In recent years, the deterioration of artificial materials used in structures has become a serious social issue, increasing the importance of inspections. Non-destructive testing is gaining increased demand due to its capability to inspect for defects and deterioration in structures while preserving their functionality. Among these, Laser Ultrasonic Visualization Testing (LUVT) stands out because it allows the visualization of ultrasonic propagation. This makes it visually straightforward to detect defects, thereby enhancing inspection efficiency. With the increasing number of the deterioration structures, challenges such as a shortage of inspectors and increased workload in non-destructive testing have become more apparent. Efforts to address these challenges include exploring automated inspection using machine learning. However, the lack of anomalous data with defects poses a barrier to improving the accuracy of automated inspection through machine learning. Therefore, in this study, we propose a method for automated LUVT inspection using an anomaly detection approach with a diffusion model that can be trained solely on negative examples (defect-free data). We experimentally confirmed that our proposed method improves defect detection and localization compared to general object detection algorithms used previously.
Recent studies of multimodal industrial anomaly detection (IAD) based on 3D point clouds and RGB images have highlighted the importance of exploiting the redundancy and complementarity among modalities for accurate classification and segmentation. However, achieving multimodal IAD in practical production lines remains a work in progress. It is essential to consider the trade-offs between the costs and benefits associated with the introduction of new modalities while ensuring compatibility with current processes. Existing quality control processes combine rapid in-line inspections, such as optical and infrared imaging with high-resolution but time-consuming near-line characterization techniques, including industrial CT and electron microscopy to manually or semi-automatically locate and analyze defects in the production of Li-ion batteries and composite materials. Given the cost and time limitations, only a subset of the samples can be inspected by all in-line and near-line methods, and the remaining samples are only evaluated through one or two forms of in-line inspection. To fully exploit data for deep learning-driven automatic defect detection, the models must have the ability to leverage multimodal training and handle incomplete modalities during inference. In this paper, we propose CMDIAD, a Cross-Modal Distillation framework for IAD to demonstrate the feasibility of a Multi-modal Training, Few-modal Inference (MTFI) pipeline. Our findings show that the MTFI pipeline can more effectively utilize incomplete multimodal information compared to applying only a single modality for training and inference. Moreover, we investigate the reasons behind the asymmetric performance improvement using point clouds or RGB images as the main modality of inference. This provides a foundation for our future multimodal dataset construction with additional modalities from manufacturing scenarios.
As automation advances in manufacturing, the demand for precise and sophisticated defect detection technologies grows. Existing vision models for defect recognition methods are insufficient for handling the complexities and variations of defects in contemporary manufacturing settings. These models especially struggle in scenarios involving limited or imbalanced defect data. In this work, we introduce MemoryMamba, a novel memory-augmented state space model (SSM), designed to overcome the limitations of existing defect recognition models. MemoryMamba integrates the state space model with the memory augmentation mechanism, enabling the system to maintain and retrieve essential defect-specific information in training. Its architecture is designed to capture dependencies and intricate defect characteristics, which are crucial for effective defect detection. In the experiments, MemoryMamba was evaluated across four industrial datasets with diverse defect types and complexities. The model consistently outperformed other methods, demonstrating its capability to adapt to various defect recognition scenarios.
Additive manufacturing (AM), particularly 3D printing, has revolutionized the production of complex structures across various industries. However, ensuring quality and detecting defects in 3D-printed objects remain significant challenges. This study focuses on improving defect detection in 3D-printed cylinders by integrating novel pre-processing techniques such as Region of Interest (ROI) selection, Histogram Equalization (HE), and Details Enhancer (DE) with Convolutional Neural Networks (CNNs), specifically the modified VGG16 model. The approaches, ROIN, ROIHEN, and ROIHEDEN, demonstrated promising results, with the best model achieving an accuracy of 1.00 and an F1-score of 1.00 on the test set. The study also explored the models' interpretability through Local Interpretable Model-Agnostic Explanations and Gradient-weighted Class Activation Mapping, enhancing the understanding of the decision-making process. Furthermore, the modified VGG16 model showed superior computational efficiency with 30713M FLOPs and 15M parameters, the lowest among the compared models. These findings underscore the significance of tailored pre-processing and CNNs in enhancing defect detection in AM, offering a pathway to improve manufacturing precision and efficiency. This research not only contributes to the advancement of 3D printing technology but also highlights the potential of integrating machine learning with AM for superior quality control.
Unmanned Aerial Vehicles (UAVs) will be critical infrastructural components of future smart cities. In order to operate efficiently, UAV reliability must be ensured by constant monitoring for faults and failures. To this end, the work presented in this paper leverages signal processing and Machine Learning (ML) methods to analyze the data of a comprehensive vibrational analysis to determine the presence of rotor blade defects during pre and post-flight operation. With the help of dimensionality reduction techniques, the Random Forest algorithm exhibited the best performance and detected defective rotor blades perfectly. Additionally, a comprehensive analysis of the impact of various feature subsets is presented to gain insight into the factors affecting the model's classification decision process.
Laser Additive Manufacturing (LAM) presents unparalleled opportunities for fabricating complex, high-performance structures and components with unique material properties. Despite these advancements, achieving consistent part quality and process repeatability remains challenging. This paper provides a comprehensive review of various state-of-the-art in-situ process monitoring techniques, including optical-based monitoring, acoustic-based sensing, laser line scanning, and operando X-ray monitoring. These techniques are evaluated for their capabilities and limitations in detecting defects within Laser Powder Bed Fusion (LPBF) and Laser Directed Energy Deposition (LDED) processes. Furthermore, the review discusses emerging multisensor monitoring and machine learning (ML)-assisted defect detection methods, benchmarking ML models tailored for in-situ defect detection. The paper also discusses in-situ adaptive defect remediation strategies that advance LAM towards zero-defect autonomous operations, focusing on real-time closed-loop feedback control and defect correction methods. Research gaps such as the need for standardization, improved reliability and sensitivity, and decision-making strategies beyond early stopping are highlighted. Future directions are proposed, with an emphasis on multimodal sensor fusion for multiscale defect prediction and fault diagnosis, ultimately enabling self-adaptation in LAM processes. This paper aims to equip researchers and industry professionals with a holistic understanding of the current capabilities, limitations, and future directions in in-situ process monitoring and adaptive quality enhancement in LAM.
Photovoltaic (PV) systems allow us to tap into all abundant solar energy, however they require regular maintenance for high efficiency and to prevent degradation. Traditional manual health check, using Electroluminescence (EL) imaging, is expensive and logistically challenging which makes automated defect detection essential. Current automation approaches require extensive manual expert labeling, which is time-consuming, expensive, and prone to errors. We propose PV-S3 (Photovoltaic-Semi Supervised Segmentation), a Semi-Supervised Learning approach for semantic segmentation of defects in EL images that reduces reliance on extensive labeling. PV-S3 is a Deep learning model trained using a few labeled images along with numerous unlabeled images. We introduce a novel Semi Cross-Entropy loss function to deal with class imbalance. We evaluate PV-S3 on multiple datasets and demonstrate its effectiveness and adaptability. With merely 20% labeled samples, we achieve an absolute improvement of 9.7% in IoU, 13.5% in Precision, 29.15% in Recall, and 20.42% in F1-Score over prior state-of-the-art supervised method (which uses 100% labeled samples) on UCF-EL dataset (largest dataset available for semantic segmentation of EL images) showing improvement in performance while reducing the annotation costs by 80%. For more details, visit our GitHub repository:https://github.com/abj247/PV-S3.
Most advanced unsupervised anomaly detection (UAD) methods rely on modeling feature representations of frozen encoder networks pre-trained on large-scale datasets, e.g. ImageNet. However, the features extracted from the encoders that are borrowed from natural image domains coincide little with the features required in the target UAD domain, such as industrial inspection and medical imaging. In this paper, we propose a novel epistemic UAD method, namely ReContrast, which optimizes the entire network to reduce biases towards the pre-trained image domain and orients the network in the target domain. We start with a feature reconstruction approach that detects anomalies from errors. Essentially, the elements of contrastive learning are elegantly embedded in feature reconstruction to prevent the network from training instability, pattern collapse, and identical shortcut, while simultaneously optimizing both the encoder and decoder on the target domain. To demonstrate our transfer ability on various image domains, we conduct extensive experiments across two popular industrial defect detection benchmarks and three medical image UAD tasks, which shows our superiority over current state-of-the-art methods.
In the food industry, assessing the quality of poultry carcasses during processing is a crucial step. This study proposes an effective approach for automating the assessment of carcass quality without requiring skilled labor or inspector involvement. The proposed system is based on machine learning (ML) and computer vision (CV) techniques, enabling automated defect detection and carcass quality assessment. To this end, an end-to-end framework called CarcassFormer is introduced. It is built upon a Transformer-based architecture designed to effectively extract visual representations while simultaneously detecting, segmenting, and classifying poultry carcass defects. Our proposed framework is capable of analyzing imperfections resulting from production and transport welfare issues, as well as processing plant stunner, scalder, picker, and other equipment malfunctions. To benchmark the framework, a dataset of 7,321 images was initially acquired, which contained both single and multiple carcasses per image. In this study, the performance of the CarcassFormer system is compared with other state-of-the-art (SOTA) approaches for both classification, detection, and segmentation tasks. Through extensive quantitative experiments, our framework consistently outperforms existing methods, demonstrating remarkable improvements across various evaluation metrics such as AP, AP@50, and AP@75. Furthermore, the qualitative results highlight the strengths of CarcassFormer in capturing fine details, including feathers, and accurately localizing and segmenting carcasses with high precision. To facilitate further research and collaboration, the pre-trained model and source code of CarcassFormer is available for research purposes at: \url{https://github.com/UARK-AICV/CarcassFormer}.
Images captured from the real world are often affected by different types of noise, which can significantly impact the performance of Computer Vision systems and the quality of visual data. This study presents a novel approach for defect detection in casting product noisy images, specifically focusing on submersible pump impellers. The methodology involves utilizing deep learning models such as VGG16, InceptionV3, and other models in both the spatial and frequency domains to identify noise types and defect status. The research process begins with preprocessing images, followed by applying denoising techniques tailored to specific noise categories. The goal is to enhance the accuracy and robustness of defect detection by integrating noise detection and denoising into the classification pipeline. The study achieved remarkable results using VGG16 for noise type classification in the frequency domain, achieving an accuracy of over 99%. Removal of salt and pepper noise resulted in an average SSIM of 87.9, while Gaussian noise removal had an average SSIM of 64.0, and periodic noise removal yielded an average SSIM of 81.6. This comprehensive approach showcases the effectiveness of the deep AutoEncoder model and median filter, for denoising strategies in real-world industrial applications. Finally, our study reports significant improvements in binary classification accuracy for defect detection compared to previous methods. For the VGG16 classifier, accuracy increased from 94.6% to 97.0%, demonstrating the effectiveness of the proposed noise detection and denoising approach. Similarly, for the InceptionV3 classifier, accuracy improved from 84.7% to 90.0%, further validating the benefits of integrating noise analysis into the classification pipeline.
From a process development perspective, diamond growth via chemical vapor deposition has made significant strides. However, challenges persist in achieving high quality and large-area material production. These difficulties include controlling conditions to maintain uniform growth rates for the entire growth surface. As growth progresses, various factors or defect states emerge, altering the uniform conditions. These changes affect the growth rate and result in the formation of crystalline defects at the microscale. However, there is a distinct lack of methods to identify these defect states and their geometry using images taken during the growth process. This paper details seminal work on defect segmentation pipeline using in-situ optical images to identify features that indicate defective states that are visible at the macroscale. Using a semantic segmentation approach as applied in our previous work, these defect states and corresponding derivative features are isolated and classified by their pixel masks. Using an annotation focused human-in-the-loop software architecture to produce training datasets, with modules for selective data labeling using active learning, data augmentations, and model-assisted labeling, our approach achieves effective annotation accuracy and drastically reduces the time and cost of labeling by orders of magnitude. On the model development front, we found that deep learning-based algorithms are the most efficient. They can accurately learn complex representations from feature-rich datasets. Our best-performing model, based on the YOLOV3 and DeeplabV3plus architectures, achieved excellent accuracy for specific features of interest. Specifically, it reached 93.35% accuracy for center defects, 92.83% for polycrystalline defects, and 91.98% for edge defects.
Due to potential pitch reduction, the semiconductor industry is adopting High-NA EUVL technology. However, its low depth of focus presents challenges for High Volume Manufacturing. To address this, suppliers are exploring thinner photoresists and new underlayers/hardmasks. These may suffer from poor SNR, complicating defect detection. Vision-based ML algorithms offer a promising solution for semiconductor defect inspection. However, developing a robust ML model across various image resolutions without explicit training remains a challenge for nano-scale defect inspection. This research's goal is to propose a scale-invariant ADCD framework capable to upscale images, addressing this issue. We propose an improvised ADCD framework as SEMI-SuperYOLO-NAS, which builds upon the baseline YOLO-NAS architecture. This framework integrates a SR assisted branch to aid in learning HR features by the defect detection backbone, particularly for detecting nano-scale defect instances from LR images. Additionally, the SR-assisted branch can recursively generate upscaled images from their corresponding downscaled counterparts, enabling defect detection inference across various image resolutions without requiring explicit training. Moreover, we investigate improved data augmentation strategy aimed at generating diverse and realistic training datasets to enhance model performance. We have evaluated our proposed approach using two original FAB datasets obtained from two distinct processes and captured using two different imaging tools. Finally, we demonstrate zero-shot inference for our model on a new, originating from a process condition distinct from the training dataset and possessing different Pitch characteristics. Experimental validation demonstrates that our proposed ADCD framework aids in increasing the throughput of imaging tools for defect inspection by reducing the required image pixel resolutions.
Maintaining sewer systems in large cities is important, but also time and effort consuming, because visual inspections are currently done manually. To reduce the amount of aforementioned manual work, defects within sewer pipes should be located and classified automatically. In the past, multiple works have attempted solving this problem using classical image processing, machine learning, or a combination of those. However, each provided solution only focus on detecting a limited set of defect/structure types, such as fissure, root, and/or connection. Furthermore, due to the use of hand-crafted features and small training datasets, generalization is also problematic. In order to overcome these deficits, a sizable dataset with 14.7 km of various sewer pipes were annotated by sewer maintenance experts in the scope of this work. On top of that, an object detector (EfficientDet-D0) was trained for automatic defect detection. From the result of several expermients, peculiar natures of defects in the context of object detection, which greatly effect annotation and training process, are found and discussed. At the end, the final detector was able to detect 83% of defects in the test set; out of the missing 17%, only 0.77% are very severe defects. This work provides an example of applying deep learning-based object detection into an important but quiet engineering field. It also gives some practical pointers on how to annotate peculiar "object", such as defects.
Training defect detection algorithms for visual surface inspection systems requires a large and representative set of training data. Often there is not enough real data available which additionally cannot cover the variety of possible defects. Synthetic data generated by a synthetic visual surface inspection environment can overcome this problem. Therefore, a digital twin of the object is needed, whose micro-scale surface topography is modeled by texture synthesis models. We develop stochastic texture models for sandblasted and milled surfaces based on topography measurements of such surfaces. As the surface patterns differ significantly, we use separate modeling approaches for the two cases. Sandblasted surfaces are modeled by a combination of data-based texture synthesis methods that rely entirely on the measurements. In contrast, the model for milled surfaces is procedural and includes all process-related parameters known from the machine settings.
Few-shot segmentation models excel in metal defect detection due to their rapid generalization ability to new classes and pixel-level segmentation, rendering them ideal for addressing data scarcity issues and achieving refined object delineation in industrial applications. Existing works neglect the \textit{Intra-Class Differences}, inherent in metal surface defect data, which hinders the model from learning sufficient knowledge from the support set to guide the query set segmentation. Specifically, it can be categorized into two types: the \textit{Semantic Difference} induced by internal factors in metal samples and the \textit{Distortion Difference} caused by external factors of surroundings. To address these differences, we introduce a \textbf{L}ocal d\textbf{E}scriptor based \textbf{R}easoning and \textbf{E}xcitation \textbf{Net}work (\textbf{LERENet}) to learn the two-view guidance, i.e., local and global information from the graph and feature space, and fuse them to segment precisely. Since the relation structure of local features embedded in graph space will help to eliminate \textit{Semantic Difference}, we employ Multi-Prototype Reasoning (MPR) module, extracting local descriptors based prototypes and analyzing local-view feature relevance in support-query pairs. Besides, due to the global information that will assist in countering the \textit{Distortion Difference} in observations, we utilize Multi-Prototype Excitation (MPE) module to capture the global-view relations in support-query pairs. Finally, we employ an Information Fusion Module (IFM) to fuse learned prototypes in local and global views to generate pixel-level masks. Our comprehensive experiments on defect datasets demonstrate that it outperforms existing benchmarks, establishing a new state-of-the-art.
This paper proposes an optimization of an existing Deep Neural Network (DNN) that improves its hardware utilization and facilitates on-device training for resource-constrained edge environments. We implement efficient parameter reduction strategies on Xception that shrink the model size without sacrificing accuracy, thus decreasing memory utilization during training. We evaluate our model in two experiments: Caltech-101 image classification and PCB defect detection and compare its performance against the original Xception and lightweight models, EfficientNetV2B1 and MobileNetV2. The results of the Caltech-101 image classification show that our model has a better test accuracy (76.21%) than Xception (75.89%), uses less memory on average (847.9MB) than Xception (874.6MB), and has faster training and inference times. The lightweight models overfit with EfficientNetV2B1 having a 30.52% test accuracy and MobileNetV2 having a 58.11% test accuracy. Both lightweight models have better memory usage than our model and Xception. On the PCB defect detection, our model has the best test accuracy (90.30%), compared to Xception (88.10%), EfficientNetV2B1 (55.25%), and MobileNetV2 (50.50%). MobileNetV2 has the least average memory usage (849.4MB), followed by our model (865.8MB), then EfficientNetV2B1 (874.8MB), and Xception has the highest (893.6MB). We further experiment with pre-trained weights and observe that memory usage decreases thereby showing the benefits of transfer learning. A Pareto analysis of the models' performance shows that our optimized model architecture satisfies accuracy and low memory utilization objectives.
Automatic optical inspection (AOI) plays a pivotal role in the manufacturing process, predominantly leveraging high-resolution imaging instruments for scanning purposes. It detects anomalies by analyzing image textures or patterns, making it an essential tool in industrial manufacturing and quality control. Despite its importance, the deployment of models for AOI often faces challenges. These include limited sample sizes, which hinder effective feature learning, variations among source domains, and sensitivities to changes in lighting and camera positions during imaging. These factors collectively compromise the accuracy of model predictions. Traditional AOI often fails to capitalize on the rich mechanism-parameter information from machines or inside images, including statistical parameters, which typically benefit AOI classification. To address this, we introduce an external modality-guided data mining framework, primarily rooted in optical character recognition (OCR), to extract statistical features from images as a second modality to enhance performance, termed OANet (Ocr-Aoi-Net). A key aspect of our approach is the alignment of external modality features, extracted using a single modality-aware model, with image features encoded by a convolutional neural network. This synergy enables a more refined fusion of semantic representations from different modalities. We further introduce feature refinement and a gating function in our OANet to optimize the combination of these features, enhancing inference and decision-making capabilities. Experimental outcomes show that our methodology considerably boosts the recall rate of the defect detection model and maintains high robustness even in challenging scenarios.
We present the Open Stamped Parts Dataset (OSPD), featuring synthetic and real images of stamped metal sheets for auto manufacturing. The real part images, captured from 7 cameras, consist of 7,980 unlabeled images and 1,680 labeled images. In addition, we have compiled a defect dataset by overlaying synthetically generated masks on 10\% of the holes. The synthetic dataset replicates the real manufacturing environment in terms of lighting and part placement relative to the cameras. The synthetic data includes 7,980 training images, 1,680 validation images and 1,680 test images, each with bounding box and segmentation mask annotations around all holes. 10\% of the holes in the synthetic data mimic defects generated in the real image dataset. We trained a hole-detection model on the synthetic-OSPD, achieving a modified recall score of 67.2\% and a precision of 94.4\% . We anticipate researchers in auto manufacturing use OSPD to advance the state of the art in defect detection of stamped holes in the metal-sheet stamping process. The dataset is available for download at: https://tinyurl.com/hm6xatd7.
In this paper, we present an empirical study introducing a nuanced evaluation framework for text-to-image (T2I) generative models, applied to human image synthesis. Our framework categorizes evaluations into two distinct groups: first, focusing on image qualities such as aesthetics and realism, and second, examining text conditions through concept coverage and fairness. We introduce an innovative aesthetic score prediction model that assesses the visual appeal of generated images and unveils the first dataset marked with low-quality regions in generated human images to facilitate automatic defect detection. Our exploration into concept coverage probes the model's effectiveness in interpreting and rendering text-based concepts accurately, while our analysis of fairness reveals biases in model outputs, with an emphasis on gender, race, and age. While our study is grounded in human imagery, this dual-faceted approach is designed with the flexibility to be applicable to other forms of image generation, enhancing our understanding of generative models and paving the way to the next generation of more sophisticated, contextually aware, and ethically attuned generative models. Code and data, including the dataset annotated with defective areas, are available at \href{https://github.com/cure-lab/EvaluateAIGC}{https://github.com/cure-lab/EvaluateAIGC}.
This paper introduces a robust approach for automated defect detection in tire X-ray images by harnessing traditional feature extraction methods such as Local Binary Pattern (LBP) and Gray Level Co-Occurrence Matrix (GLCM) features, as well as Fourier and Wavelet-based features, complemented by advanced machine learning techniques. Recognizing the challenges inherent in the complex patterns and textures of tire X-ray images, the study emphasizes the significance of feature engineering to enhance the performance of defect detection systems. By meticulously integrating combinations of these features with a Random Forest (RF) classifier and comparing them against advanced models like YOLOv8, the research not only benchmarks the performance of traditional features in defect detection but also explores the synergy between classical and modern approaches. The experimental results demonstrate that these traditional features, when fine-tuned and combined with machine learning models, can significantly improve the accuracy and reliability of tire defect detection, aiming to set a new standard in automated quality assurance in tire manufacturing.