14 includes a rotating block 17 and a protrusion 18, with the protrusion 18 located on the side of the rotating block 17. The top block 14 is mounted on the output shaft of the lifting motor 13 via the rotating block 17. The cross-section of the protrusion 18 is arc-shaped, and the radius of the arc on the lifting surface is smaller than the radius of the arc on the buffer surface. The slope of the lifting surface is greater to speed up the lifting operation. The rotating block 17 rotates with the rotation of the output shaft of the lifting motor 13. As a result, the protrusion 18 on the side of the rotating block 17 rotates with the rotation of the rotating block 17. Since the protrusion 18 is a curved surface, when the protrusion 18 contacts the force-bearing end of the clamping block 16 above it, the purpose of gradually lifting the entire clamping block 16 is achieved by using the protrusion 18, and then the inkjet printing operation is performed. After the inkjet printing, the protrusion 18 causes the clamping block 16 to gradually descend as the rotating block 17 rotates. Finally, the clamping block 16 separates from the protrusion 18 and descends to the lowest point, increasing the distance between the inkjet printer 7 held by the clamping block 16 and the film above. The position of the protrusion 18 is set by the existing simple motor rotation frequency control program to the fastest response to the inkjet printing operation when the motor drives the rotating block 17 to stop rotating each time.

[0038] The clamping end is used to clamp the inkjet printer 7. It clamps the printer after receiving a coding instruction.

[0039] The defect detection host 6 is electrically connected to the speed sensor 4, the inkjet printer 7, and the lifting motor 13 of the lifting device. The defect detection host 6 is also electrically connected to the power supply for the speed sensor 4, the inkjet printer 7, and the lifting motor 13 of the lifting device. Specific Implementation Method Two:

[0041] The thin film defect detection device with inkjet marking function in this embodiment differs from the first embodiment in that the rotating block 17 is disc-shaped and the protrusion 18 is disposed on the outer circular side. Specific implementation method three:

[0043] The difference between the film defect detection device with inkjet marking function in one or two embodiments of this invention and embodiment three is that the first crossbeam at the top of the upper support 1 slides up and down on the upper support 1, and the sliding direction of the first industrial camera 8 on the first crossbeam is consistent with the width direction of the conveying track 3; the second crossbeam on the side of the upper support 1 slides up and down on the upper support 1, and the sliding direction of the second industrial camera 10 on the second crossbeam is consistent with the width direction of the conveying track 3; the third crossbeam can slide up and down inside the upper support 1, and the light source 9 can slide on the third crossbeam in the same direction as the width direction of the conveying track 3;

[0044] Threaded holes are provided at both ends of the first, second, and third crossbeams for detachably mounting the first, second, and third crossbeams onto the upper bracket 1 using screws. Slides are provided in the horizontal direction of the first, second, and third crossbeams, and the first industrial camera 8, the second industrial camera 10, and the light source 9 are correspondingly mounted on the first, second, and third crossbeams via the slides. Specific implementation method four:

[0046] This embodiment of the film defect detection device with inkjet marking function differs from specific embodiment three in that the bottom of the housing 5 is further provided with two slide rails. The housing 5 is slidably mounted on the inner bottom layer of the lower support 2 via these slide rails. Universal casters are also provided on the outer side of the bottom of the housing 5. When the housing 5 slides out of the frame of the lower support 2 via the slide rails, the universal casters serve as both steering and support components. The housing 5 facilitates wiring or maintenance through the top opening.

[0047] Working principle:

[0048] Combination Figure 1-8 Explanation of the working process of this utility model:

[0049] The first industrial camera 8 and the second industrial camera 10 are mounted above the film production line conveyor via the first and second crossbeams of the upper bracket 1 to take pictures of the film surface. As the conveyor runs, the defect detection host 6 acquires images of the film surface by collecting data from the first industrial camera 8 and the second industrial camera 10. The speed sensor 4 is mounted below the film production line conveyor to scan its surface and obtain the current speed value of the conveyor. The inkjet printer 7 is mounted below the film production line conveyor and, upon receiving a communication signal from the defect detection host 6, will print a mark on the bottom of the film. This invention can also include a touch screen for communication with the defect detection host 6. The touch screen is mounted on the side of the upper bracket 1, and various operating parameters of the device can be set via the touch screen.

[0050] The defect detection host 6 stores and runs commercially available defect image detection software. It determines whether a defect exists on the film based on the surface image. If a defect is detected, it communicates with the speed sensor 4 to obtain the current speed value of the film's movement. Based on the relative positions of the first industrial camera 8, the second industrial camera 10, and the inkjet printer 7, it infers when the defect will reach the inkjet printer 7. When the defect arrives, it sends a communication signal to instruct the inkjet printer 7 to print a mark, thus marking the defect location on the bottom of the film defect, i.e., the back of the film. Simultaneously, various operating parameters of the device can be set via a touchscreen.

[0051] It should be noted that thin film defect detection technology has become increasingly diversified, including optical detection methods, ultrasonic detection methods, capacitive sensors, and machine vision systems. The appropriate method can be selected based on the specific requirements. This invention does not improve any particular method but uses existing technologies in the field, so it will not be described in detail here.

[0052] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A film defect detection device with inkjet marking function, comprising an upper support and a lower support, characterized in that: The upper bracket is located above the lower bracket, and the bottom of one side of the upper bracket is hinged to the top of the corresponding side of the lower bracket. The lower support is a square frame. A conveyor track is installed on each of the two opposite sides of the top of the lower support. The conveyor track is equipped with a film production line conveyor device. A speed sensor is installed on the outer side of one of the conveyor tracks. The chassis is installed inside the frame of the lower support. The defect detection host is installed inside the chassis. The space between the top of the chassis and the conveyor track is the inkjet printing operation space. The inkjet printer and lifting device are installed in the inkjet printing operation space. The upper support is a square frame, and the first industrial camera is slidably mounted on the first crossbeam at the top of the upper support; on two opposite sides that are aligned with the length direction of the conveyor track, a light source is slidably mounted on the third crossbeam of one side, and a second industrial camera is slidably mounted on the second crossbeam of the other side. The film production line conveying device includes a set of supports and a set of long shaft rollers; the supports are evenly arranged on each conveying track, and the supports on the two conveying tracks are set correspondingly, with a long shaft roller installed between two corresponding supports; The top of the chassis is fitted with a cover that covers half of the top of the chassis, making the chassis a semi-open cuboid. One side of the chassis has a hinged door; The lifting device includes a lifting motor, a top block, a column, and a clamping block. The column is vertically mounted on the cover at the top of the chassis, the clamping block is slidably mounted on the column, the lifting motor is mounted on the cover, and the top block is mounted on the output end of the lifting motor. The force-bearing end of the clamping block is located above the top cover of the chassis, the clamping end of the clamping block is located above the semi-opening on the top of the chassis, and the top block is located below the force-bearing end of the clamping block. The top block includes a rotating block and a protrusion. The rotating block has a protrusion on its side. The top block is mounted on the output shaft of the lifting motor through the rotating block. The cross-section of the protrusion is arc-shaped, and the radius of the arc of the lifting surface is smaller than the radius of the arc of the buffer surface. The clamping end is used to clamp the inkjet printer. The defect detection host is electrically connected to a speed sensor, an inkjet printer, and a lifting motor for the lifting device.

2. The thin film defect detection device with inkjet marking function according to claim 1, characterized in that: The rotating block is disc-shaped with protrusions on its outer circumference.

3. A film defect detection device with inkjet marking function according to claim 1 or 2, characterized in that: The first crossbeam at the top of the upper support slides up and down on the upper support, and the sliding direction of the first camera on the first crossbeam is consistent with the width direction of the conveying track; the second crossbeam on the side of the upper support slides up and down on the upper support, and the sliding direction of the second camera on the second crossbeam is consistent with the width direction of the conveying track; the third crossbeam can slide up and down inside the upper support, and the light source can slide on the third crossbeam in a direction consistent with the width direction of the conveying track. Threaded holes are provided at both ends of the first, second, and third crossbeams for detachably mounting the first, second, and third crossbeams onto the upper bracket using screws. Slides are provided in the horizontal direction of the first, second, and third crossbeams, and the first camera, second camera, and light source are mounted on the first, second, and third crossbeams respectively via the slides.

4. A film defect detection device with inkjet marking function according to claim 3, characterized in that: The chassis is also equipped with two slide rails at the bottom, through which the chassis is slidably mounted on the bottom inner layer of the lower bracket. The chassis is also equipped with casters on the outer side of the bottom.

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