Statistical pattern Modeling in vision-based quality control systems

Machine vision technology improves productivity and quality management and provides a competitive advantage to industries that employ this technology. In this article, visual inspection and quality control theory are combined to develop a robust inspection system with manufacturing applications. The inspection process might be defined as the one used to determine if a given product fulfills a priori specifications, which are the quality standard. In the case of visual inspection, these specifications include the absence of defects, such as lack ( or excess) of material, homogeneous visual aspect, required color, predetermined texture, etc. The characterization of the visual aspect of metallic surfaces is studied using quality control chars, which are a graphical technique used to compare on-line capabilities of a product with respect to these specifications. Original algorithms are proposed for implementation in automated visual inspection applications with on-line execution requirements. The proposed artificial vision method is a hybrid between the two usual methods of pattern comparison and theoretical decision. It incorporates quality control theory to statistically model the pattern for defect-free products. Specifically, individual control charts with 6-sigma limits are set so the inspection error is minimized. Experimental studies with metallic surfaces help demonstrate the efficacy and robustness of the proposed methodology.