JP2009075043A - Defect information display device and method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To instantly determine the quality of a transparent film having passed a saponifying process, and to analyze a cause of a defect. <P>SOLUTION: This defect information display device comprises a photographing means (12) for photographing a line-shaped area over the whole width on the transparent film (11) whose surface is hydrophilic with caustic soda and flows, a length measuring means (13) for measuring, with respect to a flow directional length, a flow directional position of the area on the transparent film photographed by the photographing means, and a computer (14) connected to the photographing means and the length measuring means. The computer has a means for detecting defects of the transparent film and recording the number of the defects on a file per unit length by software, and a means for reading the number of the defects from the file, calculating the number of the defects per unit area, and displaying it. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a technique for outputting defect information of an inspection object.

  Conventionally, a device that detects reflected light by vertically applying scattered light to a transparent film held on a support roll by a line sensor camera, and outputs a portion where the intensity of the reflected light is greater than a threshold value as a defect is known. (For example, refer to Patent Document 1).

  By the way, an optical film called a highly functional film, which is a kind of transparent film, generally has a liquid material composed of necessary components depending on the purpose on a thin base material (PET, etc.) of several tens of μm. Manufactured by applying to layers or multiple layers.

  In this case, it is processed and manufactured in the form of a long roll in consideration of the final form of the product and the manufacturing processing conditions and technology.

  In addition to the application of the liquid substance that is a direct component of the product, this manufacturing process includes a number of processes such as ground treatment and post-treatment for that purpose.

  One of them includes a process of hydrophilizing the surface of the substrate with caustic soda (saponification process) for the purpose of improving adhesion, and it is performed by immersing it in a chemical solution or drying it with hot air. In some cases, a spot-like mark may remain in this step.

Since the product is an optical film, water stains or the like are generated, and if the product remains on the product, the quality is significantly reduced.
JP 2005-62119 A

  The water stain on the transparent film is in a state where it can be more clearly confirmed in the final confirmation step by applying a liquid material necessary for the optical film after the saponification step as a pretreatment.

  However, in that case, it will be found in a process close to the end of the manufacturing process, and not only materials are wasted but also in terms of delivery time.

  Therefore, it is necessary to detect this water stain at one of the earliest steps in which a water stain problem on the base film can occur.

  And even if a water spot is not caught in this process, since it is confirmed that the water spot has not been generated up to that process, the cause such as the identification of the occurrence point can be investigated.

  Furthermore, it is not necessary to report the result of simply detecting the occurrence of water spots, and it is necessary to be able to analyze later what kind of situation it has occurred.

In addition, the number of defects per unit area is used as a criterion for determining whether a transparent film is good or bad. Conventionally, after manufacturing, the cumulative number of defects is divided by the area (= production length × width).

  However, since this does not take into account the occurrence of defects (number of defects generated according to the position), there is a possibility that even if there is a bias (such as increasing at the end of winding) when a defect occurs, it may be OK. there were.

  The present invention has been made in view of such background art, and an object of the present invention is to make it possible to immediately determine whether a transparent film that has undergone a saponification process is good or bad and to analyze the cause of the defect.

In order to solve the above problems in the present invention, first, in the invention of claim 1,
A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A length measuring means for measuring the length in the flow direction, and a computer connected to the photographing means and the length measuring means,
The computer uses software to detect defects in the transparent film and record the number of defects in a file for each unit length, and read the number of defects from the file to calculate and display the number of defects per unit area. And a defect information display device characterized by comprising:

In the invention of claim 2,
A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A length measuring means for measuring the length in the flow direction, and a computer connected to the photographing means and the length measuring means,
The computer detects, by software, a defect of the transparent film and records the number of defects in a file for each unit length, means for inputting a range for obtaining the number of defects per unit area, and the defect from the file The defect information display device includes means for reading out the number and calculating and displaying the number of defects per unit area within the range.

In the invention of claim 3,
A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A computer connected to a length measuring means for measuring the length in the flow direction is executed by software,
Detecting the defects of the transparent film and recording the number of defects in a file for each unit length; and reading the number of defects from the file and calculating and displaying the number of defects per unit area. This is a characteristic defect information display method.

In the invention of claim 4,
A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A computer connected to a length measuring means for measuring the length in the flow direction is executed by software,
Detecting defects in the transparent film and recording the number of defects in a file for each unit length; inputting a range for obtaining the number of defects per unit area; and reading the number of defects from the file and within the range And a step of calculating and displaying the number of defects per unit area.

  In the inventions of claims 1 and 3, since the number of defects per unit of the transparent film is displayed while the surface is hydrophilized with caustic soda in the saponification process, the number of defects per unit is determined as good / defective. It is possible to determine a defect and to deal with a defect immediately. In the inventions of claims 1 and 3, since the number of defects of the transparent film is recorded in a file for each unit length, quality information over a large number of lots can be obtained, and the generation timing and number of defects are analyzed. Thus, there is an effect that information that leads to improvement of the manufacturing process can be obtained.

  According to the second and fourth aspects of the invention, by narrowing the range for obtaining the number of defects per unit, it is possible to correctly grasp the quality of the actual product, and to take measures against a defect that has occurred in some cases.

  As described above, it is possible to immediately determine whether the transparent film that has undergone the saponification process is good or bad, and to analyze the cause of the defect.

  Embodiments of the present invention will be described below.

  As shown in FIG. 1, the defect information display apparatus according to the present invention includes a length measuring roller 13 attached to the surface of a roller 15 of a manufacturing apparatus, a defect detection area camera 12 for a transparent film 11, and a length measuring roller. 13 and a defect detection area camera 12, and a defect detection and result display personal computer 14 is provided.

  The manufacturing apparatus performs at least a saponification step of obtaining a transparent film 11 by hydrophilizing the substrate surface with caustic soda.

  Further, the length measuring roller 13 may use an encoder signal attached to the shaft of the roller 15 closest to the defect detection area camera 12.

  Further, the defect detection area camera 12 is a CCD camera and photographs a line-shaped area over the entire width on the transparent film 11.

  The personal computer 14 has water stain defect number display monitor software installed.

  First, in order to accurately indicate the length of the transparent film 11 at the location where the defect detection area camera 12 is attached, the length measurement roller 13 indicates in advance so as to correctly indicate the flow direction position of the transparent film 11. Adjust it.

  The adjustment is performed by measuring in advance from the unwinding of the original fabric and the processing of the product to the position of the defect detection area camera 12 and starting the measurement after the length is unwound.

  Next, the personal computer 14 stores the number of water spots detected by the defect detection area camera 12 in a specific folder as a file for each meter based on the length measured by the length measuring roller 13.

  The water stain defect number display monitor software constantly monitors whether or not a file has been generated in the folder. If the file has been generated, the file is opened and the defect number information is extracted.

  Then, the water stain defect number display monitor software displays the defect number information extracted from the file in association with the m information in which the file is generated, on the monitor screen of the personal computer 14.

  At this time, since the defect number information is generated in units of 1 m, it is output as it is in units of 1 m on the monitor screen (see FIG. 3).

  Based on the data collected in this way, the water stain defect number display monitor software performs a process of calculating and outputting the number of defects per unit area. The flow of this process will be described with reference to the flowchart of FIG.

  First, with regard to the cumulative number of defects that occurred in the manufactured length (the length from the start position to the end position) that was possible in the past, the length information and the product width information Based on the above, when calculating the number of defects per unit area (YES in S1), the cumulative number of defects is divided by the length to calculate the number of defects per unit area and display it on the monitor screen (S2). ).

  In the case of calculating and outputting the number of defects per unit area by accumulating the number of generated water blot defects in an arbitrary length such as 10 m, 30 m, 50 m, etc. and converting it per unit area (S3 YES), a numerical value (unit of determination length) in a range to be checked in advance is input (S4).

  When determining the location of the product whose number of defects is to be checked, if the location to be determined every 1 m is moved (YES in S5), the number of defects per unit area is changed every 1 m while shifting the numerical range input in S4. The number of defects per unit area is displayed on the monitor screen every 1 m (S7).

  On the other hand, when the place to be determined every 1 m is not moved (NO in S5), the value is skipped from a roll-shaped position (this position may be set to any value) for each numerical value input in S4 ( S6) The number of defects per unit area is calculated, and the number of defects per unit area is displayed on the monitor screen for each numerical value input in S4 (S7).

  Through the above processing flow, information related to good and bad can be obtained directly in real time, so that product quality information can be provided in an easy-to-understand and easy-to-understand manner by operators etc. became.

  As for the primary defect count information, since the monitor screen has a resolution limit, the range of the length that can be resolved and displayed in 1 m units is about 500 m, so the length is 500 m or more. If there is, there is a need to devise the display method.

  Therefore, in the present invention, a transparent film transport start signal is used as a start signal, and a screen for displaying the entire history up to the point when the user wants to view the history information is provided separately.

  Here, the water stain defect number display monitor software displays a history display button on the monitor screen, and based on the length information up to the point when the history display button is pressed, the length is set as the maximum value on the horizontal axis. Display the total number of defects from the start. FIG. 4 shows a display example when the length is 2500 m.

As a result, a screen that displays detailed information in units of 1 m in real time and a screen that does not resolve the information in units of 1 m but can grasp all the information from the start can make a glance at the previous trend.

The schematic diagram which shows the structure of the defect information display apparatus of a transparent film. The flowchart which shows the flow of the process which calculates and outputs the number of defects per unit area. The figure which shows the example which displayed the number of defects per 1 m on the monitor screen. The figure which shows the example which displayed the log | history of the number of defects on the monitor screen.

Explanation of symbols

11 ... Transparent film 12 ... Defect detection area camera (line CCD camera)
13 ... Length measuring roller (or encoder)
14 ... PC for defect detection and result display 15 ... Roller

Claims (4)

A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A length measuring means for measuring the length in the flow direction, and a computer connected to the photographing means and the length measuring means,
The computer uses software to detect defects in the transparent film and record the number of defects in a file for each unit length, and read the number of defects from the file to calculate and display the number of defects per unit area. And a defect information display device. A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A length measuring means for measuring the length in the flow direction, and a computer connected to the photographing means and the length measuring means,
The computer detects, by software, a defect of the transparent film and records the number of defects in a file for each unit length, means for inputting a range for obtaining the number of defects per unit area, and the defect from the file And a means for calculating and displaying the number of defects per unit area within the range. A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A computer connected to a length measuring means for measuring the length in the flow direction is executed by software,
Detecting the defects of the transparent film and recording the number of defects in a file for each unit length; and reading the number of defects from the file and calculating and displaying the number of defects per unit area. Characteristic defect information display method. A photographing means for photographing a line-shaped area over the entire width of the transparent film flowing with the surface hydrophilized by caustic soda, and the position in the flow direction for the area on the transparent film photographed by the photographing means A computer connected to a length measuring means for measuring the length in the flow direction is executed by software,
Detecting defects in the transparent film and recording the number of defects in a file for each unit length; inputting a range for obtaining the number of defects per unit area; and reading the number of defects from the file and within the range And a step of calculating and displaying the number of defects per unit area.

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