AI visual inspection technology is an untapped and non-intrusive automated methodology, highly effective for attaining equipment automation, intelligence, and meticulous control in fabric inspections. This approach offers notable merits, including utmost safety, unwavering reliability, a wide response range across various spectrums, prolonged operation viability in harsh environments, and exceptional production efficiency.
In large-scale textile production processes, reliance on manual visual inspection often leads to subpar efficiency and compromised accuracy in ensuring product quality. However, the integration of machine visual detection methods can significantly augment production efficiency and elevate automation levels in fabric inspections.
Components and Working Principles
Machine visual inspection technology for fabric inspections comprises four key modules: the image acquisition module, image processing module, image analysis module, and data management module.
Image Acquisition Module:
This module includes industrial cameras, optical lenses, lighting sources, and their holding devices. Its primary function is to capture high-quality surface images of fabrics. By using appropriate lighting, the optical lens projects the fabric's surface onto the camera sensor. The light signal is converted into an electrical signal, then digitally processed by a computer. Industrial cameras predominantly use CCD or CMOS chips, with CCD being prevalent in machine visual technology.
Image Processing Module:
Responsible for tasks such as image denoising, image enhancement, restoration, defect detection, and object segmentation. Advanced algorithms process and refine the acquired images, ensuring optimal quality for subsequent analysis.
Image Analysis Module:
This module compares processed images against predefined standards to identify and annotate defective areas. It uses sophisticated comparison techniques to accurately pinpoint deviations from desired quality standards.
Data Management Module:
Stores and organizes selected defective images for comprehensive analysis. For fabric inspection, this module stores information like defect types, sizes, locations, and quantities detected in each fabric roll, enabling efficient quality control and facilitating necessary production adjustments.
By utilizing suitable lighting sources and image sensors, such as CCD cameras, machine visual inspection effectively captures detailed surface images of fabrics. Advanced image processing algorithms extract pertinent features from these images. Using this information, operations such as defect localization, identification, grading, discrimination, statistical analysis, storage, and retrieval are performed. Machine visual inspection essentially replaces human eyes, employing state-of-the-art technology for measurements and judgments. It transforms the target into an image signal using specialized visual products, like CMOS and CCD sensors, and transmits it to a dedicated image processing system. Based on pixel distribution, brightness, color, and other relevant data, the image system conducts intricate calculations to extract key features of the fabric. The system then controls on-site equipment actions based on the discrimination results. This invaluable mechanism is critical in fabric production, assembly, or packaging processes, serving as a tool for defect detection and preventing faulty products from reaching consumers.
Deep Analysis of the Visual Inspection Industry Status
Despite being a relatively young field, visual inspection technology has experienced remarkable growth due to the global wave of technological revolution and industrial transformation. Initially confined to automotive manufacturing, its applications now extend across diverse sectors, including textile manufacturing.
From the standpoint of industry development, the international visual inspection industry has reached a mature stage. Looking ahead, it is anticipated that visual inspection technology in Europe, America, and Japan will continue to innovate, ensuring sustained market growth. Meanwhile, the domestic machine visual industry in China is rapidly expanding. Building on years of technological advancements, market exploration, and industry expertise, China’s visual inspection sector has entered a phase of remarkable development.
The visual inspection industry chain encompasses various components, including upstream raw materials and components, midstream equipment manufacturing, and downstream end-user industries. The integration of machine visual inspection in fabric production represents a significant leap towards enhanced quality control, operational efficiency, and technological advancement.
