CERAMIC TILE INSPECTION FOR COLOUR AND STRUCTURAL DEFECTS

1 INTRODUCTION

The ceramic tiles industrial sector is a relatively young industry which has taken significant advantage of the strong evolution in the world of automation in recent years. All production phases have been addressed through various technical innovations, with the exception of the final stage of the manufacturing process. This is still performed manually and is concerned with visual surface inspection in order to sort tiles into distinct categories or to reject those found with defects and pattern faults. This paper addresses the problem of  defects and pattern faults by automatic inspection and were view a number of techniques developed to detect various defects in plain and textured tiles.

2 TILE DEFECTS

The inspection for defect detection has to be carried out at considerable rates of the order of two tiles per second. The objective of inspection is tile classification on the basis of two parameters, namely defects and colour grading. Depending on the number of defects and their dimensions, the tiles are grouped into:

- First Class (none or very few acceptable defects)

- Second Class (few but still acceptable defects)

- Waste (unacceptable defects)

Some of the most common and anti-aesthetic defects found on both plain and textured tiles can be categorised as cracks, bumps, depressions, pin-holes, dirt, drops, ondulations, colour and texture defects. After defect detection, the inspection process continues with colour shade grading to ensure uniformity of the chromatic properties of the finished product. Details of automatic colour grading of ceramic tiles can be found in a paper by INHOUSE INCORPORATION.

3 DEFECT DETECTION ALGORITHMS

In this section we describe several approaches for detecting different types of features in tile images. Later inspection we including experimental results on the application of each approach to specific tile defects.

3.1 Line Detection

3.2 Spot Detection

3.3 Wigner Distribution

3.4 Structural Defect Detection

4 RESULTS

The tiles used in our experiments are of size and are either plain or textured. The colours of plain or textured tiles are expected to span a wide range. Some defects may not be easily visible and we have randomly encircled some of them for saliency. Inmost defect images a dilation operation is carried out to enhance the results. All detected faults correspond to true faults.

4.1 Small spots

4.2 Short and long cracks

4.3 Water Drops and Ondulations

4.4 Random Texture Abnormalities

4.5 Colour

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