CN114322796A - System and method for intelligently detecting coating film thickness uniformity of optical coating machine - Google Patents
System and method for intelligently detecting coating film thickness uniformity of optical coating machine Download PDFInfo
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- 239000011248 coating agent Substances 0.000 title claims abstract description 121
- 230000003287 optical effect Effects 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 title claims description 35
- 239000010408 film Substances 0.000 claims abstract description 534
- 238000007747 plating Methods 0.000 claims abstract description 73
- 239000012788 optical film Substances 0.000 claims abstract description 26
- 238000012545 processing Methods 0.000 claims abstract description 20
- 239000012528 membrane Substances 0.000 claims description 108
- 239000000463 material Substances 0.000 claims description 43
- 238000010586 diagram Methods 0.000 claims description 42
- 238000009501 film coating Methods 0.000 claims description 36
- 230000001419 dependent effect Effects 0.000 claims description 24
- 239000007888 film coating Substances 0.000 claims description 24
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- 238000012935 Averaging Methods 0.000 claims description 8
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- 238000004458 analytical method Methods 0.000 abstract description 4
- 238000001514 detection method Methods 0.000 abstract description 2
- 238000011897 real-time detection Methods 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 3
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- 239000002184 metal Substances 0.000 description 1
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Abstract
The invention relates to the technical field of coating detection, in particular to a system for intelligently detecting the coating thickness uniformity of an optical coating machine, which comprises a coating unit, a film identification unit, a cloud storage unit, a processor, a coating treatment unit, a coating judgment unit and a coating alarm unit, wherein the coating unit is used for judging the coating thickness uniformity of the optical coating machine; the plating unit is used for collecting data related to the film plating of the optical film plating machine in real time, marking the data related to the film plating of the optical film plating machine collected in real time as real plating information and transmitting the real plating information to the film identification unit; according to the invention, the relevant data of the coating film is integrated and processed to obtain the relevant data, variable value analysis processing is carried out according to the relevant data, so that the influence value of each value is calculated, the relevance is calculated according to the influence value, and comparison judgment is carried out according to the calculated data, so that the uniformity of the coating film is judged, the accuracy of data analysis is increased, and the working efficiency is improved.
Description
Technical Field
The invention relates to the technical field of coating detection, in particular to a system and a method for intelligently detecting the coating thickness uniformity of an optical coating machine.
Background
The optical coating refers to a process of coating one (or more) layers of metal (or medium) films on the surface of an optical part, and the purpose of coating the film on the surface of the optical part is to meet the requirements of reducing or increasing light reflection, beam splitting, color separation, light filtering, polarization and the like. Commonly used coating methods are vacuum coating (one kind of physical coating) and chemical coating.
In the coating process, because the type of coating film is different, the article that needs the coating film is different, leads to the even inequality of thickness at the coating film in-process to lead to the whole quality and the pleasing to the eye degree of coating film, simultaneously, current check out test set can't detect the thickness homogeneity of coating film, leads to the system to judge the mistake, can't carry out data analysis according to the relevant influence factor when the coating film, and then carries out the analysis judgement of numerical value conversion to the coating film.
Therefore, a system and a method for intelligently detecting the coating film thickness uniformity of an optical coating machine are provided.
Disclosure of Invention
The invention aims to provide a system and a method for intelligently detecting the coating thickness uniformity of an optical coating machine, which are characterized in that relevant data of coating are integrated to obtain relevant data, variable numerical value analysis processing is carried out according to the relevant data, so that the influence numerical values of all numerical values are calculated, the relevance calculation is carried out according to the influence numerical values, comparison judgment is carried out according to the calculated data, the coating uniformity is judged, the data analysis accuracy is increased, and the working efficiency is improved; the acquired influence is identified and processed according to various acquired image values through the calculated related data, virtual imaging is carried out according to the identification processing result, and virtual-real conversion is carried out through the virtual imaging values, so that the actual value of the required data is judged, the time consumed by data analysis is saved, and the identification accuracy is improved.
The purpose of the invention can be realized by the following technical scheme: a system for intelligently detecting the coating film thickness uniformity of an optical coating machine comprises a coating unit, a film identification unit, a cloud storage unit, a processor, a coating branch processing unit, a coating judgment unit and a coating alarm unit;
the plating unit is used for collecting data related to the film plating of the optical film plating machine in real time, marking the data related to the film plating of the optical film plating machine collected in real time as real plating information and transmitting the real plating information to the film identification unit;
the film identification unit is used for acquiring film recording information from the cloud storage unit, performing film coating identification operation on the film recording information and the real coating information, and transmitting piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and timing data corresponding to the obtained film machine name data to the processor;
the processor is used for carrying out film coating branch processing operation on the piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data, and transmitting the processed film drawing data, piece drawing high data, film temperature initial value, temperature recording initial value, wind recording initial value, film thickness initial value, film output initial value, film temperature factor, temperature recording factor, wind recording factor, film thickness factor, film output factor and time consumption score value to the plating judging unit together with the real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data;
the plating judging unit is used for performing plating judging operation on film drawing data, drawing height data, film temperature initial values, temperature recording initial values, wind recording initial values, film thickness initial values, film temperature factors, temperature recording factors, wind recording factors, film thickness factors, film output factors, time consumption evaluation values, real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data together to obtain uniform signals and non-uniform signals, and transmitting the uniform signals and the non-uniform signals to the warning plating unit;
the plating alarm unit is used for receiving and displaying the uniform signal and the non-uniform signal and sending out a corresponding prompt signal.
Further, the specific operation process of the coating identification operation is as follows:
acquiring real shadow data, film map data and film machine name data corresponding to the film map data, and matching the real shadow data with the film map data to obtain a selection signal and an acquisition signal;
the method comprises the steps of extracting a selection signal and a collection signal, identifying the selection signal and the collection signal, sending the selection signal and the collection signal to a plating unit when identifying the collection signal, performing data re-acquisition by the plating unit according to the collection signal, extracting corresponding film machine name data according to the film image data when identifying the selection signal, and extracting corresponding piece drawing high data, piece image data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film machine name data.
Further, the specific operation process of the film coating sorting operation is as follows:
selecting corresponding film material data according to the film machine name data, and selecting a plurality of corresponding film consumption data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film material data;
extracting a plurality of film thickness data corresponding to a plurality of same film material data, carrying out average value calculation on the plurality of film thickness data, calculating a film thickness average value, carrying out difference value calculation on the film thickness average value and the plurality of film thickness data so as to calculate a plurality of film thickness difference values, carrying out average value calculation on the plurality of film thickness difference values, and calculating a film thickness average difference value;
calculating a corresponding average value of a plurality of film temperature data, temperature recording data, wind recording data and film outlet data corresponding to a plurality of same film material data according to a calculation mode of a film thickness average value, sequentially marking the average value as a film temperature average value, a temperature recording average value, a wind recording average value and a film outlet average value, calculating an average value of a plurality of film consumption data corresponding to a plurality of same film material data, and calculating a film consumption average value;
carrying out variable processing on a plurality of film consumption average values, film temperature average values, temperature recording average values, film thickness average difference values, air recording average values and film outlet average values to obtain film temperature factors, temperature recording factors, air recording factors, film thickness factors, film outlet factors, initial film temperature values, initial temperature recording values, initial air recording values, initial film thickness values and initial film outlet values;
and (3) bringing the membrane temperature initial value, the wind initial value, the membrane thickness initial value, the membrane output initial value, the membrane temperature factor, the wind factor, the membrane thickness factor, the membrane output factor, the membrane temperature mean value, the wind mean value, the membrane thickness difference value and the membrane output mean value into a time-consuming scoring calculation formula, and calculating a time-consuming scoring value Pr.
Further, the specific processing procedure of variable processing is as follows:
the method comprises the following steps of (1) calibrating a plurality of membrane consumed average values as dependent variables, sequentially calibrating membrane temperature average values, temperature recording average values, membrane thickness average difference values, wind recording average values and membrane output average values as independent variables, selecting one of the independent variables to change, keeping other values unchanged, selecting a plurality of corresponding data of the independent variables, carrying out difference calculation on the independent variables to calculate independent variable difference values, carrying out difference calculation on the dependent variables corresponding to the independent variables to calculate dependent variable difference values, and bringing the dependent variable difference values into a calculation formula: the dependent variable difference is independent variable difference independent variable influence factor, calculating independent variable influence factor, sequentially marking the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as independent variables, calculating independent variable influence factor, thereby calculating influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value, and sequentially marking the influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as membrane temperature factor, temperature recording factor, wind recording factor, membrane thickness factor and membrane output factor;
calibrating a plurality of independent variable difference values and dependent variable difference values in a virtual rectangular coordinate, wherein the independent variable difference values are X-axis numerical values, the dependent variable difference values are Y-axis numerical values, when the independent variable difference values change but the dependent variable difference values do not change, calibrating the corresponding independent variable difference values as initial independent variables, and sequentially calibrating the initial independent variables as film temperature initial values, air initial values, film thickness initial values and film outlet initial values according to film temperature mean values, temperature recording mean values, film thickness average difference values, air recording mean values and film outlet mean values.
Further, the specific calculation process of the time-consuming scoring calculation formula is as follows:
where Pr is represented as a time-consuming score value, MWr is represented as a film temperature mean value, MCr is represented as a film temperature initial value, u1 is represented as a film temperature factor, MHr is represented as a film thickness mean difference value, HCr is represented as a film thickness initial value, u4 is represented as a film thickness factor, CMr is represented as a film averaging value, CCr is represented as a film averaging value, u5 is represented as a film averaging factor, e1 is represented as an integral deviation adjustment factor of the film temperature mean value, the film thickness mean difference value, and the film averaging value, JFr is represented as a note wind mean value, FCr is represented as a note wind initial value, u3 is represented as a note wind factor, JWr is represented as a note temperature mean value, JCr is represented as a note temperature initial value, u2 is represented as a note wind factor, e2 is represented as an integral deviation adjustment factor of the note wind mean value and the note temperature initial value, and e1 and e2 are preset values.
Further, the specific operation process of the coating judging operation is as follows:
acquiring film diagram data, part height data and real image data, and performing virtual and real processing on the film diagram data, the part height data and the real image data to obtain a film real value;
respectively calibrating two time points of film coating into a first time and a second time, selecting corresponding film real value, real temperature data, ring temperature data, real wind data and real output data in the first time and the second time, respectively carrying out mean value calculation on the film real value, real temperature mean value, ring temperature mean value, real wind mean value and real output mean value;
according to a time-consuming scoring calculation formula, carrying out time-consuming scoring calculation on the membrane real average value, the real temperature average value, the environment temperature average value, the real wind average value, the real output average value, the membrane temperature initial value, the temperature recording initial value, the membrane thickness initial value, the membrane output initial value, the membrane temperature factor, the temperature recording factor, the wind recording factor, the membrane thickness factor and the membrane output factor to calculate an actual scoring value;
and calculating the difference between the actual value and the time-consuming value, calculating the actual consumption value, setting a preset value of the actual consumption value, calibrating the preset value of the actual consumption value as the actual preset value, comparing the actual preset value with the actual consumption value, judging that the coating uniformity is high when the actual consumption value is less than the actual preset value, generating a uniform signal, and judging that the coating uniformity is low when the actual consumption value is more than or equal to the actual preset value, and generating an uneven signal.
Further, the specific process of performing virtual-real processing on the film drawing data, the part height data and the real shadow data is as follows:
identifying real image data and piece diagram data, carrying out coordinate marking on the identified real image data in a virtual space rectangular coordinate system so as to mark an image of the piece diagram data, horizontally placing the image of the piece diagram data, carrying out difference calculation on the maximum value and the minimum value of a Z axis in coordinate points of the piece diagram data, calculating a virtual height value, carrying out ratio calculation on the virtual height value and the piece height data, and calculating a virtual-real ratio;
and identifying film image data in the real image data, calculating a difference value between the maximum value of the Z axis and the minimum value of the Z axis of the film image data, calculating a film virtual value, and calculating a product of the film virtual value and a virtual-real ratio to calculate a film real value, namely the actual horizontal height of the film.
A method for intelligently detecting a system for detecting the film thickness uniformity of a coated film of an optical coating machine is characterized by comprising the following steps:
the method comprises the following steps: collecting relevant data of the optical coating machine in real time through a coating unit, marking the data collected in real time relevant to the coating of the optical coating machine as real coating information, and transmitting the real coating information to a film identification unit;
step two: the film identification unit is used for acquiring film recording information from the cloud storage unit, performing film coating identification operation on the film recording information and the real coating information, and transmitting piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and timing data corresponding to the obtained film machine name data to the processor;
step three: coating film distribution operation is carried out on the piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data through a processor, and the processed film drawing data, piece drawing high data, film temperature initial value, temperature recording initial value, wind recording initial value, film thickness initial value, film output initial value, film temperature factor, temperature recording factor, wind recording factor, film output factor and time consumption value are transmitted to a coating judging unit together with real image data, real temperature data, environment temperature data, real wind data, real output data and time data;
step four: coating film judging operation is carried out on film diagram data, piece height data, a film temperature initial value, a temperature recording initial value, a wind recording initial value, a film thickness initial value, a film outlet initial value, a film temperature factor, a temperature recording factor, a wind recording factor, a film thickness factor, a film outlet factor, a time consumption evaluation value, real shadow data, real temperature data, environment temperature data, real wind data, real outlet data and time data through a coating judging unit to obtain a uniform signal and a non-uniform signal, and the uniform signal and the non-uniform signal are transmitted to a plating alarm unit;
step five: and receiving and displaying the uniform signal and the non-uniform signal through the plating alarm unit, and sending out a corresponding prompt signal.
The invention has the beneficial effects that:
(1) relevant data of the coating film are integrated and processed to obtain relevant data, variable numerical value analysis processing is carried out according to the relevant data, so that influence numerical values of various numerical values are calculated, relevance calculation is carried out according to the influence numerical values, comparison and judgment are carried out according to the calculated data, so that the uniformity of the coating film is judged, the accuracy of data analysis is improved, and the working efficiency is improved;
(2) the acquired influence is identified and processed according to various acquired image values through the calculated related data, virtual imaging is carried out according to the identification processing result, and virtual-real conversion is carried out through the virtual imaging values, so that the actual value of the required data is judged, the time consumed by data analysis is saved, and the identification accuracy is improved.
Drawings
The invention will be further described with reference to the accompanying drawings.
FIG. 1 is a system block diagram of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention is a system and method for intelligently detecting the coating film thickness uniformity of an optical coating machine, including a coating unit, a film recognition unit, a cloud storage unit, a processor, a coating management unit, a coating judgment unit and a coating alarm unit;
the plating unit is used for collecting relevant data of the optical film plating machine in real time, and marking the relevant data of the optical film plating machine collected in real time as real plating information, the real plating information comprises real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data, the real shadow data refers to image data of the optical film plating machine for real-time detection, the real temperature data refers to the temperature of the optical film plating machine for real-time detection, the environment temperature of the optical film plating machine for real-time detection during film plating, the real wind data refers to the wind power of the optical film plating machine in the environment during film plating, the real output data refers to the film output speed of the optical film plating machine for real-time detection, and the time data refers to each time point during film plating of the optical film plating machine for real-time detection, and the real shadow data, the real temperature data, the environment temperature data, the real wind data, The real data and the time data are transmitted to a film identification unit;
the cloud storage unit stores film recording information of film coating correlation degrees of the optical film coating machine, the film recording information comprises film name data, film map data, part height data, part map data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and time recording data, the film name data refers to the name and the model of the optical film coating machine in record, the film map data refers to the appearance image of the optical film coating machine in record, the film material data refers to the material of a film used by the optical film coating machine in record, the film temperature data refers to the temperature of the film coated by the optical film coating machine in record, the temperature recording data refers to the ambient temperature of the optical film coating machine in record during film coating, the wind recording data refers to the ambient temperature of the optical film coating machine in record during film coating, and the part height data refers to the horizontal height of a multi-degree workpiece of the optical film coating machine in record, the workpiece drawing data refers to an appearance image of a workpiece needing to be coated by the optical coating machine in record, the film thickness data refers to the thickness of the workpiece needing to be coated by the optical coating machine in record, the film discharging data refers to the film discharging speed of the optical coating machine in record during coating, the timing data refers to a corresponding time point of the optical coating machine in record during coating, and the film consumption data refers to the consumption time of the optical coating machine in record during coating;
the film identification unit acquires film machine name data, film diagram data, film height data, film diagram data, film material data, film temperature data, film consumption data, temperature recording data, wind recording data, film thickness data, film output data and time recording data from the cloud storage unit, and carries out film coating identification operation on the film machine name data, the film diagram data, the film height data, the film diagram data, the film material data, the film temperature data, the temperature recording data, the wind recording data, the film thickness data, the film output data, the time recording data, real image data, real temperature data, environment temperature data, real wind data, real output data and time data, and the specific operation process of the film coating identification operation is as follows:
the method comprises the following steps of obtaining real shadow data, film diagram data and film machine name data corresponding to the film diagram data, and matching the real shadow data with the film diagram data, wherein the film machine name data specifically comprise: when the matching results of the real image data and the film map data are consistent, judging that an image matched with one film plating machine in the film map data exists in the real image data, generating a selection signal, and when the matching results of the real image data and the film map data are inconsistent, judging that an image matched with one film plating machine in the film map data does not exist in the real image data, and generating an acquisition signal;
extracting a selection signal and an acquisition signal, identifying the selection signal and the acquisition signal, sending the acquisition signal to a plating unit when the acquisition signal is identified, performing data acquisition again by the plating unit according to the acquisition signal, extracting corresponding film machine name data according to the film image data when the selection signal is identified, and extracting corresponding piece-drawing high data, piece image data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film machine name data;
transmitting corresponding real temperature data, environment temperature data, real wind data, real output data and time data to a plating judging unit according to the real shadow data;
transmitting piece-drawing high data, piece-drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and timing data corresponding to the film machine name data to a plating branch management unit through a processor;
the coating dividing and managing unit is used for performing coating dividing and managing operation on piece-drawing high data, piece-drawing data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data, and the specific operation process of the coating dividing and managing operation is as follows:
selecting corresponding film material data according to the film machine name data, and selecting a plurality of corresponding film consumption data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film material data;
the method comprises the steps of calculating a plurality of film thickness data corresponding to a plurality of same film material data, summing the plurality of film thickness data, dividing the data obtained after the summation calculation by the number of the plurality of film thickness data to calculate a film thickness average value, calculating the difference value between the film thickness average value and the plurality of film thickness data to calculate a plurality of film thickness difference values, summing the plurality of film thickness difference values, dividing the value obtained after the summation calculation by the number of the plurality of film thickness difference values to calculate a film thickness average difference value;
calculating a corresponding average value of a plurality of film temperature data, temperature recording data, wind recording data and film outlet data corresponding to a plurality of same film material data according to a calculation mode of a film thickness average value, sequentially marking the average value as a film temperature average value, a temperature recording average value, a wind recording average value and a film outlet average value, calculating an average value of a plurality of film consumption data corresponding to a plurality of same film material data, and calculating a film consumption average value;
the method comprises the following steps of (1) calibrating a plurality of membrane consumed average values as dependent variables, sequentially calibrating membrane temperature average values, temperature recording average values, membrane thickness average difference values, wind recording average values and membrane output average values as independent variables, selecting one of the independent variables to change, keeping other values unchanged, selecting a plurality of corresponding data of the independent variables, carrying out difference calculation on the independent variables to calculate independent variable difference values, carrying out difference calculation on the dependent variables corresponding to the independent variables to calculate dependent variable difference values, and bringing the dependent variable difference values into a calculation formula: the dependent variable difference is independent variable difference independent variable influence factor, calculating independent variable influence factor, sequentially marking the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as independent variables, calculating independent variable influence factor, thereby calculating influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value, and sequentially marking the influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as membrane temperature factor, temperature recording factor, wind recording factor, membrane thickness factor and membrane output factor;
calibrating a plurality of independent variable difference values and dependent variable difference values in a virtual rectangular coordinate, wherein the independent variable difference values are X-axis numerical values, the dependent variable difference values are Y-axis numerical values, when the independent variable difference values change but the dependent variable difference values do not change, the corresponding independent variable difference values are calibrated as initial independent variables, and the initial independent variables are sequentially calibrated as film temperature initial values, air initial values, film thickness initial values and film outlet initial values according to film temperature mean values, temperature recording mean values, film thickness average difference values, air recording mean values and film outlet mean values;
bringing the initial value of the membrane temperature, the initial value of the wind, the initial value of the membrane thickness, the initial value of the membrane output, the factor of the membrane temperature, the factor of the wind, the factor of the membrane thickness, the factor of the membrane output, the mean value of the membrane temperature, the mean value of the wind, the difference value of the membrane thickness and the mean value of the membrane output into a time-consuming scoring calculation formula:
wherein Pr is represented as a time-consuming score value, MWr is represented as a membrane temperature mean value, MCr is represented as a membrane temperature initial value, u1 is represented as a membrane temperature factor, MHr is represented as a membrane thickness average difference value, HCr is represented as a membrane thickness initial value, u4 is represented as a membrane thickness factor, CMr is represented as a membrane mean value, CCr is represented as a membrane thickness initial value, u5 is represented as a membrane thickness factor, e1 is represented as an integral deviation adjustment factor of the membrane temperature mean value, the membrane thickness average difference value and the membrane thickness mean value, JFr is represented as a note wind mean value, FCr is represented as a note wind initial value, u3 is represented as a note wind factor, JWr is represented as a note temperature mean value, JCr is represented as a note temperature initial value, u2 is represented as a note wind factor, e2 is represented as an integral deviation adjustment factor of the note wind mean value and the note temperature initial value, and e1 and e2 are preset values;
the film diagram data, the film height data, the film temperature initial value, the temperature recording initial value, the wind recording initial value, the film thickness initial value, the film outlet initial value, the film temperature factor, the temperature recording factor, the wind recording factor, the film thickness factor, the film outlet factor and the time consumption score value are transmitted to a plating judging unit together with the real shadow data, the real temperature data, the environment temperature data, the real wind data, the real outlet data and the time data;
the coating judging unit is used for carrying out coating judging operation on the film drawing data, the drawing height data, the film temperature initial value, the wind initial value, the film thickness initial value, the film temperature factor, the wind factor, the film thickness factor, the film output factor, the time consumption evaluation value, the real shadow data, the real temperature data, the environment temperature data, the real wind data, the real output data and the time data together, and the specific operation process of the coating judging operation is as follows:
acquiring film diagram data, piece height data and real image data, identifying the real image data and the piece diagram data, carrying out coordinate marking on the identified real image data in a virtual space rectangular coordinate system so as to mark an image of the piece diagram data, horizontally placing the image of the piece diagram data, carrying out difference calculation on the maximum value and the minimum value of a Z axis in coordinate points of the piece diagram data, calculating a virtual height value, carrying out ratio calculation on the virtual height value and the piece height data, and calculating a virtual-real ratio;
identifying film image data in the real image data, calculating a difference value between the maximum value of the Z axis and the minimum value of the Z axis of the film image data, calculating a film virtual value, and calculating a product of the film virtual value and a virtual-real ratio to calculate a film real value, namely the actual horizontal height of the film;
respectively calibrating two time points of film coating into a first time and a second time, selecting corresponding film real value, real temperature data, ring temperature data, real wind data and real output data in the first time and the second time, respectively carrying out mean value calculation on the film real value, real temperature mean value, ring temperature mean value, real wind mean value and real output mean value;
the time-consuming scoring calculation formula carries out time-consuming scoring calculation on the membrane real average value, the real temperature average value, the environment temperature average value, the real wind average value, the real output average value, the membrane temperature initial value, the temperature recording initial value, the membrane thickness initial value, the membrane output initial value, the membrane temperature factor, the temperature recording factor, the wind recording factor, the membrane thickness factor and the membrane output factor to calculate the actual scoring value;
calculating the difference between the actual value of the evaluation and the time-consuming value of the evaluation, calculating the actual value of the evaluation, setting a preset value of the actual value of the evaluation, calibrating the preset value of the actual value of the evaluation as the actual value of the evaluation, comparing the actual value of the evaluation with the actual value of the evaluation, judging that the coating uniformity is high when the actual value of the evaluation is less than the actual value of the evaluation, generating a uniform signal, and judging that the coating uniformity is low when the actual value of the evaluation is greater than or equal to the actual value of the evaluation, and generating a non-uniform signal;
transmitting the uniform signal and the non-uniform signal to a plating alarm unit;
the plating alarm unit is used for receiving and displaying the uniform signals and the non-uniform signals and sending out corresponding prompt signals, and the plating alarm unit is specifically a tablet personal computer.
A method applied to a system for intelligently detecting the coating film thickness uniformity of an optical coating machine comprises the following steps:
the method comprises the following steps: the real shadow data, the real temperature data, the environment temperature data, the real wind data, the real output data and the time data are transmitted to the film identification unit;
step two: film recording information of film coating correlation degree of the chemical film coating machine is stored through a cloud storage unit, and the film recording information comprises film machine name data, film drawing data, part height data, part drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and time recording data;
step three: the method comprises the steps that film machine name data, film diagram data, part height data, part diagram data, film material data, film temperature data, film consumption data, temperature recording data, wind recording data, film thickness data, film output data and time recording data are obtained from a cloud storage unit through a film identification unit, film machine name data, film diagram data, part height data, part diagram data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data, time recording data, real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data are subjected to film coating identification operation, and piece height data, part diagram data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and time recording data corresponding to the obtained film machine name data are transmitted to a plating branch processing unit through a processor;
step four: coating film dividing operation is carried out on the piece-included high data, piece diagram data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data through a coating dividing operation unit, and the obtained film diagram data, piece high data, film temperature initial value, temperature recording initial value, wind recording initial value, film thickness initial value, film output initial value, film temperature factor, temperature recording factor, wind recording factor, film thickness factor, film output factor and time consumption value are transmitted to a coating judging unit together with real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data;
step five: coating film judging operation is carried out on film diagram data, piece height data, a film temperature initial value, a temperature recording initial value, a wind recording initial value, a film thickness initial value, a film outlet initial value, a film temperature factor, a temperature recording factor, a wind recording factor, a film thickness factor, a film outlet factor, a time consumption evaluation value, real shadow data, real temperature data, environment temperature data, real wind data, real outlet data and time data through a coating judging unit to obtain a uniform signal and a non-uniform signal, and the uniform signal and the non-uniform signal are transmitted to a plating alarm unit;
step six: and receiving and displaying the uniform signal and the non-uniform signal through the plating alarm unit, and sending out a corresponding prompt signal.
When the optical film coating machine works, the data related to the film coating of the optical film coating machine is collected in real time through the film coating unit, the data related to the film coating of the optical film coating machine is marked as real coating information, the real coating information comprises real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data, the real shadow data, the real temperature data, the environment temperature data, the real wind data, the real output data and the time data are transmitted to the film identification unit, the film recording information related to the film coating of the optical film coating machine is stored through the cloud storage unit, the film recording information comprises film name data, film diagram data, part diagram data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and time recording data, and the film name data, the film diagram data, the part diagram data, the real temperature data, the environment temperature data, the wind recording data, the film consumption data, the film output data and the time recording data are obtained from the cloud storage unit through the film identification unit, Film material data, film temperature data, film consumption data, temperature recording data, wind recording data, film thickness data, film output data and time recording data, coating identification operation is carried out on film machine name data, film drawing data, piece height data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data and real image data, real temperature data, ring temperature data, real wind data, real output data and time data, the piece height data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and time recording data corresponding to the obtained film machine name data are transmitted to a plating dividing unit through a processor, and the piece height data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data and time recording data corresponding to the film machine name data are transmitted to a plating dividing unit through the plating dividing unit, Film consumption data, film thickness data, film output data and timing data are subjected to film coating treatment operation, the obtained film diagram data, piece height data, film temperature initial value, wind initial value, film thickness initial value, film temperature factor, wind factor, film thickness factor, film output factor and time consumption evaluation value are transmitted to a plating judging unit together with real image data, real temperature data, environment temperature data, real wind data, real output data and time data, the film diagram data, piece height data, film temperature initial value, wind initial value, film thickness initial value, film output initial value, film temperature factor, wind factor, film output factor and time consumption evaluation value are subjected to film coating judging operation together with the real image data, real temperature data, environment temperature data, real wind data, real output data and time data by the plating judging unit, and obtaining uniform signals and non-uniform signals, transmitting the uniform signals and the non-uniform signals to a plating alarm unit, receiving and displaying the uniform signals and the non-uniform signals through the plating alarm unit, and sending corresponding prompt signals.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (8)
1. A system for intelligently detecting the coating film thickness uniformity of an optical coating machine is characterized by comprising a coating unit, a film identification unit, a cloud storage unit, a processor, a coating branch processing unit, a coating judgment unit and a coating alarm unit;
the plating unit is used for collecting data related to the film plating of the optical film plating machine in real time, marking the data related to the film plating of the optical film plating machine collected in real time as real plating information and transmitting the real plating information to the film identification unit;
the film identification unit is used for acquiring film recording information from the cloud storage unit, performing film coating identification operation on the film recording information and the real coating information, and transmitting piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and timing data corresponding to the obtained film machine name data to the processor;
the processor is used for carrying out film coating branch processing operation on the piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data, and transmitting the processed film drawing data, piece drawing high data, film temperature initial value, temperature recording initial value, wind recording initial value, film thickness initial value, film output initial value, film temperature factor, temperature recording factor, wind recording factor, film thickness factor, film output factor and time consumption score value to the plating judging unit together with the real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data;
the plating judging unit is used for performing plating judging operation on film drawing data, drawing height data, film temperature initial values, temperature recording initial values, wind recording initial values, film thickness initial values, film temperature factors, temperature recording factors, wind recording factors, film thickness factors, film output factors, time consumption evaluation values, real shadow data, real temperature data, environment temperature data, real wind data, real output data and time data together to obtain uniform signals and non-uniform signals, and transmitting the uniform signals and the non-uniform signals to the warning plating unit;
the plating alarm unit is used for receiving and displaying the uniform signal and the non-uniform signal and sending out a corresponding prompt signal.
2. The system of claim 1, wherein the specific process of the coating identification operation comprises:
acquiring real shadow data, film map data and film machine name data corresponding to the film map data, and matching the real shadow data with the film map data to obtain a selection signal and an acquisition signal;
the method comprises the steps of extracting a selection signal and a collection signal, identifying the selection signal and the collection signal, sending the selection signal and the collection signal to a plating unit when identifying the collection signal, performing data re-acquisition by the plating unit according to the collection signal, extracting corresponding film machine name data according to the film image data when identifying the selection signal, and extracting corresponding piece drawing high data, piece image data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film machine name data.
3. The system of claim 2, wherein the specific process of the coating sorting operation comprises:
selecting corresponding film material data according to the film machine name data, and selecting a plurality of corresponding film consumption data, film temperature data, temperature recording data, wind recording data, film thickness data, film output data and time recording data according to the film material data;
extracting a plurality of film thickness data corresponding to a plurality of same film material data, carrying out average value calculation on the plurality of film thickness data, calculating a film thickness average value, carrying out difference value calculation on the film thickness average value and the plurality of film thickness data so as to calculate a plurality of film thickness difference values, carrying out average value calculation on the plurality of film thickness difference values, and calculating a film thickness average difference value;
calculating a corresponding average value of a plurality of film temperature data, temperature recording data, wind recording data and film outlet data corresponding to a plurality of same film material data according to a calculation mode of a film thickness average value, sequentially marking the average value as a film temperature average value, a temperature recording average value, a wind recording average value and a film outlet average value, calculating an average value of a plurality of film consumption data corresponding to a plurality of same film material data, and calculating a film consumption average value;
carrying out variable processing on a plurality of film consumption average values, film temperature average values, temperature recording average values, film thickness average difference values, air recording average values and film outlet average values to obtain film temperature factors, temperature recording factors, air recording factors, film thickness factors, film outlet factors, initial film temperature values, initial temperature recording values, initial air recording values, initial film thickness values and initial film outlet values;
and (3) bringing the membrane temperature initial value, the wind initial value, the membrane thickness initial value, the membrane output initial value, the membrane temperature factor, the wind factor, the membrane thickness factor, the membrane output factor, the membrane temperature mean value, the wind mean value, the membrane thickness difference value and the membrane output mean value into a time-consuming scoring calculation formula, and calculating a time-consuming scoring value Pr.
4. The system for intelligently detecting the coating thickness uniformity of an optical coating machine according to claim 3, wherein the specific processing procedures of variable processing are as follows:
the method comprises the following steps of (1) calibrating a plurality of membrane consumed average values as dependent variables, sequentially calibrating membrane temperature average values, temperature recording average values, membrane thickness average difference values, wind recording average values and membrane output average values as independent variables, selecting one of the independent variables to change, keeping other values unchanged, selecting a plurality of corresponding data of the independent variables, carrying out difference calculation on the independent variables to calculate independent variable difference values, carrying out difference calculation on the dependent variables corresponding to the independent variables to calculate dependent variable difference values, and bringing the dependent variable difference values into a calculation formula: the dependent variable difference is independent variable difference independent variable influence factor, calculating independent variable influence factor, sequentially marking the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as independent variables, calculating independent variable influence factor, thereby calculating influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value, and sequentially marking the influence factors sequentially corresponding to the membrane temperature average value, the temperature recording average value, the membrane thickness average value, the wind recording average value and the membrane output average value as membrane temperature factor, temperature recording factor, wind recording factor, membrane thickness factor and membrane output factor;
calibrating a plurality of independent variable difference values and dependent variable difference values in a virtual rectangular coordinate, wherein the independent variable difference values are X-axis numerical values, the dependent variable difference values are Y-axis numerical values, when the independent variable difference values change but the dependent variable difference values do not change, calibrating the corresponding independent variable difference values as initial independent variables, and sequentially calibrating the initial independent variables as film temperature initial values, air initial values, film thickness initial values and film outlet initial values according to film temperature mean values, temperature recording mean values, film thickness average difference values, air recording mean values and film outlet mean values.
5. The system of claim 4, wherein the calculation formula of the time-consuming score is calculated by the following steps:
where Pr is represented as a time-consuming score value, MWr is represented as a film temperature mean value, MCr is represented as a film temperature initial value, u1 is represented as a film temperature factor, MHr is represented as a film thickness mean difference value, HCr is represented as a film thickness initial value, u4 is represented as a film thickness factor, CMr is represented as a film averaging value, CCr is represented as a film averaging value, u5 is represented as a film averaging factor, e1 is represented as an integral deviation adjustment factor of the film temperature mean value, the film thickness mean difference value, and the film averaging value, JFr is represented as a note wind mean value, FCr is represented as a note wind initial value, u3 is represented as a note wind factor, JWr is represented as a note temperature mean value, JCr is represented as a note temperature initial value, u2 is represented as a note wind factor, e2 is represented as an integral deviation adjustment factor of the note wind mean value and the note temperature initial value, and e1 and e2 are preset values.
6. The system of claim 5, wherein the specific operation process of the coating judgment operation comprises:
acquiring film diagram data, part height data and real image data, and performing virtual and real processing on the film diagram data, the part height data and the real image data to obtain a film real value;
respectively calibrating two time points of film coating into a first time and a second time, selecting corresponding film real value, real temperature data, ring temperature data, real wind data and real output data in the first time and the second time, respectively carrying out mean value calculation on the film real value, real temperature mean value, ring temperature mean value, real wind mean value and real output mean value;
according to a time-consuming scoring calculation formula, carrying out time-consuming scoring calculation on the membrane real average value, the real temperature average value, the environment temperature average value, the real wind average value, the real output average value, the membrane temperature initial value, the temperature recording initial value, the membrane thickness initial value, the membrane output initial value, the membrane temperature factor, the temperature recording factor, the wind recording factor, the membrane thickness factor and the membrane output factor to calculate an actual scoring value;
and calculating the difference between the actual value and the time-consuming value, calculating the actual consumption value, setting a preset value of the actual consumption value, calibrating the preset value of the actual consumption value as the actual preset value, comparing the actual preset value with the actual consumption value, judging that the coating uniformity is high when the actual consumption value is less than the actual preset value, generating a uniform signal, and judging that the coating uniformity is low when the actual consumption value is more than or equal to the actual preset value, and generating an uneven signal.
7. The system of claim 6, wherein the virtual-real processing of the film drawing data, the part height data and the real image data comprises:
identifying real image data and piece diagram data, carrying out coordinate marking on the identified real image data in a virtual space rectangular coordinate system so as to mark an image of the piece diagram data, horizontally placing the image of the piece diagram data, carrying out difference calculation on the maximum value and the minimum value of a Z axis in coordinate points of the piece diagram data, calculating a virtual height value, carrying out ratio calculation on the virtual height value and the piece height data, and calculating a virtual-real ratio;
and identifying film image data in the real image data, calculating a difference value between the maximum value of the Z axis and the minimum value of the Z axis of the film image data, calculating a film virtual value, and calculating a product of the film virtual value and a virtual-real ratio to calculate a film real value, namely the actual horizontal height of the film.
8. The method for implementing the system for intelligently detecting the coating thickness uniformity of the optical coating machine according to claim 1 is characterized by comprising the following steps:
the method comprises the following steps: collecting relevant data of the optical coating machine in real time through a coating unit, marking the data collected in real time relevant to the coating of the optical coating machine as real coating information, and transmitting the real coating information to a film identification unit;
step two: the film identification unit is used for acquiring film recording information from the cloud storage unit, performing film coating identification operation on the film recording information and the real coating information, and transmitting piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film thickness data, film consumption data, film output data and timing data corresponding to the obtained film machine name data to the processor;
step three: coating film distribution operation is carried out on the piece drawing high data, piece drawing data, film material data, film temperature data, temperature recording data, wind recording data, film consumption data, film thickness data, film output data and time recording data corresponding to the film machine name data through a processor, and the processed film drawing data, piece drawing high data, film temperature initial value, temperature recording initial value, wind recording initial value, film thickness initial value, film output initial value, film temperature factor, temperature recording factor, wind recording factor, film output factor and time consumption value are transmitted to a coating judging unit together with real image data, real temperature data, environment temperature data, real wind data, real output data and time data;
step four: coating film judging operation is carried out on film diagram data, piece height data, a film temperature initial value, a temperature recording initial value, a wind recording initial value, a film thickness initial value, a film outlet initial value, a film temperature factor, a temperature recording factor, a wind recording factor, a film thickness factor, a film outlet factor, a time consumption evaluation value, real shadow data, real temperature data, environment temperature data, real wind data, real outlet data and time data through a coating judging unit to obtain a uniform signal and a non-uniform signal, and the uniform signal and the non-uniform signal are transmitted to a plating alarm unit;
step five: and receiving and displaying the uniform signal and the non-uniform signal through the plating alarm unit, and sending out a corresponding prompt signal.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116228043A (en) * | 2023-05-05 | 2023-06-06 | 苏州德耐纳米科技有限公司 | Coating uniformity evaluation system of coating machine |
| CN116641035A (en) * | 2023-07-26 | 2023-08-25 | 南京诺源医疗器械有限公司 | Film coating method for laparoscopic optical piece |
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2021
- 2021-12-30 CN CN202111658771.6A patent/CN114322796A/en not_active Withdrawn
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116228043A (en) * | 2023-05-05 | 2023-06-06 | 苏州德耐纳米科技有限公司 | Coating uniformity evaluation system of coating machine |
| CN116641035A (en) * | 2023-07-26 | 2023-08-25 | 南京诺源医疗器械有限公司 | Film coating method for laparoscopic optical piece |
| CN116641035B (en) * | 2023-07-26 | 2023-10-13 | 南京诺源医疗器械有限公司 | Film coating method for laparoscopic optical piece |
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