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Artificial intelligence based system to improve the inspection of plastic mould

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Article  in  Journal of Intelligent Manufacturing · September 2014

DOI: 10.1007/s10845-014-0969-5

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This is the version of a manuscript accepted for publication in The Journal of Intelligent
Manufacturing. Springer US is not responsible for any errors or omissions in this version of the
manuscript or any version derived from it. The published article can be accessed at
https://doi.org/10.1007/s10845-014-0969-5 and should be cited as follows:
A. F. H. Librantz, S. A. Araújo, W. A. L. Alves, P. A. Belan, R. A. Mesquita, A. H. P. Selvaticci.
Artificial intelligence based system to improve the inspection of plastic mould surfaces. Journal of
Intelligent Manufacturing, v. 28 (1), p. 181-190, 2017.

Artificial intelligence based system to improve the

inspection of plastic mould surfaces
André. F. H. Librantz*, Sidnei A. de Araújo, Wonder A. L. Alves, Peterson A. Belan, Rafael A. Mesquita,
Antonio H. P. Selvatici
Industrial Engineering Post-Graduation Program, Nove de Julho University − UNINOVE,
Av. Francisco Matarazzo, 612, Água Branca, Zip Code: 05001-100, São Paulo – SP, Brazil
*Corresponding Author: librantz@uninove.br

Abstract

Plastic industry is today in a constant growth, demanding several products from other segments, which includes
the plastic moulds, used mainly in the injection moulding process. This paper presents a methodology for the
surface evaluation of plastic moulds, aiming the automation of the polishing surface analysis. Provided that this
type of analysis by traditional procedures can be slow and expensive, the development of automatic system could
lead to considerable improvements regarding the speed and reliability of information. The starting point of the
evaluation procedure is the image generated by the laser light scattered over the sample mould surface that could be
captured and analysed by image processing and artificial intelligence techniques. The results showed that the
proposed system is able to mapping and classifying several damages over the polished surface and could be an
alternative to reduce efficiently the costs and the spending time in mould surface inspection tasks.

Keywords: Artificial intelligence, Mould surface, quality control, computer vision, plastic injection.

1 Introduction
Computer vision systems are being increasingly used for sophisticated applications such as
recognition and classification in a number of processes [1]. The fast development of
‘‘intelligent’’ inspection systems is mainly due to the rapid growth of computing power in the

1
recent years, coupled with the idea of successfully emulating the low-level mechanisms of the
brain. Thanks to the methodology offered by the artificial intelligence methods, difficult
computational problems of object recognition are possible to be solved [2, 3].
The industrial applications of computer vision aim to improve the quality in manufacturing
process seeking higher productivity, cost reductions or quality improvements. In the last years,
an increasing interest in computer vision has been observed, new technological developments
have enabled the creation of several applications in several industrial fields [1]. In addition, the
lower costs of high quality digital cameras and computer systems with high data processing
capability have led to an intense development in the evaluation of complex systems with
computer vision [4].
One application of the computer vision is the evaluation of complex surfaces on plastic
moulds. These moulds could be applied to a number of plastic processing conditions, but the
most complex situation is observed in the injection moulding for producing daily-used objects
or complex automotive components. In this process, the quality of moulds surface is essential
because plastic parts produced will retain any detail in the mould surface, which can be
intentional, such as textured mould [5, 6, 7], or unintentional, like scratches, porosities or other
defects on the mold surface. Currently, those controls are made visually and most of the times
based on personal experience of the finishing operators.
In the literature there are many approaches employing artificial intelligence and computer
vision techniques for material surface inspection. Among them, we can cite the works
[8,9,10,11] dealing with surface roughness prediction; [12,13] proposing approaches for
prediction of surface defects and [14] that developed an expert system to predict optimal
parameters in a process of mould surface polishing.
However, despite of the technological importance of plastic parts few works have been
reported about the quantitative evaluation of surface moulds [15, 16]. On the other hand, several
authors affirm that the product cost in the concept design stage accounts for only 6% of the total
cost, but determines 70–80% of product cost and 80% of quality [17]. In this context, the present
paper proposes a new methodology to improve the surface evaluation of plastic moulds. This
methodology is implemented in a System, which is composed by three main steps: i)
Segmentation by Texture Analysis; ii) Circularity measurement and iii) Surface evaluation. For
the second step, we proposed a circularity measure (CM) that is the key of success of defects
detection in the third step. Unfortunately, we did not identify in the literature the proposition of
similar systems for fine surface defects like those investigated by the present paper. Thus, the
present results are not compared to others. On the other hand, samples with known surface

2
roughness (measured by traditional point-roughness methods) were employed, being those
values correlated to the computer-added visual results.

2 Materials and methods

2.1 Moulds
In this work, five samples moulds were used. For reference a Gage Block from Mitutoyo was
used. The roughness values were measured by a point-touch roughness test. Defects were
introduced in the surface of the samples 2 and 3, with different sizes and depths. The details of
these moulds are depicted in Table 1.

Table 1. Characteristic of samples moulds.

Sample Manufactured Model Material Size (mm) Polish Roughness Defect
by method
1 Mitutoyo Gage Block Steel 08 × 15 Automatic 0.020 µm No
Series 516
2 Machining Steel P20 13 × 20 Manual 0.029 µm Overpolishing
3 Machining Steel P20 13 × 20 Manual 0.029 µm Scratch
4 Machining Steel P20 10 × 10 Manual 0,034 µm No
5 Machining Steel P20 10 × 10 Manual 0,045 µm No

2.2 Experimental apparatus

For the generation of the images surface, a He-Ne laser working in mode CW and tuned at 808
nm was used. The diagram of the experimental setup is shown in Fig. 1.

(a)

3
 (b)

Fig. 1. Experimental setup. (a) experimental setup scheme ; (b) implemented apparatus.

The automation was designed to allow that the surface can be scanned uniformly. The image
acquisition over de surface was performed by two step-motors and a driver interfaced to the
parallel port of PC, in which the camera is also connected.

2.3 Database of images

In order to carry out the experiments, a database of images was generated, based on the five
samples of mould described previously (Tab. 1). A total of 3,420 images were acquired, being
420 images for the first sample and 750 images for the other four samples. The Fig. 2 shows
some images of this database.

Fig. 2. Examples of four sequential images acquired in the scanning of the mould surface over a damaged region.
The distortion effect is related to the proximity of the defect spot.

4
 After the acquisition, the images were analysed and classified by means of the proposed
systems described in section 3.

2.4 Artificial intelligence techniques applied to the system

2.4.1 Gabor Filter

Gabor filters are a family of linear filters defined in the spatial domain with many applications
in image processing, specially texture classification [18] and detection of specific structures
[19].
Gabor filters have been traditionally used for modelling the response of primary cortex cells
that process natural vision, helping to explain their role in texture recognition [20]. The 2-D
Gabor filters used in image processing are linear filters defined in the spatial domain as

g (x, y;θ, f 0 , ,σ a ,σ b ) = Ks(x, y;θ, f 0 , )w(x, y;θ,σ a ,σ b ) (1)

being the product of a scaling constant K, a 2D Gaussian function

 − 1  a (x, y; θ )
 b(x, y; θ ) 

, known as envelope, and a complex sinusoidal waveform
2 2
w(x, y; θ,σ a ,σ b ) = exp  + 
 σa σb 
2 2
 2  

( b(x, y; θ ))
s(x, y; θ, f 0 , ) = e
j  + 2ππ0
, known as carrier [20, 21]. The point coordinates (a,b), with

a(x, y; θ ) = xcos(θ ) + ysin (θ ) and b(x, y;θ ) = − xsin (θ )+ ycos(θ ) , result from rotating the image coordinates

with such an angle θ that the b-axis coincide with the wave-front propagation direction. The
other sinusoidal parameters are the frequency f 0 and phase  , while σ a and σ b are parameters
that control the envelop decay along the a and b-axis respectively, and are closely related to the
kernel size. Fig. 3 illustrates the role of the different parameters in the construction of a Gabor
filter kernel.

Fig. 3. Intensity images of real and imaginary parts of a given Gabor filter kernel. The red arrow indicates the
wave-front propagation direction (b-axis). In the example, the image sizes are 128x128 pixels and the Gabor
filter parameters are: θ = −45o , (1 / f 0 ) = 56.57 pixels,  = 0o , σ a = 20 pixels and σ b = 16 pixels (adapted from [20]).

5
 In texture classification, a bank of m Gabor filters was used to generate m complex response
images having the same size of the original one, as described in [22]. Then, for each image
pixel i, the set of m response magnitude values at the same position (xi,yi) (one value from each
response image) is collected into a feature vector fi, used to feed the classifier.
In this work, a bank of 24 kernels was used, with frequencies f 0  1 / 2,1/ 3,1/ 4,1/ 6,1/ 8,1/ 12 and

orientations θ  0 ,45 ,90 ,135 . The decay parameters were defined as σ a = σ b = 1 /(2f 0 ) for each kernel,
o o o o

keeping the parameters  = 0 o and K=1 constant. The kernel widths and heights were defined as

2σ a +1 . It was also applied a Multi-layer Perceptron (MLP) Neural Network preceded by

Principal Component Analysis (PCA) step as a supervised classifier.

2.4.2 Principal Component Analysis (PCA)

Since the number of input neurons of the MLP affects considerably its performance, the PCA
method [23] was used in order to reduce the input features vector dimension. PCA analyses the
input data covariance and determines the linear transformation that best reduces feature vectors
dimension, reducing their variability as little as possible. Originally, the bank of Gabor filters
would generate a 24-dimensional input vector for the MLP classifier, but after the PCA process,
this dimension was reduced to 6. In the next paragraph, it is explained how this technique works.
Suppose that n input feature vectors f1 , f 2 , , f n , each one being m-dimensional, have an

average vector f . If they are placed column-wise in an m-by-n data matrix

M =  f1 − f  f n − f  , the input data covariance is given by C = MM T . The covariance

eigenvalues and eigenvectors are thus respectively represented by:

D =  λ1 0  0 
 
0 λ2  0 
 
     (2)
 
0 0  λm 

and V = v1 v2  vm ,

where D is a diagonal matrix containing the covariance eigenvalues {λi }im=1 , with

λ1 > λ2 >  > λm , and V is the orthonormal matrix containing the eigenvectors v1 ,v2 ,,vm

placed column-wise, such that C = V T DV .

V is also a linear transform matrix that projects input feature vectors into a special coordinate
system, where data has large variability along some coordinates and usually much smaller

6
variability along others. Thus, the last step in PCA transform is removing the coordinates along
which data has small variability. This step is performed by choosing the smallest index k such
that
k m

 λi  Factor  λi ,
i=1 i=1
(3)

where 0 < Factor < 1 indicates a fraction of the sum of all covariance eigenvalues. After
choosing the index, a new m-by-k projection matrix Vk = v1 ,v2 ,,vk  is defined. After being

projected by Vk , the dimension of input vectors reduce from m to k. The projection of an input

feature vector f results in a new vector f' through the operation

f' = VkT f (4)

2.4.3 Multi-layer Perceptron (MLP)

Artificial Neural Network (ANN) is an artificial intelligence technique that imitates the
structure and working of the human brain and is usually applied in tasks involving pattern
recognition. An ANN is composed by interconnected elements named artificial neurons, which
are responsible for processing information.
MLP is a kind of ANN model that has one or more hidden layers, in addition to the input
and output layers of most ANN models. The most used algorithm for training is the
backpropagation, which is composed by two main steps. In the first step, when a pattern is
presented to network through the input layer, the activation signal is propagated layer by layer,
until the response is produced by the output layer. In the second step, the obtained output is
compared to desired output for the considered pattern producing an error signal. This error is
then propagated from the output layer to input layer and the synaptic weights are being adjusted,
so that the actual response of the network approximates the desired response [23].
In the present work, we built a MLP with 6 neurons in its input layer (for receiving the output
of PCA method), 12 neurons in the hidden layer and 4 neuron in the output layer (representing
the classes of texture). In order to obtain the number of neurons in hidden layer, several
experiments varying this parameter were conducted and then the architecture of ANN with the
minimum mean square error (MSE) was chosen. Other parameters used in the ANN were: i)
transfer functions: logistic and linear; ii) learning rate: 0.1; iii) momentum rate: 0.9; and iv) stop
criteria: MSE ≤10e-4.

7
3 Proposed system
The proposed system for analysing the surface moulds can be described as follows: in the first
step, RGB colour images are acquired and their grayscale versions are generated by averaging
RGB components of each pixel. It is important to mention that the images acquired by a digital
camera are, by default, represented with the RGB colour system, which is widely used for
colour reproduction in electronic devices. Furthermore, when it is needed to convert the
acquired RGB color image into grayscale before applying the steps of processing and analysis,
different weights for the components can be adopted, in order to enhance some feature in the
converted image.

The second step is the image segmentation by texture analysis. It involves filtering by Gabor
functions, reduction of dimensionality of features vector using PCA, texture classification by
MLP and the detection of region of interest (ROI). The third step consists in analysing the
circularity of the ROI, using the proposed circularity measure, which is described in section
3.2. Finally, in the last step, the evaluation of the mould surface is conducted. All routines of
the proposed system involving image processing were building with the use of PROEIKON
library [24].

3.1 Segmentation by Texture Analysis

Starting with a greyscale image from a region of mould surface, such as the example in Fig. 4a,
the first operation is filtering it using a bank of Gabor filters is performed generating a vector
of 24 elements for each pixel. In the sequence, each feature vector is reduced to 6 elements by
using PCA. After that, MLP is applied to reconstruct the segmented image, as shown in Fig.
4b.

Fig. 4. Segmentation by texture analysis: (a) grayscale image from a point of mould surface (b) segmented image
by texture analysis.

8
 The Figure 4b shows the four classes denoted by different intensities of grey levels. The
kernel and the background of the image are classified as class #1 (indicated by darker grey
level), since they have the same texture. The other classes (#2, #3 and #4) are located around
the kernel and denoted by grey levels that become lighter.
After performing the segmentation by texture analysis, a new binary image with the ROI is
generated. This process is divided into two stages: the first consists in separating one of the
classes, the class of interest, generated by the texture segmentation process. The class of interest
(#2) was determined experimentally, analysing the four classes generated in the reconstructed
images. The next stage is to generate a binary image with the ROI, as illustrated in Fig. 5a. The
circularity of external edge of ROI (Fig. 5b) finally indicates the condition of mould surface at
the point analysed.

Fig. 5. Example of ROI determination: (a) ROI (b) external edge (contour) of ROI.

3.2 Circularity measurement

Evaluating the mould surface quality at a point consists in determining how circular the contour
of ROI extracted from that point is. For this purpose, a circularity measure (CM) was proposed,
obtained as follows: considering C the set of pixels along the contour of ROI, the distance
between i-th pixel (xi ,yi) of C to the centroid (xc, yc) of ROI and the mean of these distances
can be defined, respectively, as:

distCi = ( xi - xc )2 + ( yi - yc )2 (5)

N
1
distM =
N
∑ distC , i (6)
i =1

where N is the number of pixels over C.

9
 Thus, the standard deviation of the distances from the pixels of C to (xc, yc) can be calculated
as:

1 N
stdC =  (distCi - distM )2 (7)
N i =1

Finally, the proposed circularity measure is defined as:

 max- min 
circularity =  stdC (8)
 max  ,

where min and max are the smallest and largest distCi, respectively. In other words, the
circularity is characterized by the normalized standard deviation of the distances from the pixels
of C to (xc, yc). This normalization penalizes large differences between smaller and larger
distances, which can indicate a mould surface problem.

3.3 Surface evaluation

Finally, in this step, the circularity of the contour of ROI is calculated and the value obtained is
compared to a threshold. This procedure is performed for each acquired image that represents
a point of the mould surface. From the circularity value it is possible to evaluate if there is some
defect and also its type. If the circularity of ROI is larger than the threshold, it indicates that the
region of the surface has some damage. Thus, it must be classified as overpolishing ("orange
peel") or a scratch. In order to discriminate two different damages, the proposed approach takes
into account the circularity values of the neighbours of the analysed point. The overpolishing
damage has high levels of circularity, in general values larger than 15. Other features, like the
area affected by damage, can also be used to classify the surface region. For instance, the area
affected by overpolishing is usually larger than the area affected by scratch [15, 16].
Fig. 6 illustrates a set of images acquired from different regions of a mould surface. Different
characteristics can be observed in these images. For instance, samples shown in Fig. 6a
represent regions without damage and 6b and 6c illustrate two regions with defects.

10
 Fig. 6. Images acquired from different regions of the mould surface. (a) no damage, (b) scratch damage and (c)
overpolishing damage.

Two examples of evaluation of mould surface by measuring the circularity of ROI contour
are shown in Fig. 7. The first one shows a point on the surface where there is no damage, while
the second image was obtained at point of the surface that contains a scratch damage.

Fig. 7. Results of the proposed approach. (a) acquired images, (b) segmented images by texture analysis and (c)
contours of ROIs and their circularity values.

As can be seen, the circularity measure for the first image has smaller value (1.37) when
compared to the second one (11.63), indicating the better quality at that point.

11
4 Results and discussion
Table 2 presents the subset of the CM results obtained from different points over the samples
mould surface. The threshold (based on its roughness) and the difference (Diff) between each
CM value and adopted threshold for each mould are presented.

Table 2. CM values obtained from the surfaces of five samples. Roughness values are the same as in Tab. 1.
Mould 1 Mould 2 Mould 3 Mould 4 Mould 5
Threshold=0.769 Threshold=1.493 Threshold=1.527 Threshold=30.226 Threshold=83.492
Roughness: 0.020 µm Roughness: 0.029 µm Roughness: 0.029 µm Roughness: 0.034 µm Roughness: 0.045 µm
CM Diff. CM Diff. CM Diff. CM Diff. CM Diff.
0.478 -0.292 12.737 11.244 5.531 4.038 20.211 -10.046 44.151 -39.341
0.370 -0.400 26.847 25.354 4.082 2.589 18.735 -11.521 43.546 -39.946
0.428 -0.341 10.166 8.673 3.507 2.014 18.853 -11.403 43.391 -40.101
0.479 -0.290 0.425 -1.068 2.705 1.212 20.056 -10.200 43.020 -40.472
0.423 -0.347 2.093 0.600 0.529 -0.964 19.229 -11.028 42.482 -41.010
0.312 -0.458 10.156 8.663 1.180 -0.313 13.261 -16.995 42.342 -41.150
0.328 -0.441 0.698 -0.795 13.299 11.806 13.989 -16.267 41.942 -41.550
0.406 -0.363 0.607 -0.886 17.262 15.769 16.652 -13.605 42.569 -40.923
0.403 -0.366 0.507 -0.986 0.469 -1.024 14.577 -15.679 41.484 -42.008
0.389 -0.380 0.479 -1.014 0.477 -1.016 10.927 -19.330 36.267 -47.225
0.272 -0.497 0.629 -0.864 3.415 1.922 15.433 -14.823 39.569 -43.923
0.397 -0.372 1.208 -0.285 0.386 -1.107 18.611 -11.645 41.028 -42.464
0.306 -0.463 1.191 -0.302 3.063 1.570 19.226 -11.031 39.954 -43.538
0.278 -0.492 1.046 -0.447 2.050 0.557 15.630 -14.626 39.477 -44.015
0.451 -0.319 0.558 -0.935 0.419 -1.074 15.880 -14.376 39.306 -44.186
0.306 -0.463 0.406 -1.087 0.490 -1.003 17.290 -12.967 39.779 -43.713
0.295 -0.475 3.753 2.260 1.615 0.122 11.919 -18.338 39.793 -43.699
0.526 -0.244 1.597 0.104 3.550 2.057 16.177 -14.079 39.726 -43.766
0.572 -0.197 0.517 -0.976 8.145 6.652 18.412 -11.844 39.341 -44.151
0.277 -0.492 0.534 -0.959 5.608 4.115 18.060 -12.196 36.388 -47.104

The threshold was determined by averaging the circularity values of the each analysed
mould, taking into account the roughness of each surface. As can be seen in Table 2, all
values of difference between the CM and adopted thresholds for moulds 1, 4 and 5 are
negative, indicating that in all analysed points no damage. Another important aspect in
analysis of mould 1 (used as reference) is that all values of CM are closer to zero, which
indicates a perfect polishing, as expected by the lowest roughness data. After this observation,
all the roughness and average CM were then graphically correlated, as shown in Figure 8. It is
easy to identify a correlation between the two methods; a power-type trend line seems to fit,
but the authors have not evaluated the physical significance of this.

12
 Fig. 8. Correlation of Average Roughness versus Average CM.

One important point to consider about Figure 8 is that the roughness or average CM cannot
represent point-defects, such as porous or scratches, but only an average on the peaks and
valleys of the surface. And, for plastic mould surfaces, one single defect can be crucial and
invalidate the whole mould, regardless the overall quality of the rest of mould surface.
Therefore, a Figures 9, 10 and 11 were drawn, illustrating the graphical results of the proposed
system from the evaluation of the whole mould surface, for moulds 1, 2 and 3, respectively.
Each graphic was generated from the values of CM for all image acquired from the mould.

Fig. 9. Representation of sample mould 1 surface.

13
 Fig. 10. Representation of sample mould 2 surface.

Fig. 11. Representation of sample mould 3 surface.

The uniformity in the surface obtained for the mould 1 (Fig. 8) cannot be observed on
the surface of the moulds 2 and 3 (Figs. 9 and 10), once they present defects, such as
overpolishing and scratching (described in Table 1) both correctly detected by the system. The
representation of the surfaces of the moulds 4 and 5 were omitted, as they are very similar to
that obtained to the sample mould 1. The only difference is that uniformity is not close to zero,
but at a higher level, that could be represented by a shift towards the Z axis (height). One can
also observe that CM values for the samples 2 and 3 present large varieties. However, this
difference itself does not mean that the surface presents defects. This classification depends on
the threshold and the identification of the damage type represented by the irregularities, and it
must take into account the behaviour of the neighbour points. Figure 12a shows a linear
representation of the surface quality of the sample mould 2. The dotted line on the Y axis
represents the threshold assigned for this sample.

14
Fig. 12. Results for the circularity obtained for all 750 points analysed for the sample mould 2. (a) CM values for
analysed points; (b) CM value at point 81 = 23.563, (c) CM value at point 381 = 5.840 and (d) CM value at point
661 = 11.785.

In Fig. 12a, many CM values are well above the threshold, characterizing damaging regions.
The three higher peaks are related to the Figs. 11b, 11c and 11d respectively. The peak related to
the Fig. 11b, is the highest one in the Fig. 11a) and has a large value of CM that can indicate a
region with “orange peel” damage. In addition, other two higher peaks generated from Figs. 11c
and 11d could indicate a scratching damage.
By the proposed system, it is also possible to estimate the area that presents defects. For instance,
for the sample 2 the damaging area is about 10% of the total surface and for the sample 3 the damage
are spread over 7.6% of the total area.

5 Conclusion
The present paper has presented an automatic approach to evaluate moulds surfaces by using
artificial intelligence and image processing techniques. The starting point of the evaluation
procedure is the image generated by the laser light scattered over the sample surface. Experimental
results showed that the proposed system may be applied to map mould surfaces, bringing several
new information in terms of surface quality. As an overall average, the obtained results correlate
well to traditional roughness evaluations. However, an important advantage is indicated, concerning
the ability of the proposed method to detect spot damaged regions and assigning the damage type
over each region. The results thus point that the proposed approach could be an alternative for mould

15
surface inspection tasks, as well as accomplished to polishing or other plastic mould finishing
processes, as a quantitative and precise quality control method.

Acknowledgments
The authors would like to thank Uninove, CAPES and CNPq for the scholarship granted to two of the authors, as
well as Villares Metals for providing the samples of polished moulds.

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