Automated Brittle Fracture Rate Estimator for Steel Property Evaluation Using Deep Learning After Drop-Weight Tear Test

This study proposes an automated brittle fracture rate (BFR) estimator using deep learning. As the demand for line-pipes increases in various industries, the need for BFR estimation through dropweight tear test (DWTT) increases to evaluate steel's property. Conventional BFR or ductile fracture rate (DFR) estimation methods require an expensive 3D scanner. Alternatively, a rule-based approach is used with a single charge-coupled device (CCD) camera. However, it is sensitive to the hyper-parameter. To solve these problems, we propose an approach based on deep learning that has recently been successful in the fields of computer vision and image processing. The method proposed in this study is the first to use deep learning approach for BFR estimation. The proposed method consists of a VGG-based U-Net (VU-Net) which is inspired by U-Net and fully convolutional network (FCN). VU-Net includes a deep encoder and a decoder. The encoder is adopted from VGG19 and transferred with a pre-trained model with ImageNet. In addition, the structure of the decoder is the same as that of the encoder, and the decoder uses the feature maps of the encoder through concatenation operation to compensate for the reduced spatial information. To analyze the proposed VU-Net, we experimented with different depths of networks and various transfer learning approaches. In terms of accuracy used in real industrial application, we compared the proposed VU-Net with U-Net and FCN to evaluate the performance. The experiments showed that VU-Net was the accuracy of approximately 94.9 %, and was better than the other two, which had the accuracies of about 91.8 % and 93.7 %, respectively.11Ysciescopu

Automated defect inspection system for metal surfaces based on deep learning and data augmentation

Recent efforts to create a smart factory have inspired research that analyzes process data collected from Internet of Things (IOT) sensors, to predict product quality in real time. This requires an automatic defect inspection system that quantifies product quality data by detecting and classifying defects in real time. In this study, we propose a vision-based defect inspection system to inspect metal surface defects. In recent years, deep convolutional neural networks (DCNNs) have been used in many manufacturing industries and have demonstrated the excellent performance as a defect classification method. A sufficient amount of training data must be acquired, to ensure high performance using a DCNN. However, owing to the nature of the metal manufacturing industry, it is difficult to obtain enough data because some defects occur rarely. Owing to this imbalanced data problem, the generalization performance of the DCNN-based classification algorithm is lowered. In this study, we propose a new convolutional variational autoencoder (CVAE) and deep CNN-based defect classification algorithm to solve this problem. The CVAE-based data generation technology generates sufficient defect data to train the classification model. A conditional CVAE (CCVAE) is proposed to generate images for each defect type in a single CVAE model. We also propose a classifier based on a DCNN with high generalization performance using data generated from the CCVAE. In order to verify the performance of the proposed method, we performed experiments using defect images obtained from an actual metal production line. The results showed that the proposed method exhibited an excellent performance. © 2020 The Society of Manufacturing Engineers1