CN116056806A - Method for manufacturing sheet-like member - Google Patents
Method for manufacturing sheet-like member Download PDFInfo
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- CN116056806A CN116056806A CN202180052544.0A CN202180052544A CN116056806A CN 116056806 A CN116056806 A CN 116056806A CN 202180052544 A CN202180052544 A CN 202180052544A CN 116056806 A CN116056806 A CN 116056806A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
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Abstract
The present invention provides a method for manufacturing a sheet member, comprising: a step of forming a coating layer on the substrate sheet being transferred in one direction; a step of irradiating the coating layer at the inspection position with a plurality of pattern lights from an oblique direction with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position of the coating layer; photographing the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the perpendicular line; a step of extracting specular reflection components from the plurality of images acquired in the imaging step, synthesizing the extracted specular reflection components, and generating an inspection image; and a step of setting at least 1 or more inspection areas with respect to the inspection image, and calculating a measurement value indicating a coating state of the coating layer.
Description
Technical Field
The present invention relates to a method for manufacturing a sheet member having a coating layer provided on a base sheet.
Background
Conventionally, various techniques for forming a coating layer on a substrate and inspecting the coating layer on line to manufacture a member having a desired coating layer have been proposed.
For example, patent document 1 describes an apparatus for checking whether or not a plurality of hot melt adhesives applied to a case are good (whether or not they are acceptable). The hot-melt adhesive contains a light-emitting material that emits light by ultraviolet rays, and the apparatus irradiates ultraviolet rays on the hot-melt adhesive-coated surface of the case and photographs the case from the vertical direction. Based on the captured image, the relative ratio or difference in the number of pixels between the application portions of the hot-melt adhesive is obtained, and the quality of the hot melt is determined.
Prior art literature
Patent literature
Patent document 1: japanese patent application laid-open No. 2015-137953
Patent document 2: japanese patent laid-open No. 2003-247950
Patent document 3: japanese patent laid-open No. 2006-162274
Patent document 4: japanese patent laid-open publication No. 2011-102759
Disclosure of Invention
The present invention provides a method for manufacturing a sheet member, comprising: a step of forming a coating layer on the substrate sheet being transferred in one direction; a step of irradiating the coating layer at the inspection position with a plurality of pattern lights from an oblique direction with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position of the coating layer; photographing the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the perpendicular line; a step of extracting specular reflection components from the plurality of images acquired in the imaging step, synthesizing the extracted specular reflection components, and generating an inspection image; and a step of setting at least 1 or more inspection areas with respect to the inspection image, and calculating a measurement value indicating a coating state of the coating layer.
The present invention also provides an apparatus for manufacturing a sheet-like member, comprising: a coating device for forming a coating layer on the substrate sheet being transferred in one direction; an illumination device for illuminating a plurality of pattern lights from an oblique direction to an inspection position of the coating layer with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position; an imaging device for imaging the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the vertical line; and an image processing device for extracting regular reflection components from the image data of the inspection position irradiated with the plurality of pattern lights obtained by the image pickup device, and processing the extracted regular reflection components to determine whether the coating state is good or bad.
The above features and other features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings.
Drawings
Fig. 1 is an apparatus configuration diagram showing an example of a sheet member manufacturing apparatus preferable for carrying out the sheet member manufacturing method according to the present invention.
Fig. 2 is an illumination pattern diagram showing an example of stripe pattern light of 8 patterns illuminated in 1 line as an example of stripe pattern illumination.
Fig. 3 is a schematic configuration diagram showing an illumination device and an imaging device at an inspection position on a roller surface.
Fig. 4 is a plan view schematically showing an example of an inspection image (specular reflection component composite image).
Fig. 5 is a plan view showing an example of applying a hot-melt adhesive to a base sheet.
Fig. 6 shows an irradiation angle θ of illumination light of the illumination device L And a photographing angle theta of the photographing device C Each of 15 ° ((a) drawing), 30 ° ((B) drawing) and 45 ° ((C) drawing) schematically represents a top view of an inspection image (upper section of each drawing); and a gradation (depth) chart (lower section of each chart) expressed by the Frequency (Frequency) of the base material sheet and the hot melt adhesive (vertical axis) and the gradation (horizontal axis) of 256 steps.
Fig. 7 is a flowchart showing a preferred example of the inspection process.
Fig. 8 is a plan view showing an example of an inspection region arranged in the inspection image of fig. 4.
Fig. 9 is a diagram illustrating a method of setting a threshold value, in which (a) the vertical axis represents a characteristic value of a base material sheet, the horizontal axis represents a grammage of a hot-melt adhesive, and (B) the vertical axis represents an area value of a white pixel, and the horizontal axis represents a grammage of a hot-melt adhesive.
In fig. 10, (a) is a graph showing the movement of the measured value, the vertical axis shows the area value of the white pixel, the horizontal axis shows the number of inspections, (B) is a plan view schematically showing an inspection image including a defective portion due to contamination caused by paper dust, and (C) is a plan view schematically showing an inspection image including a defective portion due to entrained air.
Detailed Description
The present invention relates to a method for manufacturing a stable sheet member, which can improve the inspection accuracy of the coating state of a coating layer formed on a substrate sheet in a production line.
The sheet-like member obtained by providing the coating layer on the base sheet is assembled into various articles or the like to exhibit desired properties. From the viewpoint of maintaining the performance thereof, it is necessary to uniformly form the coating layer at a predetermined position. The formation of the coating layer is usually performed continuously on a production line for continuously conveying (transferring) a substrate sheet, and it is required to detect the formation of the coating layer with high accuracy on line. In addition, the coating material of the coating layer includes various materials, and it is necessary to be able to cope with inspection and control of all these materials.
In this regard, in the technique described in patent document 1, it is impossible to inspect a hot melt adhesive to which a light-emitting material that emits light by ultraviolet rays is not added, and the inspection object is limited. In addition, the inspection requires strong ultraviolet rays, and there is a limit to achieving good inspection.
In the inspection technique described in patent document 2 that uses total reflection light instead of ultraviolet light, not only the irradiation angle of the irradiation light but also the imaging angle needs to be almost parallel to the surface of the coating layer. However, in a production line, it is necessary to avoid contact between a continuously conveyed object to be processed and an illumination or imaging device, and it is often difficult to optimize conditions such as an imaging angle and an irradiation angle. Even if the color difference on the image of the region of the coating layer and the other substrate region is insufficient, there is a possibility that false detection may occur depending on the coating state. The problem of insufficient gradation is also similar to the inspection technique using diffuse reflection light described in patent document 4. In addition, in the technique described in patent document 3, since only edge data of the adhesive can be extracted, it is difficult to grasp the application state in the region of the coating layer.
According to the method for producing a sheet-like member of the present invention, the accuracy of inspecting the coating state of the coating layer formed on the base sheet can be improved, and the sheet-like member can be stably produced.
A preferred embodiment of the method for producing a sheet member according to the present invention will be described below with reference to the drawings.
In the method for producing a sheet member of the present invention, a base sheet of various materials can be used. Examples of the material of the base sheet include a polymer sheet, a nonwoven fabric, a paper sheet (paper), and a resin film. As the coating material used for forming the coating layer, various materials that can be coated on the base sheet can be used. Examples of the coating material include an adhesive (a hot melt adhesive or other various adhesives), a functional agent such as a lotion or a skin care agent. The coating layer may be a transparent coating layer or a colored (colored or achromatic) coating layer, as long as the coating layer is a coating layer that regular reflects illumination light.
The method for producing a sheet member of the present invention includes the following steps (I) to (V) (hereinafter, simply referred to as steps (I) to (V), respectively).
(I) And forming a coating layer on the substrate sheet being transferred in one direction.
(II) irradiating the coating layer at the inspection position with a plurality of pattern lights from an oblique direction with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position.
(III) photographing the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the perpendicular line.
(IV) a step of extracting specular reflection components from the plurality of images acquired in the imaging step, and synthesizing the specular reflection components to generate an inspection image.
(V) setting at least 1 or more inspection areas with respect to the inspection image, and calculating a measurement value indicating a coating state of the coating layer.
Through the above steps, the specular reflection component of the reflected light on the coating layer can be appropriately generated and captured, and the difference in the shade between the coating layer and the base material sheet on the image in the acquired image data can be increased. In this way, the inspection accuracy of the coating state in the entire region of the coating layer can be improved, and a stable sheet-like member can be manufactured.
The method for producing a sheet-like member according to the present invention is a method using the above-described specular reflection component, and therefore can cope with various coating layers, and can achieve the above-described effects regardless of whether the coating layer is transparent or colored.
The method for producing a sheet-like member according to the present invention preferably includes (VI) a step of comparing the measured value with a predetermined threshold value to determine whether the coating state of the coating layer is good or bad (hereinafter, simply referred to as step (VI)).
The method for producing a sheet-like member of the present invention having such a step can be carried out, for example, by using the production apparatus 1 shown in fig. 1.
First, upstream of the manufacturing apparatus 1, there is provided a mechanism (not shown) for continuously transferring the base sheet 51 from the roll of material in one direction, and applying a coating material to the base sheet 51 in the transfer to form a coating layer 52 (step (I)) thereon.
As shown in fig. 1, the manufacturing apparatus 1 includes a transfer mechanism 10 for transferring the substrate sheet 51 having the coating layer 52 formed thereon in one direction, a line control unit 20, and an inspection system 30 for inspecting the coating layer 52 at an inspection position. The above steps (II) to (VI) are performed by these steps.
The manufacturing apparatus 1 further includes a cutting section 41 for cutting the sheet-like member into a desired size after the inspection, and a defective member discharge device 46. Thus, the sheet-like member judged to be defective among the sheet-like members for which the quality judgment of the coating layer 52 has been made in the above-described step (VI) can be removed from the production line, and the sheet-like member judged to be a good (good) can be transferred downstream as it is. The sheet-like member manufactured as a conforming product in this way is assembled together with other members to manufacture a predetermined product (sheet-like article). For example, the sheet-like member is laminated, bonded, cut, or the like with other members as necessary, and is incorporated into a predetermined product (sheet-like article).
The transfer mechanism 10 is not limited to the configuration of the transfer mechanism 10 as long as it is a mechanism for transferring the substrate sheet 51 to the inspection position 53. For example, the transfer mechanism 10 includes 2 rollers 11, 12, and a rotatably arranged conveyor belt 13 wound around them. Preferably, at least one of the rollers, for example, the roller 12, is provided with a motor 14 as a driving device for rotating the roller. The driving method by the motor 14 may be belt driving in which a motor shaft (not shown) and a roller shaft (not shown) are coupled, direct driving in which the roller shaft is directly driven by the motor shaft, or another driving method.
The motor 14 is driven in response to a drive signal from the motor control unit 21. The motor amplifier 16 that amplifies the drive signal to an appropriate drive voltage is preferably disposed between the motor control unit 21 and the motor 14. An encoder 15 is further connected to the motor 14.
The encoder 15 outputs a mechanical change in position as an electrical signal. For example, in accordance with the rotation of the motor 14, a pulse signal S is output P . The encoder 15 may measure a rotational position (for example, a rotational angle) or a rotational speed (for example, an angular velocity) of a drive shaft (not shown) of the motor 14 by a sensor (not shown), and output the measurement result as an electrical signal. If the rotational position or rotational speed of the motor 14 can be measured, the position or transfer speed of the coating layer 52 coated by the base material sheet 51 on the conveyor belt 13 of the transfer mechanism 10 that moves in conjunction with the motor 14 can be obtained. The encoder 15 can use, for example, a rotary encoder.
The motor amplifier 16 receives an operation signal from a motor control unit 21 included in the line control unit 20 described later, amplifies the operation signal to an appropriate voltage for driving the motor 14, and supplies the voltage to the motor 14. Further, the motor amplifier 16 outputs an electric signal (pulse signal) S from the encoder 15 P To an image processing device 31 included in an inspection system 30 described later.
The line control unit 20 includes a motor control unit 21, a timing control unit 22, and a discharge control unit 23.
As described above, the motor control unit 21 transmits an operation signal of a target value such as the rotation number or the rotation speed of the motor 14 to the motor amplifier 16.
The timing control unit 22 receives signals generated for processing each article from a position detector 45 described later as a checkThe signal of the start is the trigger signal S T To the image processing device 31. In the image processing device 31, upon receiving the trigger signal S T After that, the pulse signal S is received P Shooting is performed. That is, the trigger signal S transmitted for each article T After being input, corresponds to the pulse signal S P Shooting is performed. Pulse signal S P Each time the base sheet 51 travels a predetermined distance, it is sent from the encoder 15 a plurality of times for a length corresponding to the amount of 1 article. As described later, when a line scan camera is used, only a predetermined number of lines is used to capture an image, and a pulse signal S is set in accordance with the number of lines p 。
The discharge control unit 23 is based on the determination signal S by the image processing device 31 J Whether or not (ON and OFF) is transmitted, and a discharge signal S of the sheet member 54 determined by the image processing apparatus 31 as defective in the coating layer 52 is determined E To the discharge device 46. The discharge control unit 23 is based on the determination signal S by the image processing device 31 J Whether or not (ON and OFF) is transmitted, and how many components pass through and are discharged from the discharge device 46 based ON the distance from the inspected portion to the discharge device and the conveying speed of the production line.
The inspection system 30 has: an illumination device 32 for illuminating the coating layer 52 at the inspection position 53, and an imaging device 33 for imaging the illuminated coating layer 52 at the inspection position 53; and an image processing device 31 for extracting the specular reflection component from the image data captured by the imaging device 33, and processing the extracted specular reflection component to determine whether the coating layer 52 is good or bad.
< Lighting device >
The illumination device 32 performs the above-described step (II).
The illumination device 32 is arranged on a vertical line L perpendicular to the surface of the coating layer at the inspection position 53 of the coating layer 52 on the substrate sheet 51 P From oblique direction (relative to vertical L P Angle of inclination theta L The direction of (c) of the illumination light. The angle theta is set to L Also referred to as the illumination angle θ L . Angle theta L The angle is appropriately set according to the material used, and is preferably in the following range. I.e. angleθ L The angle is set so as to be capable of effectively generating the specular reflection component of the light reflected by the surface of the coating layer 52 by the illumination light. Angle theta L Relative to the vertical line L p Is set in a range of more than 0 degrees and less than 90 degrees. With respect to angle theta L The difference in the gradation between the coating layer 52 and the image of the base sheet 51 is preferably 15 degrees or more, more preferably 25 degrees or more, from the standpoint of effectively generating the specular reflection component and making the difference in the gradation on the image of the base sheet 51 more clear in an inspection image generated from the acquired image data, which will be described later. In addition, regarding the angle θ L In the inspection image generated from the acquired image data, which will be described later, the ratio of the information in the height (thickness) direction of the coating layer 52 and the base material sheet 51 is preferably 45 degrees or less, more preferably 35 degrees or less, from the viewpoint of not excessively increasing.
The position of the illumination device 32 is not particularly limited as long as it can accurately irradiate the coating layer 52 at the inspection position 53. From the viewpoint of appropriately grasping the coating state of the whole width direction (direction orthogonal to the transfer direction, hereinafter also referred to as X direction) of the coating layer 52, it is preferable to irradiate in the same direction as the transfer direction (hereinafter also referred to as Y direction).
Furthermore, a perpendicular L to the inspection position 53 on the plane shown in FIG. 1 P Which is a line perpendicular to the plane of the inspection position 53.
The illumination device 32 can sequentially irradiate illumination light composed of a plurality of pattern lights (light of a special pattern). For example, a stripe pattern illumination device is used, which can sequentially irradiate pattern light having a stripe illuminance distribution while changing the phase of the illuminance distribution. The stripe pattern illumination device can emit light while changing the phase in synchronization with imaging of 2 ten thousand lines or more per second. The inspection position 53 is configured to be able to irradiate 1 line in the width direction (X direction) with pattern light having the entire illuminance distribution.
By applying the above-described plurality of pattern lights to the coating layer 52 to generate the specular reflection component, the imaging device 33 described later captures the pattern light, and thereby the gradation difference on the image of the coating layer 52 and the base sheet 51 can be uniformly generated over the entire region.
As an example of the stripe pattern illumination device, for example, stripe pattern light which can illuminate 8 patterns on 1 line as shown in fig. 2 can be exemplified. Patterns 1 to 4 are patterns obtained by changing the phase of the stripe-shaped illuminance distribution in the width direction (X direction) of the base sheet 51. The patterns 5 to 8 are patterns obtained by changing the phase of the stripe-shaped illuminance distribution in the transfer direction (Y direction) of the base material sheet 51. An example of such a lighting device is a stripe pattern lighting device CA-DZW30X (trade name) manufactured by KEYENCE CORPORATION. The stripe pattern illumination device is a device in which a plurality of line illuminators extending in the width direction (X direction) are arranged in the transfer direction (Y direction), and is an illumination device that illuminates with the stripe pattern light shown in fig. 2.
The timing of the light emission of the lighting device 32 is controlled by the timing control unit 22 included in the line control unit 20. That is, the image processing device 31 uses the trigger signal S from the timing control unit 22 T The manner in which light is emitted for the opportunity is controlled. At the same time, according to the pulse signal S P The image processing device 31 is controlled so that the imaging time is synchronized with the light emission time.
< imaging device >
The imaging device 33 performs the above step (III).
The imaging device 33 is arranged on a vertical line L perpendicular to the surface of the coating layer at the inspection position 53 of the coating layer 52 on the substrate sheet 51 P From oblique direction (relative to vertical L P Inclined at an angle theta C The direction of) of the coating layer 52. The direction of inclination (relative to the vertical L P Inclined at an angle theta C Is a direction inclined from the illumination device 32 (with respect to the vertical line L) P Inclined at an angle theta L Is the direction of the angle) of the first arm. The angle theta is set to C Also called shooting angle theta C 。
Angle θ of image pickup device 33 C Is set so as to be capable of appropriately capturing specular reflection components reflected by the surface of the coating layer 52 irradiated by the illumination device 32And suppresses the capturing angle of other reflection components. Angle theta C The angle is appropriately set according to the material used, and is preferably in the following range. I.e. angle θ C Is set relative to the vertical line L p In the range of greater than 0 degrees and less than 90 degrees. Angle theta C The difference in the gradation between the coating layer 52 and the image of the base sheet 51 in the inspection image generated from the acquired image data, which will be described later, is preferably 15 degrees or more, more preferably 25 degrees or more, from the viewpoint of capturing the specular reflection component effectively. In addition, θ C In view of not excessively increasing the ratio of the information in the height (thickness) direction of the coating layer 52 and the base sheet 51 in an inspection image generated from the acquired image data, which will be described later, it is preferably 45 degrees or less, more preferably 35 degrees or less.
From the viewpoint of clearly capturing an image of the coating layer 52 at the inspection position 53, the imaging device 33 is preferably arranged on the vertical line L across the inspection position 53 as shown in fig. 1 P Opposite the lighting device 32. The imaging device 33 preferably captures images in the same direction as the transfer direction (hereinafter also referred to as the Y direction) from the viewpoint of appropriately grasping the coating state in the entire width direction (direction orthogonal to the transfer direction, hereinafter also referred to as the X direction) of the coating layer 52.
The imaging device 33 is a device capable of sequentially capturing reflected light composed of a plurality of pattern lights. For example, by a line scanning camera (line sensor). An example of such a line scanning camera is a line scanning camera CA-HL02MX (trade name) manufactured by KEYENCE CORPORATION.
Angle (irradiation angle) θ of illumination device 32 L Angle θ with the imaging device 33 (imaging angle) C Preferably equal in value. Equal means the difference in angle Δθ (= |θ) L -θ C I) is 5 degrees or less, preferably 1 degree or less, more preferably 0 degree. This enables the imaging angle θ of the imaging device 33 to be set C Angle of illumination theta with illumination device 32 L The regular reflection angle of the regular reflection component from the coating layer 52 is uniform, and the regular reflection component can be captured more appropriately. In additionIn an inspection image generated from the acquired image data, which will be described later, the difference in gradation between the image of the coating layer 52 and the image of the base sheet 51 can be made clear.
The inspection position 53 is more preferably on the curved surface of the roller peripheral surface than on the plane of the conveyor belt 13. For example, as shown in fig. 3, the inspection position 53 of the coating layer 52 of the substrate sheet 51 transferred on the peripheral surface of the roller 70 is arranged on a curved surface in the transfer direction. Since the base sheet 51 disposed on the curved surface is in a state where a tensile force (tensile force) is applied, wrinkles are less likely to occur in the base sheet 51. In addition, since the illumination light is reflected only at the apex of the roller, stray light is not easily generated. Therefore, the specular reflection component of the coating layer 52 at the inspection position 53 can be more appropriately captured by the imaging device 33. From this point of view, the inspection position 53 is preferably located on the curved surface of the roller peripheral surface.
In the case where the inspection position 53 is located on a curved surface, as shown in fig. 3, a perpendicular line L at the inspection position 53 on the surface 70S (roll surface) of the roll 70 P A tangent line L to the circumferential surface of the roller (circumferential surface along the rotation direction of the roller) at the inspection position 53 T Becomes a vertical line.
< image processing apparatus >
The image processing apparatus 31 performs the above steps (IV) to (VI).
The image processing device 31 generates a plurality of images corresponding to the plurality of pattern lights acquired by the imaging device 33 at the inspection position 53. The multiple images are based on pulse signal S P A two-dimensional image generated by combining successively generated line images (one-dimensional images). More specifically, the line image (one-dimensional image) is obtained by capturing only the number of pattern lights with respect to 1 line, and the two-dimensional image formed by combining the line images is generated in a plurality of pieces only by the number of pattern lights. The specular component is extracted from the plurality of images (two-dimensional images). The respective extracted specular reflection components are synthesized to generate a specular reflection component synthesized image. The specular reflection component composite image becomes an inspection image. For example, an inspection image (specular component composite image) shown in fig. 4 is generated.
As shown in fig. 5, the inspection image shown in fig. 4 is an image obtained by photographing a base sheet on which a coating layer 52 is formed by intermittently applying a hot melt adhesive on the base sheet 51 in a belt shape along the transfer direction (Y direction) and in the width direction (X direction) from the coating layer 52 side. However, the arrangement structure of the coating layer 52 shown in fig. 5 is only an example, and the present invention is not limited to this structure, and various arrangement structures can be obtained. Fig. 4 to 6 and 8 to 10 show examples in which a polymer sheet is used as the base sheet 51 and a hot melt adhesive is used as the coating layer 52. However, this is just an example, and various materials can be used in the present invention.
The image processing apparatus 31 further includes a measurement value calculation means (not shown). The measured value calculating means sets at least 1 or more inspection areas with respect to the inspection image, and calculates a measured value indicating the coating state of the coating layer 52 after performing the 2-valued processing. For example, the number of white pixels (area or width (length in the X direction)) corresponding to the coating layer 52 in the inspection region of the inspection image can be calculated as a measurement value. At this time, the portion corresponding to the base sheet 51 is the number of black pixels.
The image processing apparatus 31 further includes a quality (measured value) determination means (not shown). The quality judging means judges whether the coating state of the coating layer 52 is good or bad by comparing the measured value with a predetermined threshold value.
The image processing device 31 extracts specular reflection components from the reflected light of the plurality of pattern lights captured by the imaging device 33 in this manner, and can generate an inspection image. Then, a 2-valued processing is performed on the inspection image setting inspection area, and the number of white pixels in the inspection area is measured, for example, to obtain a measured value indicating the coating layer 52. By comparing the measured value with a predetermined threshold value, the quality of the inspection area can be judged. For example, the inspection image is divided into a plurality of inspection areas, and a threshold value is set for each of the inspection areas, and in 1 inspection image, whether the inspection areas of a plurality of portions are good or bad can be independently determined. The inspection area at this time can be set arbitrarily as appropriate, and can be set according to the arrangement of the coating layer 52, for example.
In the method for producing a sheet member of the present invention, as described above, the specular reflection component of the reflected light is appropriately generated and captured, and thus, the difference in the gradation on the image of the base sheet 51 and the coating layer 52 can be increased when the measured value is calculated. The larger the gradation difference is, the more easily and accurately 2-valued processing or the like is performed, and the inspection based on the inspection image obtained by this becomes highly accurate and stable.
From this point of view, the irradiation angle θ L And a shooting angle theta C The above range is more preferable, and is set appropriately according to the material used. For example, as shown in FIG. 6, with θ C ＝θ L In the case of =15° (graph a), the ratio of θ C ＝θ L In the case of =30° (fig. B) or θ C ＝θ L In the case of =45° (fig. (C)) the difference between the gradation value indicating that the number of pixels of the coating layer 52 is a peak value and the gradation value indicating that the number of pixels of the base material sheet 51 is a peak value is large, and the gradation difference is large. In fig. 6, PS represents a polymer sheet as the base sheet 51, and HM represents a layer of the hot melt adhesive as the coating layer 52.
In order to make the density difference larger, it is preferable to dispose a low-reflection material having a lower reflectance than the coating layer 52 portion on the side (back surface side) of the base sheet 51 opposite to the coating surface for photographing. More specifically, in the manufacturing apparatus 1, it is preferable that the low-reflection material be a member (for example, the conveyor belt 13) of the transfer surface of the transfer mechanism 10, which is disposed on the side opposite to the coating surface of the base sheet 51. This can suppress the influence of the reflection of the background of the base sheet 51 to a small extent, and can appropriately acquire the information on the outermost surface. The light reflectance of the reflective material is preferably 30% or less, more preferably 10% or less, further preferably 5% or less, and particularly preferably 0%. The light reflectance is the light reflectance of the low-reflection material when light (for example, white light) composed of the wavelength band of illumination light to be used is irradiated. Specifically, the low reflection material is, for example, a material of a material having no gloss, a black material, or the like. The black color may be black brown or dark gray.
In addition, from the viewpoint of making the concentration difference larger, it is preferable that the surface roughness of the coating layer 52 is smaller than that of the base sheet 51. As a result, the specular reflection component of the reflected light on the surface of the coating layer 52 becomes stronger than that on the surface of the base sheet 51, and the area of the coating layer 52 becomes whiter in the inspection image. On the other hand, the diffuse reflection component of the reflected light on the surface of the base sheet 51 becomes a main component as compared with the surface of the coating layer 52, and the region of the base sheet 51 becomes darker in the inspection image. As a result, in the inspection image, the difference in shade between the image of the base material sheet 51 and the coated layer 52 becomes larger.
According to this structure, the coating layer 52 is preferably formed smoothly on the surface of the base sheet 51 so as to fill the irregularities of the base sheet 51. Therefore, the higher the viscosity of the coating layer 52, the more likely it is to remain on the surface of the base sheet 51, which is also based on the density of the base sheet 51, and is effective for improving the gradation difference of the inspection image. For example, in the case of a hot melt adhesive, the viscosity is preferably about 1000 to 50000mpa·s.
The manufacturing apparatus 1 further includes a cutting unit 41 for cutting the continuous body of the sheet-like member having the coating layer 52 formed on the base sheet 51 into individual sheet-like members 54 after the completion of the inspection. Examples of the cutting portion 41 include a rotary cutter. The rotary cutting machine is composed of opposed rollers 42, 43, and a cutter 44 is disposed on one roller 43. A position detector 45 is connected to the roller 43 having the cutter 44. The position detector 45 transmits a signal generated for processing each article to the timing control unit 22.
Next, a preferred example of a method for producing a sheet member according to the present invention using the production apparatus 1 shown in fig. 1 will be specifically described.
First, in the step (I), as shown in fig. 5, a hot-melt adhesive is applied to a base sheet 51 to form a coating layer 52.
Next, the above steps (II) to (IV) are performed according to the flowchart shown in fig. 7.
First, a "photographing process" is performed. In the "photographing step", the above-described steps (II) and (III) are performed. Specifically, the trigger signal S generated by processing each article T (see FIG. 1) as a trigger, according to the ANDPulse signal S generated in accordance with transfer distance of substrate sheet 51 P (see fig. 1) a plurality of pattern lights are sequentially irradiated to the inspection position 53 and photographed. Here, 8 pattern lights are irradiated to 1 line in the width direction (X direction) of the inspection position 53, and the image is captured by a line scanning camera.
At this time, the irradiation angle θ L Shooting angle theta C Respectively, with respect to a perpendicular L perpendicular to the surface of the coating layer at the inspection position 53 P At an angle of the oblique direction. The direction of inclination of the irradiation and the direction of inclination of the photographing are directions different from each other. Although the directions are different from each other, the irradiation angle θ is preferably L And shooting angle theta C Equal. In addition, the irradiation angle θ L And a shooting angle theta C The respective preferable ranges are preferably set.
Then, an "image generation step" is performed. Thus, the above step (IV) is performed. Specifically, in the "image generation step", the regular components are extracted from the plurality of images obtained by photographing the coating layer 52 at the inspection position 53 where the plurality of pattern lights are irradiated, and synthesized, thereby generating a regular component synthesized image.
Then, a "measurement process" is performed. In the "measurement step", the above-mentioned step (V) is performed. Specifically, for example, as shown in fig. 8, inspection areas A1 to A9 divided in the width direction (X direction) are set in association with the coating pattern, and after 2-valued processing is performed for each inspection area, a measurement value indicating the coating state of the coating layer 52 is calculated. In the illustrated example, the measurement values are calculated based on the areas of the respective inspection areas. In this case, the number of pixels of white pixels existing in each of the inspection areas A1 to A9 after the 2-valued processing is measured. That is, the total area of the white image is obtained from the number of pixels of the white pixel. The total area of the white image becomes a measurement of the area of the coating layer 52 in each inspection area. In the case where the area of the coating layer 52 is not taken as a measurement value but the width is taken as a measurement value, for example, the edge portion of the white image in the inspection area is extracted, and the coating width is measured by calculating each edge width. Instead of white pixels, black pixels may also be measured.
Next, a "judgment step" is performed. The above step (VI) is performed in the "judgment step". Specifically, the measured value is compared with a predetermined threshold value to determine whether the coating state of the coating layer 52 is good or bad. The threshold value, which is a reference value for judging whether or not the inspection is good, is preferably set for each inspection area, in order to improve the inspection accuracy.
The threshold value is appropriately set according to the relative relationship between each inspection region and the characteristic value of the coating layer 52. The characteristic value is a value satisfying a functional condition required for an article to which the sheet member is applied. For example, in the case where the coating layer 52 is a layer of a hot melt adhesive, the coating layer is a characteristic value satisfying the functional condition that a sufficient bonding strength is imparted to the base sheet 51.
In the case where the coating layer 52 is not an adhesive but a functional agent (for example, a skin care agent), a value satisfying a functional condition required for providing an effect on skin can be set as a characteristic value.
In this way, a threshold value for judging whether the image is good or not (whether the image is good or not) is set, and if the measured value (the number of white pixels) exceeds the threshold value, the image is judged to be good or not, and if the measured value is not more than the threshold value, the image is judged to be not good (not good).
For example, in the example of the inspection image shown in fig. 8, the threshold value can be set as follows.
That is, as shown in FIG. 9 (A), if the grammage of the coating layer 52 of the hot melt adhesive coated on the base sheet 51 exceeds 80g/m 2 The characteristic value in the sheet member is satisfied. Accordingly, as shown in FIG. 9B, the limit of the gram weight of the hot melt adhesive satisfying the characteristic value can be set to 80g/m 2 Corresponding white pixel area value 4 x 10 5 pixel is set to a threshold. As shown in the graph of fig. 9 (B), if the white pixel area value set as the threshold value is exceeded by 4×10 5 The white pixel area value of pixel indicates that the gram weight of the hot melt adhesive is sufficiently high and the coating state is good.
In this way, by setting the threshold based on the characteristic value and judging whether the coating state is good or bad based on whether the threshold is exceeded, it is possible to judge whether a sheet-like member actually having a good coating layer 52 formed thereon is manufactured.
When the sheet member 54 is determined to be defective, it is preferable to identify the sheet member 54NG determined to be defective from among the sheet members 54 which have been individually cut after the inspection, and discharge the sheet member from the production line as described below.
First, when the image processing apparatus 31 determines that the product is acceptable, the image processing apparatus causes the determination signal S to be J Is "ON". Judgment signal S J The image processing device 31 of the inspection system 30 is transmitted to the discharge control unit 23 of the line control unit 20. That is, the transmission signal transmits "OK" information to the discharge control unit 23. On the other hand, if it is determined that the image processing apparatus 31 causes the determination signal S to be J Is "OFF". That is, no signal is transmitted, and thus information of "NG" is transmitted to the discharge control section 23.
When the discharge control section 23 receives the determination signal S set to "ON J When the discharge device 46 is not operated, the sheet member 54OK determined to be a good product is passed to the next step. In the process of making the judgment signal S J In the case of "OFF", the discharge control unit 23 transmits the discharge signal S to the discharge device 46 E The discharge device 46 determines the defective sheet member 54NG and discharges it. The discharge is preferably performed by flowing the defective component to a line that merges the defective components.
In this determination step, if a failure determination (determination signal "OFF") detected based on the measured value frequently occurs, an alarm notifying coating failure can be output to, for example, the image display device 34. If the operation is continued, the manufacturing apparatus 1 can be stopped.
As described above, the phenomenon determined to be defective is represented as a decrease in the area value of the white pixel in the continuous transfer and continuous coating process of the production line, as seen from the portions indicated by reference numerals 91 and 92 of the chart of fig. 10 (a).
For example, if there is a sheet in which paper dust is likely to be generated depending on the type of the base sheet, in such a sheet, the paper dust may remain at the tip of the hot-melt gun (not shown), and the bleeding of the hot-melt adhesive may continue to occur (see the region of reference numeral 91 in the inspection image of fig. 10B).
In addition, since air is trapped in the hose of the hot-melt gun, the hot-melt adhesive may leak over a large area (see the region 92 in the inspection image of fig. 10 (C)). In this case, the missing coating occurs suddenly unlike the clogging such as the paper dust pollution.
When such an abnormal situation occurs, the non-defective (defective) is detected by the quality judgment as described above. Based on the detection result, the non-defective product can be discharged. In addition, when the failure determination is frequent, an abnormal alarm such as a jam alarm or an entrained air alarm can be output. And if continued, the manufacturing apparatus 1 can be stopped for confirmation.
According to the method for producing a sheet-like member of the present invention, the specular reflection component of the reflected light on the coating layer can be appropriately generated and captured, and the difference in the shade between the coating layer and the image of the base sheet in the obtained image data can be increased. In this way, the inspection accuracy of the coating state can be improved over the entire region of the coating layer, and stable production of the sheet member can be performed. Further, since the above-described specular reflection component is used, it is possible to cope with various coating layers regardless of the presence or absence of a light-emitting material that emits light by ultraviolet rays, and the range (type) of coating layers that can be inspected can be widened.
Further, according to the apparatus for producing a sheet member of the present invention, the above-described method for producing a sheet member of the present invention can be suitably carried out.
The present invention has been described based on embodiments and examples thereof, but unless otherwise specified, any details of the description of the invention are not to be construed in a limiting sense and should not be construed in a broader sense as the scope of the invention is also defined in the appended claims.
The present application claims priority based on japanese patent application publication No. 2020-143757, 8/27 in 2020, which is incorporated herein by reference as part of the description of the present specification.
Description of the reference numerals
1. Manufacturing apparatus
10. Transfer mechanism
20. Production line control part
21. Motor control unit
22. Timing control part
23. Discharge control unit
30. Inspection system
31. Image processing apparatus and method
32. Lighting device
33. Image pickup apparatus
34. Image display device
41. Cutting part
42. 43 roller
44. Cutting tool
51. Base material sheet
52. Coating layer
53. Inspection position
54. Sheet-like member
Sheet-like member for 54OK qualified product
Sheet-like member with 54NG failure
A1 to A9 examination areas
L P Vertical line
L T Tangent line
θ L Irradiation angle
θ C Shooting angle
Claims (12)
1. A method for manufacturing a sheet member, comprising:
a step of forming a coating layer on the substrate sheet being transferred in one direction;
a step of irradiating the coating layer at the inspection position with a plurality of pattern lights from an oblique direction with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position of the coating layer;
photographing the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the perpendicular line;
a step of extracting specular reflection components from the plurality of images acquired in the imaging step, synthesizing the extracted specular reflection components, and generating an inspection image; and
and a step of setting at least 1 or more inspection areas with respect to the inspection image, and calculating a measurement value indicating a coating state of the coating layer.
2. A method of manufacturing a sheet member as claimed in claim 1, wherein:
an angle θ of the oblique direction of the pattern light with respect to the perpendicular L An angle θ with respect to the perpendicular line with respect to the other oblique direction in which the photographing is performed C Difference Δθ= |θ L -θ C And I is more than 0 degree and less than 5 degrees.
3. A method of manufacturing a sheet member as claimed in claim 1 or 2, wherein:
a low-reflection material having a lower reflectance than that of the coating layer portion is disposed on the side of the substrate sheet opposite to the coating surface, and imaging is performed.
4. A method of producing a sheet member according to any one of claims 1 to 3, wherein:
in the calculation of the measurement value, any one or more of the area and the width of the coating layer in the inspection region of the inspection image is used.
5. The method of manufacturing a sheet member according to any one of claims 1 to 4, wherein:
the method comprises the step of comparing the measured value with a preset threshold value and judging whether the coating state of the coating layer is good or bad.
6. A method of manufacturing a sheet member as claimed in claim 5, wherein:
the method includes a step of discharging the sheet member judged to be in a poor state of application of the coating layer by the judging step.
7. A method of manufacturing a sheet member as claimed in claim 5 or 6, wherein:
in the step of determining whether the coating is defective, an alarm notifying an abnormal coating is output or the manufacturing apparatus is stopped when the defect is detected.
8. The method for producing a sheet-like member according to any one of claims 1 to 7, wherein:
the coating layer is an adhesive.
9. A method of manufacturing a sheet-like article, characterized by:
a sheet-like article manufactured by assembling the sheet-like member obtained by the method for manufacturing a sheet-like article according to any one of claims 1 to 8.
10. An apparatus for manufacturing a sheet-like member, comprising:
a coating device for forming a coating layer on the substrate sheet being transferred in one direction;
an illumination device for illuminating the inspection position of the coating layer with a plurality of pattern lights from an oblique direction with respect to a perpendicular line perpendicular to the surface of the coating layer at the inspection position;
an imaging device for imaging the coating layer at the inspection position from another oblique direction different from the oblique direction with respect to the perpendicular line; and
and an image processing device for extracting and processing specular reflection components from image data of the inspection position irradiated with the plurality of pattern lights, which is obtained by the imaging device, and judging whether the coating state is good or bad.
11. The sheet member manufacturing apparatus according to claim 10, wherein:
the image processing apparatus includes:
an inspection image generating means for extracting specular reflection components from the image data composed of the plurality of line images acquired by the imaging device, and synthesizing the specular reflection components to generate an inspection image;
a measurement value calculation means for setting at least 1 or more inspection areas with respect to the inspection image, and calculating a measurement value indicating a coating state of the coating layer; and
and a quality judging means for judging the quality of the coating state of the coating layer by comparing the measured value with a preset threshold value.
12. The sheet member manufacturing apparatus according to claim 10 or 11, wherein:
the manufacturing apparatus includes a transfer mechanism for the substrate sheet, and a member of a transfer surface of the transfer mechanism disposed on a side of a surface of the substrate sheet opposite to the coating surface is a low-reflection material having a lower reflectance than the coating layer.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2020143757A JP7030914B1 (en) | 2020-08-27 | 2020-08-27 | Manufacturing method of sheet-shaped member |
| JP2020-143757 | 2020-08-27 | ||
| PCT/JP2021/027972 WO2022044677A1 (en) | 2020-08-27 | 2021-07-28 | Method for producing sheet-like member |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN116056806A true CN116056806A (en) | 2023-05-02 |
| CN116056806B CN116056806B (en) | 2024-05-28 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202180052544.0A Active CN116056806B (en) | 2020-08-27 | 2021-07-28 | Method for manufacturing sheet-like member |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP7030914B1 (en) |
| CN (1) | CN116056806B (en) |
| WO (1) | WO2022044677A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118122579A (en) * | 2024-02-01 | 2024-06-04 | 东莞市鹏锦机械科技有限公司 | Visual detection method, system and medium for coating effect of coating and recycling integrated machine |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US12091863B2 (en) | 2021-10-07 | 2024-09-17 | Alexander Lorenz | Flood resistant wall |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN116056806B (en) | 2024-05-28 |
| JP2022042521A (en) | 2022-03-15 |
| JP7030914B1 (en) | 2022-03-07 |
| WO2022044677A1 (en) | 2022-03-03 |
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