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MIDA X, the Next Generation in Optical Inspection

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Presentation on theme: "MIDA X, the Next Generation in Optical Inspection"— Presentation transcript:

1 MIDA X, the Next Generation in Optical Inspection
How Today’s QC-Systems Can Be Made More Powerful Jochen Koenig Schenk Vision Inspection Systems

2 Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary

3 Dr. Schenk – The Solution Provider
Local defect detection & overall properties monitoring Design & manufacture Modular in-line and off-line inspection and measurement systems Quality & process control of flat surfaces for the following industries: Nonwoven Inspection Textile Inspection Paper Inspection Plastic Inspection Metal Inspection Glass Inspection Display & Touch Panel Inspection Solar Inspection Material Handling Customized Solutions

4 Ready for Your Project

5 Production Line with In-Line Inspection
base film after coating Extrusion, . Coating dr. schenk after drying Drying

6 Quality & Process Control for Coated Materials
Final Inspection of Base Material / Incoming Quality Inclusions Fish-eyes Gels, Knots ... Inspection of Converting Steps / Final Quality Coating voids Pinholes Inclusions in coating layer Bubbles Coating streaks … Production of Base Material Converting of Material Coating … Blow Line Castline Extruder Delivery to customer Defect Detection Grammage Reflectivity, gloss ... Layer thickness Surface structures (haze) ... Material Properties Monitoring 6

7 MIDA Camera Technology
System Configuration Reflection Darkfield + Brightfield Transmission Brightfield dr. schenk dr. schenk dr. schenk Illumination BRIGHT_LINE MIDA Camera Technology Material Illumination BRIGHT_LINE

8 MIDA: Single Camera – Multiple Illuminations
Example: combination reflection + transmission channels Transmission Material Camera Illumination for transmission dr. schenk Reflection dr. schenk Illumination for reflection Reflection DF Reflection HF Transmission HF High sensitivity for many different defects (e.g. inclusions, holes, contaminations, embossing defects, lines, cluster, wrinkles, …) Comprehensive defect analysis for reliable defect classification Only one camera - ► saves footprint and investment costs

9 EasyInspect with EasyMeasure is a complete & unique solution
One System – Two Tasks Shared Hardware Local Defects Material Analysis EasyInspect with EasyMeasure is a complete & unique solution

10 Base Film: Detection of Local Defects
Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Base Film: Detection of Local Defects

11 Inspection & Measurement of Plastic Films
Problem Cause Effect Solution Local defects in base material Gels, fisheyes: P-gel (polymerization) E-gel (extrusion) Carbon specs (die pickoff) Air bubbles Striations (die-/weld-lines) Scratches Wrinkles Insects Roller marks …….. Poor production process Poor material quality P-gels: bad incoming resin E-gels: mostly unmelted / degraded resins Poor crystallization Inhomogeneous film, danger of tearing Performance in end product (sealing capability of goods) Cosmetic problems Local Defect Detection after coating Coating voids Pinholes Inclusions MD-Streaks ……. Poor pre-treatment of base material Particles on base material before coating Defective coating die Loss of coating function (e.g. sealing capability) Problems with printing Film / coating inhomogeneity Layer thickness Surface topology Clarity of the film Reflectivity Poor material deposition Poor surface of rollers Inhomogeneous mixture of granulate with master batch (M.B.) (i.e. because of heavier M.B.) Performance of end product Cosmetic problem in end product Film Properties Monitoring

12 Inspection Results Base Film
Material: Flexible Packaging Base Film Defect: Particle, Inclusion dr. schenk Camera RBF RDF TBF Transmission Brightfield Reflection Brightfield Reflection Darkfield

13 Inspection Results Base Film
Material: Flexible Packaging Base Film Defect: Gels dr. schenk Camera TBF Transmission Brightfield Transmission Brightfield Knife Edge

14 Inspection Results Base Film
Material: Flexible Packaging Base Film Defect: Wrinkles dr. schenk Camera RBF RDF TBF Transmission Brightfield Reflection Darkfield

15 Coated Film: Detection of Local Defects
Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Coated Film: Detection of Local Defects

16 Examples for Defects and Inhomogeneities
Examples for local defects in coated films Coating agglomeration Inclusion, stain Through hole Stain, particle Overcoated particle Pinhole Scratch Coating layer Plastic film Examples for layer inhomogeneities in coated films Variation in layer thickness Variation in layer surface topology (haze) Coating layer Plastic film

17 Inspection & Measurement of Plastic Films
Problem Cause Effect Solution Local defects in base material Gels, fisheyes: P-gel (polymerization) E-gel (extrusion) Carbon specs (die pickoff) Air bubbles Striations (die-/weld-lines) Scratches Wrinkles Insects Roller marks …….. Poor production process Poor material quality P-gels: bad incoming resin E-gels: mostly unmelted / degraded resins Poor crystallization Inhomogeneous film, danger of tearing Performance in end product (sealing capability of goods) Cosmetic problems Local Defect Detection after coating Coating voids Pinholes Inclusions MD-Streaks ……. Poor pre-treatment of base material Particles on base material before coating Defective coating die Loss of coating function (e.g. sealing capability) Problems with printing Film / coating inhomogeneity Layer thickness Surface topology Clarity of the film Reflectivity Poor material deposition Poor surface of rollers Inhomogeneous mixture of granulate with master batch (M.B.) (i.e. because of heavier M.B.) Performance of end product Cosmetic problem in end product Film Properties Monitoring

18 Inspection Results Coated Film
Material: Packaging film, coated Defect: Spot / coating void dr. schenk Camera RBF TBF Brightfield Transmission Brightfield Reflection

19 Inspection Results Coated Film
Material: Packaging film, coated Defect: Coating void / particles dr. schenk Camera RBF RDF Brightfield Reflection Darkfield Reflection

20 Inspection Results Coated Film
Material: Packaging film, coated Defect: Oil contamination dr. schenk Camera RBF TBF Transmission Brightfield Reflection Brightfield

21 Inspection Results Coated Film
Material: Packaging film, coated Defect: Orange peel, gels dr. schenk Camera TBF Transmission Brightfield Transmission Brightfield/ Knife Edge

22 Inspection Results Coated Film
Material: Plastic film, waterbased coating Defect: Dewetting dr. schenk Camera RBF RDF Reflection Brightfield Reflection Darkfield

23 Inspection Results Coated Film
Material: Plastic film, extrusion coating Defect: Coating streak dr. schenk Camera RBF Reflection Brightfield Reflection Brightfield Streak detection AWD

24 Inspection Results Coated Film
Material: Plastic film Defect: Bubbles in extrusion coating dr. schenk Camera RBF RDF TBF Transmission Brightfield Reflection Brightfield Reflection Darkfield AWD

25 Inspection Results Metallized Film
Material: Packaging Film / Metallized Defect: Metal void, pinholes dr. schenk Camera RBF TBF Transmission Brightfield Reflection Brightfield Knife Edge

26 MIDA → MIDA X: Closing the Intelligence Gap
The 1st revolution in optical inspection The 2nd revolution in optical inspection Hardware Multi-CPU / GPU Architecture Multi-Processor Technology Software Multi-threading capability Architecture EXPLOITS hardware optimally

27 MIDA X: Visual Intelligence
The way to higher yield Gray image with reduced noise MIDA X: real defect size Enhanced evaluation

28 MIDA X: Visual Intelligence
MIDA X: Precise defect differentiation Gray Image Standard Inspection MIDA X Contamination Insect

29 Dr. Schenk MCI Technology
Filter Mat / Nonwoven dr. schenk Conventional: white light + color line camera MCI Technology: 3x more light ! Multi-Color-Illumination + monochrome line camera

30 Dr. Schenk MCI Technology
Filter Mat / Nonwoven Conventional Color Camera Dr. Schenk MCI Technology

31 EasyInspect with EasyMeasure is a complete & unique solution
One System – Two Tasks Shared Hardware Local Defects Material Analysis EasyInspect with EasyMeasure is a complete & unique solution

32 Coated Film: Monitoring of Film Properties
Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Coated Film: Monitoring of Film Properties

33 Inspection & Measurement of Plastic Films
Problem Cause Effect Solution Local defects in base material Gels, fisheyes: P-gel (polymerization) E-gel (extrusion) Carbon specs (die pickoff) Air bubbles Striations (die-/weld-lines) Scratches Wrinkles Insects Roller marks …….. Poor production process Poor material quality P-gels: bad incoming resin E-gels: mostly unmelted / degraded resins Poor crystallization Inhomogeneous film, danger of tearing Performance in end product (sealing capability of goods) Cosmetic problems Local Defect Detection after coating Coating voids Pinholes Inclusions MD-Streaks ……. Poor pre-treatment of base material Particles on base material before coating Defective coating die Loss of coating function (e.g. sealing capability) Problems with printing Film / coating inhomogeneity Layer thickness Surface topology Clarity of the film Reflectivity Poor material deposition Poor surface of rollers Inhomogeneous mixture of granulate with master batch (M.B.) (i.e. because of heavier M.B.) Performance of end product Cosmetic problem in end product Film Properties Monitoring

34 Examples for Defects and Inhomogeneities
Examples for local defects in coated films Coating agglomeration Inclusion, stain Through hole Stain, particle Overcoated particle Pinhole Scratch Coating layer Plastic film Examples for layer inhomogeneities in coated films Variation in layer thickness Variation in layer surface topology (haze) Coating layer Plastic film

35 Monitoring Coating Thickness
Material: PET with coating Samples: V0 V1 V2 V3 V4 Variation in coating layer thickness

36 In-Line Coating after MDO / Monitoring after TDO
MDO-stretching TDO - Extrusion Coating stretching dr. schenk dr. schenk dr. schenk Coating after MDO, thickness 5 µm Thickness after TDO: Base film: 30 µm Coating: 1000 nm 1000 nm ~1.200 Graylevels (GL) => 1 GL~ 0,8 nm

37 Homogeneity Map Material: Plastic film, extrusion coating
Defect: Flow lines dr. schenk Camera RBF RDF Reflection Brightfield Reflection Darkfield Gray Image Homogeneity Map AWD

38 Monitoring Adhesive Coating / Tapes
Material: Coated paper Defect: Gloss variation Camera RBF dr. schenk Gray image  homogeneity map  tile histgram map (e.g. as basis for histogram evaluation) Reflection Brightfield

39 Film / Coating Properties Monitoring
Material: Battery electrode film Monitoring of calandering not calandered area calandered area Camera dr. schenk Grayvalue count RDF Grayvalue count

40 Inspection Results Coated Film
Material: Plastic film Defect: Missing adhesive dr. schenk Camera RBF RDF Reflection Brightfield Reflection Darkfield AWD

41 Summary and Conclusion
Advantages of AOI Cost reduction in converting In-line quality check prior to subsequent process steps Increased Yield Continuous monitoring of material/coating layer  Process remains within process window Consistent Performance 24 h/day + 7 days/week ROI < 2 years Based on customer experience depending on various factors

42 Summary and Conclusion
Delivery to customer Rejects Production process Quality data Reports and statistics Inline quality control Process parmameters adaption Process optimization Inspection system MES (Management Execution System) PIs (Performance Indicators)

43

44 Thank you for your attention
Jochen Koenig Managing Director Schenk Vision Inspection Systems

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