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CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 1
How Today’s QC-Systems Can Be Made More Powerful
MIDA X, the Next Generation in Optical Inspection
Jochen KoenigSchenk Vision Inspection Systems
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 2
IntroducingDr. Schenk
Base Material Inspection
Properties Monitoring
Converted Material Inspection
Summary
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 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:
Glass Inspection
SolarInspection
Display & Touch Panel Inspection
NonwovenInspection
PlasticInspection
TextileInspection
MetalInspection
MaterialHandling
Paper Inspection
Customized Solutions
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 4
Ready for Your Project
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 5
Production Line with In-Line Inspection
Inspectionbase film Inspection
after coating
Extrusion, .
Coating
Inspectionafter drying
Drying
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 6
Production of Base Material
…B
low
Lin
e
Cas
tline
Extr
uder Delivery to customer
Grammage Reflectivity, gloss ...
Layer thickness Surface structures (haze) ...
Coating voids Pinholes Inclusions in coating layer Bubbles Coating streaks …
Converting of Material
Coa
ting
Inclusions Fish-eyes Gels, Knots ...
Quality & Process Control for Coated Materials
Defect Detection
Material Properties Monitoring
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 7
Material
MIDA CameraTechnology
IlluminationBRIGHT_LINE
IlluminationBRIGHT_LINE
System Configuration
Reflection Darkfield + BrightfieldTransmission Brightfield
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 8
MIDA: Single Camera – Multiple Illuminations
Example: combination reflection + transmission channels
Reflection
Illumination for reflection
Transmission
Material
Camera
Illumination for transmission
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
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 9
One System – Two Tasks
Shared Hardware
Local Defects Material Analysis
EasyInspect with EasyMeasure is a complete & unique solution
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 10
IntroducingDr. Schenk
Base Material Inspection
Properties Monitoring
Converted Material Inspection
Summary
Base Film: Detection of Local Defects
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 11
Inspection & Measurement of Plastic Films
Problem Cause Effect Solution
Local defectsin 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
Local defectsafter coating
Coating voids Pinholes Inclusions Scratches 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
Cosmetic problems
Local Defect Detection
Film / coating inhomogeneity
Layer thickness Surface topology Clarity of the film Reflectivity
Poor material deposition Poor material quality 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
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 12
Inspection Results Base Film
Material: Flexible Packaging Base Film
Defect: Particle, Inclusion
Camera
RBF
RDF
TBF
Transmission Brightfield Reflection Brightfield Reflection Darkfield
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 13
Inspection Results Base Film
Material: Flexible Packaging Base Film
Defect: Gels
Camera
TBF
Transmission Brightfield Transmission BrightfieldKnife Edge
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 14
Inspection Results Base Film
Material: Flexible Packaging Base Film
Defect: Wrinkles
Camera
RBF
RDF
TBF
Transmission Brightfield Reflection Darkfield
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 15
IntroducingDr. Schenk
Base Material Inspection
Properties Monitoring
Converted Material Inspection
Summary
Coated Film: Detection of Local Defects
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 16
Examples for Defects and Inhomogeneities
Examples for local defects in coated films
Coating layerPlastic film
Coating layerPlastic film
Examples for layer inhomogeneities in coated films
Variation in layer thickness Variation in layer surface topology (haze)
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 17
Inspection & Measurement of Plastic Films
Problem Cause Effect Solution
Local defectsin 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
Local defectsafter coating
Coating voids Pinholes Inclusions Scratches 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
Cosmetic problems
Local Defect Detection
Film / coating inhomogeneity
Layer thickness Surface topology Clarity of the film Reflectivity
Poor material deposition Poor material quality 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
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 18
Brightfield Transmission Brightfield Reflection
Inspection Results Coated Film
Material: Packaging film, coated
Defect: Spot / coating void
Camera
RBF
TBF
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 19
Brightfield Reflection Darkfield Reflection
Inspection Results Coated Film
Material: Packaging film, coated
Camera
RBF
RDF
Defect: Coating void / particles
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 20
Transmission Brightfield Reflection Brightfield
Inspection Results Coated Film
Material: Packaging film, coated
Camera
RBF
TBF
Defect: Oil contamination
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 21
Transmission Brightfield Transmission Brightfield/Knife Edge
Inspection Results Coated Film
Material: Packaging film, coated
Defect: Orange peel, gels
Camera
TBF
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 22
Inspection Results Coated Film
Material: Plastic film, waterbased coating
Camera
RBF
RDF
Defect: Dewetting
Reflection Brightfield Reflection Darkfield
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 23
Inspection Results Coated Film
Material: Plastic film, extrusion coating
AWD17314-0
Reflection Brightfield Reflection BrightfieldStreak detection
CameraRBF
Defect: Coating streak
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 24
Inspection Results Coated Film
Material: Plastic film
AWD17314-0
Defect: Bubbles in extrusion coating
Transmission Brightfield Reflection Brightfield Reflection Darkfield
Camera
RBF
RDF
TBF
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 25
Inspection Results Metallized Film
Material: Packaging Film / Metallized
Transmission Brightfield Reflection BrightfieldKnife Edge
Camera
RBF
TBF
Defect: Metal void, pinholes
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 26
MIDA → MIDA X: Closing the Intelligence Gap
MIDA
The 1st revolution in optical inspection
SoftwareMulti-threading capability
Architecture EXPLOITS hardware optimally
HardwareMulti-CPU / GPU Architecture
Multi-Processor Technology
The 2nd revolution in optical inspection
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 27
MIDA X: Visual Intelligence
The way to higher yield
Gray image with reduced noise MIDA X: real defect size
Enhancedevaluation
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 28
MIDA X: Visual Intelligence
MIDA X: Precise defect differentiation
Gray Image MIDA XStandardInspection
Inse
ctC
onta
min
atio
n
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 29
Dr. Schenk MCI Technology
Filter Mat / Nonwoven
Conventional: white light + color line camera
MCI Technology: 3x more light !Multi-Color-Illumination + monochrome line camera
dr. schenk
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 30
Dr. Schenk MCI Technology
Filter Mat / Nonwoven
ConventionalColor Camera
Dr. Schenk MCI Technology
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 31
One System – Two Tasks
Shared Hardware
Local Defects Material Analysis
EasyInspect with EasyMeasure is a complete & unique solution
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 32
IntroducingDr. Schenk
Base Material Inspection
Properties Monitoring
Converted Material Inspection
Summary
Coated Film: Monitoring of Film Properties
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 33
Inspection & Measurement of Plastic Films
Problem Cause Effect Solution
Local defectsin 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
Local defectsafter coating
Coating voids Pinholes Inclusions Scratches 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
Cosmetic problems
Local Defect Detection
Film / coating inhomogeneity
Layer thickness Surface topology Clarity of the film Reflectivity
Poor material deposition Poor material quality 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
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 34
Examples for Defects and Inhomogeneities
Examples for local defects in coated films
Coating layerPlastic film
Coating layerPlastic film
Examples for layer inhomogeneities in coated films
Variation in layer thickness Variation in layer surface topology (haze)
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 35
Variation in coating layer thickness
Samples:V0
V1V2V3V4
Monitoring Coating Thickness
Material: PET with coating
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 36
In-Line Coating after MDO / Monitoring after TDO
MDO-stretching TDO -Extrusion Coating stretching
dr. schenk
dr. schenk
1000 nm ~1.200 Graylevels (GL) => 1 GL~ 0,8 nm
Thickness after TDO: • Base film: 30 µm• Coating: 1000 nm
Coating after MDO, thickness 5 µm
dr. schenk
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 37
Homogeneity Map
Material: Plastic film, extrusion coating
AWD17314-0
Defect: Flow lines
Camera
RBF
RDF
Reflection Brightfield Reflection DarkfieldGray Image Homogeneity Map
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 38
Monitoring Adhesive Coating / Tapes
Material: Coated paper
Reflection Brightfield
Defect: Gloss variation
Camera
RBF
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 39
Film / Coating Properties Monitoring
Material: Battery electrode film
calandered area
not calandered area
Camera
RDF
Gra
yval
ue c
ount
Gra
yval
ue c
ount
Monitoring of calandering
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 40
Inspection Results Coated Film
Material: Plastic film
AWD17314-0Reflection Brightfield Reflection Darkfield
Defect: Missing adhesive
Camera
RBF
RDF
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 41
Adv
anta
ges
of A
OI
Cost reduction in converting
In-line quality check prior to subsequent process steps
Increased YieldContinuous monitoring of material/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
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 42
Summary and Conclusion
Delivery to customer
RejectsProduction process
Quality data
Reports and statistics
Inlinequalitycontrol
Process parmameters
adaption
Process optimization
Inspection system
MES (ManagementExecution System)
PIs (Performance Indicators)
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 43
CONFIDENTIAL Copyright © Dr. Schenk GmbH AIMCAL USA 2018 Page 44
Thank you for your attention
Jochen KoenigManaging Director
Schenk VisionInspection Systems www.schenkvision.com
MIDA X, the Next Generation in Optical InspectionSlide Number 2Dr. Schenk – The Solution ProviderReady for Your ProjectProduction Line with In-Line Inspection Quality & Process Control for Coated MaterialsSystem ConfigurationMIDA: Single Camera – Multiple IlluminationsOne System – Two TasksSlide Number 10Inspection & Measurement of Plastic Films Inspection Results Base FilmInspection Results Base FilmInspection Results Base FilmSlide Number 15Examples for Defects and InhomogeneitiesInspection & Measurement of Plastic Films Inspection Results Coated FilmInspection Results Coated FilmInspection Results Coated FilmInspection Results Coated FilmInspection Results Coated FilmInspection Results Coated FilmInspection Results Coated FilmInspection Results Metallized Film MIDA → MIDA X: Closing the Intelligence GapMIDA X: Visual IntelligenceMIDA X: Visual IntelligenceDr. Schenk MCI TechnologyDr. Schenk MCI TechnologyOne System – Two TasksSlide Number 32Inspection & Measurement of Plastic Films Examples for Defects and InhomogeneitiesMonitoring Coating ThicknessIn-Line Coating after MDO / Monitoring after TDOHomogeneity MapMonitoring Adhesive Coating / TapesFilm / Coating Properties MonitoringInspection Results Coated FilmSummary and ConclusionSummary and ConclusionSlide Number 43Slide Number 44