COMPUTER INTEGERATED APPAREL MANUFACTURING

FAULT ANALYSIS USING IMAGE PROCESSING TECHNIQUE

INTRODUCTION
Defects are generated in fabric due to improper treatments. The economic viability of a fabric is significantly influenced

by the extent of its success in eliminating defects in fabric. Detection of defects is generally carried out by human inspection. Such manual inspection procedures are commonly agreed upon to be inefficient with detection efficiency suffering from deterioration due to boredom and lack of vigilance. The problem is accentuated by the presence of several types of defects those may occur in the fabric at random.

WOVEN FABRIC DEFECT

Bull Mark Mixed Ends (Yarn)

Drawbacks
Dropped Pick End Out

Mixed Filling
Open Reed Slub

FLY
Harness Breakdown Jerk-in

Smash
Soiled Filling/End Stop Mark

Defect
Knots

Thin Place

KNITTED FABRIC DEFECTS

Barre Press-off

Birdseye
Broken Color Pattern Drop Stitches

Runner
Slub Straying End

End out
Hole Missing Yarn

Mixed Yarn
Needle Line

FABRIC DEFECT CHECKING

Cost impact of defect can reduced by detecting defect early in production

cycle. Fully automatic defect recognition systems uses variety of sensing technologies to acquire data relating to fabric condition Sensing methods can be broadly categorized according to whether they are active or passive. Active sensing requires illumination source to highlight fabric, whereas passive sensing does not. Illumination source may be light beam reflection, laser beam reflection or video image processing. Video image processing gives higher reliability in results. This involves a CCD camera (two or more according to width of fabric), analogue to digital converter, image storage unit, digital to analogue converter for input to monitor, CPU to analyze video data from camera and mass storage system to store results after processing. Image processing algorithms are applied to identify or describe type of defect Numerical description: classifies defects according to length and breadth. Inspection speeds: 120m/min Fault location, size and severity are identified and classified into three types warp, weft and surface faults.

MANUAL VS AUTOMATIC INSPECTION

With visual fabric inspection, a trained person inspects

all types of fabrics, find and correctly identify all defects and divide them into the corresponding classes. The highest level of concentration is maintained only for a period of 20 to 30 minutes. After that, a person will tire continuously. Even in a well-run operation, the reproducibility of a visual inspection will rarely be over 50%. With automated inspection, the results are reliable, reproducible and free from the subjective deficiencies of the manual fabric inspection.

FABRIC INSPECTION MACHINES

MANUAL INSPECTION AUTOMATIC INSPECTION (USTER FABRIC SCAN )

VARIOUS CONCEPTS OF AUTOMATIC DEFECT ANALYSIS

STATISTICAL APPROACHES
Defect detection using co-occurrence matrix

SPECTRAL APPROACHES
Defect detection using discrete Fourier

features
Defect detection using local linear transforms
Defect detection using fractal dimension Defect detection using edge detection Defect detection using cross-correlation

transform
Defect detection using Gabor filter Defect detection using wavelet transform

Defect detection using bi-level thresholding

Defect detection using morphological

operations
Defect detection using neural networks

Defect detection using histogram

DIGITAL IMAGE PROCESSING SYSTEM

FAULT ANALYSIS USING IMAGE PROCESSING

OPERATING PRINCIPLE
The cloth passes over a two-part illumination module

that is designed for an inspection in either reflected or transmitted light. The choice of the illumination type is dependent on the density of the fabric, the special types of defects or the textile process stage in which the inspection is carried out. Above the light source, there are 3 to 6 or, in special cases, up to 8 CCD high-resolution line scan cameras depending on the inspection width. The cameras scan the fabric continuously for deviations.
To be cont

PRINCIPLE
Video camera Video monitor Image display

Fabric under inspection Light box

Frame grabber and store

Image acquisition IBM compatible PC

Output results

Image processing

 In this process, the fabric is inspected with the resolution

that is achieved by an inspection person at a distance of one metre to the fabric. The inspection system is operated from an operating terminal, where article-specific inspection parameters are set and the necessary piece data are entered or read in with a bar code reader. The various reports are also called up via, the operating terminal. The complex image processing is achieved with printed circuit boards that have been developed specifically for this application. After the inspection, the detected defects can be displayed on the screen for a quick and easy visual analysis.

Image Processing Activity

Portion of defect less fabric is first scanned and stored as standard raster

image (pixel information stored) for reference. Roll of fabric is exposed to image processing set up where camera starts examining fabric little by little. Sensed image is translated to digital image in form of 2-dimensional array (raster image) of numbers by analogue to digital converter. This sensed image is compared with standard image using algorithms and filters. Drop stitch run can be detected by applying low-pass filter to image. Low pass filter effectively averages out areas in image to highlight regions of different light intensities (hole or normal fabric). Small areas of light between stitches will be eliminated but larger areas of light caused by passing through hole remain and thus hole is identified. Other details like dimensions and technical details of defect are also identified There are other types of algorithms and filters which complete fabric defect checking process. These algorithms demand large processing time and hence require special purpose powerful for complete real time inspection for eg: parallel processing hardware like transputers or PC with frame grabber could be employed. This would take a sensed image, process it identify defects and then takes next frame. This frame management is highlight of using frame grabbers. Transputers are not economically viable.

DIGITAL IMAGE PROCESSING INCLUDES

Image acquirement and modelling, Image quality improvement and highlighting its

distinguishing features, Reinstating the desired image features, and Compression of image data.

IMAGE ACQUIREMENT AND MODELLING

Image modelling is based on digitising the real image. This

process consists of sampling and quantifying the image. The digital image can be described in the form of a twodimensional matrix, whose elements include quantified values of the intensity function, referred to as grey levels. The digital image is defined by the spatial image resolution and the grey level resolution. The smallest element of the digital image is called the pixel. The number of pixels and the number of brightness levels may be unlimited, although while presenting computer technique data it is customary to use values which are multiplications of the number 2, for example 512512 pixels and 256 grey levels.

IMAGE QUALITY IMPROVEMENT

Image quality improvement and highlighting its

distinguished features are the most often used application techniques for image processing. The process of image quality improvement does not increase the essential information represented by the image data, but increases the dynamic range of selected features of the acquired object, which facilitates their detection.

The following operations are carried out during image quality improvement:
changes of the grey level system and contrast

improvement, edge exposition, pseudo-colorisation, improvement of sharpness, decreasing the noise level, space filtration, interpolation and magnification, and compensation of the influence of interference factors, e.g. possible under-exposure.

REINSTATING DESIRED IMAGE FEATURES

Reinstating desired image features is connected with

eliminating and minimising any image features which lower its quality. Acquiring images by optical, opto-electronic or electronic methods involves the unavoidable degradation of some image features during the detection process.

REINSTATING THE DESIRED IMAGE FEATURES MAINLY INCLUDES THE FOLLOWING CORRECTIONS:
Reinstating the sharpness lowered as the result of

disadvantageous features of the image sensor or its surrounding, Noise filtration, Distortion correction, and Correction of sensors nonlinearity

COMPRESSION OF DATA
Image data compression is based on minimising the

number of bytes demanded for image representation. The compression effect is achieved by transforming the given digital image to a different number table in such a manner that the preliminary information amount is packed into a smaller number of samples.

Flaw Management System

GERBERsaver Flaw Management System - SP-SMS-SAVER
GERBERsaver is available as an option to all Synchron XX1

spreaders that are equipped with Spreading Management System. System is used for registration of flaws in fabric when spreading one-way face-up. GERBER saver is mounted on front of spreader above cutting device and is operated by joystick. By means of joystick and laser beam pointing on fabric operator marks flaw and system subsequently registers size, shape, and position of flaw in fabric. Image of flaw is created and displayed on PC screen allowing operator to see if flaw affects any pattern pieces or if it is in waste area only. With GERBER saver, material utilization during spreading process will increase considerably thereby resulting in savings in time, labor, and fabric.

GERBER FLAW MANAGEMENT SYSTEM

APPLICATION OF IMAGE PROCESSING TECHNIQUES TO ANALYSE AND RECOGNISE OBJECTS

The image processing technique is

based on using analogue and digital optoelectronic devices and systems which allow an image with special information distribution to be placed at the input or output of the system. The image processing technique includes image recognition and computer graphics. The image analysis and recognition is connected with image detection and processing, its projection, transmission and information storage, as well as image recognition and generation.

To be cont

 The broad interdisciplinary field of image techniques

includes more and more subsequent areas of theoretical and experimental knowledge, of constructional, technological, system, hardware, and software experience. The dynamic development of the image processing technique means that application of this technique is broadened, and covers other areas of science, including textile science, which results from significant development into fields such as material engineering and technology, as well as digital techniques and computer engineering. At present, informatics and micro processing technology have broadly influenced the rapid development of the image processing technique.

CONCLUSIONS
The development of computer techniques offers many

opportunities for its applying in textile science and practice. Use of computer image analysis, among other techniques, has enabled the identification of geometrical dimensions of very small textile objects. Using image correction techniques allowed the elimination of structural faults in the fabric which earlier would have been ignored. Applying image correction techniques enables a detailed identification of the structure and geometry of linear textile fabrics. Elaborating the digitization algorithm, combined with numerical methods, allows the numerical characteristics of a textile products structure to be obtained.

REFERENCE
Journal of Theoretical and Applied Information

Technology

International Journal of Chemical Sciences and

Applications. Vol 1, Issue 1, June, 2010, pp 37-41

Advances in Computational Research, ISSN: 0975

3273, Volume 1, Issue 2, 2009, pp-18-29

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