JP3974400B2 - Test result recording method, test result recording system and roll-shaped molded product of sheet-shaped molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an inspection result recording method, an inspection result recording system, a roll-shaped molded body, and a sheet material for a sheet-shaped molded body for inspecting defects such as surface irregularities present on the surface of the sheet-shaped molded body.
[0002]
[Prior art]
Conventionally, for inspection results such as fine surface irregularities of a sheet-like molded body such as a polarizing film and a retardation film, marking is performed at a position where an operator or an inspection apparatus has a defect. And when a defect is detected, the production line is temporarily stopped. Further, position data and the like where defects exist are stored in a recording device. There is also a method in which the sheet-shaped molded body is once wound up in a roll shape and transferred to another process, and then the sheet-shaped molded body is fed out and transferred again to collate with the position data recorded in the recording apparatus.
[0003]
However, the method of marking directly at the defect position may mark the position deviating from the defect position, or the marking may protrude from the defect position. was there. In addition, if the marking mechanism (for example, the printing mechanism) is not properly marked, even if the inspection device can recognize the defect, it cannot be reflected in the sheet-like molded product. As a result, there is a possibility that a defective product is handled as a non-defective product.
[0004]
Furthermore, when punching or cutting a sheet-like molded product to make a sheet (product), a method of directly marking the defect position when judging the quality by the number of defects in the area and the distance between the defects I can't take it.
In addition, the method of stopping the production line at the time of detecting a defect as described above causes a reduction in production efficiency. Further, the method of collating position data after storing the defect position data in the recording apparatus is once shifted after the verification position on the sheet-like molded body is shifted. Therefore, there is a problem that the reliability of the inspection result is lowered. In such a case, it will be inspected after punching or cutting the sheet from the sheet-like molded body. However, it takes more time for inspection than in-line inspection. It was a situation that became difficult.
[0005]
[Problems to be solved by the invention]
The present invention has been made in view of the above circumstances, and the problem is that in recording a sheet-like molded body in-line and recording the inspection result, the reliability of the sheet-like molded body can be improved. To provide a test result recording method and system.
[Means for Solving the Problems]
In order to solve the above problems, the inspection result recording method for a sheet-like molded body according to the present invention is as follows.
Irradiating light to the sheet-like molded body that is continuously transferred; and
In the step of irradiating light, obtaining image data of the sheet-like molded body;
Image processing the image data, encoding the inspection result of the sheet-like molded body for each area set along the transfer direction;
And a step of printing a code obtained by encoding the inspection result at predetermined intervals of the sheet-like molded body.
[0006]
The operation and effect of the inspection result recording method for the sheet-like molded body with this configuration is as follows. That is, light is irradiated to the sheet-like molded body that is continuously transferred. For example, the light is irradiated from below or above the sheet-like molded body. Next, the image data of a sheet-like molded object is acquired in the state irradiated with light. For acquisition, for example, a CCD camera is used. The image of the sheet-shaped molded body is a transmitted light image or a reflected light image, and is appropriately selected according to the characteristics of the sheet-shaped molded body.
[0007]
Next, the acquired image data is subjected to image processing. In this case, the inspection result is encoded for each area set along the transfer direction of the sheet-like molded body. This area is set by, for example, (the width of the sheet-like molded body × a constant distance along the transfer direction). This code is printed at predetermined intervals of the sheet-like molded body. For example, a code is printed for each predetermined number of areas. Since printing is performed at predetermined intervals of the sheet-like molded body, the inspection result corresponding to the read code position can be known by reading the printed code. In this case, compared with the conventional system in which the position data is stored in the recording apparatus, there is no problem that the collation position is shifted and the reliability is high. Further, since the inspection result is encoded and printed at a predetermined position instead of directly marking the defect position, it is possible to cope with the case where the quality is determined by the number of defects in the area and the distance between the defects. As described above, it is possible to provide an inspection result recording method for a sheet-like molded body that can improve the reliability of the inspection result in inspecting the sheet-like molded body in-line and recording the inspection result.
[0008]
As a preferred embodiment of the present invention, there is one that encodes a defect distribution of a sheet-like molded body as the inspection result.
[0009]
The defect distribution is, for example, a distribution indicating how many defects exist in which area. By reading this code, the defect distribution can be known immediately, and the data can be used effectively when the sheet is taken out in a later process.
[0010]
As another preferred embodiment of the present invention, the inspection result is encoded by a one-dimensional or two-dimensional code.
[0011]
By encoding using a bar code, the code can be read using a commercially available bar code reader. In addition, existing algorithms for coding can be used. Therefore, it has a cost advantage.
[0012]
As yet another preferred embodiment of the present invention, the step of reading the code formed on the sheet-like molded body,
And a step of taking out a sheet from the sheet-like molded body while avoiding a defect position based on the read code.
[0013]
The contents of the inspection result can be acquired by reading the code. That is, it is possible to obtain in which area of the sheet-like molded body a defect exists. Based on this code reading, the sheet can be removed by punching or cutting while avoiding the defect position. Therefore, it is possible to obtain a high quality sheet without defects.
[0014]
In order to solve the problems of the present invention, an inspection result recording system for a sheet-like molded body according to the present invention is:
A light source unit for irradiating light onto a sheet-like molded body that is continuously transferred;
Image acquisition means for acquiring image data from the sheet-like molded article irradiated with light;
An image processing unit for image processing the image data;
Coding means for coding the inspection result of the sheet-like molded body for each area set along the transfer direction;
It has a printing part which prints the code obtained by coding the inspection result on a sheet-like molded object.
[0015]
The operation and effect of this system is the same as described above, and the reliability of the inspection result can be improved. Note that the image acquisition means can be constituted by, for example, a CCD camera. The image processing unit and the encoding unit can be configured by a computer and a processing program installed in the computer.
[0016]
In order to solve the problems of the present invention, another sheet-like molded product inspection result recording method according to the present invention is:
Irradiating light to the sheet-like molded body that is continuously transferred; and
In the step of irradiating light, obtaining image data of the sheet-like molded body;
Image processing the image data, and recording the inspection result of the sheet-like molded body for each area set along the transfer direction;
A step of printing a position correction code on the sheet-like molded body at predetermined intervals along the transfer direction,
The position correction code and the inspection result are recorded in association with each other.
[0017]
The operation and effect of the inspection result recording method for the sheet-like molded body with this configuration is as follows. That is, light is irradiated to the sheet-like molded body that is continuously transferred. For example, the light is irradiated from below or above the sheet-like molded body. Next, the image data of a sheet-like molded object is acquired in the state irradiated with light. For acquisition, for example, a CCD camera is used. The image of the sheet-shaped molded body is a transmitted light image or a reflected light image, and is appropriately selected according to the characteristics of the sheet-shaped molded body.
[0018]
Next, the acquired image data is subjected to image processing. In this case, the inspection result is recorded for each area set along the transfer direction of the sheet-like molded body. This area is set by, for example, (the width of the sheet-like molded body × a constant distance along the transfer direction). Unlike the previous case, the inspection result is not printed on the sheet-like molded body, but is recorded in, for example, a recording device provided inside the computer. Instead, a position correction code is printed on the sheet-like molded body at predetermined intervals.
[0019]
This code is printed at predetermined intervals of the sheet-like molded body. For example, a code is printed for each predetermined number of areas. Since printing is performed at predetermined intervals of the sheet-like molded body, the inspection result corresponding to the read code position can be known by reading the printed code. In this case, compared with a conventional system that stores position data in a recording device (previously, position data is not printed), there is no problem that the collation position is shifted and reliability is high. Further, since the inspection result is encoded and printed at a predetermined position instead of directly marking the defect position, it is possible to cope with the case where the quality is determined by the number of defects in the area and the distance between the defects. As described above, it is possible to provide an inspection result recording method for a sheet-like molded body that can improve the reliability of the inspection result in inspecting the sheet-like molded body in-line and recording the inspection result.
[0020]
As a preferred embodiment of the present invention, the step of reading the position correction code formed on the sheet-like molded body,
And a step of taking out the sheet from the sheet-like molded body while avoiding the defect position based on the read position correction code and the recorded inspection result.
[0021]
By reading the position correction code, it is possible to acquire the contents of the inspection result of the area corresponding to the position. That is, it is possible to obtain in which area of the sheet-like molded body a defect exists. Based on this code reading, the sheet can be removed by punching or cutting while avoiding the defect position. Therefore, it is possible to obtain a high quality sheet without defects.
[0022]
In order to solve the problems of the present invention, another sheet-like molded product inspection result recording system according to the present invention is:
A light source unit for irradiating light onto a sheet-like molded body that is continuously transferred;
Image acquisition means for acquiring image data from the sheet-like molded article irradiated with light;
An image processing unit for image processing the image data;
An inspection result recording unit for recording the inspection result of the sheet-like molded body for each area set along the transfer direction;
A printing unit that prints a position correction code on the sheet-like molded body at predetermined intervals along the transfer direction;
The position correction code and the inspection result are recorded in association with each other.
[0023]
The operation and effect of this system is the same as described above, and the reliability of the inspection result can be improved. Note that the image acquisition means can be constituted by, for example, a CCD camera. The image processing unit can be configured by a computer and a processing program installed in the computer.
[0024]
DETAILED DESCRIPTION OF THE INVENTION
<Configuration of First Embodiment>
DESCRIPTION OF EXEMPLARY EMBODIMENTS A preferred embodiment of an inspection result recording method (system) for a sheet-like molded body according to the invention will be described with reference to the drawings. In FIG. 1, FIG. 1A shows a system configuration (first embodiment) for recording inspection results, and FIG. 1B shows a system configuration (first embodiment) for determining inspection results. FIG. FIG. 2 is a diagram showing details of the inspection unit in FIG. 1A, and FIG. 3 is a diagram showing details of the determination unit in FIG. In addition, the structure shown here presents one embodiment, and the present invention is not limited to this structure.
[0025]
A sheet-like molded body 1 (for example, a polarizing film, a retardation film, a plastic sheet for organic EL, a plastic sheet for a liquid crystal cell substrate, a plastic sheet for a solar cell substrate) is conveyed from the right side to the left side in FIG. Transported by mechanism. The sheet-like molded body 1 is long and continuously supplied. The inspection unit 2 acquires an image of the sheet-like molded body 1 and inspects a surface defect or the like based on the acquired image data. The surface defect is a minute unevenness existing on the surface or a foreign matter adhering to the surface. The printing unit 3 codes the inspection result obtained by the inspection unit 2 and prints it on the sheet-like molded body 1. The printed sheet-like molded body 1 is temporarily wound around the take-up roll 5 in a roll shape after the protective tape 4 is adhered to both sides thereof.
[0026]
Next, the inspection unit will be described in detail with reference to FIG. A fluorescent lamp 11 as a light source for inspection is provided below the conveyance path of the sheet-like molded body 1. The fluorescent lamp 11 irradiates light from the lower surface side of the sheet-like molded body 1. A camera 10 as an image acquisition unit is provided above the sheet-like molded body 1. The camera 10 acquires a transmitted light image of the sheet-like molded body 1.
[0027]
The image processing apparatus 12 includes an inspection personal computer 13 and a control personal computer 14. The image signal captured by the camera 10 is transmitted to the inspection personal computer 13 and converted into digital data. Image processing is performed using the digitalized image data. The image processing can be performed by a known method. For example, the image data is first subjected to a smoothing process or the like to remove noise components. Next, differential processing for emphasizing the defect is performed as necessary, and binarization is performed to extract the defect. Further, it is determined whether or not the defect is a true defect based on the defect area and the feature amount of the shape, and the defect is detected. For example, it is determined that the defect is a true defect only when a portion that appears to be a detected defect has a predetermined area or more. The inspection results are collected by the inspection personal computer 13 and the collected results are transmitted to the control personal computer 14.
[0028]
The control personal computer 14 transmits the print content (code signal) as the inspection result and the print start signal to the print unit 3. The printing unit 3 includes a print head and prints a code 15 on the sheet-like molded body 1. The printed portion is printed on an end portion that becomes a cut residue when a product (sheets) is punched from the sheet-like molded body 1. As a result, the inspection result can be printed on the product without any influence. Note that the means for encoding can be configured by a program for encoding.
[0029]
In this embodiment, the inspection personal computer 13 and the control personal computer 14 are separated, and a desired inspection speed is maintained by sharing the processing. Of course, if the inspection time is sufficient, the inspection personal computer 13 and the control personal computer 14 can be used together. The number of cameras 10 is the number of cameras 10 installed. If one camera has insufficient resolution, a plurality of cameras 10 may be provided. Also, not only one inspection personal computer 13 but also a plurality of inspection personal computers 13 may be provided to increase the processing capability. Further, the structure of the printing apparatus used for the printing unit 3 is not limited to a specific one. For example, an ink jet method, an ink ribbon method, or the like can be used.
[0030]
The form of the code 15 printed by the printing unit 3 is not limited to a code having a specific content, but an example thereof will be described with reference to FIGS. 4 and 5. As shown in FIG. 4, an inspection area is set along the transfer direction of the sheet-like molded body. The size of the area is set by (the width A of the sheet-like molded body × the constant distance B along the transfer direction). A portion C indicated by a black square indicates a portion where a code is printed. In the print location C, the inspection result of the area including the areas (1) to (10) is encoded and printed. That is, the area is divided into ten, and the inspection result of each area portion is coded and printed.
[0031]
In the present embodiment, the defect distribution is encoded and printed. This is shown in FIG. In FIG. 5, it is assumed that one defect is detected in the area portions (1) and (7) and two defects are detected in the area portion (9). Therefore, when coded according to the number of defects in the area, “1000001020” is obtained. This represents the defect distribution. That is, the numbers of defects are arranged in the order of the divided area portions, converted into one code, and printed. The code collected in this way is printed at regular intervals (every 10 areas in the example). Also, “1” is added at the end as a confirmation code (described later).
[0032]
FIG. 6 shows another print example. However, when no defect is detected in the area portions (11) to (20), the code is not printed at the original print location C2. The additional code “N” to that effect may be printed at the next printing location C1. According to this method, when a code is not printed due to a trouble in the printing unit, a defective product is not erroneously determined as a non-defective product.
[0033]
4 to 6, one code is printed per one area. Further, the number of divisions is not limited to ten. Also, the size (area) of the area can be set and changed as appropriate. In general, this division number may be set to m (m is a positive integer). Further, although the area is not divided in the width direction, it may be divided into n (n is a positive integer) in the width direction. The code printing interval, code content, area size, etc. are the printing speed of the printing section, the speed of the production line, the code reading speed at the inspection result judging section, the processing speed at the image processing device 12, and the sheet shape It is determined by the size of the molded body (product).
[0034]
In this embodiment, since the inspection result is a defect distribution, a code is printed regardless of the presence or absence of a defect. Therefore, if there is a missing code, it is determined as defective. As shown in FIG. 5, the defect distribution for 10 area portions is represented by 10 digits as “1000001020” as a code. However, in the present embodiment, the number of defects in one area is displayed in one digit, and even if nine or more defects are detected, “9” is displayed. In addition, in the case of an abnormality in the inspection unit, it is represented by an unused character such as “X”.
[0035]
Here, the abnormality of the inspection unit includes, for example, a case where data from the inspection personal computer cannot be transmitted successfully, or a case where the fluorescent lamp 11 is turned off for some reason and the inspection cannot be performed. In this embodiment, a confirmation code is provided with a one-digit serial number so that it can be confirmed when there is a missing code or an error in updating the print contents. Therefore, a code of 11 digits in total, that is, 10 digits of defect distribution + 1 digit of confirmation code, can be expressed as “10000010201”.
[0036]
The code signal is transmitted from the control personal computer 14 to the printing unit 3, and the code 15 is printed on the sheet-like molded body based on the print start signal. Note that the form of the code is, for example, a one-dimensional barcode, a two-dimensional code, or alphanumeric characters. If the code is a two-dimensional code to which an error correction code is added, it can be read even if dirt is attached to the code, and the amount of information can be increased.
[0037]
Next, the inspection result determination unit will be described. In FIG.1 (b), the sheet-like molded object 1 once wound up by the roll by the test | inspection part is again drawn out from the left side of a figure along the conveyance path | route, and is conveyed. The reading / determining unit 6 reads the code printed on the sheet-like molded body, and performs pass / fail determination based on the read code. The marking unit 7 marks the center of the area determined to be defective. The punching device 8 punches a product from the sheet-like molded body 1. The punched product is conveyed to a predetermined location by a belt conveyor. The sheet-like molded body 1 after the product is punched out is taken up by a take-up roll 9.
[0038]
Next, details of the inspection result determination unit will be described with reference to FIG. The sheet-like molded body 1 once wound up by the inspection unit is successively drawn out sequentially. A code 15 is printed at predetermined intervals on the end of the sheet-like molded body 1 in the width direction. A code position detection sensor 16 is provided, and the shutter of the code reader 18 is released at the timing when the code 15 passes the code position detection sensor 16. As a result, the read code signal is input to the control personal computer 17. The control personal computer 17 determines pass / fail based on the read code. As a result of the pass / fail determination, marking is performed by the pen marker 7 in the center of the area portion determined to have a defect. In a subsequent process, after punching into a product size by the punching device 8, a non-defective product / defective product is selected based on the marking. The remaining portion on which the code 15 is printed is wound around the winding roll 9 as a scrap.
[0039]
In the present embodiment, the defective product is marked with the pen marker 7, but the marking method is not limited to this. A sticker may be attached to the center of the defective area. Further, the defective area portion may be wound up as a cut scrap without cutting. Further, a configuration may be adopted in which either a good product or a defective product is automatically extracted after the product is cut.
[0040]
Further, the interval at which the code 15 is printed may not coincide with the product size (length in the transfer direction). In the present embodiment, description will be made assuming that the distance between the cords is 10 cm and the product size is 12 cm. In this case, as shown in FIG. 7, the pass / fail judgment is performed from the inspection results for two or three codes. In the case of FIG. 7, since the area A for punching the product corresponds to (1) to (12), the inspection results of the area A from the code 1 and the code 2 are totaled, and pass / fail judgment is performed. The inspection results (13) to (20) of the remaining portion of the code 2 are tabulated together with the inspection results of the region B portions (21) to (24) of the code 3 when determining the quality of the region B. Thus, two codes are included in one area. In the above example, there are cases where three codes are included in one area. In that case, the inspection results in the area are totaled from the three codes, and pass / fail judgment is performed. The max of codes that fall within the area is a + 2 when b ≠ 0 and a + 1 when b = 0, assuming that the distance between codes is x, the product size is y, and y ÷ x = a (remainder b). .
[0041]
Second Embodiment
Next, an inspection result recording method (system) for a sheet-like molded body according to the second embodiment will be described. In the second embodiment, the inspection result is not printed as a code, but is recorded on a recording device inside the computer.
[0042]
The basic configuration of the inspection unit may be almost the same as that shown in FIGS. The inspection result of the sheet-like molded body 1 is recorded on a hard disk inside the inspection personal computer 13 or another recording device (server) connected to the inspection unit via the LAN. In addition, a position correction code 15 is printed on the sheet-like molded body 1 by the printing unit 3 instead of the inspection result. The interval for printing the position correction code 15 may be the same as in the first embodiment. In the recording apparatus, the inspection result is stored in such a form that the position correction code 15 and the inspection result can be associated with each other. The position correction code 15 is printed on an end portion that becomes a remaining cut residue when a product is punched from the sheet-like molded body 1. In the present embodiment, the defect distribution is recorded as the inspection result as in the first embodiment.
[0043]
As the inspection result stored in the recording device, for example, the coordinates and area of the defect are recorded. The position correction code 15 to be printed is for correcting the position, and prints a 3-digit serial number at predetermined intervals. However, no printing is performed when a problem occurs in the inspection personal computer 13 or the control personal computer 14. When the system is operating normally, the position correction code 15 can be printed in a sequential number to not only correct the position, but also prevent a portion that could not be inspected due to a device trouble from being judged as a non-defective product. .
[0044]
In the inspection result determination unit, the sheet-like molded body 1 once wound up in a roll shape is successively drawn out sequentially, and the printed position correction code 15 is read. Then, the inspection result corresponding to the read position correction code 15 is read from the recording device, and the quality of the product to be cut is predicted and the quality is determined. Then, only non-defective products are punched from the sheet-like molded body, and the remaining portion is wound as a cut residue on a winding roll.
[0045]
FIG. 8 is a diagram illustrating a detailed configuration of the inspection result determination unit. The sheet-like molded body 1 once wound up in the inspection unit is fed out and transferred along the conveyance path. At the timing when the position detection sensor 16 detects the presence of the position correction code 15, the shutter is released to the code reader 18, and the read position correction code 15 is transmitted to the control personal computer 17. The control personal computer 17 calls the inspection result corresponding to the read position correction code 15 from the recording device, and makes a pass / fail judgment by predicting an area to cut the product. Further, if there is a defective product, marking is performed with a pen marker 7 in the center of the defective product area. When punching out the product, only the non-defective product is punched out, and the remaining defective portion is wound around the winding roll 9 together with the portion on which the position correction code 15 is printed.
[0046]
In the pass / fail determination, not only when the number of defects is greater than a certain value, but also when the area of the result is greater than a certain value or when the distance between defects is closer than a certain value, the defect may be determined as defective. In this case, there is an advantage that it is easy to perform pass / fail judgment if the area and coordinates are stored as data. In addition, when the inspection result is coded as in the first embodiment, since the amount of information is limited, the area division is finely divided into a lattice shape, and the number of defects included in the lattice is recorded. It is preferable.
[0047]
Furthermore, when the information amount of the inspection result is large, it is preferable that the inspection result is not encoded and printed, but stored in the recording apparatus as in the second embodiment. In this case, as already described, only the position correction code is printed on the sheet-like molded body.
[0048]
<Another embodiment>
As the light source, other white light sources may be used instead of fluorescent lamps. Moreover, you may use the light source which irradiates the light of a specific wavelength range according to the characteristic of a sheet-like molded object. Further, the camera (image acquisition means) for acquiring an image is not limited to a specific structure, and a line sensor, an area sensor, a photomultiplier (photomultiplier), or the like may be used. Furthermore, the image to be acquired is not limited to the transmitted light image, and may be configured to acquire the reflected light image. This can be appropriately changed according to the characteristics of the sheet-like molded body.
[Brief description of the drawings]
1A shows a system configuration for recording inspection results, and FIG. 1B shows a system configuration for determining inspection results. FIG. 2 shows the system configuration for FIG. FIG. 3 is a diagram illustrating details of the inspection unit. FIG. 3 is a diagram illustrating details of the determination unit in FIG. 1B. FIG. 4 is a diagram illustrating areas and print locations. FIG. FIG. 6 is a diagram illustrating another example of printing. FIG. 7 is a diagram illustrating the relationship between the area size and the product size. FIG. 8 is a diagram illustrating details of the determination unit according to the second embodiment. Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Sheet-like molded object 2 Inspection part 3 Printing part 4 Protective tape 5 Winding roll 6 Reading / judgment part 7 Marking part 8 Punching device 9 Winding roll 10 Camera 11 Fluorescent lamp 12 Image processing apparatus 13 Inspection personal computer 14 Control personal computer 15 Code, position correction code C Print location

Claims (6)

Irradiating light to the sheet-like molded body that is continuously transferred; and
In the step of irradiating light, obtaining image data of the sheet-like molded body;
Image processing the image data, encoding the inspection result of the sheet-like molded body for each area set along the transfer direction;
And a step of printing a code obtained by encoding the inspection result at predetermined intervals of the sheet-like molded body.  The inspection result recording method for a sheet-like molded product according to claim 1, wherein the defect distribution of the sheet-like molded product is coded as the inspection result.  3. The inspection result recording method for a sheet-like molded body according to claim 1, wherein the inspection result is encoded by a one-dimensional or two-dimensional code. Reading the code formed on the sheet-like molded body;
The sheet-like molded article according to any one of claims 1 to 3, further comprising a step of taking out a sheet from the sheet-like molded article while avoiding a defect position based on the read code. Inspection result recording method. A roll-shaped molded body, in which a code is printed based on the inspection result recording method according to any one of claims 1 to 4. A light source unit for irradiating light onto a sheet-like molded body that is continuously transferred;
Image acquisition means for acquiring image data from the sheet-like molded article irradiated with light;
An image processing unit for image processing the image data;
Coding means for coding the inspection result of the sheet-like molded body for each area set along the transfer direction;
An inspection result recording system for a sheet-like molded body, comprising: a printing unit that prints a code obtained by encoding the inspection result at predetermined intervals of the sheet-like molded body.

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