Ceramic Tiles Quality Inspection

The ceramic tiles industrial sector is a comparatively young industry that has taken significant gain of the robust development in the world of automation in the past few years. Ceramic tiles are one of the huge areas covered in the industrial sector, when manufacturing crosses through many automati

Project Title

Ceramic Tiles Quality Inspection

Project Area of Specialization

Artificial Intelligence

Project Summary

The ceramic tiles industrial sector is a comparatively young industry that has taken significant gain of the robust development in the world of automation in the past few years. Ceramic tiles are one of the huge areas covered in the industrial sector, when manufacturing crosses through many automation processes. Tiles process through different stages of production with technologies except the final process of detecting the defective products which are still done manually by human vision in many manufacturing industries. Detecting the defects manually takes a lot of human work in enormous industries which also costs much and is time-consuming as well. Humans easily get tired and can sometimes miss minute details. This project will help detect any defect in tile that is broken, cracked, or have holes in it without any mistake. Image processing techniques are used for the development of this project. The outcome of this project is to detect defects in tiles, then indicating any defect signaling red or green light using raspberry pie and mentioning that defect ratio with an inspection report at the end.

Project Objectives

The project will capture image of a tile with help of a camera and match it with the standard image making sure the image position and size is satisfactory and there is no noise present.

This project will give the clearer image so that any defect can be detected and operations can be performed easily.

The main objective is to identify any defect in the tile, which will be identified through displaying red light using raspberry pie which will depend on the ratio of defects in a tile.

Project Ceramic Tiles Quality Inspection will meet the following objectives:

• Transformation of Image
• Image Enhancement
• Defect Detection
• Feedback (Indicating Red or Green Light)

Project Implementation Method

This project provides a solution to detect defects in a tile. It includes any holes, cracks, or dots detected in a tile. We are detecting the defects by using different preprocessing techniques. Image capturing and enhancement can be used to detect the defects in tiles. The ceramic tiles can be captured through a good resolution mobile phone while being moved in the assembly line. The image will be converted to a grayscale as the defects can be detected without the need for color and RBG values which will make the system more efficient.

Image enhancement techniques are used to make the image enhanced and clear without blurred or distorted images. The image contrasts are layer between 0 and 1. As a grayscale image, we can find the intensity levels with a proper adjustment to the span of values.

Defect detection will allow the system to detect defects on the tiles and can detect even minute defects not visible to the human eye by working on the following steps.

The project will first work on the input provided by capturing the image of a tile fitted on the system through the camera and match it with the standard image making sure the image position and size is satisfactory and there is no noise present. It will give a clearer image so that any defect can be detected and operations can be performed easily. This input then will compared with the standard image of a tile defined in the system already.

Secondly, input of that image will proceed into the processing stage, in which the input is being processed using translation, scaling, and rotation.

Translation: Moves the image to the standard size image

Scaling: Normalizing the image with the standard image

Rotation: Rotating the imaging clockwise or anticlockwise by standard image size

The next step is the enhancement of input using multiple techniques like alpha enhancement technique and RBG values study through histogram.

Inspection of defect will be carried out by subtracting the image with the standard image and detecting any unusual pattern on the image inspection. The ratio of the defect will depend on the threshold set for detect, if the ratio of a defect in tile is more than 20% then the system will show a red light using raspberry pie else it will indicate green light. The system will show the details of the defect and the rate of defect.

Benefits of the Project

the most important benifit is quality assured tiles manufactured by the factoy. As assurance in industries are the most important part that develops customer's trust.

The benefits of this inspection system are:

Time management:

The main problem which occurs in industrial sector doing work manually is time management. Inspecting so many tiles in industry with the help of humans slows down the process which affects the next steps of packaging and sending those products to warehouses to traders. The system will be automated and time will be saved which will help in manufacturing more products.

No Human Error

One of the causes that mostly occur is when a defect is missed by the human eye and that defected product is sent to warehouses to traders who do not pay money for defected products which leads the company to loss. When the system is automated there will be no human error in inspection.

Healthy Environment

In dynamic industries like ceramic tiles where they go through a huge process from atomization, shaping, drying, glazing to fast firing. The need of humans in such an unhealthy and hazardous environment is not necessary which also affects the health of humans. So, this project will help keeping the environment safe and healthy for humans.

Automation

In manufacturing products tiles goes through every process with technical innovations but inspection is done manually which is time-consuming and is inefficient.

Cost effective

Industries require a huge amount of labor work for inspecting purposes which costs a lot to the company and is un-economical as well. Inspection will be more robust and less costly.

Processing Stability

It will increase the processing stability and improved overall production performances through the removal of a major bottleneck.

Technical Details of Final Deliverable

Standardized Image set Module

Image Transformation and Enhancement Model

Tile defect detection Module

Defect Indication Module

The recommended requirements of the hardware where the system is deployed are:
1. At least 4GB of HDD space
2. At least 8GB of RAM.
3. Multicore processor i.e., cores 2 duos are recommended.

Hardware Requirements Analysis:

This section expands on different hardware required, and their role in the project.
1. Raspberry Pi
2. Typical LEDs
3. Smart Phone
4. Outdoor Wireless IP Camera

Raspberry Pi:
Raspberry Pi is a microcomputer which has modest features as a computer. It is most prior
because, in our project, we need to indicate the error with the help of LED lights. LED
lights are being controlled by a Raspberry Pi. A Raspberry must be Wi-Fi enable to work
with our system and to be synchronized with the server. The requirements are listed below:

• SoC: Broadcom BCM2837
• CPU: 4× ARM Cortex-A53, 1.2GHz
• GPU: Broadcom Video Core IV
• RAM: 1GB LPDDR2 (900 MHz)
• Networking: 10/100 Ethernet, 2.4GHz 802.11n wireless
• Bluetooth: Bluetooth 4.1 Classic, Bluetooth Low Energy
• Storage: MicroSD
• Ports: HDMI, 3.5mm analog audio-video jack, 4× USB 2.0, Ethernet,
Camera Serial Interface (CSI), Display Serial Interface (DSI)

Ceramic Tiles Quality Inspection CS Department

 Typical LEDs:
LEDs are required to burn only one color. Minimum Three LEDs are required, Red for a
severe defect, orange/yellow for mild defects, and green LED for no defect indication.
LEDs will be controlled with the help of Raspberry Pi. A power source will also be required
for successful implementation.

 Smart Phone:
As we are detecting the defects, present in a tile, we need to pass the images of the tiles to
our system where all the computation takes place. There are multiple methods to achieve
this process. We can use the Smart to capture the images of the tiles and then pass it to the
system. Both the Android and iPhone can be used to take the images as input.
In an Android phone, the minimum hardware requirements are given as:
• Android OS with minimum Android Marshmallow (6.0)
• Minimum 2GB RAM
• Minimum 2GHz dual processer
• Minimum 8MP Camera, greater resolution is preferred for better results.

In an iPhone, the minimum hardware requirements are given below:

• Operating System with minimum iOS 9
• THE minimum CPU required is Dual-core 1.84 GHz.
• Minimum 2GB RAM
• Minimum 8MP Camera, greater resolution is preferred for better results.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

IT

Other Industries

Manufacturing

Core Technology

Artificial Intelligence(AI)

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com