Automated Shirt Inspection System Using Image Comparison
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Solution Overview
Problem
Conventional methods for inspecting printed designs on shirts rely on manual visual inspection, which is prone to errors and inefficiencies, particularly in detecting misalignment and defects after printing and drying.
Innovation Solution
An inspection system that uses an image sensor and projector to capture and compare images of printed shirts with pre-defined target images, automatically detecting defects and providing defect information, while also projecting guide frames and attribute information to facilitate accurate placement and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to check printed designs on shirts, then the inspection process is simple and requires minimal equipment, but the inspection accuracy is low and prone to human error
Solution Approach 1:
The patent uses image data of the printed shirt as a copy of the actual product and compares it with the original design data. This copying approach enables automated inspection while maintaining accuracy, as the digital copy can be precisely overlaid with the target design for pixel-by-pixel comparison without human intervention.
Solution Approach 2:
The patent replaces the manual mechanical inspection process with an automated image processing system. The image sensor captures the printed shirt, and the processor automatically compares the captured image with the original design data using computational algorithms, substituting human visual inspection with electronic processing for higher precision.
2Productivity
If automated image-based inspection is implemented, then inspection accuracy and efficiency are improved, but the device complexity and initial setup requirements increase
Solution Approach 1:
The inspection system is designed to handle multiple inspection tasks through a single integrated platform. The same image sensor and processing system can detect various types of defects (misalignment, color deviations, missing elements) and accommodate different shirt sizes and designs, providing universal inspection capability that improves productivity across the board.
Solution Approach 2:
The system performs preliminary actions by capturing image data of the printed shirt and preparing comparison data from the original design before the actual inspection comparison. This preliminary data preparation enables rapid automated inspection without requiring complex real-time processing during the inspection moment, thereby improving efficiency.
3Loss of time
If operators manually inspect each printed shirt, then flexibility in handling different designs is maintained, but inspection time and labor requirements increase
Solution Approach 1:
The inspection system performs self-service by automatically capturing, processing, and comparing images without requiring operator intervention. The system independently completes the entire inspection process from data capture to defect detection, eliminating the time-consuming manual inspection while maintaining the ability to handle diverse designs through programmable comparison algorithms.
Data Source
AI summary
An inspection system, an inspection method, and non-transitory recording medium. The inspection system acquires an image, captured by an image sensor, of the object to be inspected placed on a placement surface, the object having a printed image printed thereon, displays by a projector, print image data of the print image and attribute information of the object to be inspected, on the placement surface, compares a captured image of the object to be inspected with the print image data to determine whether there is a defect, and based on a determination that there is a defect, output defect information for specifying the defect.