A Lightweight Reconstruction Network for Surface Defect Inspection

Currently, most deep learning methods cannot solve the problem of scarcity of industrial product defect samples and significant differences in characteristics. This paper proposes an unsupervised defect detection algorithm based on a reconstruction network, which is realized using only a large number of easily obtained defect-free sample data. The network includes two parts: image reconstruction and surface defect area detection. The reconstruction network is designed through a fully convolutional autoencoder with a lightweight structure. Only a small number of normal samples are used for training so that the reconstruction network can be A defect-free reconstructed image is generated. A function combining structural loss and $\mathit{L}1$ loss is proposed as the loss function of the reconstruction network to solve the problem of poor detection of irregular texture surface defects. Further, the residual of the reconstructed image and the image to be tested is used as the possible region of the defect, and conventional image operations can realize the location of the fault. The unsupervised defect detection algorithm of the proposed reconstruction network is used on multiple defect image sample sets. Compared with other similar algorithms, the results show that the unsupervised defect detection algorithm of the reconstructed network has strong robustness and accuracy.Comment: Journal of Mathematical Imaging and Vision(JMIV

Lightweight CNN Models for Product Defect Detection with Edge Computing in Manufacturing Industries

Detecting product defects is one of the manufacturing industry's most essential processes in quality control. Human visual inspection for product defects is the traditional method employed in the industry. Nevertheless, it can be laborious, prone to human mistakes, and unreliable. Deep Learning-based Convolution Neural Networks (CNN) has been extensively used in fully automating product defect detection systems. However, real-time edge devices installed at the manufacturing site generally have limited computing capability and cannot run different CNN models. A lightweight CNN model is adopted in this scenario to find a balance between defect detection, model training time, memory consumption, computing time and efficiency. This work provides lightweight CNN models with transfer learning for product defect detection on fabric, surface, and casting datasets. We deployed the trained model to the NVIDIA Jetson Nano-kit edge device for detection speed with better simulation results in terms of accuracy, sensitivity rate, specificity rate, and F1 measure in the workplace context of the Manufacturing Industries

Deep CNN-Based Automated Optical Inspection for Aerospace Components

ABSTRACT The defect detection problem is of outmost importance in high-tech industries such as aerospace manufacturing and is widely employed using automated industrial quality control systems. In the aerospace manufacturing industry, composite materials are extensively applied as structural components in civilian and military aircraft. To ensure the quality of the product and high reliability, manual inspection and traditional automatic optical inspection have been employed to identify the defects throughout production and maintenance. These inspection techniques have several limitations such as tedious, time- consuming, inconsistent, subjective, labor intensive, expensive, etc. To make the operation effective and efficient, modern automated optical inspection needs to be preferred. In this dissertation work, automatic defect detection techniques are tested on three levels using a novel aerospace composite materials image dataset (ACMID). First, classical machine learning models, namely, Support Vector Machine and Random Forest, are employed for both datasets. Second, deep CNN-based models, such as improved ResNet50 and MobileNetV2 architectures are trained on ACMID datasets. Third, an efficient defect detection technique that combines the features of deep learning and classical machine learning model is proposed for ACMID dataset. To assess the aerospace composite components, all the models are trained and tested on ACMID datasets with distinct sizes. In addition, this work investigates the scenario when defective and non-defective samples are scarce and imbalanced. To overcome the problems of imbalanced and scarce datasets, oversampling techniques and data augmentation using improved deep convolutional generative adversarial networks (DCGAN) are considered. Furthermore, the proposed models are also validated using one of the benchmark steel surface defects (SSD) dataset

Machine Learning Based AFP Inspection: A Tool for Characterization and Integration

Automated Fiber Placement (AFP) has become a standard manufacturing technique in the creation of large scale composite structures due to its high production rates. However, the associated rapid layup that accompanies AFP manufacturing has a tendency to induce defects. We forward an inspection system that utilizes machine learning (ML) algorithms to locate and characterize defects from profilometry scans coupled with a data storage system and a user interface (UI) that allows for informed manufacturing. A Keyence LJ-7080 blue light profilometer is used for fast 2D height profiling. After scans are collected, they are process by ML algorithms, displayed to an operator through the UI, and stored in a database. The overall goal of the inspection system is to add an additional tool for AFP manufacturing. Traditional AFP inspection is done manually adding to manufacturing time and being subject to inspector errors or fatigue. For large parts, the inspection process can be cumbersome. The proposed inspection system has the capability of accelerating this process while still keeping a human inspector integrated and in control. This allows for the rapid capability of the automated inspection software and the robustness of a human checking for defects that the system either missed or misclassified