Automated Optical Inspection for Gypsum Board Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inspection methods for complex patterns on large-size building boards, such as gypsum boards, are inefficient and fail to detect irregularities, leading to defective products being overlooked in final products.
Innovation Solution
An inspection method and apparatus that uses image processing to capture and analyze patterns on gypsum boards, employing edge detection, pattern clarification, and defect determination, with uniform illumination to enhance inspection accuracy and efficiency, regardless of pattern type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by workers is used, then inspection cost is low, but inspection accuracy and efficiency deteriorate due to laborious work and inability to detect defects in complex patterns
Solution Approach 1:
The patent replaces the mechanical visual inspection system performed by workers with an automated optical inspection system using imaging devices and image processing. The system captures images of the inspection object surface and automatically analyzes them to detect defects, eliminating the need for manual visual inspection and enabling high-accuracy detection even in complex patterns.
Solution Approach 2:
The patent introduces image processing as an intermediary between the inspection object and the detection system. By capturing images and processing them through algorithms that analyze luminance values and pattern recognition, the system mediates the detection process to identify defects that would be difficult for human workers to distinguish from complex patterns.
2Measurement precision
If machine inspection with image processing is implemented, then inspection accuracy improves for complex patterns, but device complexity increases
Solution Approach 1:
The patent designs an inspection system that can handle multiple types of patterns and inspection objects using a unified approach. The image processing algorithm performs luminance value analysis and pattern recognition that works across different pattern types, making the system versatile and reducing the need for multiple specialized devices for different inspection scenarios.
3Adaptability or versatility
If workers visually inspect processed product surfaces, then flexibility in handling various shapes is maintained, but inspection time increases and defects remain undetected
Solution Approach 1:
The patent replaces manual visual inspection with automated image capture and processing systems that can rapidly analyze various shapes and patterns. The imaging devices capture surfaces regardless of their geometry, and the image processing algorithms automatically adapt to different shapes, eliminating the time-consuming nature of manual inspection while maintaining versatility.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An inspection method for inspecting a board-shaped inspection object with a pattern includes an imaging step of capturing an original image of an inspection surface of the inspection object, a digitization step of generating an image with two or three gradation levels by digitizing the original image captured by the imaging step using a threshold, and a determination step of inspecting the inspection object using the image generated by the digitization step.