Intelligent Inspection Solutions for Modern Architectural Glass
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1 for Modern Architectural Glass Ulrich Bauereiss Dr. Schenk GmbH Industriemesstechnik 10_2014 Page 1
2 Modern Architecture 10_2014 Page 2
3 Modern Architecture: Quantity, Variety Low-e glass Safety glass (ESG/ Laminated) Self-cleaning Sun protection Electrochrome 10_2014 Page 3
4 Product Requirements: Quantity, Variety Transparency, homogeneity Stability Design variations (e.g. etched) Image source: Schüco, Safety Effectiveness, function.. and many more stringent quality control necessary 10_2014 Page 4
5 Float Glass Inspection Tasks Glass + Coating Defects Stress Measurement Thickness Measurement Homogeneity Measurement Cutting Optimization Interface Marker Interface Quality Visualization System (SQL Database) 10_2014 Page 5 = Quality & Process Control
6 State-of-the-Art Configuration Inspection line Marker with traversing unit Marking Defect Cutter with cutting optimization Glass section with defects 10_2014 Page 6 Glass sheet Glass sheet Glass sheet
7 Production Flow adapted Quality & Process Control Furnace + Tin Bath Float Glass Inspection Float glass inspection: Bubbles Stones, Knots, Inclusions Tin-Defects Ream Glass thickness Glass stress Defects Scrap Cutting Optimization Defect Detection Monitoring and Measurement Glass grinding & drilling, tempering, printing,. Coatings (Low-e, Sun protection, Electrochrome) 10_2014 Page 7
8 Production Flow adapted Quality & Process Control Furnace + Tin Bath + inline coating Float Glass Inspection Float glass inspection: Bubbles Stones, Knots, Inclusions Tin-Defects Ream Coating inspection: Coating defects Glass thickness Glass stress Coating homogeneity Color variations... Defects Scrap Cutting Optimization Defect Detection Monitoring and Measurement Coatings (Low-e, Sun protection, Electrochrome) Glass grinding & drilling, hardening, printing,. 10_2014 Page 8
9 Production Flow adapted Quality & Process Control GlassInspect.float Cutting Optimization Defects Stones Bubbles Knots Tin Defects... Inline - Coating GlassInspect Coating Defects Cathode Defects Crazing/Arcing Handling defects Cleaning residue Coating thickness Homogeneity Color variations... Local Defect Detection Monitoring of Glass Properties 10_2014 Page 9
10 Production Flow adapted Quality & Process Control GlassInspect.float Cutting Optimization Defects Stones Bubbles Knots Tin Defects... Inline - Coating GlassInspect Offline - Coating Coating Defects Cathode Defects Crazing/Arcing Handling defects Cleaning residue GlassInspect Coating thickness Homogeneity Color variations... Local Defect Detection Monitoring of Glass Properties 10_2014 Page 10
11 AOI Tasks after Offline-Coating Glass coating (Low-e, Electrochrome, AR, ) Crazing defect 10_2014 Page 11
12 Coating Example: Low-e Glass Part 1 Low-E coating layer parameters can influence visual appearance of the glass: 10_2014 Page 12
13 Coating Example: Low-e Glass Part 2 Low-E coating layer parameters can influence function & performance of the glass: 10_2014 Page 13
14 Coating Example: Low-e Glass Part 2 Functional defect (homogeneity) Image source: 10_2014 Page 14
15 Coating Inspection Tasks: Visual Defect Control Functional Quality & Process + Defect Control = Control Image source: 10_2014 Page 15
16 Technical Implementation Spot measurement with spectrometer generates reference color values L*a*b Color channel is monitoring the L*a*b values over entire glass panel Evaluation Electronics 10_2014 Page 16
17 Coating Layer Homogeneity Evaluation of the homogeneity of a coating layer (e.g. for layer thickness, surface roughness/haze, color,..) with two wavelengths: Red Blue 10_2014 Page 17
18 Spectral Transmission Homogeneity Evaluation of the spectral transmission with multiple wavelengths: VLT: Visual Light Transmission IR: Infra-red 10_2014 Page 18
19 Coating Example: Electrochromic Glass 1 / 2 Visual defect in electrochromic coating (coating void) 10_2014 Page 19
20 Coating Example: Electrochromic Glass 2 / 2 Functional defect in electrochromic coating (homogeneity) 10_2014 Page 20
21 Variety of the Inspection tasks Low-e glass Safety Glass (ESG/ Laminated) Self-cleaning Sun protection Electrochrome 10_2014 Page 21
22 MIDA enables this flexibility 10_2014 Page 22
23 MIDA enables this flexibility MIDA stands for Multiple Image Defect Analysis MIDA developed by Dr. Schenk is the leading technology concept to enable this flexibility MIDA combines inspection with measurement and monitoring functionality MIDA means one camera controls various kinds of illuminations 10_2014 Page 23
24 MIDA enables this flexibility MIDA combines different inspection and monitoring tasks to an integrated solution Coating Defects Homogeneity Monitoring Camera 3 Camera 1 Camera 2 Glass Defects 10_2014 Page 24
25 Modern, Flexible Integration Options Remote Visualization PST: Production Statistics Tool PHC: Production History Client PST PHC TCP/IP Data Base PLC Digital IO for e.g. waste mode, glas cullet sorting. TCP/IP e.g. recipe ID for recipe selection External Measurement Technology RS422 / 24V synchronized pulsed signal Dr. Schenk Encoder External TCP/IP e.g. thickness, stress, color MD Position Dr. Schenk Inspection System Information for cutting optimization TCP/IP, glass width, top-roller position, defect types, weighting and defect position Marker TCP/IP or digital IO External Marker TCP/IP and digital IO Assignment of cutting information External Cutter 10_2014 Page 25
26 Inspection + Handling / Glass Sheet Control Inage source: 10_2014 Page 26
27 Video: Inspection of Super-Thin Glass 10_2014 Page 27
28 The Return on Your Investment Advantages of modern glass inspection: Quality Control of glass, handlings and process defects Process Control Reduce Recalls Increase Customers satisfaction Early Indicator for process instabilities Ideal toll for process improvement ; Yield No bad material slips though to customers / subsequent processing steps 10_2014 Page 28
29 Thank you for your attention Visit our booth E 20 in hall 14 for more information. Copyright Dr. Schenk GmbH glass technology live _2014 Page 29
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