MIDA X the Next Generation in Optical Inspection

MIDA X, the Next Generation in Optical Inspection How Today’s QC-Systems Can Be Made More Powerful Jochen Koenig Schenk Vision Inspection Systems CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 1

Introducing Dr. Schenk Base Material Inspection CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Converted Material Inspection Properties Monitoring Summary AIMCAL USA 2018 Page 2

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 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 3

Ready for Your Project CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 4

Production Line with In-Line Inspection base film Inspection after coating dr. sc nk he Inspection after drying dr. sc nk he Extrusion, . Coating Drying CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 5

Quality & Process Control for Coated Materials on cti ial / ty e p er li Ins Mat Qua l a g Fin ase min B co f o In Converting of Material Coating … Blow Line Castline Extruder Production of Base Material / of on teps i t c y pe g S alit Ins ertin l Qu nv ina Co F Delivery to customer § § § Inclusions Fish-eyes Gels, Knots. . . § § § Coating voids Pinholes Inclusions in coating layer Bubbles Coating streaks … § § § Grammage Reflectivity, gloss. . . § § § Layer thickness Surface structures (haze). . . CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Defect Detection Material Properties Monitoring AIMCAL USA 2018 Page 6

System Configuration Reflection Darkfield + Brightfield Transmission Brightfield dr. sc he nk Illumination BRIGHT_LINE MIDA Camera Technology Material Illumination BRIGHT_LINE CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 7

MIDA: Single Camera – Multiple Illuminations Example: combination reflection + transmission channels Transmission Reflection Camera dr. . nk dr he nk sc he sc Illumination for reflection Material Illumination for transmission § 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 Reflection DF Transmission HF CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection HF AIMCAL USA 2018 Page 8

One System – Two Tasks Shared Hardware Local Defects Material Analysis Easy. Inspect with Easy. Measure is a complete & unique solution CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 9

Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Base Film: Detection of Local Defects CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 10

Inspection & Measurement of Plastic Films Local defects in base material Local defects after coating Film / coating inhomogeneity Problem Cause Effect § 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 § § § § 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 § § Coating voids Pinholes Inclusions Scratches MD-Streaks ……. Layer thickness Surface topology Clarity of the film Reflectivity CONFIDENTIAL Copyright © Dr. Schenk Gmb. H § § 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 Solution Local Defect Detection Film Properties Monitoring AIMCAL USA 2018 Page 11

Inspection Results Base Film Material: Flexible Packaging Base Film Defect: Particle, Inclusion Camera RBF dr. sche nk RDF TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Brightfield Reflection Darkfield AIMCAL USA 2018 Page 12

Inspection Results Base Film Material: Flexible Packaging Base Film Defect: Gels Camera dr. sche nk TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Transmission Brightfield Knife Edge AIMCAL USA 2018 Page 13

Inspection Results Base Film Material: Flexible Packaging Base Film Defect: Wrinkles Camera RBF dr. sche nk RDF TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Darkfield AIMCAL USA 2018 Page 14

Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Coated Film: Detection of Local Defects CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 15

Examples for Defects and Inhomogeneities io n ag ing gl om er at at Co St a in , pa n, sio In clu ol e Pi nh Ov er pa coa rti ted cle Sc ra tch sta le ho ou gh Th r rti cle in Examples for local defects in coated films 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 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 16

Inspection & Measurement of Plastic Films Local defects in base material Local defects after coating Film / coating inhomogeneity Problem Cause Effect § 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 § § § § 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 § § Coating voids Pinholes Inclusions Scratches MD-Streaks ……. Layer thickness Surface topology Clarity of the film Reflectivity CONFIDENTIAL Copyright © Dr. Schenk Gmb. H § § 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 Solution Local Defect Detection Film Properties Monitoring AIMCAL USA 2018 Page 17

Inspection Results Coated Film Material: Packaging film, coated Defect: Spot / coating void Camera RBF dr. sche nk TBF Brightfield Transmission CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Brightfield Reflection AIMCAL USA 2018 Page 18

Inspection Results Coated Film Material: Packaging film, coated Defect: Coating void / particles Camera RBF dr. sche nk RDF Brightfield Reflection CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Darkfield Reflection AIMCAL USA 2018 Page 19

Inspection Results Coated Film Material: Packaging film, coated Defect: Oil contamination Camera RBF dr. sche nk TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Brightfield AIMCAL USA 2018 Page 20

Inspection Results Coated Film Material: Packaging film, coated Defect: Orange peel, gels Camera dr. sche nk TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Transmission Brightfield/ Knife Edge AIMCAL USA 2018 Page 21

Inspection Results Coated Film Material: Plastic film, waterbased coating Defect: Dewetting Camera RBF dr. sche nk RDF Reflection Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Darkfield AIMCAL USA 2018 Page 22

Inspection Results Coated Film Material: Plastic film, extrusion coating Defect: Coating streak Camera RBF dr. sche nk Reflection Brightfield AWD 17314 -0 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Brightfield Streak detection AIMCAL USA 2018 Page 23

Inspection Results Coated Film Material: Plastic film Defect: Bubbles in extrusion coating Camera RBF dr. sche nk RDF TBF AWD 17314 -0 Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Brightfield Reflection Darkfield AIMCAL USA 2018 Page 24

Inspection Results Metallized Film Material: Packaging Film / Metallized Defect: Metal void, pinholes Camera RBF dr. sche nk TBF Transmission Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Brightfield Knife Edge AIMCAL USA 2018 Page 25

MIDA → MIDA X: Closing the Intelligence Gap MIDA The 1 st revolution in optical inspection CONFIDENTIAL Copyright © Dr. Schenk Gmb. H The 2 nd revolution in optical inspection Hardware Multi. Processor Technology Multi-CPU / GPU Architecture Software Multithreading capability Architecture EXPLOITS hardware optimally AIMCAL USA 2018 Page 26

MIDA X: Visual Intelligence The way to higher yield Gray image with reduced noise MIDA X: real defect size Enhanced evaluation CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 27

MIDA X: Visual Intelligence MIDA X: Precise defect differentiation Standard Inspection MIDA X Insect Contamination Gray Image CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 28

Dr. Schenk MCI Technology Filter Mat / Nonwoven dr. schenk Conventional: white light + color line camera CONFIDENTIAL Copyright © Dr. Schenk Gmb. H MCI Technology: 3 x more light ! Multi-Color-Illumination + monochrome line camera AIMCAL USA 2018 Page 29

Dr. Schenk MCI Technology Filter Mat / Nonwoven Conventional Color Camera CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Dr. Schenk MCI Technology AIMCAL USA 2018 Page 30

One System – Two Tasks Shared Hardware Local Defects Material Analysis Easy. Inspect with Easy. Measure is a complete & unique solution CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 31

Introducing Dr. Schenk Base Material Inspection Converted Material Inspection Properties Monitoring Summary Coated Film: Monitoring of Film Properties CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 32

Inspection & Measurement of Plastic Films Local defects in base material Local defects after coating Film / coating inhomogeneity Problem Cause Effect § 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 § § § § 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 § § Coating voids Pinholes Inclusions Scratches MD-Streaks ……. Layer thickness Surface topology Clarity of the film Reflectivity CONFIDENTIAL Copyright © Dr. Schenk Gmb. H § § 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 Solution Local Defect Detection Film Properties Monitoring AIMCAL USA 2018 Page 33

Examples for Defects and Inhomogeneities io n ag ing gl om er at at Co St a in , pa n, sio In clu ol e Pi nh Ov er pa coa rti ted cle Sc ra tch sta le ho ou gh Th r rti cle in Examples for local defects in coated films 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 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 34

Monitoring Coating Thickness Material: PET with coating Variation in coating layer thickness CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Samples: V 0 V 1 V 2 V 3 V 4 AIMCAL USA 2018 Page 35

In-Line Coating after MDO / Monitoring after TDO Extrusion MDO-stretching Coating TDO stretching dr. schen k Coating after MDO, thickness 5 µm Thickness after TDO: • Base film: 30 µm • Coating: 1000 nm ~1. 200 Graylevels (GL) => 1 GL~ 0, 8 nm CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 36

Homogeneity Map Material: Plastic film, extrusion coating Defect: Flow lines Camera RBF dr. sche nk RDF Reflection Brightfield AWD 17314 -0 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Darkfield Gray Image Homogeneity Map AIMCAL USA 2018 Page 37

Monitoring Adhesive Coating / Tapes Material: Coated paper Defect: Gloss variation Camera RBF dr. sche nk Reflection Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 38

Film / Coating Properties Monitoring Material: Battery electrode film Monitoring of calandering calandered area not calandered area dr. sche nk Grayvalue count RDF Grayvalue count Camera CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 39

Inspection Results Coated Film Material: Plastic film Defect: Missing adhesive Camera RBF dr. sche nk RDF AWD 17314 -0 Reflection Brightfield CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Reflection Darkfield AIMCAL USA 2018 Page 40

Advantages of AOI Summary and Conclusion Cost reduction in converting Increased Yield In-line quality check prior to subsequent process steps 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 CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 41

Summary and Conclusion Quality data MES (Management Execution System) Reports and statistics PIs (Performance Indicators) Inspection system Process optimization Process parmameters adaption Production process CONFIDENTIAL Copyright © Dr. Schenk Gmb. H Inline quality control Delivery to customer Rejects AIMCAL USA 2018 Page 42

CONFIDENTIAL Copyright © Dr. Schenk Gmb. H AIMCAL USA 2018 Page 43

Thank you for your attention Jochen Koenig Managing Director Schenk Vision Inspection Systems CONFIDENTIAL Copyright © Dr. Schenk Gmb. H www. schenkvision. com AIMCAL USA 2018 Page 44