Review of the mathematical foundations of data fusion techniques in surface metrology

The recent proliferation of engineered surfaces, including freeform and structured surfaces, is challenging current metrology techniques. Measurement using multiple sensors has been proposed to achieve enhanced benefits, mainly in terms of spatial frequency bandwidth, which a single sensor cannot provide. When using data from different sensors, a process of data fusion is required and there is much active research in this area. In this paper, current data fusion methods and applications are reviewed, with a focus on the mathematical foundations of the subject. Common research questions in the fusion of surface metrology data are raised and potential fusion algorithms are discussed

Physics-Informed Computer Vision: A Review and Perspectives

Incorporation of physical information in machine learning frameworks are opening and transforming many application domains. Here the learning process is augmented through the induction of fundamental knowledge and governing physical laws. In this work we explore their utility for computer vision tasks in interpreting and understanding visual data. We present a systematic literature review of formulation and approaches to computer vision tasks guided by physical laws. We begin by decomposing the popular computer vision pipeline into a taxonomy of stages and investigate approaches to incorporate governing physical equations in each stage. Existing approaches in each task are analyzed with regard to what governing physical processes are modeled, formulated and how they are incorporated, i.e. modify data (observation bias), modify networks (inductive bias), and modify losses (learning bias). The taxonomy offers a unified view of the application of the physics-informed capability, highlighting where physics-informed learning has been conducted and where the gaps and opportunities are. Finally, we highlight open problems and challenges to inform future research. While still in its early days, the study of physics-informed computer vision has the promise to develop better computer vision models that can improve physical plausibility, accuracy, data efficiency and generalization in increasingly realistic applications

In-situ crack and keyhole pore detection in laser directed energy deposition through acoustic signal and deep learning

Cracks and keyhole pores are detrimental defects in alloys produced by laser directed energy deposition (LDED). Laser-material interaction sound may hold information about underlying complex physical events such as crack propagation and pores formation. However, due to the noisy environment and intricate signal content, acoustic-based monitoring in LDED has received little attention. This paper proposes a novel acoustic-based in-situ defect detection strategy in LDED. The key contribution of this study is to develop an in-situ acoustic signal denoising, feature extraction, and sound classification pipeline that incorporates convolutional neural networks (CNN) for online defect prediction. Microscope images are used to identify locations of the cracks and keyhole pores within a part. The defect locations are spatiotemporally registered with acoustic signal. Various acoustic features corresponding to defect-free regions, cracks, and keyhole pores are extracted and analysed in time-domain, frequency-domain, and time-frequency representations. The CNN model is trained to predict defect occurrences using the Mel-Frequency Cepstral Coefficients (MFCCs) of the lasermaterial interaction sound. The CNN model is compared to various classic machine learning models trained on the denoised acoustic dataset and raw acoustic dataset. The validation results shows that the CNN model trained on the denoised dataset outperforms others with the highest overall accuracy (89%), keyhole pore prediction accuracy (93%), and AUC-ROC score (98%). Furthermore, the trained CNN model can be deployed into an in-house developed software platform for online quality monitoring. The proposed strategy is the first study to use acoustic signals with deep learning for insitu defect detection in LDED process.Comment: 36 Pages, 16 Figures, accepted at journal Additive Manufacturin

Multimodal sensor fusion for real-time location-dependent defect detection in laser-directed energy deposition

Real-time defect detection is crucial in laser-directed energy deposition (L-DED) additive manufacturing (AM). Traditional in-situ monitoring approach utilizes a single sensor (i.e., acoustic, visual, or thermal sensor) to capture the complex process dynamic behaviors, which is insufficient for defect detection with high accuracy and robustness. This paper proposes a novel multimodal sensor fusion method for real-time location-dependent defect detection in the robotic L-DED process. The multimodal fusion sources include a microphone sensor capturing the laser-material interaction sound and a visible spectrum CCD camera capturing the coaxial melt pool images. A hybrid convolutional neural network (CNN) is proposed to fuse acoustic and visual data. The key novelty in this study is that the traditional manual feature extraction procedures are no longer required, and the raw melt pool images and acoustic signals are fused directly by the hybrid CNN model, which achieved the highest defect prediction accuracy (98.5 %) without the thermal sensing modality. Moreover, unlike previous region-based quality prediction, the proposed hybrid CNN can detect the onset of defect occurrences. The defect prediction outcomes are synchronized and registered with in-situ acquired robot tool-center-point (TCP) data, which enables localized defect identification. The proposed multimodal sensor fusion method offers a robust solution for in-situ defect detection.Comment: 8 pages, 10 figures. This paper has been accepted to be published in the proceedings of IDETC-CIE 202

Recognition of Planar Segments in Point Cloud Based on Wavelet Transform

Within industrial automation systems, three-dimensional (3-D) vision provides very useful feedback information in autonomous operation of various manufacturing equipment (e.g., industrial robots, material handling devices, assembly systems, and machine tools). The hardware performance in contemporary 3-D scanning devices is suitable for online utilization. However, the bottleneck is the lack of real-time algorithms for recognition of geometric primitives (e.g., planes and natural quadrics) from a scanned point cloud. One of the most important and the most frequent geometric primitive in various engineering tasks is plane. In this paper, we propose a new fast one-pass algorithm for recognition (segmentation and fitting) of planar segments from a point cloud. To effectively segment planar regions, we exploit the orthonormality of certain wavelets to polynomial function, as well as their sensitivity to abrupt changes. After segmentation of planar regions, we estimate the parameters of corresponding planes using standard fitting procedures. For point cloud structuring, a z-buffer algorithm with mesh triangles representation in barycentric coordinates is employed. The proposed recognition method is tested and experimentally validated in several real-world case studies

ShipGen: A Diffusion Model for Parametric Ship Hull Generation with Multiple Objectives and Constraints

Ship design is a years-long process that requires balancing complex design trade-offs to create a ship that is efficient and effective. Finding new ways to improve the ship design process can lead to significant cost savings for ship building and operation. One promising technology is generative artificial intelligence, which has been shown to reduce design cycle time and create novel, high-performing designs. In literature review, generative artificial intelligence has been shown to generate ship hulls; however, ship design is particularly difficult as the hull of a ship requires the consideration of many objectives. This paper presents a study on the generation of parametric ship hull designs using a parametric diffusion model that considers multiple objectives and constraints for the hulls. This denoising diffusion probabilistic model (DDPM) generates the tabular parametric design vectors of a ship hull for evaluation. In addition to a tabular DDPM, this paper details adding guidance to improve the quality of generated ship hull designs. By leveraging classifier guidance, the DDPM produced feasible parametric ship hulls that maintain the coverage of the initial training dataset of ship hulls with a 99.5% rate, a 149x improvement over random sampling of the design vector parameters across the design space. Parametric ship hulls produced with performance guidance saw an average of 91.4% reduction in wave drag coefficients and an average of a 47.9x relative increase in the total displaced volume of the hulls compared to the mean performance of the hulls in the training dataset. The use of a DDPM to generate parametric ship hulls can reduce design time by generating high-performing hull designs for future analysis. These generated hulls have low drag and high volume, which can reduce the cost of operating a ship and increase its potential to generate revenue