A combined three-dimensional digitisation and subsurface defect detection data using active infrared thermography

International audienceIn recent years, NonDestructive Testing (NDT) systems have been upgraded with three-dimensional information. Indeed, combine the three-dimensional and thermal information allows a more meaningful analysis. In the literature, the data for NDT and three-dimensional (3D) reconstruction analysis are commonly acquired from independent systems. However, the use of two such systems leads to error analysis during the data registration. In an attempt to overcome such problems, we propose a single system based on active thermography approach using heat point-source stimulation to get the 3D digitization as well as subsurface defect detection. The experiments are conducted on steel and aluminum objects, and a combined 3D / thermal-information is presented

A review of three-dimensional imaging technologies for pavement distress detection and measurements

With the ever-increasing emphasis on maintaining road assets to a high standard, the need for fast accurate inspection for road distresses is becoming extremely important. Surface distresses on roads are essentially three dimensional (3-D) in nature. Automated visual surveys are the best option available. However, the imaging conditions, in terms of lighting, etc., are very random. For example, the challenge of measuring the volume of the pothole requires a large field of view with a reasonable spatial resolution, whereas microtexture evaluation requires very accurate imaging. Within the two extremes, there is a range of situations that require 3-D imaging. Three-dimensional imaging consists of a number of techniques such as interferometry and depth from focus. Out of these, laser imagers are mainly used for road surface distress inspection. Many other techniques are relatively unknown among the transportation community, and industrial products are rare. The main impetus for this paper is derived from the rarity of 3-D industrial imagers that employ alternative techniques for use in transportation. In addition, the need for this work is also highlighted by a lack of literature that evaluates the relative merits/demerits of various imaging methods for different distress measurement situations in relation to pavements. This overview will create awareness of available 3-D imaging methods in order to help make a fast initial technology selection and deployment. The review is expected to be helpful for researchers, practicing engineers, and decision makers in transportation engineering

3D inspection methods for specular or partially specular surfaces

Deflectometric techniques are a powerful tool for the automated quality control of specular or shiny surfaces. These techniques are based on using a camera to observe a reference pattern reflected on the surface under inspection, exploiting the dependence of specular reflections on surface normals to recover shape information from the acquired images. Although deflectometry is already used in industrial environments such as the quality control of lenses or car bodies, there are still some open problems. On the one hand, using quantitative deflectometry, the normal vector field and the 3D shape of a surface can be obtained, but these techniques do not yet take full advantage of their local sensitivity because the achieved global accuracies are affected by calibration errors. On the other hand, qualitative deflectometry is used to detect surface imperfections without absolute measurements, exploiting the local sensitivity of deflectometric recordings with reduced calibration requirements. However, this qualitative approach requires further processing that can involve a considerable engineering effort, particularly for aesthetic defects which are inherently subjective. The first part of this thesis aims to contribute to a better understanding of how deflectometric setups and their calibration errors affect quantitative measurements. Different error sources are considered including the camera calibration uncertainty and several non-ideal characteristics of LCD screens used to generate the light patterns. Experiments performed using real measurements and simulations show that the non-planarity of the LCD screen and the camera calibration are the dominant sources of error. The second part of the thesis investigates the use of deep learning to identify geometrical imperfections and texture defects based on deflectometric data. Two different approaches are explored to extract and combine photometric and geometric information using convolutional neural network architectures: one for automated classification of defective samples, and another one for automated segmentation of defective regions in a sample. The experimental results in a real industrial case study indicate that both architectures are able to learn relevant features from deflectometric data, enabling the classification and segmentation of defects based on a dataset of user-provided examples.Teknika deflektometrikoak tresna baliotsuak dira gainazal espekular edo distiratsuen kalitate kontrol automatikoa gauzatzeko. Teknika hauetan, kamera bat erabiltzen da ikuskatu beharreko gainazalean islatutako erreferentziazko patroi bat behatzeko, eta isladapen espekularrek gainazalen bektore normalengan duten menpekotasuna ustiatzen dute irudietatik informazio geometrikoa berreskuratzeko. Zenbait industria-aplikaziotan deflektometria jada erabiltzen bada ere –adibidez, betaurrekoen edo autoen karrozerien kalitate kontrolean-, oraindik badaude hobetu beharreko hainbat esparru. Batetik, deflektometria kuantitatiboak aukera ematen du gainazal baten bektore-eremu normala eta 3D forma lortzeko, baina gaur egun teknika hauek ez dute beren sentsibilitate lokal guztia aprobetxatzen kalibrazio-akatsek zehaztasun globalean duten eraginagatik. Bestetik, deflektometria kualitatiboa neurketa absoluturik egin gabe gainazal akatsak antzemateko erabili daiteke, kalibrazio-eskakizun murriztuekin sentsibilitate lokala ustiatuz. Hala ere, teknika horiek algoritmoen garapenean esfortzu handia ekar dezakeen prozesamendu bat eskatzen dute, bereziki bere baitan subjektiboak diren akats estetikoetarako. Hala ere, teknika horiek algoritmoen garapenean esfortzu handia ekar dezakeen prozesamendu bat eskatzen dute, bereziki bere baitan subjektiboak diren akats estetikoetarako. Tesi honen lehen zatiaren helburua adkizizio sistema osatzen duten gailuek eta horien kalibrazioek neurketa kuantitatiboei nola eragiten dieten hobeto ulertzen laguntzea da. Hainbat errore-iturri hartzen dira kontuan, besteak beste kameraren kalibrazioaren ziurgabetasuna, eta argi-patroiak sortzeko erabilitako LCD pantailen zenbait ezaugarri ez-ideal. Neurketa errealetan eta simulazioetan egindako esperimentuek erakusten dute LCD pantailaren deformazioak eta kameraren kalibrazioak eragindako erroreak direla neurketen akats eta ziurgabetasun iturri nagusiak. Tesiaren bigarren zatian, datu deflektometrikoetatik abiatuz, inperfekzio geometrikoak eta testura-akatsak identifikatzeko ikaskuntza sakoneko metodoen erabilera ikertzen da. Helburu honekin, irudietatik informazio fotometrikoa eta geometrikoa atera eta konbinatzen duten sare neuronal konboluzionaletan oinarritutako bi arkitektura proposatzen dira: bata, lagin akastunak automatikoki sailkatzeko; eta, bestea, laginetako eremu akastunak automatikoki segmentatzeko. Automobilgintza industriako kasu praktiko baten lortutako emaitzek erakusten dute erabilitako arkitekturek datu deflektometrikoetatik ezaugarri esanguratsuak ikas ditzaketela, erabiltzaileak emandako adibide multzo batean oinarrituta gainazal akatsak sailkatu eta segmentatzea ahalbidetuz.Las técnicas deflectométricas son una herramienta valiosa para automatizar el control de calidad de superficies especulares o reflectantes. Estas técnicas se basan en el uso de una cámara para observar un patrón de referencia reflejado en la superficie bajo inspección, explotando la dependencia de los reflejos especulares en la normal de la superficie para recuperar información geométrica a partir de las imágenes adquiridas. Aunque la deflectometría ya se usa en algunas aplicaciones industriales, tales como el control de calidad de lentes o carrocerías de coches, todavía hay algunos problemas abiertos. Por un lado, la deflectometría cuantitativa permite obtener el campo vectorial normal y la forma 3D de una superficie, pero a día de hoy no es capaz de aprovechar al máximo su sensibilidad local ya que la precisión global se ve afectada por errores de calibración. Por otro lado, la deflectometría cualitativa se utiliza para detectar imperfecciones de la superficie sin mediciones absolutas, explotando la sensibilidad local de la deflectometría con requisitos de calibración reducidos. Sin embargo, estos métodos requieren un procesamiento adicional que puede implicar un esfuerzo considerable en el desarrollo de algoritmos, particularmente para defectos estéticos que son inherentemente subjetivos. La primera parte de esta tesis tiene como objetivo contribuir a una mejor comprensión de cómo el sistema de adquisición y su calibración afectan a las mediciones cuantitativas. Se consideran dife-rentes fuentes de error, incluida la incertidumbre de calibración de la cámara y varias características no ideales de las pantallas LCD utilizadas para generar los patrones de luz. Los experimentos realizados con mediciones reales y simulaciones indican que los errores inducidos por la deformación de la pantalla LCD y la calibración de la cámara son las principales fuentes de error e incertidumbre. La segunda parte de la tesis investiga el uso del aprendizaje profundo para identificar imperfecciones geométricas y defectos de textura a partir de datos deflectométricos. Se adoptan dos enfoques diferentes para extraer y combinar información fotométrica y geométrica utilizando sendas arquitecturas basadas en redes neuronales convolucionales: una para la clasificación automatizada de muestras defectuosas y otra para la segmentación automatizada de regiones defectuosas en una muestra. Los resultados experimentales en un caso de estudio industrial real indican que ambas arquitecturas pueden aprender características relevantes de los datos deflectométricos, permitiendo la clasificación y segmentación de defectos en base a un conjunto de datos de ejemplos proporcionados por el usuario

CHARACTERIZATION OF SEED DEFECTS IN HIGHLY SPECULAR SMOOTH COATED SURFACES

Many smooth, highly specular coatings such as automotive paints are subjected to considerable performance demands as the customer expectations for appearance of coatings are continually increasing. Therefore it is vital to develop robust methods to monitor surface quality online. An automated visual assessment of specular coated surface that would not only provide a cost effective and reliable solution to the industries but also facilitate the implementation of a real-time feedback loop. The scope of this thesis is a subset of the inspection technology that facilitates real-time close loop control of the surface quality and concentrates on one common surface defect the seed defect. This machine vision system design utilizes surface reflectance models as a rational basis. Using a single high-contrast image the height of the seed defect is computed; the result is obtained rapidly and is reasonably accurate approximation of the actual height

QUANTIFICATION OF SURFACE DEFECTS USING PRIMARY HIGHLIGHT IN DIFFUSE ANGLE GRAY SCALE IMAGES

The thesis presented is an effort to gather all possible information of one particular type of common paint defect the seed defect, from gray scale images of highly specular painted surface. The proposed approach in the thesis utilizes a white light source to illuminate the surface and utilizes a camera to capture its gray scale image at different diffused angles. While attempting to explain the physics of highlight formation in terms of location on the surface of a seed defect, the thesis also extends to utilize this information from gray scale images to accurately predict the parameters of seed defects including the height, size and position in real time. Since the primary highlight in a gray scale image is more defined, contrary to the past researches on diffuse angle images that use both primary / seed highlight and mirror highlight to estimate height of the seed, this thesis formulates a theory of highlight translation and estimates the height of seed based on primary / seed highlight. The other common type of surface defect - crater defect, is also addressed in the thesis

AN INVESTIGATION OF IMAGE PROCESSING TECHNIQUES FOR PAINT DEFECT DETECTION USING A MACHINE VISION SYSTEM

Detection and inspection of metal surface corrosion in the ballast tanks of U.S. Navy ships has been a long time problem. The adverse climatic conditions to which the ballast tanks are exposed and the uneven geometry of ballast tanks makes the visual inspection process of surface coatings a difficult job. Thousands of tanks are inspected yearly, with the average cost of an individual tank inspection at approximately $8-15 thousand/each. To aid the visual inspection process, this research is conducted to develop a new technique to automate the visual task of metal surface inspection by image acquisition and post processing. The best results of image processing are achieved by the enhanced contrast between the paint defect and the background using a newly developed optically active additive (OAA) used in paints. Thorough investigation of image processing algorithms has been carried out and a background of imaging theory and experiments is illustrated in this work

A comparative study of image processing thresholding algorithms on residual oxide scale detection in stainless steel production lines

The present work is intended for residual oxide scale detection and classification through the application of image processing techniques. This is a defect that can remain in the surface of stainless steel coils after an incomplete pickling process in a production line. From a previous detailed study over reflectance of residual oxide defect, we present a comparative study of algorithms for image segmentation based on thresholding methods. In particular, two computational models based on multi-linear regression and neural networks will be proposed. A system based on conventional area camera with a special lighting was installed and fully integrated in an annealing and pickling line for model testing purposes. Finally, model approaches will be compared and evaluated their performance..Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech