Ceramic Tile Decoration Line with Real-Time Defect Detection
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Solution Overview
Problem
Current decoration lines lack real-time quality control and automatic defect detection, leading to inefficiencies in ensuring the quality of ceramic tile decoration and potential production of defective products.
Innovation Solution
A decoration line equipped with a conveyor system, piezoelectrically-controlled jet nozzles for enamel application, and a control and diagnostic module featuring a linear CCD camera and adjustable lighting for real-time defect detection, enabling accurate identification and automatic rejection of defective products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional analog decoration devices are used, then the decoration process is simple and reliable, but the quality control and defect detection cannot be performed in real-time
Solution Approach 1:
The patent replaces mechanical/analog decoration devices with digital decoration devices that use piezoelectrically-controlled nozzles for enamel application. This substitution enables integration of digital control systems and vision inspection systems, allowing real-time quality control and defect detection that were not possible with traditional mechanical systems.
Solution Approach 2:
The patent introduces a vision inspection system with linear CCD cameras as an intermediary between the decoration process and quality assessment. This intermediary captures images of the decorated products and enables automated defect detection, bridging the gap between decoration application and quality control without requiring full surface inspection.
2Measurement precision
If full surface inspection is performed to detect defects, then detection accuracy is improved, but inspection time and productivity are reduced
Solution Approach 1:
The patent extracts the critical inspection function to only those areas of the product surface where defects are most likely to occur or are most critical. The vision system uses lighting means positioned to illuminate specific areas and cameras configured to capture only relevant regions, rather than inspecting the entire surface. This extraction maintains defect detection accuracy while significantly reducing inspection time and improving productivity.
3Manufacturing precision
If digital decoration devices with high graphics resolution are used, then the aesthetic quality is improved, but the complexity of control and verification increases
Solution Approach 1:
The patent implements a feedback system where the vision inspection system continuously monitors the decoration process and provides real-time information about defects and quality issues. This feedback loop allows the control system to adjust parameters and verify results without increasing overall system complexity, as the same digital infrastructure is used for both decoration and inspection.
Solution Approach 2:
The patent designs the vision inspection system to perform multiple functions: detecting defects, verifying decoration quality, and providing process control information. By making the inspection system multi-functional, the need for separate verification systems is eliminated, thereby controlling complexity while maintaining high graphics resolution capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time, accurate detection and rejection of defects, improving product quality and operational efficiency by quickly identifying chromatic and structural issues without requiring a full surface check, thus enhancing the decoration process.
Implementation Method 1
heads delivering a jet actuated by piezoelectrically-controlled nozzles
Implementation Method 2
a control and diagnostic module (9) of the decorated products (3), in use, located downstream of the decorating device (5) with respect to the advancement direction (A) of the products (3) on the conveyor (2)
Data Source
Figure 1~3
AI summary
A line for decorating and controlling products (3), in particular ceramic tiles and the like, comprises a conveyor (2) of products (3) to be decorated, at least one decorating device (5) of the jet type actuated by piezoelectric-control nozzles adapted to apply at least one layer of enamel (4) on the products (3) passing on said conveyor (2); the line further comprises at least one control and diagnostic module (9) of the decorated products (3), provided with means (10) for detecting decoration and/or structural defects (15-19) of the products (3) themselves.