Quality Of Ceramic Tiles Research Articles

A supervised approach for automated surface defect detection in ceramic tile quality control

Surface defect detection is very important to guarantee the quality of ceramic tiles production. At present, this process is usually performed manually in the ceramic tile industry, which is low efficiency and time-consuming. For small surface defects detection of high-resolution ceramic tiles image, an intelligent detection method for surface defects of ceramic tiles based on an improved you only look once version 5 (YOLOv5) algorithm is presented. Firstly, the high-resolution ceramic tile images are cropped into slices, and the Bottleneck module in the YOLOv5s network is optimized by introducing depthwise convolution and replaced in the whole network. Then, feature extraction is performed using the improved Shufflenetv2 backbone, and an attention mechanism is added to the backbone network to improve the feature extraction ability. The path aggregation network (PAN) and Feature Pyramid Networks (FPN) neck are used to enhance the feature extraction, and finally, the YOLO head is used to identify and locate the ceramic tile defects. The multiple sliding windows detection method is proposed to detect the original ceramic tile image which is faster than the single sliding window detection method. The experimental results show that compared with the original YOLOv5s detection algorithm, the parameters of the model are reduced by 20.46 %, the floating point operations are reduced by 26.22 %, and the mean average precision (mAP) of the proposed method is 96.73 % in the ceramic tile image slice test set which has 1.93 % improvement in mAP than the original YOLOv5s. Compare with other object detection methods, the method proposed in this paper also has certain advantages. In the high-resolution ceramic tile images test set, the mAP of the proposed algorithm is 86.44 % by using the multiple sliding window detection method. The ceramic defect detection experiment has verified the feasibility of the method proposed in this paper.

Valorization of granite waste powder as a secondary flux material for sustainable production of ceramic tiles

Granite waste is one of the most abundant industrial by-products released from the construction industries. Irrespective of its unique chemical properties granite waste is still discarded in enormous amount without further use that has potential adverse environmental impacts. For that reason, the study presents a practical approach to recover and exploit granite waste as a secondary flux for production of ceramic tiles. The granite waste was crushed and ground to obtain a fine powder. Different batch compositions containing a varied proportion of granite powder were prepared and fired at different sintering temperatures: 1100, 1150 and 1200 °C. The raw materials and ceramic bodies were characterized for their chemical compositions, microstructural, mineralogical and physical–mechanical properties. The results showed that, a change in batch compositions and sintering temperature enhanced the quality of ceramic tiles in terms of mechanical strength and physical properties. The final experimental deduction showed that, the prospect to produce ceramic tiles containing up to 40 % of granite powder, at the firing temperature of 1200 °C with enhanced engineering properties that meet the minimum standards specified by ISO-13006 is feasible.

The Effect of Beneficiation on Some Properties of Osun State Ceramic Raw Materials

Clay, feldspar and silica sand are important industrial minerals which often need treatment commonly known as beneficiation to improve the quality of ceramic tiles produced from these materials. The different minerals, after sorting, were treated separately in distilled water, alcohol and hydrochloric acid before being crushed in a ball mill; they were then characterized using a pelletron accelerator. The results show an increased silicon content for clay, silica sand and feldspar; and reduced aluminum content for clay and silica sand but not for feldspar. Iron impurity and its oxide are also shown to reduce by over 50% in all the minerals while potassium was found to be the dominant element in feldspar among the defining elements. In conclusion, the increased quartz in the mineral will improve the hardness, density, porosity, and rigidity of ceramic tiles as well as providing support and controlling shrinkage. Furthermore, increasing the mineral quotient in feldspar will enhance its fluxing potential.

Optimal Non-Invasive Fault Classification Model for Packaged Ceramic Tile Quality Monitoring Using MMW Imaging

Millimeter wave (MMW) frequency has emerged as an efficient tool for different stand-off imaging applications. In this paper, we have dealt with a novel MMW imaging application, i.e., non-invasive packaged goods quality estimation for industrial quality monitoring applications. An active MMW imaging radar operating at 60 GHz has been ingeniously designed for concealed fault estimation. Ceramic tiles covered with commonly used packaging cardboard were used as concealed targets for undercover fault classification. A comparison of computer vision-based state-of-the-art feature extraction techniques, viz, discrete Fourier transform (DFT), wavelet transform (WT), principal component analysis (PCA), gray level co-occurrence texture (GLCM), and histogram of oriented gradient (HOG) has been done with respect to their efficient and differentiable feature vector generation capability for undercover target fault classification. An extensive number of experiments were performed with different ceramic tile fault configurations, viz., vertical crack, horizontal crack, random crack, diagonal crack along with the non-faulty tiles. Further, an independent algorithm validation was done demonstrating classification accuracy: 80, 86.67, 73.33, and 93.33 % for DFT, WT, PCA, GLCM, and HOG feature-based artificial neural network (ANN) classifier models, respectively. Classification results show good capability for HOG feature extraction technique towards non-destructive quality inspection with appreciably low false alarm as compared to other techniques. Thereby, a robust and optimal image feature-based neural network classification model has been proposed for non-invasive, automatic fault monitoring for a financially and commercially competent industrial growth.

Testing Quality of Ceramic Tiles in Order to Evaluate Condition of the Manufacturing Process

Problem of the research on quality of ceramic floor tiles remains still open. Their strength, and as a consequence possible applications, depend both on the constitution of ceramic composite, and on their degree of homogeneity. The method of controlling tile strength should be based on evaluating this feature in various cross-sections. Such measurements are very important because their mechanical properties are often not uniform across the whole surface. Standard control tests are not compliant with this requirement because they anticipate only destructive strength tests in their middle cross section.Application of the ultrasound method allows for the easy homogeneity estimation of ceramic composite in the tile. Transformation of the direct results for the resistance of material requires scaling of the measuring device what considerably expands the scope of research, however resistance parameters are not always necessary.Paper presents the research on the probe composed of 23 floor tiles with dimensions 600 x 600 and 600 x 300mm. Tiles has been sampled from the lot of material that had been built in the floor and shown excessive defectiveness (broken edges, pop-offs and breaks). The main purpose of experimental tests was to determine the homogeneity of ceramic material in various cross-sections of each tile. Big variation of ultrasound wave velocity within the range of many tiles shown the cause of quick loss of expected serviceable properties. In addition, has been carried out the measurements of the length, width and deformation of the surface of tiles. Dimensional deviations and deformations didn’t exceed the admissible values.

Curvature Evolution of Porcelain Tile during Firing

Planarity is one of indispensable attribute of a ceramic tile quality. During the firing changes on curvature may be permanent causing damage on quality and productivity. The objective was to evaluate curvature evolution on porcelain tile during heating stage of firing. Effects of engobe and glaze coating were evaluated. The performance of two compositions of porcelain tile was studied on industrial (1000 mm x 500 mm x 10 mm) and laboratorial (100 mm x 50 mm x 6 mm) scale. Industrial test pieces were fired at 950 and 1200 °C. Final curvature was measured by conventional dial indicator. Curvature evolution of laboratorial test pieces was evaluated by thermal fleximetry from 25 to 1200 °C. This characterization was capable to identify very significant positive curvature deflection on temperature range from 930 to 1200 °C, directly associated to permanent planarity defects. Differences on composition affect significantly the curvature evolution.

An Enhanced Automatic Surface and Structural Flaw Inspection and Categorization using Image Processing Both for Flat and Textured Ceramic Tiles

As the price of ceramic tiles depend on its limpidness and precision of surface texture, color and shape, it’s in fact a great challenge to control surface eminence and uphold production rate in the field of industrial fabrication of ceramic tiles. Under consideration these criteria, in this research paper, we have proposed an enhanced automatic surface flaw detection and categorization procedure that is able to guarantee the quality of ceramic tiles as well as production rate in industrial fabrication. Our proposed model plays an important role for automatic revealing of surface flaw during production and packaging. This proposed model includes an automatic categorization technique using computer vision that helps us to make sense about the pattern of surface defect within a very short time and also helps to make quick decision about the recovery process. Moreover, it also ensures the quality of tiles automatically during packaging procedure so that the defected tiles may not be mixed up with the fresh tiles.

Characterization of cellular ceramics made by porcelain tile residues

This work deals with physical, structural and mechanical characterization of cellular ceramics obtained from porcelain tile polishing residues expanded with silicon carbide abrasive residues [A.M. Bernardin, et al., Proceedings of the VIII World Congress on Ceramic Tile Quality, vol. 3, 2004, pp. 195–199]. In a previous work it was studied the expansion process, that means, SiC decomposition simultaneous with the polishing residue melting, both at ∼1200 °C. Starting at 1000 °C SiC particles decomposes into SiO 2 and CO 2, the last one used as an expanding agent, promoting the expansion of the melt (porcelain tile residue) formed at 1200 °C. Now, the microstructure, expansion, density and mechanical properties (flexural tests) were determined to characterize the product. Cellular ceramics can substitute polymers (expanded polystyrene) and wood in internal partition walls and linings, and cellular concrete in the building industry.

Effect of biological treatment of the ceramic mass on the drying and firing of facing tiles

The authors studied the ceramic masses of the Minsk Building Materials Production complex (MZSM) and the Kishinev FinishingMaterials Plant (KZOM) having the following compositions: MZSM--48% Vesejovsk VGP clay, 22% nepheline concentrate, 17% quartz sand, 8% dolomite, 5% title scrap, and above 100% 3% bentonite, 0.1% soda ash, and 0.28% liquid glass; KZOM-48% Veselovsk VGP clay, 28% nepheline-syenite, 8% limestone filings (scrap), 16% title scrap, and, above 100%, 1% bentonite and 3% sodium tripolyphosphate. Improving the quality of ceramic tiles and reducing the mineral and fuel-energy consumption in their production are among the practical industrial problems. This paper discusses a method of solving them by improving the drying and firing processes of the products.

Automation of production and improvement of the quality of ceramic tiles

Automation of production and improvement of the quality of ceramic tiles