Novel methods of object recognition and fault detection applied to non-destructive testing of rail’s surface during production

A series of rail image inspection algorithms have been developed for Tata Steels Scunthorpe rail production line. The following thesis describes the contributions made by the author in the design and application of these algorithms. A fully automated rail inspection system that has never been implemented before in any such company or setup has been developed. An industrial computer vision system (JLI) already exists for the image acquisition of rails during production at a rail manufacturing plant in Scunthorpe. An automated inspection system using the same JLI vision system has been developed for the detection of rail‟s surface defects during manufacturing process. This is to complement the human factor by developing a fully automated image processing based system to recognize the faults with an improved efficiency and to allow an exhaustive detection on the entire rail in production. A set of bespoke algorithms has been developed from a plethora of available image processing techniques to extract and identify components in an image of rail in order to detect abnormalities. This has been achieved through offline processing of the rail images using the blended use of different object recognition and image processing techniques, in particular, variation of standard image processing techniques. Several edge detection methods as well as adapted well known Artificial Neural Network and Principal Component Analysis techniques for fault detection on rail have been developed. A combination of customised existing image algorithms and newly developed algorithms have been put together to perform the efficient defect detection. The developed system is fast, reliable and efficient for detection of unique artefacts occurring on the rail surface during production followed by fault classification on the rail imaging system. Extensive testing shows that the defect detection techniques developed for automated rail inspection is capable of detecting more than 90% of the defects present in the available data set of rail images, which has more than 100,000 images under investigation. This demonstrates the efficiency and accuracy of the algorithms developed in this work

A Tutorial on Learning Human Welder\u27s Behavior: Sensing, Modeling, and Control

Human welder\u27s experiences and skills are critical for producing quality welds in manual GTAW process. Learning human welder\u27s behavior can help develop next generation intelligent welding machines and train welders faster. In this tutorial paper, various aspects of mechanizing the welder\u27s intelligence are surveyed, including sensing of the weld pool, modeling of the welder\u27s adjustments and this model-based control approach. Specifically, different sensing methods of the weld pool are reviewed and a novel 3D vision-based sensing system developed at University of Kentucky is introduced. Characterization of the weld pool is performed and human intelligent model is constructed, including an extensive survey on modeling human dynamics and neuro-fuzzy techniques. Closed-loop control experiment results are presented to illustrate the robustness of the model-based intelligent controller despite welding speed disturbance. A foundation is thus established to explore the mechanism and transformation of human welder\u27s intelligence into robotic welding system. Finally future research directions in this field are presented

Imaging Sensors and Applications

In past decades, various sensor technologies have been used in all areas of our lives, thus improving our quality of life. In particular, imaging sensors have been widely applied in the development of various imaging approaches such as optical imaging, ultrasound imaging, X-ray imaging, and nuclear imaging, and contributed to achieve high sensitivity, miniaturization, and real-time imaging. These advanced image sensing technologies play an important role not only in the medical field but also in the industrial field. This Special Issue covers broad topics on imaging sensors and applications. The scope range of imaging sensors can be extended to novel imaging sensors and diverse imaging systems, including hardware and software advancements. Additionally, biomedical and nondestructive sensing applications are welcome