Fault detection system for paper cup machine based on real-time image processing

Abstract

In the production of paper cups in industrial factories, it is tried to print high quality cups with less waste loss with the help of sensors and heating resistances mounted on the paper cup machine. In this study, a system that detects faulty products based on image processing and removes it by controlling the machine with servo motors, asynchronous motors and programmable logic controller (PLC) is designed. For fault product detection, classification has been performed using real-time Haarcascade algorithm and You Only Look Once (YOLO) algorithm which is a deep learning methods, and real-time object detection has been carried out using the OpenCv library. With this study, an effective faulty product detection and removing hardware system was realized by adapting artificial intelligence algorithms to a machine used in industry. Based on the results, a whole system can be applied to systems that involve removing a faulty product from a band in any production, packaging etc. facility is proposed.A hardware consisting of servo motors, asynchronous motors and PLC was designed to separate faulty cups from the existing paper cup production machine in this study. Then, a data set composed of 1068 images was created with images taken from the camera for faulty and faultless paper cups. Using this dataset, the effect of different deep learning methods on performance in the real-time system has been examined and successful results have been obtained. The optimal outcome was achieved, yielding a real-time application accuracy rate of 90.8% through the utilization of the Yolov5x architecture.