DE10252340A1 - Device for detecting structure, especially adhesive track, for application to substrate consists of illumination module and sensor unit that is provided on device for applying structure - Google Patents

Abstract

The device consists of an illumination module (5) and a sensor unit (3). The sensor unit is provided on the device (1) for applying the structure (9). The sensor unit is positioned directly on the output of the device for applying the structure. The sensor unit has a video sensor that preferably records one or more image lines. The illumination module contains a white light illumination module. AN Independent claim is also included for the following: (a) a device for detecting a structure, especially an adhesive track, for application to a substrate.

Description

The following invention relates to a Device for recognizing a to be applied to a substrate Structure according to the generic term of claim 1 and suitable methods therefor.

Traditionally so far optical for recognizing a structure to be applied to a substrate Measurements carried out, being frequent various systems for fully automatic inspection of the structure, including Adhesive- and sealant beads. For this, one or several video cameras aimed at the structure to be recognized. In addition is a lighting module required to generate a high contrast Camera image is used. The review of the Structure occurs with a time delay, a few seconds after the Structure is applied to the substrate. However, the check is often only carried out after the complete structure has been applied to the substrate. The disadvantage of this is that the check is separate and independent of the application process becomes what is sometimes cumbersome and is difficult to handle. Until now, the systems for review were also closed unstable and cumbersome in parameterization.

Object of the present invention is thus the known device for recognizing one on a Structure to be applied to the substrate and suitable methods for this to further develop that, on the one hand, an immediate review of the applied structure possible is simple and on the other hand the verification is to be handled.

It is also a job, too in the event of a subsequent check Known methods for recognizing a to be applied to a substrate To further develop the structure in such a way that, on the one hand, a subsequent check is easy possible and, on the other hand, a precise error analysis of those to be applied Structure is provided.

These tasks are solved in terms of device technology with the features of claim 1 and procedural with the Features of claim 16 and claim 25.

According to the registration, the sensor unit is opened the device for applying the structure. With this measure a vision system is provided in a compact design, wherein preferably the lighting module also on the device can be provided for applying the structure. In this way Is it possible, the device according to the application to integrate into existing systems, the task of which is to Apply structure to a substrate. Process engineering according to claim 16 the structure during of the application of the substrate can be determined in the presence of a Errors can be intervened directly in the manufacturing process or the defective substrate are discarded. So that becomes a increased Efficiency in the production of structures on a substrate to disposal posed. Is the procedural according to claim 25, the review area of the structure to be determined using reference points along the one to be recognized Structure is set, so the handling is unproblematic because of the interactive Process between the user and the structure shown with today's Means is produced in a simple manner. According to the application, the tolerance range along the through the bases defined reference line, so any inaccuracies the structure is taken into account and in particular can with this measure the quality check of the structure to be determined individually. With this Simplified operator interaction can also make complex structure traces teach in easily and efficiently. Also, with the existing representation with the structure to be recognized and through the bases created reference line are immediately displayed to the user whether changes of the structure course are available.

Further advantageous configurations of the present objects are the subject of the subclaims.

The sensor unit becomes immediate positioned at the exit of the structure application device, this is a compact and highly integrated design of the device according to the application possible. The sensor unit is thus able to almost immediately after the Structure order a fully automatic high speed check of the Structure.

The sensor unit has a video sensor on, so can on conventional Image recognition method used become. If the video sensor preferably has one and / or more Image lines, a maximum of 15 lines, so a high image acquisition rate can the structure can be achieved. In this way, the device builds still small and the evaluation can take place in the sensor unit. An external data evaluation device is therefore not necessary.

If a white light lighting module is used as the lighting module, it can also be used conventional halogen lamps can be used to generate white light.

An LED lighting module is used as the lighting module can be used by a clever combination of different spectral ranges Illumination of the sensor to increase the contrast between the background and structure available be put. The evaluation as such can thus run stably and the effort for the evaluation logic is also minimized. The same applies in particular if several lighting modules are provided, thus one increased contrast sharpness can provide. If the evaluation unit is also integrated in the sensor unit, So the setting of the quality criteria can be done via an external Control unit in a simple manner of the device according to the application supplied become. The transmission advantageously takes place via radio, infrared data or Electric wire.

From a procedural point of view, the structure determination via so-called Caliper made that is preferably orthogonal to the substrate structure run, so can based on this measure special areas, preferably crossing areas, between the Caliper line and a contrast structure in the area to be determined become. If the calipers are orthogonal to the substrate structure, in particular, a width determination can be carried out in a simple manner Structure brought about become. In interaction with a corresponding visualization software can then the structure course and corresponding error areas are shown become. The user immediately recognizes whether the structure course predefined tolerances or the structure is imprecise is applied. It is also advantageous if for structure determination and corresponding error analysis, for example the given substrate data, like recesses and increases, are used, as this gives more precise information about the Structure course can be made.

It turned out to be advantageous if the structural determination over the evaluation of the brightness curve of the gray values along the Calipers is done. Based on the gray values, it can be determined where an area to be determined for to use the structural review is, in particular, a position can be determined at which the change strongest of object and background is. This is achieved by having the second derivative in the course the gray values are used to determine the structure. The ones to be determined Values are determined exactly as subpixels. Will be for everyone Caliper created a hypothesis set, so it results in particular at four nodes of the caliper a set of six possible variations, which are determined by the position distance of the individual nodes of the Calipers are different.

Are now adjacent hypothesis sets with each other connected, so can in particular, using a heuristic function Values are assigned, based on which for the structure edge relevant nodes can be determined.

Further advantageous configurations the invention are the subject of the remaining subclaims.

Using the following drawings advantageous embodiments of the invention are to be presented.

1 schematically shows an advantageous embodiment of the device according to the application.

2 shows a portion of the in 1 applied structure.

3 shows an error analysis.

4 shows the application of the caliper to an area to be determined, which contains both the structure and disturbances.

5 shows the crossing points of the relevant contrast lines and the caliper.

6 shows the generation of a hypothesis set from a caliper.

7 shows the structure determination from neighboring hypothesis sets.

8th shows the method for determining or eliminating fault edges or determining the structure.

In 1 is a device 1 for applying a structure 9 on a substrate 7 shown. The facility 1 is conventionally adjustable in the x, y and z directions. It is also conceivable that the device is rigid and the substrate can be adjusted in the x, y and z directions. The facility 1 also has a sensor unit 3 which is positioned directly in this embodiment at the exit of the device for applying the structure. In addition, the lighting module is also in this schematic representation 5 characterized, which provides the contrast sharpness when applying or registering the areas to be observed. In this embodiment it can be seen that a so-called adhesive bead 9 in a prefabricated recess 13 in the substrate 7 is applied or introduced. With the reference symbol 11 an area of the image is marked with the hatched lines, which in 2 is reproduced more clearly.

In 2 is for example the recess 13 shown, in which the structure or adhesive bead 9 is introduced. On the one hand, this selection area can be found in the evaluation unit in the sensor unit 3 processed, but it can basically be presented to the user during application, so that the user manually his bases 20 can be used to set a reference line 22 can be generated. As in 2 is clearly visible is to the reference line 22 , which approximates the structure, a tolerance range is defined, which in this case is equally spaced from the reference line. According to the application, it is thus checked whether the reference line defined by the support points lies within the tolerance range. In addition to the tolerance range is in 2 a test area 26 shown, within which the structure can be found.

In 3 For example, an error representation is shown which, in addition to the positioning of the error of the structure order, also indicates the error size to the user on the basis of the evaluation accuracy of the method according to the application. Based on the size of the error, the user can then decide whether the deviation from the target value is tolerable or whether the manufacturing process should be terminated. With the method according to the application, a decision can therefore be made on the basis of the immediate review of the structural order during the manufacturing process, specifically automatically, whether the manufacturing process has to be interrupted and / or the defective substrate has to be separated out.

Based on 4 to 8th the evaluation method according to the application is described. In 4 the so-called edge extraction of the abnormalities located in the inspection area is reproduced. For this purpose, a set of calipers, which are preferably orthogonal to the trace of the structure, is placed over the inspection area, the extraction of the edges by evaluating the brightness profile of the gray values along the caliper thus being orthogonal to the structure trace. This will determine a position that reflects the change of object and background, at which the change is strongest. This is achieved in that the second derivative is calculated in the course of the gray values. The values to be determined are precisely determined subpixels.

In 5 After the edge extraction, the trace of the structure is shown, whereby for every line all the edges found are shown on the basis of the nodes.

6 shows that for every Caliper the 4 and 5 a hypothesis set is created, for example, a total of six position hypotheses are available for four nodes of a caliper. The caliper hypotheses are then linked step by step, preferably hierarchically, to the corresponding neighbors or neighboring hypothesis sets. This link is made as in 7 is shown iteratively. To this end, more and more left and right hypotheses are generated, which in turn are linked together or evaluated with a heuristic function. A selection criterion for determining the structure determination can be, for example, that the higher the value determined, the better the hypothesis used.

In 8th shows clearly how the iterative procedure of the individual hypothesis sets is applied. Here, for example, the hypothesis theorems 2 . 3 . 4 in 6 combinatorial (I-II, I-III, II-III, II-II) connected, each with the left hypothesis of the hypothesis 3 are connected accordingly with the right hypothesis. This again leads to an assignment of the hypotheses, a value being determined on the basis of the heuristic function. Based on the predetermined definition, the larger the value, the better the hypothesis, the structure can then be determined by the fact that, if the number of hypotheses developed in this way exceeds the number of permissible hypotheses per existing node, those with a lower value of the heuristic Function specified hypotheses are taken out.

With these methods according to the application Is it possible, a structure determination precisely and with small data sets bring about, so that an immediate structure determination, for example at The structure can be applied is. Note that the heuristic function is as follows Uses criteria to determine the specified value.

• 1. Edge thickness
• 2. Structure width
• 3. Target-actual position difference
• 4. Co-linearity the actual position
• 5. Target-actual structure width difference
• 6. Co-linearity the actual structure width
• 7. Target / actual structural brightness difference
• 8. Co-linearity the actual structural brightness
• 9. Target-actual background brightness difference
• 10. Co-linearity the actual background brightness

Based on the concrete realization that the device according to the application is used when applying a bead of adhesive to a substrate, it is advantageous if the following is observed. According to an advantageous embodiment, the system according to the application or the device essentially consists of a color line video sensor with an integrated evaluation unit and illumination for highlighting and illuminating the sealing or adhesive bead. The components are in a compact protective housing. The visual inspection system is located directly behind the adhesive application system (application nozzle) strengthens and is aligned to the area just behind the adhesive nozzle in order to carry out a test immediately after the bead application. The test is therefore carried out directly after the application of the sealing material or the adhesive so that an evaluation of the quality of the bead (tears, position and position, thickness) can take place during application.

In contrast to the known approaches in this invention, a video sensor is used which is only one or multiple picture lines (maximum 15 lines) to a high To achieve image capture rate. The evaluation takes place in the color line video sensor with an integrated evaluation unit. An external data evaluation device (Evaluation - PC) is not necessary because a miniaturized evaluation computer is already available is present in the video sensor. The setting of the quality criteria (OK / NOK - limit values) takes place with an external control unit, which is connected to the sensor via a Radio connection, infrared data transmission connection (IrDa) or a cable connection (serial or network) connected is.

To illuminate the adhesive track depending on the surface properties one or more of the adhesive or sealant

• - white light lighting module, e.g. halogen lamp
• - LED lighting module in different colors

used.

The lighting modules are compact built up in a compact system structure (image sensor and lighting in a common housing). Doing so provided, various different lighting modules (design, Color) to combine with each other by a clever combination different spectral ranges of the lighting and the sensor one to create a high contrast between the background and the adhesive. Thus, the evaluation can run stably and the effort for the evaluation logic be kept low.

The visualization software serves to represent errors when applying adhesive beads. This will the adhesive track to be driven saved as a 3D track and into it the corresponding error areas are marked. The corresponding Errors are highlighted with a different color and with an additional one Described text.

The software or sensor communicates with a robot or other control unit over all common Fieldbuses (Profibus, Interbus, Devicenet), Ethernet, serial interface, OPC server or other available communication interfaces.

In the offline version, the robot track is in advance taught and saved. After the glue application process, can the visualization software can be selected. This gets itself the corresponding error areas from the robot.

In the online version, the Visualization software always shows the current position while driving along the robot path and in the event of an error, an additional error code.

In addition, data can be transferred from CAD files. The data contained in it from the component, from the adhesive track or similar. are processed with and together with the corresponding error points 3 dimensional or 2 represented dimensionally.

In order to simplify the user interaction, a GUI specially developed for the adhesive bead inspection was used. With simple mouse clicks, complex lanes can now be taught in easily and efficiently. The graphic elements are designed so that the set limit values such as min / max ranges and tolerances can be seen at a glance ( 2 ). Changes in the course of the track can also be made with a few mouse clicks. The glue track does not have to be taught in exactly, since the subsequent image processing operations are stable enough to compensate for the inaccuracies that occurred during the teaching in. The operator is informed of production errors in an additional view. By clicking on the error that has occurred, the affected area is enlarged and the error description is given in plain text ( 3 ).

With the math below shortcut becomes the heuristic function for determines the structure based on the following criteria, a heuristic value for elementary hypotheses and a heuristic value for complex hypotheses.

A. Heuristic value for elementary hypotheses

The following applies to an input vector: x = {x weight1 , x weight2 , x pos1 , x pos2 , x br , x bk } in which:
x _weight1 weight of the first point,
x _weight2 weight of the second point,
x _pos1 position from the first point,
x _pos2 position from second point,
x _br brightness of structure,
xbk brightness of background,
for which values should apply: s = {P width , P br , P bk } in which:
S _width should be width,
S _br is said to be brightness of structure,
S _bk is said to be brightness from background,
with the heuristic coefficients: a = {a const , a weight , a pos , a width , a br , a bk } b = {b pos , b width , b br , b bk }

ewidth = abs (xpos2 – xpos1 – Swidth) ebr = abs (xbr – Sbr) ebk = abs (xbk – Sbk) The heuristic value h has the following form:

e width = abs (x pos2 - x pos1 - p width ) e br = abs (x br - p br ) e bk = abs (x bk - p bk )

B. Heuristic value for complex hypotheses

The following applies to an input vector: x = {x lpos , x lwidth , x lbr , x lbk , x rpoS , x rwidh , x rbr , x rbk }, in which:
x _lpos position on the right side of the left hypothesis,
x _lwidth width on the right side of the left hypothesis,
x _lbr structure _brightness on the right side of the left hypothesis,
x _lbk background _brightness on the right side of the left hypothesis,
x _rpos position on the left side of the right hypothesis,
x _rwidth width on left side of right hypothesis,
x _rbr structure _brightness on left side of right hypothesis,
x _rbk background _brightness on left side of right hypothesis,
with the heuristic coefficients: a = {a const , a pos , a width , a br , a bk } b = {b pos , b width , b br , b bk }

wobei: epos = abs (xlpos – xrpos), ewidth = abs (xlwidth – xrwidth), ebr = abs (xlbr – xrbr), ebk = abs (xlbk – xrbk),
und
h_left heuristischer Wert von linker Hypothese
h_right heuristischer Wert von rechter HypotheseThe heuristic value h has the following form:

in which: e pos = abs (x lpos - x rpoS ) e width = abs (x lwidth - x rwidth ) e br = abs (x lbr - x rbr ) e bk = abs (x lbk - xrbk),
and
h _left heuristic value of left hypothesis
h _right heuristic value of right hypothesis

Claims (32)

Device for recognizing a structure to be applied to a substrate, preferably an adhesive bead, consisting of an illumination module and a sensor unit, characterized in that the sensor unit ( 3 ) on the facility ( 1 ) is provided for applying the structure. Device according to claim 1, characterized in that the sensor unit directly at the output of the device for Applying the structure is positioned. Device according to one of claims 1 or 2, characterized in that that the sensor unit has a video sensor, which preferably one and / or more image lines registered. Device according to one of claims 1 to 3, characterized in that that the lighting module contains a white light lighting module. Device according to one of claims 1 to 4, characterized in that that the lighting module is an LED lighting module, which the areas red, blue, green, Emits infrared and / or ultraviolet. Device according to one of claims 1 to 5, characterized in that that several lighting modules are provided. Device according to one of claims 1 to 6, characterized in that that an evaluation unit, preferably in the video sensor, is provided is, the settings of the quality criteria via a external control unit, preferably via an infrared data transmission connection, he follows. Device according to one of claims 1 to 7, characterized in that that the evaluation unit uses a set of calipers over the with the image elements determined data sets, the Caliper preferably run orthogonal to the substrate track. Apparatus according to claim 8, characterized in that the structure on the brightness curve of the Gray values along the calipers are determined. Device according to claim 9, characterized in that the second derivative in the course of the gray values for structure determination be used. Device according to one of claims 8 to 10, characterized in that that the evaluation unit for the Caliper created a hypothesis set. Device according to claim 11, characterized in that the evaluation unit links adjacent hypothesis sets. Device according to one of claims 8 to 12, characterized in that that the evaluation unit at least determines the structure one of the following criteria: a. edge thickness b. structure width c. Target-position difference d. Co-linearity of the actual position e. Target-structure width difference f. Co-linearity of the actual structure width G. Target-structure brightness difference H. Co-linearity of the actual structural brightness i. Target-background brightness difference j. Co-linearity of the actual background brightness Device according to one of claims 1 to 13, characterized in that that about the position of the sensor unit and the structure determination three-dimensional representation is made possible. Device according to one of claims 1 to 14, characterized in that that about a connection to a network connection, preferably via the Internet or intranet, control and evaluation is provided. Method for recognizing a structure, preferably Adhesive bead, and in particular for use in the device according to claim 1 to 15, which has the steps: a) Providing one Lighting module and a sensor unit on the device is provided for applying the structure. b) determining the Structure during the structure is applied to the substrate. The method of claim 14, wherein the structure determination via a Video sensor as a sensor unit with one or more, preferably up to 15, picture lines. Method according to one of claims 14 or 15, wherein the structure determination with at least one lighting module, which is a white light module and / or an LED lighting module with different colors. Method according to one of claims 14 to 16, wherein the structure determination via Caliper takes place, which are preferably orthogonal to the substrate track. Method according to one of claims 14 to 17, wherein a visualization software is provided with which the structure course, preferably as 3D representation, and corresponding error areas can be represented. Method according to one of claims 14 to 18, wherein for the structure determination and corresponding error analysis substrate data are used. Method according to one of claims 18 or 19, wherein based on different error areas separately in the visualization software can be represented. Method according to one of claims 18 to 20, wherein the structure determination on the Evaluation of the brightness curve of the gray values along the caliper, especially the second derivative in the course of the gray values. Method according to one of claims 18 to 21, wherein the structure determination is carried out according to at least one of the following criteria: a. edge thickness b. structure width c. Target-position difference d. Co-linearity of the actual position e. Target-structure width difference f. Co-linearity of the actual structure width G. Target-structure brightness difference H. Co-linearity of the actual structural brightness i. Target-background brightness difference j. Co-linearity of the actual background brightness Method for recognizing a structure, preferably Adhesive bead, and in particular for use in the device according to claim 1 to 15, which has the steps: a) Provide one Representation with the structure to be recognized; b) Placing bases along the structure to be recognized; c) connecting the bases to create a reference line, d) Define a tolerance range along the reference line, as well e) Determine whether the structure is within the tolerance range. 26. The method of claim 25, further comprising a test area along the reference line. A method according to any one of claims 25 or 26, wherein one Caliper's theorem about the data record determined with the picture elements is placed, whereby the calipers are preferably orthogonal to the substrate track. A method according to claim 27, characterized in that the structure over determined the brightness curve of the gray values along the calipers becomes. A method according to claim 28, characterized in that the second derivative in the course of the gray values for structure determination be used. Method according to one of claims 27 to 29, characterized in that that the evaluation unit for the Caliper created a hypothesis set. A method according to claim 30, characterized in that the evaluation unit links adjacent hypothesis sets. Method according to one of claims 25 to 31, wherein the structure determination is carried out according to at least one of the following criteria: a. edge thickness b. structure width c. Target-position difference d. Co-linearity of the actual position e. Target-structure width difference f. Co-linearity of the actual structure width G. Target-structure brightness difference H. Co-linearity of the actual structural brightness i. Target-background brightness difference j. Co-linearity of the actual background brightness