SICE Annual Conference 2011

September 13-18, 2011, Waseda University, Tokyo, Japan

An Image Inspection Method for Car Brake Parts

Yutaro KOYA, Yue BAO
Faculty of Knowledge Engineering, Tokyo City University, Setagaya-ku, Tokyo
(E-mail: yk85_tsubata@yahoo.co.jp)

Abstract: In order to increase productivity and efficiency, the components factory for car manufacture needs an automatic flaw detecting system by
using image processing. The conventional method could inspect flaw of a metal surface with the tiny ruggedness and the dirt which remained in the
washing process. The result of a long-term test proved parts with which the inside of a flaw is dark because of decline in the reflectivity of the surface
where time has passed or accumulation of dirt existed, and the conventional method was difficult to detect the flaw of such parts. This study proposes
the automatic flaw detecting method which can detect those flaws by adding a new procedure to the process which used the rate of the luminance of
the conventional method. By the experimental results, it was confirmed that the flaws of defective parts used as the inspecting standard can be
extracted certainly.

Key Words: metal parts, flaw detection, image processing, divided region, difference of luminance, ratio of luminance

1. INTRODUCTION polishing. Moreover, the proposal method can respond

When producing a product at a factory, some of made
products are defectives. Therefore, it is necessary to
distinguish an excellent article and a defective at the
process of inspection. If the metallic joint parts of the
brake hose of the car [1] which is the target of this study
have a flaw in the surface, they are made into the
defective. This inspection was carried out by the visual
inspection by man so far. However, the inspection by
man produces individual difference in a criterion of
judgement. As a result, since the number to be examined
is huge, if human being inspects, an inspector's fatigue
will collect by a long activity. Therefore, the incorrect
judging by careless mistake occurs because of the
fatigue. Therefore, automation of inspection by an
image processing is advanced.
As an inspection method of the metal parts by an
image processing, various methods are proposed in the
past. For example, the method of performing edge
extraction to a depth map[2], the magnetic powder
method[3], the method of carrying out binarization of
the photographed image[4], the method using
Model-based Matching by a field-band model[5][6], the
method which used the density difference between the
areas which divided the inspection surface at equal
intervals[7]. However, brake hose joint metal parts have
two or more flaws and shallow flaws of a type which
were called indentation, dent, and abrasion, and there
are the feature of having tiny irregularity and dirt on the
surface. Therefore, any approach was difficult to detect
the flaw of brake hose joint metal parts.
In order to solve these problems, we have proposed
the flaw detecting method on the surface of metal parts
which uses a gray scale image[8]. First, this method
divides the surface of parts into a block at equal
intervals, then extracts a flaw block, connects a flaw
block, and judges a flaw. This method examines the
luminance difference and distribution of the pixel value
in a flaw block. So, the proposal method can extract a
flaw block, without being influenced by the dirt which
adhered on the surface of parts, and the part from which
surface reflectivity is changing with the conditions of
also to a complicated flaw configuration flexibly by
judging after connecting a flaw block. However, as a
result of carrying out a long-term test, it turned out that
dirt is accumulated in the base of a flaw by the time
parts move to an inspection location from input port.
However, the result of a long-term test proved that the
parts with which the reflectivity of the surface where
time passed fell, and the parts which dirt accumulated in
the base of a flaw when parts moved to the location
which conducts inspection from input port existed. If
flaw detection was performed to the flaw with a flat
base in this condition, the flaw will have been
recognized as dirt. Therefore, this approach might be
unable to detect a flaw.
Then, this paper proposes the method which
improved the conventional method which uses a flaw
block. This method distinguishes a flaw and dirt more
clearly and extracts the flaw of parts certainly. By the
experiment which uses a prototype system, we
confirmed that the proposal approach was able to extract
certainly the flaw of parts, without being influenced by
change of the reflective degree of the dirt adhering to
parts, or the light under the effect of polishing.
2. EXAMINATION TARGET AND
PHOTOGRAPHY METHOD
The appearance of the parts used as a subject of
inspection is shown in Fig.1(a). These parts are called
"MEDAMA" in the production site. Metallic joint parts
of the brake hose consist of MEDAMA,sockets, and
nipples. If this part is assembled, it will become like
(a) Appearance (b) The finished product
Fig. 1 The parts to be inspected

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(a) Flaw piercing through (b) Large flaw
metal parts
Fig. 2 The flaw handled as defectives
Fig. 3 The flaw handled as quality goods
Fig.1(b). Both sides of a circular field of the MEDAMA
parts shown by Fig1 (a) are the objects of flaw detection.
In case parts are actually used, oil passes along the hole
of the center of MEDAMA parts. Therefore, if parts are
used in the condition that a flaw exists in this surface
section, it will become the cause by which oil leakage
occurs. As a result, since a poor brake is caused, you
have to avoid mixing of defective.
Fig.2 is a part of defective sample used as the
inspection standard which the factory offered. These
defective samples are defined as the standard of a flaw
by visual inspection. The type of flaw of defective has
two types like Fig.2. One is parts (a) with the flaw
which has pierced the outside from the inner side, and
another is parts (b) with the flaw in which an area is
large. On the other hand, you have to distinguish a small
flaw like Fig.3 which do not correspond to defective
samples as an excellent article.
3. PROPOSAL METHOD
The flow of the whole image processing of the flaw
detection by the proposal method is shown in Fig.4. The
image photographed with the camera is changed into
gray scale as preconditioning. And the noise of an image
is removed using smoothing. In case an image
processing is performed, pixel information is got only
from the circular portion of the surface of parts, and the
surface is divided into a block. The configuration of a
block is divided into the radiation direction and
circumference direction of a circle from a center like
Fig.5. Inspection is carried out after fixing the
inspection range in the range decided beforehand. Parts
to be examined have the parts with which time has
passed, and the parts which dirt accumulated in the flaw.
If the conventional method is applied to those parts, a
flaw will be recognized as a part with bad reflectivity
under the effect of dirt etc. Therefore, the conventional
method was not able to detect the flaw of those
conditions. Then, when inspecting the concentration of
the black pixel in flaw block combination, the process
of adding adjustment was added to the conventional
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Input image from the camera The data of the pixel
acquisition range
Gray-scaling
Noise-smoothing
Division of block
Extraction of the flaw block candidates by the difference in
the luminance value in the divided blocks. （Process 1）
Decision of the flaw block by the distribution of the pixels in
the flaw block candidates. （Process 2）
Extraction of the flaw region candidate by the connection of
the flaw blocks. （Process 3）
Decision of the flaw by area of black pixels in the flaw region
candidate （Process 4）
Decision of the flaw by concentration of black pixel in the
flaw region candidate （Process 5）
No
Is there the flaw?
Yes
Sending the part to side Sending the part to
of defective parts side of good parts
Fig. 4 The flow chart of the flaw detection
One divided block
Fig. 5 The method of dividing area for detecting
method. The judgment of a flaw including this process
consists of the following five processes.
3.1 Extraction of the flaw block by the difference of a
luminance value
The difference of the luminance value in the
boundary of a part where a flaw exists is calculated, and
a flaw block is detected by using a dynamic threshold
value. This avoids the effect of change of the reflective
degree for every parts.
First, the difference between maximum and the
minimum of the luminance value in a block is
calculated for every block, and if the value is over the
threshold, it will be judged that it is a flaw block. When
the average of the luminance value in a block is defined
as μ , standard deviation is defined as σ and the

Fig. 6 The parts with short flaws
threshold for performing a flaw judging is defined as
t d , t d is calculated from a equation (1).
td = μ + σ (1)
3.2 The judgment of the flaw block by the black pixel
in a flaw block
In the surface of parts, irregularity and a noise (fine
dirt and luminance change) may exist.
Or the short shallow flaw which has not pierced parts
like Fig.6 may exist. If flaw detection using the
difference of a luminance value is performed to the
image of the parts with which these exist, the flaw block
of those other than the flaw which should be detected
will also be extracted. The flaw of these types is
excepted from the judgment of a flaw using the
following methods.
First, the minimum of the luminance value in a block
is calculated about all flaw block candidates. The
maximum value of those values is set as the threshold
t p of a black pixel. The pixel with the luminance value
below a threshold is treated as a black pixel which exists
in a flaw part. And the rate of the pixel of the luminance
value below the threshold t p in each block is
calculated about all blocks. If the rate of the pixel in a
block is larger than a definite value (threshold value t1 ),
the block will be judged to be a flaw block. Otherwise,
the block is judged to be the block without a flaw.
3.3 Extraction of the flaw block connection by the
number of connection
In order to judge the area, the direction, and length of
a flaw, combination of a flaw block is used for a
judgment. Procedure is shown in Fig.7.
First, each block is treated as a binary format image
which consists of a block with a flaw and a block
without a flaw. Labeling processing of eight directions
about a block is performed to the block with a flaw, and
the number of connection of each label is counted. If
there is a group of the block with the large number of
connection, the group will be judged to be flaw block
connection. In this case, the standard judged to be a flaw
is an area. However, in the case of these parts, even if
the flaw which has pierced parts is small, there is a
possibility of influencing the performance of a brake.
Therefore, the criterion of two flaws is set to a condition,
and when both of conditions are fulfilled, the block
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The block judged as a flaw
The condition of the Blocks are considered as a
blocks in the image binary image which composes
of flaw block and block
without a flaw
1
1 1 1 2
1
1
1
The labeling processing is carried out in the block, and the
decision using the connectivity number is carried out
Fig. 7 The procedure of the decision using the region area
(a) The case of large flaw (b) The case of the gathering
of the small flaws
Fig.8 The example of the large flaw and the aggregate of
small flaws
combination is judged to be a flaw. The 1st condition is
that the block count more than fixed numbers (threshold
value t 2 ) has connected. The 2nd condition is that the
block more than fixed numbers (threshold value t3 ) has
connected in the radiation direction from the parts
center.
3.4 The flaw judging by the black pixel area in flaw
block combination
If the black pixel in flaw block combination is inspected,
two kinds of flaws exist. One is an original flaw and its
lump area is large like Fig.8(a). Another is the flaw in
which an excellent article judging is possible, and its
lump area is small like Fig.8(b). Then, in order to
distinguish the aggregation of a fine flaw, and an
original flaw, a flaw judging is performed by inspecting
about the size of the black pixel lump in the extracted
flaw block combination. A labeling process is performed
about the black pixel in each flaw block combination.
And if the maximum connectivity number is below
threshold value t 4 decided on beforehand, it will
judge that the inside of flaw block combination is the
aggregate of a fine flaw, and the flaw block combination
will be excepted from the judgment of a flaw.
3.5 The flaw judging by the black pixel
concentration in flaw block combination
Even if the lump of the black pixel in flaw block
combination is large, the reason for occurrence may be
change of the reflective rate of light by the effect of dirt
 (a) The flaw (b) The bad reflectivity
(c) The flaw in which dirt accumulated
Fig.9 The part with flaws and the part with bad reflectivity
or polishing. Then, in order to distinguish these and an
original flaw, the concentration value of the black pixel
in flaw block combination is inspected.
In the case of the original flaw, many dark black
pixels exist in flaw block combination like Fig.9(a). On
the other hand, when it is the effect of dirt or polishing,
many light black pixels exist in flaw block combination
like Fig.9(b). Here, threshold value tb of dark black is
calculated by a equation (2) using the black pixel
threshold value calculated by the equation (1).
tb = t d × α (2)
α in a equation is a weight coefficient.
About each flaw block combination, the total of a
black pixel darker than t d of a equation (1) and the
number of pixels darker than tb of a equation (2) are
inspected. If the ratio of a pixel darker than tb is lower
than a definite value (threshold value t5 ), the flaw
block combination will judge that it was detected under
the effect of dirt or polishing, and the flaw block
combination will be excepted from the judgment of a
flaw.
However, as for the flaw of a configuration with a flat
base like Fig.9(a), a bottom may be covered with dirt
like Fig.9(c). If a judgment is applied to a flaw after dirt
has collected like Fig.9(c), the flaw will be recognized
as a bad reflectivity like Fig.9(b). As a result, an
incorrect judging is performed like Fig.10. Here, we
considered pixel distribution of these parts. When the
bottom of a flaw is covered with dirt, the pixel of the
edge part of a flaw consists of dark black pixels, and the
pixel of the other part consists of light black pixels. In
the case of the dirt which has adhered to the location
which is not a flaw on the other hand, the pixel of all
parts consists of pixels of light black. Then, using this
feature, in case the rate of the pixel near black is
calculated, the adjustment for clarifying those
differences is performed. And after correcting, flaw
block combination is judged.
First of all, before calculating the rate of the pixel of
dark black, the number of the pixels of the light black in
each block is counted. Then, the block with many pixels
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The flaw The flaw in which dirt
accumulated
Fig. 10 The inside of the equipment
There are most
gray pixels
Remove from
calculation
Fig.11 The method of the adjustment in concentration
value calculation
of light black is partly extracted from a top like Fig.11.
And the pixel information of those blocks is excepted
from calculation of a rate. The number of the blocks to
except defines any value.
If the judgment which included this adjustment in
each parts shown in Fig.9 is applied, a judgment will
bring a result shown below. When parts other than a
flaw are bright like Fig.9(a), the pixel distribution in the
corresponding block has the high ratio of a dark pixel in
all blocks. Therefore, since the ratio of the dark pixel in
block combination maintains a high value even if
adjustment excepts a block, block combination is
recognized as a flaw. When dirt has adhered like
Fig.9(b), the pixel distribution in the corresponding
block has the low ratio of a dark pixel in all blocks.
Therefore, the ratio of the dark pixel in block
combination maintains a low value even if adjustment
excepts a block. As a result, block combination is
recognized as dirt and excepted from a flaw judging.
When dirt was being accumulated in the flaw like
Fig.9(c) and not having been corrected, the pixel
distribution in the corresponding block had the low ratio
of a dark pixel. Therefore, block combination may have
been recognized as dirt. Then, if some blocks are
excepted from block combination, the ratio of the dark
pixel as the whole will become high. Therefore, the flaw
shown in Fig.9(c) can be recognized correctly. So,
proposal method can tell clearly a part with bad surface
reflectivity from a flaw.
4. EXPERIMENT
4.1 Prototype system
The appearance of the device inside a prototype system
is shown in Fig.12, and architecture is shown in Fig.13.
The flow of an action of a system is as follows. Parts
enter from the upper part of an inspection system and
the stopper of an upper case stops parts. After inspection
and movement of front parts finish, the stopper of an
upper case opens and parts move to the location which
takes a photograph. The image of parts is photographed

Fig. 12 The inside of the equipment
Photographic
PC
system
Stopper
Sequencer Conforming
article
Defective
Fig. 13 System constitution
Metal parts
Light source Half mirror
(LED)
Convex
lens
Camera
Fig. 14 The placement of the photography system
with a photography system and the data is sent to PC.
Then, the existence of a flaw is judged by the method of
3. The stopper of the lower stage is moved in the
suitable direction by a sequencer based on a judged
result. Then, the stopper of the middle is opened and
parts are sent to the following process in consideration
of the existence of a flaw.
Arrangement of each device of a photography system
is shown in Fig.14, and a specification is shown in
Table1. Fig. 14 expresses the field of one side and the
same device is arranged also in the field of the opposite
side. Since tiny irregularity exists in the surface,
MEDAMA parts need to illuminate the surface
uniformly. Therefore, the light irradiated to parts uses a
parallel light. In order to obtain a parallel beam, a light
source uses LED and a convex lens is arranged in front
of a light source. Moreover, in order to take a
photograph from the front of metal parts, applying light
uniformly to the front of metal parts, the half mirror was
installed between a camera and parts, and since light
source light was reflected by the half mirror, light was
irradiated to parts. Moreover, the photography system is
- 41 -
Table 1 The specification of the experimental system
Windows XP
OS
Professional
Intel Core2 Duo E6850
CPU
3.00GHz
Memory 2GB
The resolution of the
800×600pixel
camera
Diaphragm F=2.5
The intensity of an
electric current run in the 190mA
light source of LED
attached in the interior of the apparatus of a shaded state
in order to prevent the effect of outside lightness.
The inspection range inputs a value beforehand
before inspection using sample parts. And, the
inspection range is set as the always same range during
inspection.
4.2 Decision of a division parameter and a threshold
value
We calculated the threshold value of flaw detection in
the experiment using 50 defective samples and 50
excellent article samples used as the inspection standard
which the factory offered. A threshold value needs to be
set up so that the proposal method can judge an
excellent article sample and a defective sample
altogether correctly. Moreover, when two or more flaws
exist in a defective sample, a threshold value needs to
be set up so that the proposal method can recognize
each flaw altogether correctly. For those reasons, the
experiment was conducted repeatedly, adjusting the
number of partitions and a threshold value. From the
result of an experiment, the division interval of the
radiation direction was every 2 times, division of a
circumference direction was six division, α was 0.3,
the number of exceptions of a block was 1, and the
values from t1 to t 5 were 0.035, 7, 5, 250, and 0.55,
respectively.
However, since there is individual specificity in the
reflective rate of the light in the surface of parts, the
value of t b may become large too much. At this time,
the experiment showed that the luminance value of the
black pixel of a flaw part was 35 or less. Then, when
t b became larger than 35, t b was set to 35.
The image of the result of having applied the
proposal method to the parts of the image of Fig.9 is
shown in Fig.15. When bright in the base of a flaw, or
when the reflectivity of the base of a flaw is bad, the
proposal method has recognized the flaw. Moreover, the
proposal method has been correctly recognized about
the part with bad reflectivity with dirt etc.
4.3 The experiment in a site
In order to confirm the flaw detection precision of the
proposal method, we actually detected the flaw of parts
using the prototype system. We conducted the

(a) The flaw
(b) The bad reflectivity
(c) The flaw in which dirt accumulated
Fig. 15 The result of a detection experiment
inspection experiment using the defective sample
submitted from the factory. Various parameters and a
threshold value used the value calculated by 4.2. As a
result of the experiment, the trial production system was
able to judge all the samples correctly. And the trial
production system was able to judge correctly the
sample which has a flaw with the flat bottom. In order
to check the practicality of the proposal method now, we
arrange an inspection system on a product line, and are
going to perform the long-term test which inspects
indiscriminately parts.
5. CONCLUSION
Based on the result of the long-term test of the flaw
inspecting method of the metallic joint parts of the
- 42 -
brake hose, this paper built the amelioration system.
The proposal method corrects by concentration value
calculation in the flaw decision processing by the
concentration of the black pixel in flaw block
combination. So, the proposal method can extract a flaw,
without receiving the effect by decline in the reflectivity
of the surface where time passed and the effect by
accumulation of dirt. As a result, the precision of flaw
inspection of the metallic joint parts of the brake hose
by an image processing was able to be raised more.
Moreover, the parameter and threshold value of the
proposal method were experimentally calculated in the
production site using the defective sample and excellent
article sample used as a standard. By this method, the
value with suitable parameter and threshold value were
able to be calculated, and the practical system suitable
for the actual condition of a production site has been
built. A future subject is verification of whether the
inspection system has a practical precision by
performing a long-term test.
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