Optical Dual Laser Based Sensor Denoising for OnlineMetal Sheet Flatness Measurement Using Hermite Interpolation

Flatness sensors are required for quality control of metal sheets obtained from steel coils by roller leveling and cutting systems. This article presents an innovative system for real-time robust surface estimation of flattened metal sheets composed of two line lasers and a conventional 2D camera. Laser plane triangulation is used for surface height retrieval along virtual surface fibers. The dual laser allows instantaneous robust and quick estimation of the fiber height derivatives. Hermite cubic interpolation along the fibers allows real-time surface estimation and high frequency noise removal. Noise sources are the vibrations induced in the sheet by its movements during the process and some mechanical events, such as cutting into separate pieces. The system is validated on synthetic surfaces that simulate the most critical noise sources and on real data obtained from the installation of the sensor in an actual steel mill. In the comparison with conventional filtering methods, we achieve at least a 41% of improvement in the accuracy of the surface reconstruction

Crack detection in "as-cast" steel using laser triangulation and machine learning

We describe a high-accuracy inspection system designed to automatically detect cracks in "as-cast" steel slabs. Real-time slab inspection requires instrumentation capable of withstanding high temperatures above the steel surface as well as coping with the dirty and dusty environment present in a steel mill. Crack detection is also challenging due to the presence of oxidation scale on the slab surface. A bespoke laser triangulation system has been developed, providing images at 250 fps with a calibrated surface resolution of 97 μm from a 1m standoff distance. Cracks are detected using a combination of morphological detection and SVM classifier. Results are reported from laboratory testing and from extended trials at a production steel mill

Depth Data Denoising in Optical Laser Based Sensors for Metal Sheet Flatness Measurement: A Deep Learning Approach

Surface flatness assessment is necessary for quality control of metal sheets manufactured from steel coils by roll leveling and cutting. Mechanical-contact-based flatness sensors are being replaced by modern laser-based optical sensors that deliver accurate and dense reconstruction of metal sheet surfaces for flatness index computation. However, the surface range images captured by these optical sensors are corrupted by very specific kinds of noise due to vibrations caused by mechanical processes like degreasing, cleaning, polishing, shearing, and transporting roll systems. Therefore, high-quality flatness optical measurement systems strongly depend on the quality of image denoising methods applied to extract the true surface height image. This paper presents a deep learning architecture for removing these specific kinds of noise from the range images obtained by a laser based range sensor installed in a rolling and shearing line, in order to allow accurate flatness measurements from the clean range images. The proposed convolutional blind residual denoising network (CBRDNet) is composed of a noise estimation module and a noise removal module implemented by specific adaptation of semantic convolutional neural networks. The CBRDNet is validated on both synthetic and real noisy range image data that exhibit the most critical kinds of noise that arise throughout the metal sheet production process. Real data were obtained from a single laser line triangulation flatness sensor installed in a roll leveling and cut to length line. Computational experiments over both synthetic and real datasets clearly demonstrate that CBRDNet achieves superior performance in comparison to traditional 1D and 2D filtering methods, and state-of-the-art CNN-based denoising techniques. The experimental validation results show a reduction in error than can be up to 15% relative to solutions based on traditional 1D and 2D filtering methods and between 10% and 3% relative to the other deep learning denoising architectures recently reported in the literature.This work was partially supported by by FEDER funds through MINECO project TIN2017-85827-P, and ELKARTEK funded projects ENSOL2 and CODISAVA2 (KK-202000077 and KK-202000044) supported by the Basque Governmen