Increasingly advanced quality control with AI

Flawmaster+ is the latest-generation automatic sorting system developed by Sacmi-Italvision for quality control of ceramic surfaces. Precision, compactness, ease of use and immediacy of operation are the key characteristics of a system designed to function as the “brain” of an interconnected digital production line.

The module can be installed upstream of the sorting line, downstream of grinding or at the kiln exit.

Using three high-resolution cameras and light sources positioned at different angles, Flawmaster+ is able to detect all types of defects (surface, mechanical, decoration, shade and colour defects, and more) with precision, accuracy and consistency.

Advanced self-learning

For digitally decorated products, the recipes are configured simply by uploading the reference graphics file.

Accurate quality control is combined with a self-learning concept that does not rely solely on a certain number of “good” tiles to be inspected but draws from the entire graphics file, which contains all possible variations of any given tile relative to the reference canvas.

The result is a much faster and far more accurate process that avoids false defect detections.

Ease of use and AI

Flawmaster+ is the only solution on the market that gives manufacturers the opportunity to create the reference model using artificial intelligence as an alternative to digital printer graphics files.

In practice, once the type of defect has been identified, the operator no longer needs to configure the machine manually. Flawmaster+ self-adjusts, automatically selecting the optimal setup according to the type of defect to be detected (e.g. a small surface scratch).

The system also evolves over time, using neural network logic to store acquired data and use it to improve performance.

Compared to alternative solutions, Flawmaster+ also facilitates:

• automatic size changes, by reloading the reference canvas and automatically adjusting the aligner, conveyor speed and the height of lenses and sensors;
• on-the-fly product changeovers. In the M2M (machine-to-machine) configuration, the subsequent batch is processed fully automatically, with the next recipe set according to the order schedule.

Two machines in one with the Caliber Planarity Integrated device

Flawmaster+ is available with an integrated Caliber Planarity Integrated (CPI) device and/or bevel control module, making it effectively two machines in one while maintaining the same overall dimensions.

In the version with integrated CPI device, the system runs additional checks on dimensions, diagonals, side shape defects, local defects, curved edges, shape deviations, warpage, concavity and convexity.

Towards a new model of digital production plant

Flawmaster+ delivers superior quality and efficiency thanks to advanced defect mapping and analysis and the ability to provide feedback to keep production flows stable.

Installed downstream from the grinding line, Flawmaster+ not only classifies tiles but also provides feedback to correct the upstream squaring machine, automatically fine-tuning sorting adjustments. This means that defective items are deleted from the machine’s reference models at the product creation stage.

Flawmaster+ paves the way for Sacmi’s Easy Factory concept, a digital ceramic plant characterised by zero defects, zero unnecessary handling and zero reworking of non-conforming pieces thanks to a simple, automatic and consistently accurate process.