Automated Panel Surface Pattern Deviation Detection
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Solution Overview
Problem
Current methods for assessing the visual quality of decorative flooring, wall, or ceiling panels are inaccurate and unreliable due to human variability and metamerism issues, leading to inconsistent panel quality and batch uniformity.
Innovation Solution
A method and system that capture images of the panel's top surface using an image capturing device, compare them to standard pattern values stored in a database, and calculate pattern deviation values, eliminating human error and accounting for metamerism by simulating different lighting conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If handheld colorimeter is used to measure panel colour, then measurement time is short, but measurement area is limited and results are highly dependent on location
Solution Approach 1:
The panel surface is divided into multiple measurement locations, and colour measurements are taken at each location. The individual measurements are then aggregated to determine overall panel colour characteristics, ensuring comprehensive coverage rather than relying on a single point measurement.
Solution Approach 2:
The system is designed to measure multiple parameters (colour values, pattern uniformity, batch consistency) using the same imaging system, making it a universal measurement tool that replaces multiple specialized devices including handheld colorimeters.
2Area of stationary object
If visual inspection by naked eye is used, then entire top surface can be measured, but measurement results vary between personnel and lack stable threshold values
Solution Approach 1:
The human visual inspection system is replaced with an automated digital imaging and image processing system. The processor objectively analyzes colour values and pattern uniformity according to predefined criteria, eliminating human variability and providing consistent, repeatable measurements across different operators and time periods.
Solution Approach 2:
The system transforms subjective visual assessment into objective numerical parameters including colour values, pattern deviation metrics, and uniformity scores. These quantifiable parameters enable precise threshold setting and automated quality decisions, replacing the ambiguous nature of human visual judgment.
3Productivity
If production speed is increased to reduce operating costs, then productivity improves, but panel quality uniformity deteriorates
Solution Approach 1:
The system provides real-time feedback on panel colour and pattern quality during production. By continuously monitoring and comparing measurements against target values, the system enables immediate adjustments to production parameters, maintaining quality consistency even as production speed increases.
Solution Approach 2:
The system establishes predefined quality thresholds and acceptance criteria before production begins. Standard pattern values and colour tolerances are set in advance, allowing automated comparison and quick quality decisions during high-speed production without compromising quality control.
Data Source
AI summary
The invention relates to a method and system for determining a pattern deviation value of a top surface of a panel, in particular a top surface of a floor panel or wall panel. The method and system enable the calculation of a pattern deviation value based upon a determined pattern value and the at least one selected standard pattern value.