GLASS INSPECTION SYSTEM

Abstract: An inspection system for a sheet of glass. The system comprises a first laser and a second laser, each of which provide a sheet of light, a cylindrical lens system, and a first light detection system and a second light detection system. The first laser is located at the focal point of the lens system. The second laser is located at a distance from the lens system that is greater than that of the first laser, and off of the axis of the lens system. The first light detection system receives light from the first laser and the second light detection system receives light from the second laser. The inspection system is adapted to position a sheet of glass between the lens system and the detection systems. A method is also described.

Description: TITLE GLASS INSPECTION SYSTEM The present invention relates to a non-contact inspection system for detection and identification of the type of defects in sheets of glass, especially flat automotive glass. The system is intended to operate on a continuous production line at line speed, and for the identification of a wide variety of types of defects, including bubbles, scratches, chips, cracks and edge defects. In processes for manufacture of glass in sheet form, it is necessary to be able to inspect the sheets of glass for defects. Such defects may be in the form of scratches, bubbles, chips, blemishes and a wide variety of other defects. However, the mere detection of defects is insufficient in that the manufacturer of the sheet glass needs to know whether the defects are insignificant e.g. minor in nature and thus acceptable to the customer, or a major flaw such that the sheet would not conform to specifications established by the customer. It is possible to use visual inspection of sheets of glass and to identify those sheets that have defects. In addition, using visual inspection, it is possible to identify the location and possibly the type of defect. However, visual inspection is not acceptable because of the time and cost involved in conducting a visual inspection, and the limitations of such a method. It would be preferable to be able to conduct the inspection on-line in the production process, at production speeds, so that defects could be rapidly identified and communicated to production personnel and/or the sheets with the defects could be readily and quickly separated from sheets meeting quality specifications in an effective manner. Methods have been developed for the inspection of sheets of glass using optical techniques. However, such methods have been limited in application, often only capable of identifying a small number of types of defects, and not capable of detecting and identifying the type, magnitude and location of a wide variety of defects. Apparatus and a method have now been found that is particularly intended for use in inspection of sheets of glass in a production line, at production speeds, in a manner that shows the magnitude, type and location of the defects in the sheet of glass, and especially intended to be an integral part of a glass processing system. Accordingly, one aspect of the present invention provides an inspection system for a sheet of glass, comprising: a) a first laser and a second laser, each of the first laser and second laser providing a sheet of light; b) a cylindrical lens system, said lens system having a focal point on the main optical axis thereof; c) a first light detection system and a second light detection system; the first laser being located at the focal point of the lens system, the second laser being located at a distance from the lens system that is greater than that of the first laser, said second laser being located off of the axis of the lens system, the first light detection system receiving light from the first laser and the second light detection system receiving light from the second laser, and providing information on the variation in intensity of light; the inspection system being adapted to position and detect a sheet of glass between the lens system and the detection systems. In preferred embodiments of the apparatus of the present invention, the system additionally comprises software that utilizes information from the first and second light detection systems to determine the location, type and magnitude of defects in the sheet of glass. In a further embodiment, the system additionally has means to record the location, type and magnitude of defects in the sheets of glass, optionally including a display or a defect map, especially a defect map displayed on a screen. In a preferred embodiment, there are at least two first lasers and at least two second lasers, preferably with at least two cylindrical lens systems, a first light detection system and a second light detection system, wherein each of the first lasers is located at the focal point of a lens system and each of the second lasers is located at a distance from the lens system that is greater than that of the first lasers, said second lasers being located off of the axis of the lens system on opposed sides of said axis, the lasers being positioned such that light from both of the first lasers is detected by the first light detection system and light from both of the second lasers is detected by the second light detection system. Another aspect of the present invention provides an inspection system for a sheet of glass, comprising: a) a source of light to provide bright field illumination and means to detect said bright field illumination and variations therein; and b) a source of light to provide dark field illumination and means to detect the dark field illumination and variations therein. A further aspect of the present invention provides a method for inspection of a sheet of glass, comprising: a) providing bright field illumination of a sheet of glass and detecting said bright field illumination thus obtained; b) providing dark illumination of a sheet of glass and detecting said dark field illumination thus obtained; and c) analyzing said bright field and dark field illumination for presence of defects in said sheet of glass. In a preferred embodiment of the method of the invention, the illumination is analyzed using computer software. In another embodiment, the inspection system is tuned to detect defects having a size of greater than 100 microns, but not recognize smaller defects e.g. dust. An additional aspect of the invention provides a method for inspection of a sheet of glass for defects therein, in apparatus comprising: a) a first laser and a second laser, each of the first laser and second laser providing a sheet of light; b) a cylindrical lens system, said lens system having a focal point on the main optical axis thereof; c) a first light detection system and a second light detection system; passing light from the first laser located at the focal point of the lens system and from the second laser located at a distance from the lens system that is greater than that of the first laser through said lens system, said second laser being located off of the axis of the lens system, the light from the first laser being collimated light, passing said light through a sheet of glass to be inspected; and detecting light from the first laser with the first light detection system and variations therein; and detecting light from the second laser with the second light detection system and variations therein. The present invention is illustrated by the embodiments shown in the drawings, in which: Fig. 1 is a schematic representation of glass inspection apparatus of the present invention; Fig. 2 is a schematic representation of a side view of the light system; Fig. 3 is a schematic representation of an end view of a light system showing use of dual bright field and dark field lasers; and Fig. 4 is a schematic representation of inspection of a sheet of glass with defects, and spectra obtained. Techniques for the manufacture of glass are known. For example, glass may be converted to a molten state and then cast onto molten tin metal so that glass with a smooth surface may be obtained. Nonetheless, the glass that has been cast may be subject to a number of defects, including the presence of bubbles, dirt, stones, tin-drip distortion and other defects. Some such defects might arise from raw materials fed to the process while other defects will arise from processing problems, including incorrect temperature or other process parameters and aging of apparatus, especially of kilns or other apparatus used in the heating of the glass. Subsequent to the casting of the glass, the glass is cut into sheets and then transferred to a manufacturer of glass articles for a particular end-use. In the automobile industry, for instance, the glass articles could be the windows of the vehicle, in which event the manufacturer will shape the glass to a particular size and configuration, prepare ground edges to the glass, cut holes in the glass in locations as required, imprint logos or other writing in the glass and otherwise process the cut glass to a predetermined set of specifications. Despite care in operation of the process, the various steps can result in the formation of chips, cracks, scratches, and other defects that might render the glass unacceptable to a customer. The manufacturer must be able to detect the defects, and separate sheets of glass conforming to specification from those that do not. Examples of some of the defects that may be present in a sheet of glass that is being prepared for use in, for instance, the automobile industry, include bubbles i.e. inclusion of gas in the glass in a generally spherical shape, blisters i.e. elongated bubbles, seeds i.e. minute bubbles, dirt, lint, shell chips i.e. small pieces of glass broken away from the main body of the glass, stones, strands i.e. very fine, string-like pieces of foreign matter embedded in the glass or laminates thereof, vents i.e. small cracks usually appearing at the corners of cut glass, pits or digs i.e. small hollows and other defects. While the glass is generally described herein as a sheet of glass, it is to be understood that in many instances the glass is in the form of a laminated or tempered glass or other glass, to give it strength, shatter resistance or other properties. The processes used to form such glass may add to the potential defects in the sheet of glass. Fig. 1 shows a glass inspection system, generally indicated by 1. As illustrated in Fig. 1 , glass inspection system 1 is located between entry conveyor 2 and exit conveyer 4, both of which would normally be part of the production line in a plant for production of glass sheet. The glass inspection system 1 has an inspection conveyor 3 that is formed in two parts, having sections 3A and 3B, each of which is of a size to support and transport a piece of glass to be inspected, as discussed herein. Inspection conveyor 3 is located within housing 5, which has housing entrance 6 and housing exit 7. Pieces of glass to be inspected travel along entry conveyor 2 onto inspection conveyer 3A, through the inspection system onto inspection conveyor 3B and then onto exit conveyor 4. Entry conveyor 2 and exit conveyer 4 are shown as outside housing 5, but could extend into housing 5. Housing 5 consists of two separate parts, upper housing 5A and lower housing 5B. Housing 5 encloses the glass inspection system. Within upper housing 5A are lasers 8B and 8D. Each of laser 8B and 8D has a laser line generator associated therewith, and preferably provided as an integral part of the source of laser light. In particular, the laser and laser line generator are a sealed unit, and such sealed units are commercially available. Laser 8B provides by means of the laser line generator, a diverging sheet of light, typically with a fan angle of 45° and adjusted to project a line approximately 100 μm in thickness and 450 mm in width. The sheets of light are first laser beam 9 and second laser beam 10. First laser beam 9 is converted to a collimated sheet of light at cylindrical lens system 11. The collimated sheet of light is obtained by placing the laser source, including the laser line generator, at the focal point of the cylindrical lens system 11. It is understood that the focal point is on the main optical axis of the lens. The collimated sheet of light of first laser beam 9 provides the bright field illumination discussed herein. The laser line generator of laser 8D is located further from the lens than laser 8B and off the main optical axis of the lens. Location of the laser line generator of laser 8D further away from the lens 11 than the focal point of lens 11 results in the light of second laser beam 10 not being collimated light, and it is intended to be focused at the second light detection system e.g. the second camera described herein. Second laser beam 10 provides the dark field illumination described herein. Inspection conveyor 3 is shown in two parts viz. 3A and 3B, and should be in at least two parts, with light window 17 located therebetween so that the laser beams may pass from the source to the detection system. Light window 17 is typically 6-10 inches in width. Each of conveyors 3A and 3B is preferably a rubber conveyor, with each being of a size to fully accommodate the sheet of glass to be inspected, and operated to provide smooth passage of the glass through the lasers. In particular, the length and width of the conveyors is customized to the particular use of the inspection system. It is important with respect to obtaining high quality images of defects that such smooth passage be provided. Thus, it is preferred that a single servo motor drive both conveyors, and that the speed of the conveyors be matched to the speed of the plant conveyors, to eliminate as much as is practical the risk of scratching of glass between conveyors. The conveyors should have an independent electrical circuit, so that the conveyors will continue to operate in the unlikely event of electrical failure in the inspection system. First laser beam 9 passes through light window 17, at which the sheet of glass would be located during inspection, and is reflected at first mirror 13 to be detected by first camera 15. In practice, the mirror 13 is provided to fold light beam 9 so that the detector may be conveniently located e.g. at 15A, although other arrangements could be used. Similarly, second laser beam 10 passes through light window 17 and is reflected at second folding mirror 14 to be detected at second camera 16. First camera 15 and second camera 16 are connected to computer systems having suitable software for analysis of the first laser beam 9 and second laser beam 10, and for computation of the visual quality of the sheet of glass. In particular, the software is used to compute the type, magnitude and location of defects in the sheet of glass, using information obtained from the cameras. It is to be understood that the cameras do not merely record an average light intensity, but rather record detail provided in the light received in the cameras and the variation therein. Fig. 2 shows a side view of the optical system. First laser 20 and a second laser 21 each provide sheets of light, as described herein. First laser light source 20 produces a light that is referred to herein as the bright field illumination, 24. Similarly, second laser 21 produces a beam of light known as the dark field illumination, 22. The bright field illumination is shown as passing perpendicularly toward the location of the glass sheet, whereas the dark field laser is shown as being disposed at a small angle e.g. 4°, to prevent parasitic reflections of laser light. Both dark field illumination 22 and the bright field illumination 24 pass through the cylindrical lens system, shown as lenses 25 and 26. Bright field laser (first laser) 20 is located at the focal point of the lens system viz. lenses 25 and 26, and consequently on the main optical axis of the lens system, with the result that the bright field illumination subsequent to the lens system is collimated. Dark field laser (second laser) 21 is located further away from the lens system than bright field laser 20, and off the main optical axis of the lens system. After passing through the glass sheet, the laser light of the bright field illumination is projected onto ground glass screen 27A and then directed towards the camera by the fresnel lens 27B. Assembly lens 27 has the ground glass screen 27A on the upper face, as viewed, and the fresnel lens 27B on the lower face. The focal length of the fresnel lens is approximately equal to the distance between the camera and the ground glass screen. Dark field illumination 22 by-passes ground glass/fresnel lens 27 and is reflected at second reflector 29 to second camera 31. Folding mirrors 28 and 29 may be used to enable positioning of cameras30 and 31 in more accessible locations 30A and 31A. Fig. 3 shows an end view of the light system described with respect to Fig 2, but showing the use of two bright field lasers and two dark field lasers, to provide for inspection of a wide sheet of glass. Two bright field lasers, 20A and 20B, provide a sheet of light 24A and 24B, shown in solid lines for clarity. The sheets of light are passed through a dual lens system having sections 25A/25B and 26A/26B. It is understood that sections 25A and 25B are aligned with polished and bonded common faces so that there is minimal interference to the quality of the laser light resulting from the bonding of the sections. Sections 26A and 26B are similarly bonded. The light sheets 24A and 24B passing from the lens system 25/26 is collimated. Such light passes through the glass sheet 23 to ground glass/fresnel lens 27, and to the light detection system, being camera 30. Camera 30 is focused on the surface of the ground glass screen 27. The dark field lasers 21 A and 21 B provide sheets of light 22A and 22B. These sheets of light are pressed through the same lens system as the sheets of light from the bright field lasers 20A and 20B. However, as lasers 21 A and 21 B are not at the focal point of the lens system, the light is not collimated. The lasers are also located off the axis of the lens system. After passing through the sheet of glass 23, the dark field illumination passes to the light detection system of camera 31. The converging sheet of light is focused in the centre of the objective lens of camera 31. The laser light is blocked with a spatial filter, which is in the form of an opaque dot attached to the centre of the objective lens. Fig. 4 shows a laser 40 having a lens 41. A sheet of glass 42 having defects is located in light beam 44. Light intensity variation 45 is produced in the collimated light beam 44 after it is passed through sheet 42. The defects represented in the sheet of glass 42 are, from the left, intended to represent a ground edge, a cold glass inclusion, a bubble, a surface contamination and broken glass. The light intensity variation, 45, correspondingly shows the ground edge of the glass, A, the cold glass inclusion, B, the bubble C, the surface contamination D and broken edge E. As discussed herein, defects tend to exhibit characteristic signatures indicating type and size of the defect. The light intensity variation also shows the edge of the sheet of glass, and will indicate the shape and other characteristics of the edge. The present invention provides a glass inspection system that is capable of automation, and which utilizes laser optics and a computer vision- based system. The system utilizes a combination of laser illumination techniques using a structured light system that includes bright and dark field illumination, as well as high-resolution photodiode CCD (charge coupled device). In preferred embodiments of the invention, the combination provides an advanced image analysis with exceptional inspection accuracy e.g. between 10 μm and 100 μm, as well as the capability to detect and differentiate a wide variety of defects including scratches, bubbles, chips, blemishes and other defects, and identifies the location, type and magnitude of the defects on the glass. The system is capable of being operated at high- speeds e.g. at lines speeds of up to 0.3 m/sec, or higher. Thus, the inspection system may be used in-line in many manufacturing processes. The software used in the system may be featured with a menu-based graphical user interface for ease of use, pass/fail specification changes and new model set ups, as well as automatic change over and calibration of the system. In a preferred embodiment, a standard user interface screen with a defect map is used, having coloured icons that represent various types of defects. For examples, circles may be used to represent bubbles, squares to represent chips, triangles to represent scratches and so on. The icons may be made to appear at the actual x,y co-ordinates where the defects are located in the sheet of glass. In addition, the icons may be coloured coded to represent the size of the defects e.g. the icons could be green to represent a very small defect, yellow to represent a medium defect and red to represent a large defect or reject. Moreover, software may be provided where the user can "click" on any icon to provide characteristics of the defect, including type, size and location. 3-D visualization and mapping of the defects is also possible. Removable surface contaminants such as dust and water, may or may not be not detected by the system, depending on the particular application of the system. It is to be understood that electronic hardware would be interfaced with the detection system. This hardware would provide for control of the detection system, collection of pixel data from the collection system, compression of the data by relaying for further processing only data that is related to areas of interest in the glass sheet, and for pre-processing of pixel data by applying multi-level thresholds and marking transitions between different levels of intensities. A dedicated Digital Signal Processor (DSP) may be used to further process the data by means of software. The processed data may then be transmitted to a gauge host computer for the purpose of visualization and control, as discussed herein. The detection system may be set to recognize a threshold of illumination that indicates the presence of glass. A further threshold may be recognized for defects that prevent the passage of light e.g. permit less light to pass through than normally would occur for a piece of glass. In addition, a third upper threshold may be recognized, which corresponds to the presence of the edge effects of bubbles, as discussed herein. The upper and lower thresholds may be set at levels that represent defects that are unacceptable in glass, but not recognize defects that would pass specification. The method may conveniently be operated to recognize transactions through any of these thresholds, and to recognize those that represent defects that are unacceptable. All other information e.g. noise or changes in light intensity that do not cause the light intensity to pass through a threshold could be ignored. The transitions that pass through the threshold may be presented on a computer display tube. The combination of the ground glass/fresnel lens and camera, as described herein, may be replaced with other systems for recording light e.g. a photodiode array of the size of the image plane, with the diode spacing being less than e.g. 100 μm. Many defects produce characteristic spectra in the light that is detected. For instance, a bubble tends to produce a dark central region but outer halo effects that often are shaped in the form of opposed crescents. A solid particle on a surface tends to produce a darkened region, whereas a defect resulting from a cold particle of glass in the molten glass that is cast tends to produce a central light spot with two areas on the edges that are of diminished brightness. In many instances, the particular defect particle may be smaller than a pixel in the camera used to detect the light, but the resultant edge effects may produce an image that is detectable and recognizable. A sheet of glass cut for a particular end-use, for example the window on the side of an automobile, may be of a complicated shape and may additionally have holes therein that are used in movement of the window. The method of the present invention can confirm the exact location of the holes and the particular shape of the piece of glass. Moreover, such glass is normally ground to remove the sharp edges, and this produces a characteristic edge pattern. In the event that the grinding wheels used to grind the edges of the glass are not aligned or of poor quality, characteristic patterns deviating from the normal pattern may be formed, which may be recognized and identify process problems. In addition, the grinding may produce chips along the edges of the section that has been ground or small cracks known as vents, which typically appear in the corners of the ground glass sheet. Logos or other writings on the glass may be identified, and the integrity can be confirmed. Many automobile windows have heating and/or antenna strips located within the glass, and the method of the present invention may be used to detect broken sections of the heating or antenna strips. Bright field illumination typically does not detect scratches or dust particles, which are typically of less than 10 microns in size i.e. below the pixel resolution, and normally will not detect lint or hair both of which tend to have point contact on the glass and hence are of small size. Dark field illumination is used to detect scratches. The position of the glass within the apparatus is not important, provided that it is located within the width of the laser beam. Moreover, the method of the present invention is capable of being used with curved glass, as the light passes straight through such glass. Computer software may be used to more precisely show the location of defects in curved glass. Some sections of the apparatus, particularly the laser and lens system, may be sealed units to prevent the presence of dust. However, other sections of the apparatus are susceptible to the presence of dust. For this reason, the apparatus is operated with an air pressure slightly above atmospheric pressure so that there is a gentle flow of air outwards from the apparatus, to prevent dust particles being brought into the apparatus. In addition, the air circulated within the apparatus is passed through at least one HEPA filter, as well as electronic filters, with the air being exchanged frequently e.g. every five minutes. Time delayed integration techniques may be used in the detection and analysis of the images that are formed and detected. The present invention has been particularly described with reference to one laser being used for bright field illumination and one laser being used for dark field illumination. The use of dark field illumination is an important aspect of the present invention, in that it is particularly useful for detection of scratches on the glass. Scratches are normally not seen under bright field illumination. In detection of dark field illumination, it is preferred that the focused light on the camera have a light stop i.e. a spatial filter, to prevent the passage of light at the most intense part of the light beam that is focused on the camera. Such light is not required for detection of scratches, and moreover would swamp the variations of light that would reflect the presence of scratches. The laser system may be capable of being used with glass up to about 250 mm in width. However in many instances, samples of glass of wider widths e.g. up to 450 mm in width may need to be inspected. In this event, two lasers may be used in conjunction to provide a broader bright field illumination. This may be achieved through use of a dual lens system or a multi-lens system, aligned and typically bonded together so that edge effects where the lens are bonded are minimal, or most preferably in which the dual or multi-lenses are disposed in a manner similar to tiles overlapping at their edges, to provide a lens system of a required width, with software being used to compensate for overlap of lenses. Similarly, two lasers are used for dark field illumination and typically located on opposed sides of the two lasers used for bright field illumination so that the dark field illumination may be focused to a single light detection system. The use of a single light detection system for both bright field illumination and dark field illumination simplifies analysis of the results. It is understood that further lasers could be added, if necessary. It is believed that interference patterns maybe used to indicate the presence of distortions and other irregularities in the flatness of the sheet of glass. The present invention provides a versatile apparatus and method for inspection of glass, and which is capable of simultaneously identifying a wide variety of defects by type, magnitude and location, in a manner that not only permits identification of glass that does not meet product specification but also assists in identifying the causes of the defects.

Claims: CLAIMS: 1. An inspection system for a sheet of glass, comprising: a) a first laser and a second laser, each of the first laser and second laser providing a sheet of light; b) a cylindrical lens system, said lens system having a focal point on the main optical axis thereof; c) a first light detection system and a second light detection system; the first laser being located at the focal point of the lens system, the second laser being located at a distance from the lens system that is greater than that of the first laser, said second laser being located off of the axis of the lens system and focused at the second detection system, said second detection system having a spatial filter, the first light detection system receiving light from the first laser and the second light detection system receiving light from the second laser; the inspection system being adapted to position a sheet of glass between the lens system and the detection systems. 2. The inspection system of Claim 1 in which the first light detection system has a semi-transparent screen and a fresnel lens, and a camera focused on the surface of the screen, and in which the second light detection system comprises a camera with a spatial filter. 3. The inspection system of Claim 1 or Claim 2 in which the system additionally comprises software to determine the location, type and magnitude of defects in the sheet of glass. 4. The inspection system of Claim 3 in which the system additionally has means to record the location, type and magnitude of defects in the sheets of glass, optionally including a display or a defect map, especially a defect map displayed on a screen. 5. The inspection system of Claim 1 in which there are at least two cylindrical lens systems, at least two first lasers and at least two second lasers, a first light detection system and a second light detection system, wherein each of the first lasers is located at the focal point of a lens system and each of the second lasers being located at a distance from the lens system that is greater than that of the first lasers, said second lasers being located off of the axis of the lens system on opposed sides of said axis, the lasers being positioned such that light from both of the first lasers is detected by the first light detection system and light from both of the second lasers is detected by the second light detection system. 6. An inspection system for a sheet of glass, comprising: a) a source of light to provide bright field illumination and means to detect said bright field illumination; and b) a source of light to provide dark field illumination and means to detect the dark field illumination. 7. A method for inspection of a sheet of glass, comprising: a) providing bright field illumination of a sheet of glass and detecting said bright field illumination thus obtained; b) providing dark illumination of a sheet of glass and detecting said dark field illumination thus obtained; and c) analyzing said bright field and dark field illumination for presence of defects in said sheet of glass. 8. The method of Claim 7 in which the illumination is analyzed using computer software. 9. The method of Claim 7 in which defects having a size of greater than 100 microns are detected. 10. A method for inspection of a sheet of glass for defects therein, in apparatus comprising: a) a first laser and a second laser, each of the first laser and second laser providing a sheet of light; b) a cylindrical lens system, said lens system having a focal point on the main optical axis thereof; c) a first light detection system and a second light detection system; passing light from the first laser located at the focal point of the lens system and from the second laser located at a distance from the lens system that is greater than that of the first laser through said lens system, said second laser being located off of the axis of the lens system, the light from the first laser being collimated light, passing said light through a sheet of glass to be inspected; and detecting light from the first laser with the first light detection system; and detecting light from the second laser with the second light detection system.

Inventors: OBOTNINE ALEXANDRE, WEISS ADAM, OBOTNINE, ALEXANDRE, WEISS, ADAM
Applicants: IMAGE PROCESSING SYSTEMS INC, IMAGE PROCESSING SYSTEMS INC.
Application year: 1999
Main classification: G01N21
IPC codes: G01B11, G01N21