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In recent years, many traditional industries are facing transformation or need to upgrade equipment toward automation. This research is based on assisting traditional tile manufacturers to turn the process of mosaic tiles into automated facilities. Improving the previous designs, the machine has been manufactured and consists of a mosaic tile puzzle machine, two automatic storage systems and a conveyor. The two automatic storage systems are the feed and storage function respectively. The storage system and the mosaic tile puzzle machine are connected by a conveyor. Moreover, equipped with a pneumatic system, a rotating multiple suction head and a mosaic tile loading and unloading mechanism are combined on a dual-axis slide table. The control program and human-machine interface are enforced by the graphic programming language LabVIEW with NI PXI-7350 motion axis card, NI PXIe-6368 DAQ and other devices for hardware control.
This study optimizes the production process and mechanism, and conducts the following research: 1. Add mosaic tile color picking system to build mosaic tile samples, 2. Add image digital pre-processing system to calculate the pixel level of the picture through the program and the algorithm to extract the color, and reduce the level of colors to the mosaic tile color owned by the tile maker, 3. Add stereoscopic display system to make the display of mosaic tiles on the human-machine interface close to the actual collage, 4. Optimize the rotary suction mechanism of mosaic tile puzzle machine, and improve the speed and accuracy by replacing the hardware structure, 5. Add image recognition system by using NI PXIe-1435 image capture card, industrial camera and fixed focus lens to compare RGB with LabVIEW VISON module for further displaying current recognition status by the human-machine interface.
After the completion of this research, the overall process and automation is more complete, and finally two new systems are produced. The complete image pre-processing flow system, image recognition system, and the optimization of the puzzle mechanism are used to enhance the hardware suction power by 88.8%, the weight of the parts reduced by 55.6%, and the speed parameter value of the rotating mechanism increased by 40 times.
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