2016 aimcal conference europe€¦ · flat aluminum, steel, & non-ferrous metal products, e.g....

CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL Conference, Dresden, June 2016

2016 AIMCAL Conference Europe

How Automatic Optical Inline Systemshelp you save money and time

New Methodes for Quality and Process Control inPlastic Film Production

Thomas Laumeyer, Hans OerleyDr. Schenk GmbH Industriemesstechnik


Location Planegg & Gräfelfing, near Munich, Germany

Dr. Schenk

ProductionArea > 12,000 m²


The Solution Provider

Design & manufacture Modular in-line and off-line inspection & measurement systems Quality & process control of flat surfaces for the following industries:

Local defect detection + overall properties monitoring

Flat aluminum, steel, & non-ferrous metal products, e.g. foils

MetalApplications

Entire thin film solar module production

Solar glass

Solar Applications

Plastic films, foils, nonwovens, textiles, paper, …

WebApplications

Float & sheet glass All sizes, all types Surface and edge Handling options

Glass Applications

Mobile displays & touch panels

All kinds, all sizes All manufacturing

technologies

Display Applications


AOI - Basics

Quality control after

coating

Quality control of

base material

Monitoring film / coating

properties


Plastic Film Production Lines


Production Line with In-Line Inspection

Inspectionafter extrusion

Inspectionafter converting

Extrusion, ….

Converting(coating, lamination,

stretching, … )


Factors for Detection Capabilities

The detection capability of AOI is determined by three main factors:

• The camera properties

• The illumination properties

• The optical setup

DetectionCapability

Cameradr. schenk

Optical Setup Reflection

Transmission

Bright-fieldNear dark-fieldDark-fieldFar dark-field

Illumination


Illumination Technology

Diffuse light Focused light

470 nm (blue) 625 nm (red)

DetectionCapability Camera Optical SetupIllumination

Reflection Transmission

Bright-field Near Dark-field

The AOI detection capability is determined by the ….

illumination optical setup


The MIDA Concept

Combination of multiple inspection channels (transmission + reflection)MIDA – Multiple Image Defect Analysis

Reflection

Illumination for reflection

Transmission

material

Camera

Illumination for transmission

Reflection DF Reflection BF Transmission BF


AOI - Basics


coating

Quality control of

base material


properties





Extrusion, ….


stretching, … )


Inspection Results Base Film

Material: Packaging Base FilmDefect: Burned Spot

BFT - Bright-Field BFT - Bright-FieldTransmission Transmission Knife-Edge

Camera

BFT



Material: Packaging Base FilmDefect: Gels


Camera

BFT


Bright-Field Transmission Bright-Field Transmission/Knife Edge


Material: Packaging Base FilmDefect: Orange Peel, Gels

Camera

BFT



Camera

BFT


Material: Packaging Base FilmDefect: Burned Spot


In-Line Inspection after TDO

Material: Flexible Packaging Base FilmDefect: Wrinkles

BFT - Bright-Field BFR - Bright-Field DFR - Dark-FieldTransmission Reflection Reflection

Camera

BFR

DFR

BFT


Among other defect types, scratches are typical defects in the manufacturing of film material

In-Line Inspection after MDO

Diagonal scratchesCross-web scratches

Scratches in down-web direction

Conventional inspection systems will not detect micro scratches in transport (down-web) direction

dr. schenk

Case Study: Scratch Detection in Stretched Film MaterialTogether with Brückner Maschinenbau GmbH & Co. KG design of special optical setup for MD-scratch detection


AOI - Basics


coating

Quality control of

base material


properties




Extrusion, ….


stretching, … )



Bright-Field Reflection Dark-Field Reflection

Coated Film: Coating Voids

Material: Packaging Film / CoatedDefect: Coating Void / Particles

Camera

BFR

DFR


Bright-Field Transmission Dark-Field Transmission

Coated Film: Agglomeration

Material: Packaging Film / CoatedDefect: Coating Agglomeration / Sub Deposit

Camera

DFTBFT


Bright-Field Transmission Bright-Field Reflection

Coated Film: Oil Stain

Material: Packaging Film / CoatedDefect: Oil Contamination

Camera

BFR

BFT


Coated Film: Missing Silicone

Material: Release liner (PET) with silicone coatingDefect: Missing Coating (caused by scratch)

BFR: Brightfield DFR: DarkfieldReflection Reflection

Camera

BFR

DFR


Adhesive Tape: Foreign Particle Bubble

Transmission Brightfield Reflection Brightfield Reflection Darkfield(before lamination)

Reflection Brightfield(after lamination)

Adhesive /Coating

LaminationLabel Film / Tape Finished Tape

Laminated Film InspectionAdhesive Inspection

Release Liner

Material: Adhesive tape Defect: Particle (adhesive layer) bubble


AOI - Basics


coating

Quality control of

base material


properties


200 mic

175 mic

150 mic

125 mic

100 mic

75 mic

for monitoring of film thickness:Measurement examples for the thickness variation of plastic film:

Film sample Video signal Gray image evaluation EasyMeasure

Monitoring Film Thickness


Material: BOPET with CoatingVariation in coating layer thickness

Samples:V0

V1V2V3V4

Monitoring Coating Thickness


0 200 400 600CD [mm]

MD

[mm

] 02040

Position

DF Refl.

HAZE

0 200 400 600CD [mm]

MD

[mm

] 02040

Position

DF Refl.

HAZE

Monitoring Haze

Correlation of the values ofEasyMeasure / Darkfield-Reflectionwith the haze values

CameraDFR


Monitoring of metal coatings

Sealing goods (e.g. food) against moisture and oxigen

Optical Density (OD) of the metal layer, indicating the layer quality

for the complete width of the material, for an

OD – range of 0 … 2.8(coating defects for OD > 2.8 will be detected by reflection channel)

Monitoring Metal Coating

Traversing sensor: Only a small part of the surface is controlled

… by Camera:Monitoring of the complete surface, no gaps !

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dr. schenk


Example for an inline-evaluation of the optical density for a metal coated packaging film.

Monitoring Metal Coating

2.2 2.4 2.7 1.7 2.0 1.9 2.7 2.4

2.2 2.2 2.4 2.0 1.9 1.7 2.0 2.8

2.3 2.4 2.7 2.4 1.9 1.5 1.9 2.4

2.4 2.6 2.7 2.6 2.0 1.9 2.3 2.6

2.4 2.6 2.7 2.6 2.2 2.0 2.4 2.0

2.2 2.2 2.7 2.6 2.6 2.3 2.5 2.6

2.0 2.2 2.7 2.5 2.5 2.3 2.5 2.6

1.8 2.5 2.7 2.7 2.2 2.0 2.7 2.8

1.7 1.9 2.3 2.4 2.6 2.6 2.3 2.6

2.1 2.2 2.7 2.6 2.6 2.4 2.6 2.8

dr. schenk

Tout

Tin

d

Metallayer

Basefilm

1.6

1.7 – 1.8

1.9 – 2.0

2.1 – 2.2

2.3 – 2.4

2.5

OpticalDensity

NG

OK


Corona Treatment of BOxx

Physical surface modification effected by corona treatment


Inline Monitoring Corona Treatment

Material: Plastic film (CPP)Measurement in Darkfield / Reflection


Patch Coating for Li-Ion Battery Film

Material: Battery Separator filmMeasurement of patch width and length + patch position (front versus back side)Check of coating homogeneity and coating edges



726 mm ~ 1,45 sec 109 mm ~ 0,22 sec

30 m/min = 500 mm/sec

Eric

Mak

i, M

egte

c Sy

stem

s, 2

010



1000 µm

Not calenderedarea


Inspection & Monitoring of Web Material

One system for both functions

Easy applicationtion in pro-duction lines and rewinders

No mechanical scannersNon-radioactive

100 % monitoring on the whole web width

(instead of random sampling with a fixed or traversing measurement head)

Unique combination: Detection of local defects + control of larger material variations

+


Adv

anta

ges

of A

OI

Cost reduction in converting

In-line quality check prior to subsequent process steps

Increased YieldContinuous monitoring of coating layer

⇒ Process remains within process window

ConsistentPerformance 24 h/day + 7 days/week

ROI < 2 years Based on customer experience depending on various factors

Summary and Conclusion


Visualization Screen

RDM (Running Defect Map) + Graph: Defect Density

RDM and graph for defect density in CD-and MD-direction,for 4 lanes separately


Thank you for your attention

Thomas Laumeyer, Hans OerleyDr. Schenk GmbH

Industriemesstechnikwww.drschenk.com

2016 aimcal conference europe€¦ · flat aluminum, steel, & non-ferrous metal products, e.g....

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