1 st Automotive Glass Bending Seminar How can ISRA s inspection or measurement systems improve the bending process? KAYSER, Jens 05 December 2017

Transcription

1 1 st Automotive Glass Bending Seminar How can ISRA s inspection or measurement systems improve the bending process? KAYSER, Jens 05 December 2017

2 ISRA on the AUTOMOTIVE GLASS PROCESS Delivery Cutting & grinding Printing bending Laminating Inspection Packaging and distribution System P²-INSPECT PRINTSCAN FORMSCAN SC-INSPECT SC-FAULTFINDER SC-RD LABSCAN-Screen Online process control Laboratory Task Surface inspection Edge inspection Printing inspection Surface inspection Form measurement Surface inspection Optical distortion measurement Curvature measurement Optical distortion measurement

3 BENDING - the heart of the process chain F G F GRAVITY BENDING Hot glass sags into one mold PRESS BENDING Hot glass is pressed between two molds

4 RISKS and CHALLENGES VISIBLE DEFECTS TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION FORM Y X Z

5 DISTORTION Transmitted distortion Reflected distortion BAD GOOD BAD GOOD

6 DISTORTION Variation in thickness caused by thickness variation e.g. draw lines Variation of refraction index caused by inhomogeneity e.g. ream Transmitted distortion Reflected distortion Variation in waviness e.g. caused by lift rollers, bending tools

7 RISKS and CHALLENGES VISIBLE DEFECTS TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION FORM Y X Z

8 TRANSMITTED DISTORTION Positive optical power (convex lens or light accumulates a lens) negative optical power (concave lens or light disperse a lens) Positive optical power

9 TRANSMITTED DISTORTION CAUSED BY INTERLEAVE POWDER STRIPES Caused by too much powder or mis-adjusted rollers CLOUD INHOMOGENITY Caused by static charge with creating of holes FLAMES LUMPS Caused by uncleaned nozzles or humidity COFIRED

10 P²-POWDER Design REFLECTION DARK FIELD (RDF) Simplified process integration (no need for gap in conveyor) Minimize risk of dust on the illumination and expected reduction of brightness Dark Field

11 INSPECTION before bending Full automatic line control Flexible structure Standardized communications protocols Data transfer for recording and statistic analysis Glass Powder Machine P²-POWDER Record Analyze Statistic server PC Station Grade Mark Alarm Inspection result Viewer Station Visualize Review Plant Manager Production Manager Quality Manager

12 P²-POWDER Results GUI: color coded overview Visualization card Views of homogeneity features Last plates overview Visualization of homogeneity Color coded map: Display of each tile: Homogeneous Critical Inhomogeneous Simple overview to react immediately Summary List of last controlled plates with overview of the quality grading

13 P²-POWDER Results Optional Profiles + Trend by Panels + Trend by Time with Monitor Master:

14 TRANSMITTED DISTORTION CAUSED BY BENDING Small point defects caused by the bending process Bulls Eyes caused by vacuum suction cup Cluster of point defects caused by interleave powder (e.g. humidity)

15 MEASUREMENT after bending & lamination Car manufacturers LABSCAN-SCREEN Moiré technology is used by leading quality carmakers Automotive glass SC-FAULTFINDER Moiré technology is used by more than 80% of the windshield manufacturers Float inspection FLOATSCAN Moiré technology is used by more than 90% of the dedicated automotive glass float lines Unique Moiré technology used in each step of the automotive glass process

16 LABSCAN Design Intensity Horizontal Finally all results with a defined unit and objective values: Diopter Vertical

17 1L 9L 18L 27L 36L 45L 53L 62L 71L 33M 5R 14R 23R 31R 40R 49R 58R 67R 75R Cg=0.1*75/(6*Sigma) Standardabweichung Detailed analyzing with MEASUREMENT POINT FUNCTION Used as a tool to verify the process stability Easy handling at the user interface Configurable box/circle size Thresholds for each point 6.0 Test der Messanlage LABSCAN-Screen Audi am mit Messpunktfunktion an Heckscheibe Golf A5 getestet Definition in EXCEL possible 6.0 Results displayed in the color coded map: RED/GREEN R = Cg(75) Stabwn Evaluation to calculate the Cgvalue with MPF Messpunkte

18 RISKS and CHALLENGES VISIBLE DEFECTS TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION FORM Y X Z

19 REFLECTED DISTORTION Radii of curvatures: Changing of defined radii at one starting point or over a defined area, independent to allowed shape tolerances r 1 f(x) r 2 +2,0mm +1,5mm CAD 0-1,5mm -2,0mm

20 REFLECTED DISTORTION caused by bending Determination of the esthetic Determination of the wiper efficiency Determination of the camera assistance field

21 SCREENSCAN-RD Design BENEFITS: Surface curvature measurement Simple color coded map Objective results (values in mdpt or radii) Defined thresholds by comparing to references PLC-connection for line control Data transfer for recording and statistic analysis Offline Inline

22 MEASUREMENT after BENDING or LAMINATION TARGET ACTUAL VALUE ACTUAL TARGET= DIFFERENCES

23 RISKS and CHALLENGES VISIBLE DEFECTS TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION FORM Y X Z

24 FORM Overall shape with defined pitches and with defined tolerances of the z-axis +2,0mm +1,5mm CAD 0-1,5mm -2,0mm

25 FORM DEVIATIONS caused by bending BASIC: Reference (golden sample or CAD) compared with the results of measurement

26 FORMSCAN Design BENEFITS: Full automatic line control View of differences to references (e.g. CAD) Simple color coded map Points of interests Standardized communications protocols P²RINTSCAN

27 MEASUREMENT after BENDING

28 RISKS and CHALLENGES VISIBLE DEFECTS TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION FORM Y X Z

29 VISIBLE DEFECTS Absorbing defects Defect detection in must be there areas of silk printing, e.g.: ADAS (camera assistance field) VIN (vehicle identification number field) Scratches Quality of coating deletion (e.g. IR coating) Pinholes Improved print inspection, e.g.: Broken glass Large print defects Missing print close to the edges

30 SC-INSPECT Design & Process Integration BENEFITS: Full automatic line control Flexible structure Standardized communications protocols Data transfer for recording and statistic analysis INSPECT Station SCFF Station Plant Quality Production Maintenance Manager 2 nd Operator Station ONE OPERATOR! THREE CONTROLS! ONLY few meters production floor required For detection of aspect defect For detection of defects causing diffusion of lights Distortion Module (SCREENSCAN-Faultfinder) For detection of optical distortion

31 INSPECTION after BENDING & LAMINATION CAMERA 1x 200µm S1 S4 MAIN PERFORMANCE (not covered by painted areas) Absorbing defects > 0,4mm: Scratches: > ASTM 7 Color blobs (e.g. paint in clear areas) Inclusions (e.g. stones, bubbles) PVB-defects (e.g. fiber of vinyl or airbubbles) Paint void > 0,4mm: E.g. pinholes Broken glass 1x LED

32 TOTAL PROCESS CONTROL VISIBLE DEFECTS P²-POWDER TRANSMITTED DISTORTION BENDING REFLECTED DISTORTION SC-FF LABSCAN SCREENSCAN-RD FORM FORMSCAN

33 Does it really make sense to measure and inspect? Quality improvements within 16 years!

34 Ages of Automotive Glazing Complexity VIEW Towards Automotive Glazing 4.0 WIPER EFFICIENCY HUD Future Functions View Display SMART glazing 4.0 Multifunctional 1896 Early 20s Early 60s Today Driver Assistance Esthetic NO glazing SIMPLE glazing SAFETY glazing FUNCTIONAL glazing DRIVER ASSISTENCE ESTHETIC

35 Thank you for your attention Feel free to visit us in Herten