Automated Visual Inspection System for Specifying Brick Quality

2010

Intelligent system for automated visual quality control of ceramic tiles based on machine vision is presented in this paper. The ceramic tiles production process is almost fully and well automated in almost all production stages with exception of quality control stage at the end. The ceramic tiles quality is checked by using visual quality control principles where main goal is to successfully replace man as part of production chain with an automated machine vision system to increase production yield and decrease the production costs. The quality of ceramic tiles depends on dimensions and surface features. Presented automated machine vision system analyzes those geometric and surface features and decides about tile quality by utilizing neural network classifier. Refined methods for geometric and surface features extraction are presented also. The efficiency of processing algorithms and the usage of neural networks classifier as a substitution for human visual quality control are conf...

International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2022

The goal of this paper is to propose an automatic system to assert the dimensional (length) accuracy of a product and the rejection of the defective products. Use of IR sensor is used to cause detection of object. after arrival of project then the motor starts running and as well as start conveyor belt. A laser is used which cuts the product and hence the system knows when the product would pass through the camera. The camera then clicks the image of each product and then compares with the image of the product with the actual dimensions. In this way a defective product can be easily identified after which it is removed from the production line with the help of a pneumatic cylinder.

Jurnal Sistem dan Manajemen Industri, 2023

Customer demands for product quality are increasingly complex, requiring better inspection accuracy. It is not enough if done manually because it requires high costs and varying operator accuracy. Automatic vision inspection was developed to check the product quality of terminal-type electronic components To solve this problem. Design intelligent inspection uses a conveyor driven by a stepper motor, a photosensor to calculate product distance, guides position to direct the product, a vision camera to detect product quality, cylinder ejection for product selection, and PLC as a control system. The process of detecting normal and abnormal product quality is carried out using computer logic control, then separating the abnormal product into the reject box through the ejection cylinder. The machine speed is 60 pieces/minute. The system evaluation results are carried out on three parts of the system: the success rate on the vision camera is 100%, automatic product sorting through the cylinder ejection rate success is 100%, and the success rate for product positioning is 97.5%. This research provides a useful reference for developing intelligent automatic inspection technology in electronic components.

The purpose of this project is to identify the external defects of the products which are manufactured in an industry and to eliminate such products form the final products to assure the quality of the final products. Currently there are many technologies regarding these kinds of quality assurance systems. Nowadays Image processing based Quality assurance systems are one of most popular technology because it reduces the errors made by human workforce and also reduces the workload on human quality checkers. Main task of this project is identifying the defective objects which arrive through conveyer lines by using a specialized camera which is controlled by the PC using the software MATLAB for processing the images which is very user friendly. This system can have a very cheap camera In the system if the light conditions of the factory is perfect or cameras which adjusts according to the light can be used and controlled easily using the PC interface. The data of the analyzed images are transferred through serial communication to the PLC and Robotic arms will be used to eliminate the identified defective objects from the conveyer line. This kind of a system is very less in cost comparing to the other Image processing quality control systems which are used in Industries. Especially the project will be made for smaller industries in countries such as Sri Lanka. This technology involved some Image processing techniques, Data transmission techniques and PLC programming techniques. The Automation Studio software will be used to validate the actual PLC ladder program design and MATLAB software will be used for Image processing. Furthermore details are provided in the document regarding the topic.

The ceramic tiles manufacturing process has now been completely automated with the exception of the final stage of production concerned with visual inspection. In this paper we describe an integrated system developed for the detection of defects on colour ceramic tiles and for the colour grading of defect-free tiles. The results suggest that the performance is adequate to provide a basis for a viable commercial visual inspection system. 1 INTRODUCTION The ceramic tiles industrial sector has taken significant advantage of the advances in the world of automation in recent years. All production phases have been addressed through various technical innovations, with the exception of the final stage of the manufacturing process, namely the product inspection. This is still performed manually and is concerned with the sorting of tiles into distinct categories or the rejection of the tiles found with defects and pattern faults. In this paper we describe the integrated system developed under...

Automation in Construction, 2012

Several areas of the quality inspection on architectural works only use subjective visual inspection, especially those involving aesthetic faults. Because people are limited in what they can detect visually, inspectors are not able to quantify the value of a defect and cannot perform an inspection that includes all possible defects. Subjective evaluations depend on individual experience and are unreliable because they do not have objective standards. Therefore, this paper presents an innovative system of defect detection and quantification. The system is able to augment subjective visual quality inspections in architectural work by specifying defect positions and quantifying defect values. This method uses defect feature analysis and quantifies the defect value from digital images using a digital image processing technique. The inspection of tiling work was chosen as a case study for developing a prototype of the system. This paper describes the conceptual framework of the proposed system's application and the methodology of the system's development. It includes a field verification of the potential and accuracy of developed prototype system by comparing the results of human inspections and those of the proposed system. A potential benefit of the system is an increase in the reliability of visual quality inspection by reducing the subjective human judgment of aesthetic faults.

MATEC Web of Conferences, 2018

Measurement of surface roughness is one of the quality control processes, usually carried out off line. Contact type surface roughness measurement method is commonly used in quality control. The processes consume lot of time with human interaction. In order to reduce or to eliminate non value added time, effective quality inspection tool and automation of the processes has to be utilized. An attempt has been made to automate the process with integration of vision camera in capturing the image of the component surface. The image process technique has the advantage of analyzing the single captured image for multiple area measurement. Hence, the in-line quality control of each component surface roughness measurement is ensured. The automation process involves component movement, image capturing, image processing, and decision making, using sensors, actuators and microcontroller. The proposed in-line quality control of surface roughness with vision system has been successfully developed. The designed automated system has fulfilled the objectives in respect of the scope of the present work.

UNITECH, 2023

Mass production is done with industrial machines. During manufacturing, the parts undergo various processes to give them their final shape. In machining, the processing of the part is inspected at the final stage. In this study, a visual inspection system has been designed to determine the quality of the part at the final stage of processing. The semi-finished cylindrical parts are processed on the rotating round magazine in the current production system. The six-step round magazine has four processing stops which are take-in, centering, drilling, and take-out the parts consecutively. The developed visual inspection system in this study is designed for the last stop of this round magazine. The part images are captured by the camera and the color and diameter of the part and areas of holes on the part are determined. The developed inspection system makes pass or failed decisions for each part by comparing measurements with the specifications of the part. Measurements of all parts are saved to the process database for further analysis. As a result of this study, the developed inspection system is considered suitable and integratable for round magazine process quality control.

Today, computer vision inspection systems are widely used for quality control in order to reduce the costs and to improve the product quality. The glass industry is constantly trying to improve quality by substituting the human control with automated inspection systems but several problems must be solved. In this paper the problem of detecting and measuring the defects of satin glasses is investigated and a real-time system is proposed that is able to analyze the glass surface under inspection, to assess its quality and to characterize its defects. A prototype has been carefully designed and optimized for validating the proposed approach and to reproduce the real issues of quality control. The prototype is composed by several CMOS cameras, a controllable conveyor bend, and an image processing system. Currently the prototype, which is cheap and reliable, is under further development in cooperation with a specialized electronic industry.

Industrial Engineering Journal

With current era of the Automobile industry, the product is manually or visually checked by using check list there is difficulty in inspection due to dependence on human skills and lack of ergonomic applications which cause fatigue. Inspection is one of the primary segments of the industrial parts production process. Machine vision is a present day strategy to inspect produced parts and it is a subcategory of engineering machinery, dealing with issues of information technology, optics, mechanics and industrial automation. Machine vision systems are used increasingly to solve problems of industrial inspection. This paper introduces an automatic vision based defect inspection or detection and dimensional measurement. The system identifies defects (Part Miss, Part Location, Welding Defects and grinding defects etc.) which usually occur in an assembly Structure component. The image processing technique used for Defect detection and algorithms developed for defect detection and linear dimension measurement. Various types of sensors were interfaced with the vision hardware and the part handling mechanism, to complete the total automated vision based inspection system. This system is an accurate, repeatable, fast and cheap solution for industries. This image processing technique is finished utilizing MATLAB programming. This work presents a strategy which decreases the manual work.

In a traditional brick manufacturing process people made brick in small bucket ,relying on relatively inefficient firing method, in this process brick might have few problems i.e. leaves a frog on depression on their top surface. In Automatic brick manufacturing based on PLC SCADA present the fundamental procedures for automatic manufacturing of clay brick. The process for forming of brick, to mixture an essential row material like different type of clay & coal ash, to obtain the desired shape through hydraulic pressure or vibration and then drying, firing and burning. Then to maintain a specific temperature with this process is not reliable. In this project we want to design a brick manufacturing system, which can resolve all the faults facing in an above said traditional method. We are using PLC to design automatic brick manufacturing which covers.

Quality inspection is one of the recurring topics among industrial community. Garnished wall plates may require inspection in terms of geometry (height, width, corner radius ...etc), Drawn Objects Orientation (Angles with respect to reference axis) and colour of drawn objects. Emulation of human decision in classification is what inspection is all about. In this thesis, we implemented a hybrid system of fuzzy logic and fuzzy c-mean clustering for quality inspection of garnished ceramic wall plates. This novel approach is designed to inspect colour, geometry, angles and existence of colour spots. The study is intended to reduce error due to human visual inspection. A developed Flexible Manufacturing Cell (FMC) is responsible for inspection of ceramic plates applying Computer Vision System (CVS) and automation of the cell. The bench marking of the proposed algorithm is considered promising compared to other published peers.

Journal of American …, 2011

Automated Visual Inspection Systems (AVIS) are becoming increasingly popular due to low cost maintenance and high accuracy. Ceramic tile factories, for example, are very much interested in these sorts of systems. This paper introduces a different strategy in ceramic tile inspection system to reveal four major problems, namely, edge curvature, thickness, size measuring and edge crack defects. It is believed that this method will cover edge curvature defects and thickness measuring of ceramic tiles in AVIS with recommending an individual algorithm for each defect based on line feature extraction techniques. In addition, it is assumed that our model makes size measuring and edge defects detection easier and more accurate rather than previous approaches. This proposed model will allow ceramic tile companies to perform quality control inspection without costly measuring tools or error-prone inspection by humans. Moreover, factories have to install and apply Flatness Control Machine (FCM) to measure the flatness curvature of ceramic tiles. This machine keeps the ceramic tiles in fixed position to investigate the upper surface only. But our strategy is independent of a specific position through inspection in various angles from top and side views. We hope that our model, which is prominent in low cost implementation, will enable companies to apply this method in different situations in their manufacturing production line systems. Hence, it will assist them to produce not only more accurate reports on defects but also permit improved manufacturing of quality products.

2016

The development of an algorithm for inspection and quality checking using machine vision was discussed in this paper. The design of the algorithm is to detect the sign of defect when a sample of the product is used for inspection purposes. It is also designed to track specific colour of product and conduct the inspection process. Programming language of python and open source computer vision library were used to design the inspection algorithm based on the algorithm required to achieve the inspection task. Illumination and surrounding environment were considered during the design as it may affect the quality of image acquisitioned by image sensor. Experiment and set-up by using CMOS image sensor were conducted to test the designed algorithm for effectiveness evaluation. The experimental results were obtained and are represented in graphical form for further analysis purposes. Besides, analysis and discussion were made based on the obtained results through the experiments. The design...