Surface Inspection System SUPERSCAN

The demand for the inspection of panel surfaces has increased due to the ever increasing production speeds and new process technologies. More and more is expected of humans as monitoring bodies. With laminate flooring being delivered almost directly to the end-user, hidden defects can lead to catastrophic consequences.

Through the use of up-to-date image processing systems and completely new technology, it is very easy to monitor many different patterns with the GreCon Surface Inspection System SUPERSCAN. Typical surface inspection systems can barely differentiate between minor gradations of shades in the pattern, such as knots, and actual defects. This problem is eliminated with the newly developed system by GreCon.

The SUPERSCAN system inspects each panel in the running production to ensure consistent sorting. Furthermore, fault and statistical reports allow adjustments to upstream production processes. Both the sorting and the entire production process can be optimized.

Technology

Each panel is inspected by a camera system that is installed above the material flow. Defective areas are detected where the surface pattern differs from the normal (perfect) pattern. Each defective area is classified (characterized) in light and dark defects. The operator can easily change the parameters and sorting criteria.

The GreCon system is self-learning. It can distinguish between new patterns and known patterns. For known patterns, the stored image data is simply called up from a database at the beginning of a new order; the system is immediately operational. For new patterns, two successive panels are compared. If the deviations are smaller than the preset tolerance limits, these panels are used as samples. All following panels will then be compared with the new pattern. This procedure is very easy and takes only a few minutes so that the machine can be trained to any kind of pattern in a short time period.

Defects on the top surface of each panel are determined and can be represented on the monitor if desired. The quality is determined by evaluating the data, such as defect type, size and position.

O-Frame

The skeletal structure of the SuperScan Surface Inspection System is the O-frame which is made out of extruded anodised aluminium. A swivelling lighting beam is suspended in a solid quadruped construction. The patented profile of the frame integrates all connection lines as well as the pneumatic of the measuring system.

Lighting Beam

The lighting beam is integrated in the frame. To obtain the best measuring results, constant and intensive lighting is essential. To achieve this, fluorescent tubes are installed just above the material to be measured. To adapt the distance between the measured material and the lighting beam to the changing material thicknesses, the system is equipped with automatic height adjustment.

Escape Run

If the height of the measured material exceeds the passage height underneath the lighting beam - due to a blister in the product, for example -, the lighting gear is swung out in the production direction. The advantage is a short reaction time. After the passage of the higher panel section, the lighting beam is lowered again to the initial position.

Camera System

High-resolution line-scan cameras are used which are installed at the frame above the material to be measured and scan the material through a precisely defined slot in the lighting beam. Depending on the width of the measured material, up to three cameras are used. For a standard width of 2.070 mm, two cameras are required.

Ink Marking System

As an option, GreCon offer an ink spray system to mark defective panels. For applications in the production of laminate floorings, the master panel is marked by 10 spray nozzles, distributed over the width of the panel, determining the later cuts to be made by the cut-off saw. Each spray nozzle is followed by a sensor which monitors the function of the nozzle. After the cut-off saw, the laminate flooring parts marked as defective are sorted out by the detection unit.

Software

The software is the interface between the operator and the measuring system. Meaningful graphics and a logical, intelligible processing of the data are of utmost importance. GreCon realise this importance and deliver a user-friendly visualisation software for the measuring system.