JP2012078144A - Surface defect inspection device for transparent body sheet-like material - Google Patents
Surface defect inspection device for transparent body sheet-like material Download PDFInfo
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本発明は、透明体のシート状物表面の凹凸状欠陥をインラインで検出および判定する低コストの検査装置に関する。 The present invention relates to a low-cost inspection apparatus that detects and determines an irregular defect on the surface of a transparent sheet in-line.
液晶等に用いる光学フィルムや電子機器部品等に用いる高機能性フィルムは、近年ますます異物や欠陥に対する要求規格が厳しくなりつつある。これらのシート状物はクリーンルームで製造され、製造ライン中にある欠陥検査機によってシート状物の異物や欠陥を検出することで品質の管理が行われている。しかしながら、工程内のロール等に付着した異物が原因となってシート状物表面に凹み欠陥や凸状欠陥等(以下、凹凸状欠陥と称す)が発生することがある。この凹凸状欠陥を検知するために、光を透過させて透過光の濃度変化によって検出する欠陥検査機が設置されているが、この検出方法では凹凸状欠陥に依って生じる濃度差が小さく、凹凸状欠陥を見逃すといった問題があった。また、出荷前の目視検査で品質規格外の凹凸状欠陥が発見されることもあり、その場合、膨大な廃棄損出や機会損出につながるといった問題があった。また、目視検査でも凹凸状欠陥を見逃して出荷するリスクがあり、多大な損出をもたらす恐れがある。 In recent years, the requirement standards for foreign substances and defects of optical films used for liquid crystals and the like and high-functional films used for electronic equipment parts are becoming stricter. These sheet-like materials are manufactured in a clean room, and quality control is performed by detecting foreign matters and defects on the sheet-like material by a defect inspection machine in the production line. However, a dent defect or a convex defect (hereinafter referred to as a concavo-convex defect) may occur on the surface of the sheet-like material due to a foreign matter adhering to a roll or the like in the process. In order to detect this irregularity defect, a defect inspection machine that transmits light and detects it by changing the density of transmitted light is installed, but this detection method has a small density difference caused by the irregularity defect, There was a problem of missing a defect. In addition, irregular inspections outside the quality standard may be found by visual inspection before shipment, and in that case, there is a problem that it leads to a huge loss of waste and loss of opportunity. In addition, there is a risk of missing the uneven defect even in the visual inspection and shipping, which may cause a great loss.
この問題を解決するため、シート状物のライン中で、走行方向から蛍光灯の直線状の光を傾けて投射し、透過光をCCDカメラで明暗信号として取り込み、光量ムラを補正しながら打痕等の凹凸状欠陥を検査する方法(例えば、特許文献1参照)が提案されている。しかしながら、曲率変化が小さな凹凸状欠陥は、蛍光灯等で構成した直線状の光では平行性に劣るため、欠陥がないシート状物の透過光との差異が小さく、欠陥を見逃す場合があるといった問題があった。 In order to solve this problem, in the line of sheet-like material, the linear light of the fluorescent lamp is projected obliquely from the running direction, the transmitted light is captured as a light / dark signal by the CCD camera, and the dent is made while correcting the unevenness of the light quantity. A method for inspecting uneven defects such as the above has been proposed (for example, see Patent Document 1). However, the uneven defect with small curvature change is inferior in parallelism with linear light composed of a fluorescent lamp or the like, so that the difference from the transmitted light of the sheet-like material having no defect is small and the defect may be overlooked. There was a problem.
また、シート状物のライン中で、斜め方向から平行光を照射し、透過光と反射光を各々独立の光学系と撮像素子で検出し、各々の強度分布を比較照合して凹凸状欠陥を検査する方法(例えば、特許文献2参照)が提案されている。しかしながら、この方法は、2つの光学系と撮像素子が必要となるため装置にコストがかかり、さらに、複数の光学系の光軸を合わせて調整することは困難であり、多大な時間を費やすといった問題があった。 Also, in the line of sheet-like material, irradiate parallel light from an oblique direction, detect transmitted light and reflected light with independent optical systems and image sensors, and compare and collate each intensity distribution to detect uneven defects A method of inspection (for example, see Patent Document 2) has been proposed. However, since this method requires two optical systems and an image sensor, the apparatus is costly. Further, it is difficult to adjust the optical axes of a plurality of optical systems together, and it takes a lot of time. There was a problem.
本発明は、従来の技術の上記問題点を解決し、透明体シート状物表面に発生した曲率変化の小さな凹凸状欠陥を、最も鮮明な明暗像になる状態で結像させることにより、欠陥を漏れなく検出し、信頼性の高い欠陥検査装置を提供することを目的としている。 The present invention solves the above-mentioned problems of the prior art, and forms defects in a state where the curvature change having a small curvature generated on the surface of the transparent sheet is in the state where it becomes the clearest bright and dark image. An object of the present invention is to provide a defect inspection apparatus that can detect without omission and has high reliability.
本発明者らは、鋭意検討した結果、上記課題を解決できることを見出し、本発明を完成するに至った。
すなわち本発明は、走行する透明体のシート状物表面に発生した凹凸状欠陥の検査において、光源から発した平行光の照射方向に配置したミラーによって反射させる機構を有した照明手段と、
この平行光をシート状物の走行方向に対して斜めに透過させ、透過した光を結像させるための曲面状のスクリーンと、
該スクリーンの曲面に結像した光を、合焦するように、スクリーンの曲面の曲率半径上に合焦点を起点として角度調節できる機構を有する撮像手段と、
該撮像手段によって該スクリーンに結像した光を明暗信号として検出する信号処理手段と、
を具備することを特徴とするシート状物の表面欠陥検査装置に関する。
As a result of intensive studies, the present inventors have found that the above problems can be solved, and have completed the present invention.
That is, the present invention provides an illumination means having a mechanism for reflecting by a mirror arranged in the irradiation direction of the parallel light emitted from the light source in the inspection of the uneven defect generated on the surface of the traveling transparent sheet.
A curved screen for transmitting the parallel light obliquely with respect to the traveling direction of the sheet and imaging the transmitted light; and
Imaging means having a mechanism capable of adjusting the angle from the focal point on the curvature radius of the curved surface of the screen so as to focus the light imaged on the curved surface of the screen;
Signal processing means for detecting light imaged on the screen by the imaging means as a light and dark signal;
It is related with the surface defect inspection apparatus of the sheet-like material characterized by comprising.
好ましい実施態様としては、前記信号処理手段が、検出した明暗信号のレベルをしきい値によって凹凸状欠陥として検知し、凹凸状欠陥の寸法及び形状を判定することを特徴とするシート状物の表面欠陥検査装置に関する。 As a preferred embodiment, the signal processing means detects the level of the detected light / dark signal as a concavo-convex defect using a threshold value, and determines the size and shape of the concavo-convex defect, and the surface of the sheet-like object The present invention relates to a defect inspection apparatus.
好ましい実施態様としては、前記照明手段のミラーで反射した光が、シート状物の走行方向に対して入射角10°〜60°で、透過することを特徴とするシート状物の表面欠陥検査装置に関する。 As a preferred embodiment, the light reflected by the mirror of the illumination means is transmitted at an incident angle of 10 ° to 60 ° with respect to the traveling direction of the sheet-like material. About.
好ましい実施態様としては、前記撮像手段は、照明手段のミラーの偏向角度と連動し、曲面のスクリーンの結像位置に合うように合焦位置を軸として角度調節する機構を有することを特徴とするシート状物の表面欠陥検査装置に関する。 As a preferred embodiment, the imaging means has a mechanism for adjusting the angle about the focusing position as an axis so as to match the imaging position of the curved screen in conjunction with the deflection angle of the mirror of the illumination means. The present invention relates to a sheet-like surface defect inspection apparatus.
好ましい実施態様としては、前記撮像手段に一次元イメージセンサを用い、スキャン毎の明暗信号を前記信号処理手段によって一定ライン数を更新しながら蓄積し、明暗信号のレベルによって複数のしきい値を設定し、その明暗信号のレベルによって凹状と凸状の判定や凹凸の大きさを推定し、しきい値を越えた幅から凹凸状欠陥の寸法として判定することを特徴とするシート状物の表面欠陥検査装置に関する。 As a preferred embodiment, a one-dimensional image sensor is used for the imaging means, and a light / dark signal for each scan is accumulated while updating a certain number of lines by the signal processing means, and a plurality of threshold values are set according to the level of the light / dark signal. The surface defect of the sheet-like material is characterized by judging the size of the concave and convex shapes and the size of the concave and convex according to the level of the brightness signal, and determining the size of the concave and convex defect from the width exceeding the threshold It relates to an inspection device.
本発明によれば、透明体シート状物表面の曲率変化の小さな凹凸状欠陥でも高感度の検出が可能となって欠陥を漏れなく検出し、比較的単純な信号処理によって欠陥の寸法や凹凸の大きさをリアルタイムに判定することができる信頼性の高い欠陥検査装置が得られる。その結果、工程異常を早期に発見して損出拡大を防止し、信頼性の高い品質管理ができるという効果を奏する。 According to the present invention, even a concave-convex defect having a small curvature change on the surface of a transparent sheet can be detected with high sensitivity, and the defect can be detected without omission. A highly reliable defect inspection apparatus capable of determining the size in real time can be obtained. As a result, it is possible to detect the process abnormality at an early stage, prevent the loss expansion, and perform highly reliable quality control.
本発明に係わる透明体シート状物の欠陥検査装置は、走行する透明体のシート状物表面に発生した凹凸状欠陥の検査において、光源から発した平行光の照射方向に配置したミラーによって偏向角度を調節して反射させる機構を有した照明手段と、この平行光をシート状物の走行方向に対して斜めに透過させ、透過した光を結像させるための曲面状のスクリーンと、該スクリーンの曲面に結像した光を、暗視野方向のどの位置からでも合焦するように、スクリーンの曲面の曲率半径上に合焦点を起点として角度調節できる機構を有する撮像手段と、該撮像手段によってスクリーンに結像した光を明暗信号として検出する信号処理手段とを具備することを特徴としている。 The defect inspection apparatus for a transparent sheet according to the present invention has a deflection angle by a mirror arranged in the irradiation direction of parallel light emitted from a light source in the inspection of uneven defects generated on the surface of a traveling transparent sheet. Illumination means having a mechanism for adjusting and reflecting the light, a curved screen for transmitting the parallel light obliquely with respect to the traveling direction of the sheet-like material, and forming an image of the transmitted light, An imaging means having a mechanism capable of adjusting the angle from the focal point of the curved surface of the screen so as to focus the light focused on the curved surface from any position in the dark field direction, and the screen by the imaging means. And signal processing means for detecting the light imaged as a light / dark signal.
本発明に係わる透明体シート状物の欠陥検査装置は、前記信号処理手段が、検出した明暗信号のレベルをしきい値によって凹凸状欠陥として検知し、凹凸状欠陥の寸法及び形状を判定することを特徴としている。 In the defect inspection apparatus for a transparent sheet according to the present invention, the signal processing means detects the detected light / dark signal level as a concavo-convex defect based on a threshold value, and determines the size and shape of the concavo-convex defect. It is characterized by.
ここで、凹凸状欠陥とは、シート状物に異物などが押し当てられた面が、湾曲して凹み、その反対面が凸状に膨らんだ欠陥をいい、両面が凹状または両面が凸状の欠陥も含む。 Here, the uneven defect is a defect in which the surface of the sheet-like material pressed against a foreign object is curved and recessed, and the opposite surface bulges in a convex shape. Both surfaces are concave or both surfaces are convex. Includes defects.
ここで、平行光とは、光束の各光線が重なることがなく、照明方向の光軸に対して平行に近い光線の成分で構成された光をいい、また、光束の各光線が重なることがなく、照明方向の光軸に対して所定の角度の拡がりがある光も含む。 Here, the parallel light means light composed of light components that are nearly parallel to the optical axis in the illumination direction without overlapping each light beam, and each light beam overlaps. It also includes light having a predetermined angle spread with respect to the optical axis in the illumination direction.
また、平行光をシート状物の走行方向に対して斜めに透過させてスクリーンに投影して結像させることにより、凹凸状欠陥がレンズと等価な屈折作用により、投影像に明暗が生じる。すなわち、光が集光される部位の像は明るく、光が屈折によって入射しない部位の像は暗くなる。 Further, by projecting parallel light obliquely with respect to the traveling direction of the sheet-like material and projecting it onto the screen to form an image, the projection-and-depression defect has a light and darkness due to the refracting action equivalent to the lens. That is, the image of the part where the light is collected is bright, and the image of the part where the light is not incident by refraction is dark.
ここで、スクリーン表面の性状は、光が正反射する鏡面ではなく、光が拡散する粗面を選択して投影像を結像させる。 Here, as the properties of the screen surface, a projected image is formed by selecting a rough surface on which light diffuses instead of a mirror surface on which light is regularly reflected.
ここで、スクリーンの走行方向の曲面は、撮像手段の合焦位置を直径とした曲率半径にすることで、投影像がスクリーンの曲面のどの位置に結像しても、合焦位置を回転軸としてカメラの角度を調節することによって常にピントが合った状態となる。また、スクリーンの走行方向の断面はシート状物の幅方向に平行で同一とし、シート状物の幅方向の検査エリアでは、投影像が結像するスクリーンの曲面の位置は幅方向で同一となる。 Here, the curved surface in the traveling direction of the screen has a curvature radius with the in-focus position of the imaging means as the diameter, so that the in-focus position is the rotation axis no matter where the projected image is formed on the curved surface of the screen. By adjusting the camera angle, the camera will always be in focus. In addition, the cross-section in the traveling direction of the screen is the same in the width direction of the sheet-like object, and the position of the curved surface of the screen on which the projection image is formed is the same in the width direction in the inspection area in the width direction of the sheet-like object. .
ここで、投影像のスクリーンの曲面での結像位置は、照明手段のミラーによって調節する平行光の入射角度によって決まっており、ミラーの回転角度から撮像手段の角度が幾何学的に決まる。 Here, the imaging position of the projected image on the curved surface of the screen is determined by the incident angle of the parallel light adjusted by the mirror of the illumination means, and the angle of the imaging means is geometrically determined from the rotation angle of the mirror.
ここで、撮像手段は一次元イメージセンサカメラ等を用い、スクリーンに結像させた画像を連続的に撮像し、凹凸状欠陥によって生じた陰影を明暗の電気信号として検出する。この明暗の電気信号を信号処理手段によって複数のしきい値で判定することにより、凹凸状欠陥の陰影の濃度による大きさが検出でき、陰影の濃度に比例する凹凸状欠陥の断面変化の大きさが推定できる。 Here, the image pickup means uses a one-dimensional image sensor camera or the like, continuously picks up images formed on the screen, and detects shadows caused by the irregular defects as light and dark electrical signals. By determining this light / dark electrical signal with a plurality of threshold values by the signal processing means, the size of the uneven defect can be detected by the shadow density, and the cross-sectional change magnitude of the uneven defect proportional to the shadow density can be detected. Can be estimated.
上記構成によれば、平行光をミラーによってシート状物の走行方向に対して斜めに透過させ、曲面状のスクリーンに結像した光を、角度調節して合焦点から撮像し、検出した明暗信号を複数のしきい値によって判定することにより、凹凸状欠陥の寸法や凹凸の大きさを検査することが可能となる。 According to the above configuration, the parallel light is transmitted obliquely with respect to the traveling direction of the sheet-like object by the mirror, the light imaged on the curved screen is imaged from the focal point by adjusting the angle, and the detected light / dark signal Can be inspected based on a plurality of threshold values to inspect the size of the concavo-convex defect and the size of the concavo-convex.
本発明に係わる透明体シート状物の欠陥検査装置は、前記照明手段のミラーで反射した光が、シート状物の走行方向に対して入射角10°〜60°で、透過することを特徴とするシート状物の表面欠陥検査装置に関する。 The defect inspection apparatus for a transparent sheet according to the present invention is characterized in that the light reflected by the mirror of the illumination means is transmitted at an incident angle of 10 ° to 60 ° with respect to the traveling direction of the sheet. The present invention relates to a surface defect inspection apparatus for sheet-like materials.
ここで、スクリーンに結像した凹凸状欠陥の部位と凹凸状欠陥がない部位との明暗の差は、凹凸状欠陥の曲率変化および平行光照明の入射角度と、シート状物の平均厚みや屈折率等の品種とに依存しており、曲率変化が小さな軽微な凹凸状欠陥でも明暗の光学的濃度差を生じさせるためには、入射角度をシート状物に対して浅くする方が有利である。入射角度を浅くすることで、軽微な凹凸状欠陥でも明暗の光学的濃度差を生じせしめ、シート状物の検査エリアも広くできる一方で、全体的に暗い画像となって地合ノイズも強調されるため、検出が必要な凹凸状欠陥と地合との明暗の差が区別できる範囲で入射角度を調整し、シート状物の検査エリアを設定することが好ましい。 Here, the difference in brightness between the part of the uneven defect imaged on the screen and the part without the uneven defect is due to the change in curvature of the uneven defect, the incident angle of the parallel light illumination, the average thickness and refraction of the sheet-like object. In order to cause a difference in optical density between light and dark even with a slight uneven defect with a small change in curvature, it is advantageous to make the incident angle shallower than the sheet-like material. . By making the incident angle shallower, even a slight uneven defect can cause a difference in optical density between light and dark, and the inspection area of the sheet-like object can be widened. Therefore, it is preferable to set the inspection area of the sheet-like object by adjusting the incident angle within a range in which the difference in brightness between the uneven defect that needs to be detected and the texture can be distinguished.
従って、入射角はシート状物の平均厚みや屈折率等の品種と、凹凸状欠陥の曲率変化によって最適な角度を決定することが好ましい。より好ましくは、予めシート状物の品種毎に検出すべき凹凸状欠陥をサンプリングしておき、適切な入射角を調査し、信号処理手段に登録し、品種毎に入射角を適切な値に自動で照明手段のミラーの角度を調節する。 Therefore, it is preferable to determine the optimum angle of incidence according to the product such as the average thickness and refractive index of the sheet-like material and the change in curvature of the irregular defect. More preferably, uneven defects to be detected for each kind of sheet-like material are sampled in advance, an appropriate incident angle is investigated, registered in the signal processing means, and the incident angle is automatically set to an appropriate value for each kind. To adjust the angle of the mirror of the illumination means.
従って、シート状物の品種と検出すべき凹凸状欠陥に対して、最適な光学条件に構成でき、感度の高い凹凸状欠陥の検査ができる点で優れている。 Therefore, it is excellent in that it can be configured under optimum optical conditions for the type of sheet material and the uneven defect to be detected, and the highly sensitive uneven defect can be inspected.
本発明に係わる透明体シート状物の欠陥検査装置は、撮像手段は、シート状物に対する斜めの入射角度を調整するために変化させた照明手段のミラーの偏向角度と連動し、曲面のスクリーンの結像位置に合うように合焦位置を軸として角度調節する機構を有することを特徴とするシート状物の表面欠陥検査装置に関する。 In the defect inspection apparatus for a transparent sheet-like material according to the present invention, the imaging means is interlocked with the deflection angle of the mirror of the illumination means changed to adjust the oblique incident angle with respect to the sheet-like material, The present invention relates to an apparatus for inspecting a surface defect of a sheet-like object, characterized by having a mechanism for adjusting an angle with an in-focus position as an axis so as to match an imaging position.
ここで、撮像手段の一次元イメージセンサカメラは、対象であるシート状物が移動中に正確に合焦することは困難であるが、撮像手段の合焦距離を半径とした曲面のスクリーンにすることで、合焦位置を軸として撮像手段の角度を調整するだけで凹凸状欠陥の投影像がスクリーンのどの位置で結像しても合焦した状態となり、感度の高い欠陥検査ができる点で優れている。 Here, it is difficult for the one-dimensional image sensor camera of the image pickup unit to focus accurately while the target sheet-like object is moving, but it is a curved screen with the focus distance of the image pickup unit as the radius. Therefore, by adjusting the angle of the imaging means around the in-focus position, the projected image of the concavo-convex defect will be in focus regardless of the position on the screen, and highly sensitive defect inspection can be performed. Are better.
ここで、投影像のスクリーンの曲面での結像位置は、照明手段のミラーによって調節する平行光の入射角度によって決まるため、ミラーの回転角度と連動して撮像手段である一次元イメージセンサカメラ等の角度を調整することが好ましい。 Here, since the image formation position on the curved surface of the screen of the projected image is determined by the incident angle of the parallel light adjusted by the mirror of the illumination means, a one-dimensional image sensor camera that is the image pickup means in conjunction with the rotation angle of the mirror, etc. It is preferable to adjust the angle.
本発明に係わる透明体シート状物の欠陥検査装置は、撮像手段に一次元イメージセンサを用い、スキャン毎の明暗信号を前記信号処理手段によって一定ライン数を更新しながら蓄積し、明暗信号のレベルによって複数のしきい値を設定し、その明暗信号のレベルによって凹状と凸状の判定や凹凸の大きさを推定し、しきい値を越えた幅から凹凸状欠陥の寸法として判定することを特徴とするシート状物の表面欠陥検査装置に関する。 A defect inspection apparatus for a transparent sheet according to the present invention uses a one-dimensional image sensor as an image pickup means, accumulates a light / dark signal for each scan while updating a certain number of lines by the signal processing means, and determines the level of the light / dark signal. A plurality of threshold values are set according to the level of the light / dark signal, and the concave / convex judgment and the size of the concave / convex shape are estimated based on the level of the light / dark signal. The present invention relates to a surface defect inspection apparatus for sheet-like materials.
ここで、撮像手段に用いる一次元イメージセンサは、スキャンレートに従って連続して一次元の電気信号に変換して明暗信号として出力され、エンコーダから換算したシート状物のライン速度に基づいて、一次元の明暗信号を信号処理装置で時系列に統合することによって二次元の画像情報が得られる。 Here, the one-dimensional image sensor used for the imaging means is converted into a one-dimensional electric signal continuously according to the scan rate and output as a light / dark signal, and based on the line speed of the sheet-like material converted from the encoder, Two-dimensional image information can be obtained by integrating the light and dark signals in a time series by a signal processing device.
ここで、明暗信号の立ち下がり幅は、凹凸状欠陥の曲率変化に依存しており、凹状の欠陥は投影像の中央部が暗い面積が大きく周囲が明るくなり、凸状の欠陥は投影像の中央部が明るい面積が大きく周囲が暗くなり、曲率変化が大きいほど、凹状の欠陥の投影像は暗い部位のより暗く、凸状の欠陥の投影像は明るい部位のより明るくなる。 Here, the fall width of the light / dark signal depends on the curvature change of the concavo-convex defect, and the concave defect has a dark area in the center of the projected image and a bright surrounding, and the convex defect has a darkness in the projected image. The brighter the central area, the darker the surroundings, and the greater the change in curvature, the darker the projected image of the concave defect and the brighter the projected image of the convex defect.
上記構成によれば、明暗信号のレベルで複数のしきい値で判定することにより、検出した欠陥の凹状と凸状の判定や、凹と凸の大きさの推定ができ、各しきい値の濃度別の凹凸状欠陥の寸法として判定が可能となる。 According to the above configuration, by determining with a plurality of threshold values at the level of the light / dark signal, it is possible to determine the concave and convex shapes of the detected defect and estimate the size of the concave and convex portions. Judgment is possible as the size of the uneven defect by density.
以下に、本発明に係わる透明体シート状物表面の凹凸状欠陥検査装置に関して図1に基づいて説明する。尚、以下の実施形態は、本発明を具体化した一例であって、本発明の技術的範囲を限定する性格のものではない。 Below, the uneven | corrugated-shaped defect inspection apparatus of the transparent body sheet-like material surface concerning this invention is demonstrated based on FIG. In addition, the following embodiment is an example which actualized this invention, Comprising: The thing of the character which limits the technical scope of this invention is not.
図1は、本発明の実施形態に係る透明体シート状物表面の凹凸状欠陥検査装置の一例を示す模式図である。 FIG. 1 is a schematic diagram showing an example of a concavo-convex defect inspection apparatus on the surface of a transparent sheet according to an embodiment of the present invention.
図1において、透明体シート状物6の走行方向をMDとし、幅方向をTDとし、その走行する透明体シート状物6のMDから平行光を斜めに透過させて照射する照明手段1と、平行光をミラー2によって回転軸Aを中心に角度調整する図示していない調整手段と、透明体シート状物6を透過した光を結像させるスクリーン3と、スクリーン3に結像した画像を合焦距離rから適切な角度で明暗信号として検出するための撮像手段4と、透明体シート状物6に図示していない凹凸状欠陥がある場合に、明暗信号のレベルを複数のしきい値によって凹凸状欠陥として検知し、凹凸状欠陥の形状や寸法を判定する信号処理手段5とを具備している。 In FIG. 1, the illumination unit 1 that irradiates parallel light obliquely from the MD of the traveling transparent sheet 6, the traveling direction of the transparent sheet 6 is MD, the width direction is TD, An adjusting means (not shown) that adjusts the angle of the parallel light around the rotation axis A by the mirror 2, the screen 3 that forms an image of the light transmitted through the transparent sheet 6, and the image formed on the screen 3 are combined. In the case where the imaging means 4 for detecting as a light / dark signal at an appropriate angle from the focal distance r and the irregular sheet-like defect (not shown) in the transparent sheet-like object 6, the level of the light / dark signal is determined by a plurality of threshold values. And signal processing means 5 for detecting the irregularity defect and determining the shape and size of the irregularity defect.
また、撮像手段4はスクリーン3のどの位置に結像した画像も合焦距離rで正確に撮像させるために、撮像手段4の回転軸Bを中心に図示していないステッピングモータ等の制御手段によって角度を調整する。この撮像手段4の回転角度は、ミラー2の角度調整用ステッピングモータ等の制御信号、または、ミラー2の回転角度を図示していないロータリーエンコーダで検出信号に基づき、その角度から幾何計算によって求めることができる。また、撮像手段4にも図示していない角度調整用ステッピングモータ等を設置し、ミラー2の回転角度と連動して撮像手段4の回転角度を調節することが好ましい。 Further, the image pickup means 4 is controlled by a control means such as a stepping motor (not shown) around the rotation axis B of the image pickup means 4 in order to accurately pick up an image formed at any position on the screen 3 at the focal distance r. Adjust the angle. The rotation angle of the imaging means 4 is obtained by geometric calculation based on the control signal of the mirror 2 angle adjustment stepping motor or the like, or the rotation angle of the mirror 2 based on the detection signal by a rotary encoder (not shown). Can do. Further, it is preferable that an angle adjusting stepping motor or the like (not shown) is also installed in the image pickup means 4 to adjust the rotation angle of the image pickup means 4 in conjunction with the rotation angle of the mirror 2.
また、透明体シート状物6の走行速度は、図示していない近傍のロールに設置したエンコーダから換算することができる。 Moreover, the traveling speed of the transparent sheet 6 can be converted from an encoder installed on a nearby roll (not shown).
ここで、凹凸状欠陥とは、シート状物に異物などが押し当てられた面が、湾曲して凹み、その反対面が凸状に膨らんだ欠陥をいい、両面が凹状または両面が凸状の欠陥も含む。この凹凸状欠陥は、ロール上やニップロールにおいて、シート状物に異物などが押し当てられた面が、湾曲して凹み、その反対面が凸状に膨らんだ欠陥が主要であるが、異物などが押し当てられてシート状物両面に凹みが生じる場合や、ロール側に凹みがある場合には、シート状物が凸状の欠陥となる場合がある。当然ながら、欠陥の凹凸の向きや大きさや高低差は、接触する異物の大きさや硬さなどによって変化する。 Here, the uneven defect is a defect in which the surface of the sheet-like material pressed against a foreign object is curved and recessed, and the opposite surface bulges in a convex shape. Both surfaces are concave or both surfaces are convex. Includes defects. The irregular defect is mainly a defect in which a surface on which a foreign object is pressed against a sheet-like material on a roll or a nip roll is curved and recessed, and the opposite surface bulges in a convex shape. If the sheet is pressed and dents are formed on both sides of the sheet or if there are dents on the roll side, the sheet may be a convex defect. Naturally, the direction, size, and height difference of the unevenness of the defect changes depending on the size and hardness of the foreign matter that comes into contact.
ここで、平行光とは、光束の各光線成分が重なることがなく、照明方向の光軸に対して平行に近い光線の成分で構成された光をいう。図1において、照明手段1の光源にはキセノン光源のように点光源であることが好ましく、点光源の出射窓にコリメータレンズなどによって一定の拡がりをもった平行光の光束とすることができ、出射窓から離れて光束が拡大されても各光線成分が重なることはない。 Here, the parallel light refers to light composed of light components that are nearly parallel to the optical axis in the illumination direction without overlapping each light component of the light flux. In FIG. 1, the light source of the illumination means 1 is preferably a point light source such as a xenon light source, and can be a parallel light beam having a certain spread by a collimator lens or the like at the exit window of the point light source. Even if the light beam is enlarged away from the exit window, the light components do not overlap.
また、透明体シート状物6の検査エリアに限定して平行光を照射するために、照明手段1とミラーの間に図示していないマスクを設置することで、TDに平行なスリット状の平行光とすることができ、周辺のロール等で乱反射した光による誤検出を防止する点で好ましい。 In addition, in order to irradiate parallel light limited to the inspection area of the transparent sheet-like object 6, a mask (not shown) is placed between the illumination means 1 and the mirror, so that a slit-like parallel parallel to the TD. It is preferable in that it can be light and prevents erroneous detection due to light irregularly reflected by a peripheral roll or the like.
ここで、照明手段1に用いるミラー2は、反射率が85%以上の光学ミラーを用いることが、光量の減衰を抑制する点で好ましい。 Here, it is preferable that the mirror 2 used in the illumination unit 1 is an optical mirror having a reflectance of 85% or more from the viewpoint of suppressing the attenuation of the light amount.
また、ミラー2の反射面に回転軸Aを配置し、例えば、0.36°/パルスのステッピングモータで正確に制御することが好ましい。当然ながら、ミラー2での入射角の変化量に対する反射角の変化量は2倍になり、ミラー2の回転角度は透明体シート状物6を透過した光がスクリーン3の範囲内に収まるように限定することが好ましい。 Further, it is preferable to arrange the rotation axis A on the reflection surface of the mirror 2 and to accurately control the rotation axis with, for example, a stepping motor of 0.36 ° / pulse. Naturally, the amount of change in the reflection angle with respect to the amount of change in the incident angle at the mirror 2 is doubled, and the rotation angle of the mirror 2 is such that the light transmitted through the transparent sheet 6 is within the range of the screen 3. It is preferable to limit.
また、ミラー2の回転軸Aは、撮像手段4の回転軸Bを中心とした合焦距離rを半径とした円の軌跡上に配置することで、ミラー2の回転角から撮像手段4の回転角を幾何計算する際に簡易になる点で好ましい。 Further, the rotation axis A of the mirror 2 is arranged on a circular locus whose radius is the in-focus distance r about the rotation axis B of the imaging unit 4, so that the imaging unit 4 rotates from the rotation angle of the mirror 2. This is preferable in that it is easy to calculate the corner geometrically.
ここで、スクリーン3は、撮像手段4の回転軸Bを中心とした合焦距離rを半径とした円の軌跡上に曲面とすることで、スクリーン3上のどの位置に結像しても撮像手段4の角度を調節するだけで、平行光の入射角度を変更する毎の合焦の操作が不要になる点で好ましい。 Here, the screen 3 has a curved surface on the locus of a circle having a focus distance r centered on the rotation axis B of the image pickup means 4, so that an image can be taken at any position on the screen 3. It is preferable in that the focusing operation is not required every time the incident angle of the parallel light is changed only by adjusting the angle of the means 4.
図2は、スクリーン3の形状の一例を示す模式図である。 FIG. 2 is a schematic diagram illustrating an example of the shape of the screen 3.
図2において、合焦距離rを曲率半径とした曲面の表面をもつスクリーン3は、MDの断面がTDで同様の形状することで、TDに平行なスリット状の光がスクリーン面上でもTDと平行に結像する。 In FIG. 2, the screen 3 having a curved surface with the in-focus distance r as the radius of curvature has the same MD cross-section, so that slit-like light parallel to TD is TD even on the screen surface. Form images in parallel.
また、スクリーン3の曲面の加工精度は、撮像手段4に用いる受光レンズと光学的検出条件によって決まる被写界深度の範囲内でよく、好ましくは、被写界深度の1/10程度に加工する。 Further, the processing accuracy of the curved surface of the screen 3 may be within the range of the depth of field determined by the light receiving lens used for the image pickup means 4 and the optical detection conditions, and preferably processed to about 1/10 of the depth of field. .
また、スクリーン3の拡散表面は、拡散反射する材質の選択、もしくは、金属への白色系の塗装によって実現でき、表面に色斑がないことが好ましい。 Moreover, the diffusing surface of the screen 3 can be realized by selecting a material that diffusely reflects or by applying a white coating on a metal, and it is preferable that the surface has no color spots.
図3は、スクリーン3の形状の一例を示す模式図である。 FIG. 3 is a schematic diagram illustrating an example of the shape of the screen 3.
図3において、合焦距離rを曲率半径とした多段の平面に加工したスクリーン3であり、MDの断面がTDで同様の形状することで、TDに平行なスリット状の光がスクリーン面上でもTDと平行に結像する。この場合、スクリーンへの結像位置は段階的となるので、照明手段1のミラー2の角度も段階的に調節することとなり、撮像手段4の角度調節も段階的になるので、ミラー2の角度の幾何計算を行わずに予め登録したデータベースから一義的に撮像手段4の角度が抽出できる。 In FIG. 3, the screen 3 is processed into a multi-step plane with the in-focus distance r as the radius of curvature, and the cross section of the MD has the same shape as that of the TD so that slit-like light parallel to the TD can be obtained on the screen surface. An image is formed parallel to TD. In this case, since the image formation position on the screen is stepwise, the angle of the mirror 2 of the illumination unit 1 is also adjusted stepwise, and the angle adjustment of the image pickup unit 4 is also stepwise, so the angle of the mirror 2 The angle of the imaging means 4 can be uniquely extracted from the database registered in advance without performing geometric calculation.
また、スクリーン3の表面の加工精度は、撮像手段4に用いる受光レンズと光学的検出条件によって決まる被写界深度の範囲内でよく、好ましくは、被写界深度の1/10程度に加工する。 Further, the processing accuracy of the surface of the screen 3 may be within the range of the depth of field determined by the light receiving lens used for the image pickup means 4 and the optical detection conditions, and preferably processed to about 1/10 of the depth of field. .
また、スクリーン3の拡散表面は、拡散反射する材質の選択、もしくは、金属への白色系の塗装や拡散シートを貼付することで実現でき、表面に色斑がないことが好ましい。 Moreover, the diffusing surface of the screen 3 can be realized by selecting a material that diffusely reflects, or by applying a white paint or a diffusion sheet to a metal, and it is preferable that the surface has no color spots.
図1において、照明手段1のミラー2が水平となる位置で正反射したスリット状の平行光が、透明体シート状物6に対して入射角θBで入射位置PBを透過し、撮像手段4を垂直方向から見たスクリーン3の水平接線上の結像位置PB’を基準とし、平行光の入射角度θLまで浅くする場合、ミラー2は基準位置から回転角度αに調節し、入射位置PLを透過した光はスクリーン3上でPL’に結像し、撮像手段4は基準位置からθL’の角度に調節し、平行光の入射角度θUまで深くする場合、ミラー2は基準位置から回転角度βに調節し、入射位置PUを透過した光はスクリーン3上でPU’に結像し、撮像手段4は基準位置からθU’の角度に調節する。 In FIG. 1, slit-like parallel light specularly reflected at a position where the mirror 2 of the illuminating means 1 is horizontal passes through the incident position P B at an incident angle θ B with respect to the transparent sheet-like object 6 and is imaged means. When the image forming position P B ′ on the horizontal tangent line of the screen 3 as viewed from the vertical direction 4 is used as a reference and the incident angle θ L of the parallel light is shallow, the mirror 2 is adjusted from the reference position to the rotation angle α to be incident. The light transmitted through the position P L is imaged on the screen 3 at P L ′, and the imaging means 4 is adjusted to an angle of θ L ′ from the reference position and deepens to the incident angle θ U of the parallel light. Is adjusted from the reference position to the rotation angle β, the light transmitted through the incident position P U is imaged on P U ′ on the screen 3, and the imaging means 4 is adjusted to an angle θ U ′ from the reference position.
図4は、本発明の実施形態に係るシート状物への光の入射角度による凹凸状欠陥の結像イメージの一例を示す模式図である。 FIG. 4 is a schematic diagram illustrating an example of an imaging image of a concavo-convex defect depending on an incident angle of light on a sheet-like object according to an embodiment of the present invention.
図4において、Rは片側が凸状で片側が凹状でレンズ状の凹凸状欠陥を平行光で垂直方向から投影して等倍率で結像させた場合のイメージ図であり、投影像暗部の平均濃度をD0とし、横と縦の直径がa0=b0となる円状の欠陥を想定した場合、シート状物への平行光の入射を深い角度から浅く変化させたときに投影像のイメージを示した。図1での基準の入射角θBでの投影像Bに対し、入射角深いθUの投影像Aは暗部の濃度が薄く、大きな像となり、入射角深いθlの投影像Cは暗部の濃度が濃く、小さな像となる。投影像の濃度は、D0<D1<D2<D3となり、MDの最大直径は b1>b2>b3≧b0となり、TDの最大直径は a1>a2>a3>a0となり、アスペクト比は b0/a0=1であり、1≧ b1/a1 > b2/a2 > b3/a3の関係を示す。 In FIG. 4, R is an image diagram in the case where one side is convex, one side is concave, and a lens-like concave / convex defect is projected from the vertical direction with parallel light and imaged at the same magnification, and the average density of the dark portion of the projected image Is assumed to be D 0, and assuming a circular defect in which the horizontal and vertical diameters are a 0 = b 0 , an image of a projected image is obtained when the incidence of parallel light on the sheet is changed from a deep angle to a shallow angle. showed that. In contrast to the projected image B at the reference incident angle θ B in FIG. 1, the projected image A with a deep incident angle θ U has a darker density and a larger image, and the projected image C with a deep incident angle θ 1 has a dark portion. The image is dense and small. The density of the projected image is D 0 <D 1 <D 2 <D 3 , the maximum diameter of MD is b 1 > b 2 > b 3 ≧ b 0 , and the maximum diameter of TD is a 1 > a 2 > a 3. > A 0 , the aspect ratio is b 0 / a 0 = 1, and 1 ≧ b 1 / a 1 > b 2 / a 2 > b 3 / a 3 .
ここで、透明体シート状物6への光の入射角の設定は、凹凸状欠陥の投影像の明暗がスクリーン上で最も鮮明になるように調節するのが好ましく、入射角を浅くするほど投影像の濃度は大きくなり、軽微な凹凸状欠陥も検出できる可能性があるが、シート状物の地合ノイズも強調されて誤検出のリスクが生じ、逆に入射角を深くするほど投影像の濃度は小さくなり、軽微な凹凸状欠陥が検出困難になるがあるが、シート状物の地合ノイズは低減するため誤検出のリスクは低減できる。 Here, it is preferable to adjust the incident angle of the light to the transparent sheet 6 so that the brightness of the projection image of the concavo-convex defect becomes the clearest on the screen. Although the density of the image increases and minor irregularities can be detected, the formation noise of the sheet-like material is also emphasized, and there is a risk of false detection. Although the density becomes small and minor uneven defects are difficult to detect, the risk of false detection can be reduced because the formation noise of the sheet is reduced.
ここで、入射角の条件は、シート状物の平均厚みや屈折率等の品種と、凹凸状欠陥の曲率変化によって最適な角度を決定することが好ましい。また、予めシート状物の品種毎に検出すべき凹凸状欠陥をサンプリングしておき、適切な入射角を調査し、信号処理手段5に登録し、品種毎に入射角を適切な値に自動で照明手段1のミラー2の角度を調節することがより好ましく、本発明者らが鋭意検討の結果、その入射角を10°〜60°の範囲とすることが適切と確認した。 Here, it is preferable that the condition of the incident angle is determined as an optimum angle according to the type such as the average thickness and refractive index of the sheet-like material and the change in curvature of the irregular defect. In addition, the irregularities to be detected for each kind of sheet-like material are sampled in advance, the appropriate incident angle is investigated, registered in the signal processing means 5, and the incident angle is automatically set to an appropriate value for each kind. It is more preferable to adjust the angle of the mirror 2 of the illuminating means 1, and as a result of intensive studies by the inventors, it has been confirmed that the incident angle is in the range of 10 ° to 60 °.
図1において、撮像手段4で検出した一次元の明暗信号を信号処理手段5に蓄積して時系列に合成することによって欠陥等の二次元画像が得られ、形状の判定が可能となる。 In FIG. 1, a one-dimensional light / dark signal detected by the image pickup means 4 is accumulated in the signal processing means 5 and synthesized in time series to obtain a two-dimensional image such as a defect, and the shape can be determined.
また、撮像手段4には一次元イメージセンサを用い、スキャン毎の明暗信号を信号処理手段5によって一定ライン数を更新しながら蓄積し、しきい値を越えたライン数をMDの欠陥の大きさとして検知し、各ラインの明暗信号の立ち下がり幅からTDの欠陥の大きさとして抽出し、MDの大きさのデータと合成して二次元化し、欠陥の寸法や面積や形状を判定することが好ましい。 In addition, a one-dimensional image sensor is used as the image pickup means 4 and the light / dark signal for each scan is accumulated while the number of lines is updated by the signal processing means 5, and the number of lines exceeding the threshold is determined as the size of the MD defect. TD is extracted as the size of the TD defect from the falling width of the light / dark signal of each line, combined with the data of the MD size, and two-dimensionalized to determine the size, area, and shape of the defect. preferable.
ここで、撮像手段4の一次元イメージセンサは、スキャンレートに従って連続して一次元の明暗信号が出力され、エンコーダ等から換算したシート状物のライン速度に基づいて、一次元の明暗信号を信号処理手段5で時系列に統合することによって二次元の画像情報が得られる。信号処理手段5ではエンコーダ等から換算したライン速度とスキャンレートから、1スキャン当たりの距離をMD最小単位とし、検知したライン数とかけ合わせて凹凸状欠陥のMD長さとして換算できる。 Here, the one-dimensional image sensor of the image pickup means 4 outputs a one-dimensional light / dark signal continuously according to the scan rate, and signals the one-dimensional light / dark signal based on the line speed of the sheet-like material converted from the encoder or the like. Two-dimensional image information is obtained by integrating the processing means 5 in time series. The signal processing means 5 can convert the distance per scan as the MD minimum unit from the line speed and scan rate converted from the encoder, etc., and convert it as the MD length of the concavo-convex defect by multiplying it with the number of detected lines.
ここで、欠陥の画像は、入射角によってアスペクト比が異なるが、系統的な誤差であるため、設定した入射角に基づいて補正が可能である。 Here, the defect image has a different aspect ratio depending on the incident angle, but it is a systematic error, so that it can be corrected based on the set incident angle.
ここで、欠陥の画像の明暗信号レベルは、入射角によって変化するが、系統的な変化であるため、設定した入射角に基づいて補正後に比較や照合が可能になり、入射角に連動して明暗のしきい値のレベルを変化させることにより、凹凸状欠陥の曲率変化に依存したNGやOKの判定が可能となる。 Here, the light / dark signal level of the image of the defect changes depending on the incident angle, but since it is a systematic change, comparison and verification can be performed after correction based on the set incident angle, and linked to the incident angle. By changing the threshold level of light and dark, it is possible to determine NG or OK depending on the curvature change of the concavo-convex defect.
ここで、明暗信号の立ち下がり幅は、凹凸状欠陥の曲率変化に依存しており、凹状の欠陥は投影像の中央部が暗い面積が大きく周囲が明るくなり、凸状の欠陥は投影像の中央部が明るい面積が大きく周囲が暗くなり、曲率変化が大きいほど、凹状の欠陥の投影像は暗い部位のより暗く、凸状の欠陥の投影像は明るい部位のより明るくなる。 Here, the fall width of the light / dark signal depends on the curvature change of the concavo-convex defect, and the concave defect has a dark area in the center of the projected image and a bright surrounding, and the convex defect has a darkness in the projected image. The brighter the central area, the darker the surroundings, and the greater the change in curvature, the darker the projected image of the concave defect and the brighter the projected image of the convex defect.
上記構成によれば、明暗信号のレベルで複数のしきい値で判定することにより、検出した欠陥の凹状と凸状の判定や、凹と凸の大きさの推定ができ、各しきい値の濃度別の凹凸状欠陥の寸法として判定が可能となる。 According to the above configuration, by determining with a plurality of threshold values at the level of the light / dark signal, it is possible to determine the concave and convex shapes of the detected defect and estimate the size of the concave and convex portions. Judgment is possible as the size of the uneven defect by density.
1 照明手段
2 ミラー
3 スクリーン
4 撮像手段
5 信号処理手段
6 透明体シート状物
MD 透明体シート状物の走行方向
TD 透明体シート状物の幅方向
A ミラーの回転軸
B 撮像手段の回転軸
θB 平行光のフィルムへの基準入射角
θU 平行光のフィルムへの基準入射角より上方の入射角
θL 平行光のフィルムへの基準入射角より下方の入射角
α 入射角θLのミラーの回転角度
β 入射角θUのミラーの回転角度
PB 平行光光軸のフィルムへの入射位置
PU 平行光光軸のフィルムへの入射位置より上方の入射位置
PL 平行光光軸のフィルムへの入射位置より下方の入射位置
PB’ 入射角θBのスクリーン上の結像位置
PU’ 入射角θUのスクリーン上の結像位置
PL’ 入射角θLのスクリーン上の結像位置
r 撮像手段の合焦距離
θU’ PU’に対応した撮像手段の回転角度
θL’ PL’に対応した撮像手段の回転角度
DESCRIPTION OF SYMBOLS 1 Illumination means 2 Mirror 3 Screen 4 Imaging means 5 Signal processing means 6 Transparent sheet-like material MD Running direction of transparent sheet-like material TD Width direction of transparent sheet-like material A Mirror rotation axis B Rotation axis of imaging means θ mirror of the reference incident angle theta U incidence angle α incident angle below the reference angle of incidence on the film above the incident angle theta L parallel light from the reference angle of incidence to the parallel light from the film theta L to films B parallel light Rotation angle β Mirror rotation angle of incident angle θ U P Incident position of B parallel light optical axis on film Incident position P U parallel light optical axis above film incident position P L Parallel light optical axis of film imaging position on the screen of the image forming position P L 'incident angle theta L on the screen of the incident angle theta U' imaging position P U on the screen of the incident angle theta B 'incidence position P B of the lower than the incident position of r Focusing distance of imaging means rotation angle of the image pickup means corresponding to theta U rotation angle of the image pickup means corresponding to 'P U' θ L 'P L'
Claims (5)
この平行光をシート状物の走行方向に対して斜めに透過させ、透過した光を結像させるための曲面状のスクリーンと、
該スクリーンの曲面に結像した光を、合焦するように、スクリーンの曲面の曲率半径上に合焦点を起点として角度調節できる機構を有する撮像手段と、
該撮像手段によって該スクリーンに結像した光を明暗信号として検出する信号処理手段と、
を具備することを特徴とするシート状物の表面欠陥検査装置。 In the inspection of the uneven defect generated on the surface of the traveling transparent sheet, the illumination means having a mechanism for reflecting by a mirror arranged in the irradiation direction of the parallel light emitted from the light source;
A curved screen for transmitting the parallel light obliquely with respect to the traveling direction of the sheet and imaging the transmitted light; and
Imaging means having a mechanism capable of adjusting the angle from the focal point on the curvature radius of the curved surface of the screen so as to focus the light imaged on the curved surface of the screen;
Signal processing means for detecting light imaged on the screen by the imaging means as a light and dark signal;
An apparatus for inspecting a surface defect of a sheet-like material, comprising:
A one-dimensional image sensor is used as the imaging means, and a light / dark signal for each scan is accumulated while updating a certain number of lines by the signal processing means, and a plurality of threshold values are set according to the level of the light / dark signal. 5. The concave / convex determination or the size of the unevenness is estimated based on the level, and the size of the uneven defect is determined from a width exceeding a threshold value. Sheet surface defect inspection equipment.
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