Search Results (72)

Defects formed during the thermite welding process of two sections of rails require the welded joints to be inspected for quality, and the most used non-destructive method for inspection is radiography testing. However, the conventional defect investigation process from the obtained radiography images is costly, lengthy, and subjective as it is conducted manually by trained experts. Additionally, it has been shown that most rail breaks occur due to a crack initiated from the weld joint defect that was either misclassified or undetected. To improve the condition monitoring of rails, the railway industry requires an automated defect investigation system capable of detecting and classifying defects automatically. Therefore, this work proposes a method based on image processing and machine learning techniques for the automated investigation of defects. Histogram Equalization methods are first applied to improve image quality. Then, the extraction of the weld joint from the image background is achieved using the Chan–Vese Active Contour Model. A comparative investigation is carried out between Deep Convolution Neural Networks, Local Binary Pattern extractors, and Bag of Visual Words methods (with the Speeded-Up Robust Features extractor) for extracting features in weld joint images. Classification of features extracted by local feature extractors is achieved using Support Vector Machines, K-Nearest Neighbor, and Naive Bayes classifiers. The highest classification accuracy of 95% is achieved by the Deep Convolution Neural Network model. A Graphical User Interface is provided for the onsite investigation of defects. Full article

In intelligent building, efficient surface defect detection is crucial for structural safety and maintenance quality. Traditional methods face three challenges in complex scenarios: locating defect features accurately due to multi-scale texture and background interference, missing fine cracks because of their tiny size and low contrast, and the insufficient generalization of irregular defects due to complex geometric deformation. To address these issues, an improved version of the You Only Look Once (YOLOv8) algorithm is proposed for building surface defect detection. The dataset used in this study contains six common building surface defects, and the images are captured in diverse scenarios with different lighting conditions, building structures, and ages of material. Methodologically, the first step involves a normalization-based attention module (NAM). This module minimizes irrelevant features and redundant information and enhances the salient feature expression of cracks, delamination, and other defects, improving feature utilization. Second, for bottlenecks in fine crack detection, an explicit vision center (EVC) feature fusion module is introduced. It focuses on integrating specific details and overall context, improving the model’s effectiveness. Finally, the backbone network integrates deformable convolution net v2 (DCNV2) to capture the contour deformation features of targets like mesh cracks and spalling. Our experimental results indicate that the improved model outperforms YOLOv8, achieving a 3.9% higher mAP50 and a 4.2% better mAP50-95. Its performance reaches 156 FPS, suitable for real-time inspection in smart construction scenarios. Our model significantly improves defect detection accuracy and robustness in complex scenarios. The study offers a reliable solution for accurate multi-type defect detection on building surfaces. Full article

This work aimed to develop both a real implementation and a digital twin for a small CNC machining center. The X-, Y-, and Z-axes feed systems were realized as closed-loop motion loops with DC servo motors and encoders. Motion control was provided by Arduino boards and Pololu motor drivers. A simulation study of the step response parameters was carried out, and then the positioning regime was studied, followed by the two-axis simultaneous motion regime (circular interpolation). This study, based on a hybrid simulation diagram realized in Simulink–Simscape, allowed a preliminary tuning of the PID (proportional integral derivative) controllers. Next, the CAE (computer-aided engineering) simulation diagram was complemented with the CAM (computer-aided manufacturing) simulation interface, the two together forming an integrated digital twin system. To validate the contouring performance of the proposed CNC system, a circular groove with an outer diameter of 31 mm and an inner diameter of 29 mm was machined using a 1 mm cylindrical end mill. The trajectory followed the simulated 30 mm circular path. Two sets of controller parameters were applied. Dimensional accuracy was verified using a GOM Atos Core 200 optical scanner and evaluated in GOM Inspect Suite 2020. The results demonstrated good agreement between simulation and physical execution, validating the PID tuning and system accuracy. Full article

Autonomous underwater vehicle inspection in 3D environments presents significant challenges in spatial mapping for obstacle avoidance and motion control. Current solutions rely on either 2D forward-looking sonar or expensive 3D sonar systems. To address these limitations, this study proposes a cost-effective 3D reconstruction method using an oscillatory forward-looking sonar with a pan-tilt mechanism that extends perception from a 2D plane to a 75-degree spatial range. Additionally, a polar coordinate-based frontier extraction method for sequential sonar images is introduced that captures more complete contour frontiers. Through bridge pier scanning validation, the system shows a maximum measurement error of 0.203 m. Furthermore, the method is integrated with the Ego-Planner path planning algorithm and nonlinear Model Predictive Control (MPC) algorithm, creating a comprehensive underwater 3D perception, planning, and control system. Gazebo simulations confirm that generated 3D point clouds effectively support the Ego-Planner method. Under localisation errors of 0 m, 0.25 m, and 0.5 m, obstacle avoidance success rates are 100%, 60%, and 30%, respectively, demonstrating the method’s potential for autonomous operations in complex underwater environments. Full article

The early detection of cancerous lesions is a challenging task given the cancer biology and the variability in tissue characteristics, thus rendering medical image analysis tedious and time-inefficient. In the past, conventional computer-aided diagnosis (CAD) and detection methods have heavily relied on the visual inspection of medical images, which is ineffective, particularly for large and visible cancerous lesions in such images. Additionally, conventional methods face challenges in analyzing objects in large images due to overlapping/intersecting objects and the inability to resolve their image boundaries/edges. Nevertheless, the early detection of breast cancer lesions is a key determinant for diagnosis and treatment. In this study, we present a deep learning-based technique for breast cancer lesion detection, namely blob detection, which automatically detects hidden and inaccessible cancerous lesions in unsupervised human breast histology images. Initially, this approach prepares and pre-processes data through various augmentation methods to increase the dataset size. Secondly, a stain normalization technique is applied to the augmented images to separate nucleus features from tissue structures. Thirdly, morphology operation techniques, namely erosion, dilation, opening, and a distance transform, are used to enhance the images by highlighting foreground and background pixels while removing overlapping regions from the highlighted nucleus objects in the image. Subsequently, image segmentation is handled via the connected components method, which groups highlighted pixel components with similar intensity values and assigns them to their relevant labeled components (binary masks). These binary masks are then used in the active contours method for further segmentation by highlighting the boundaries/edges of ROIs. Finally, a deep learning recurrent neural network (RNN) model automatically detects and extracts cancerous lesions and their edges from the histology images via the blob detection method. This proposed approach utilizes the capabilities of both the connected components method and the active contours method to resolve the limitations of blob detection. This detection method is evaluated on 27,249 unsupervised, augmented human breast cancer histology dataset images, and it shows a significant evaluation result in the form of a $98.82\%$ F1 accuracy score. Full article

Advanced non-destructive techniques play an important role in detecting surface defects in the context of additive manufacturing, with non-destructive technologies providing surface data for the recognition of surface defects. In this line, it is necessary to implement microscope vision technology for the inspection of surface defects. This study proposes an approach for microsurface defect recognition using affine moment invariants based on microlaser line contouring, allowing for the detection of microscopic holes and scratches. For this purpose, the surface is represented by a Bezier surface to characterize microsurface defects through patterns of affine moment invariants after the surface is contoured via microlaser line projection. In this way, microholes and scratches can be recognized by computing a pattern of affine moment invariants for each region of the target surface. This technique is performed using a microscope vision system, which retrieves the surface topography via microlaser line scanning. The proposed technique allows for the recognition of holes and scratches with a surface depth greater than 20 microns, with a minor relative error of less than 2%. The proposed surface defect recognition approach enhances the literature on recognition techniques performed using visual technologies based on optical microscope systems. This contribution is corroborated through a discussion focused on the recognition of holes and scratches by means of various optical-microscope-based systems. Full article

The automated detection of yarn margins is crucial for ensuring the continuity and quality of production in textile workshops. Traditional methods rely on workers visually inspecting the yarn margin to determine the timing of replacement; these methods fail to provide real-time data and cannot meet the precise scheduling requirements of modern production. The complex environmental conditions in textile workshops, combined with the cylindrical shape and repetitive textural features of yarn bobbins, limit the application of traditional visual solutions. Therefore, we propose a visual measurement method based on the geometric characteristics of binocular imaging: First, all contours in the image are extracted, and the distance sequence between the contours and the centroid is extracted. This sequence is then matched with a predefined template to identify the contour information of the yarn bobbin. Additionally, four equations for the tangent line from the camera optical center to the edge points of the yarn bobbin contour are established, and the angle bisectors of each pair of tangents are found. By solving the system of equations for these two angle bisectors, their intersection point is determined, giving the radius of the yarn bobbin. This method overcomes the limitations of monocular vision systems, which lack depth information and suffer from size measurement errors due to the insufficient repeat positioning accuracy when patrolling back and forth. Next, to address the self-occlusion issues and matching difficulties during binocular system measurements caused by the yarn bobbin surface’s repetitive texture, an imaging model is established based on the yarn bobbin’s cylindrical characteristics. This avoids pixel-by-pixel matching in binocular vision and enables the accurate measurement of the remaining yarn margin. The experimental data show that the measurement method exhibits high precision within the recommended working distance range, with an average error of only 0.68 mm. Full article

Continuous-wave laser (CW) and pulsed-wave laser (PW) are the two laser modes in direct energy deposition (DED). This paper mainly reports on a study into the effects of the two laser modes on residual stresses with a given energy input. The contour method (CM) with non-uniform spatial distribution of inspection points was used to capture residual stress distributions in DED of Fe3000 on a substrate made of 316L stainless steel. Residual stresses in the transition zone between the deposit and the substrate were carefully examined to gain an understanding of cracks frequently observed at the connection between the substrate and the deposit. Furthermore, X-ray diffraction, along with successive material removal, was used to reveal residual stresses at various depths in the substrate. The results showed that significant tensile longitudinal stresses developed at the substrate–deposit junction for both CW and PW laser modes. It increased sharply (about 64%) with the increase in energy input for CW mode, while it showed the opposite trend for PW mode; the longitudinal residual stress decreased 13.2% with the increase in energy input. PW, however, introduced lower residual stress than that of CW under the condition of high-energy input; the maximum longitudinal residual stress decreased by about 10.4% compared to CW mode. This was due to stress relaxation at high-energy inputs in PW mode. In addition, residual stresses were found to be higher than the initial yield stress, and yielding occurred in the deposited part. The results determined by the CM and X-ray diffraction depth profiling were found to be consistent. Full article

The concentricity error of automotive brake piston components critically affects the stability and reliability of the brake system. Traditional contact-based concentricity measurement methods are inefficient. In order to address the issue of low detection efficiency, this paper proposes a non-contact concentricity measurement method based on the combination of machine vision and image processing technology. In this approach, an industrial camera is employed to capture images of the measured workpiece’s end face from the top of the spring. The edge contours are extracted through the implementation of image preprocessing algorithms, which are then followed by the calculation of the outer circle center and the fitting of the inner circle center. Finally, the concentricity error is calculated based on the coordinates of the inner and outer circle centers. The experimental results demonstrate that, in comparison to a coordinate measuring machine (CMM), this method exhibits a maximum error of only 0.0393 mm and an average measurement time of 3.9 s. This technology markedly enhances the efficiency of measurement and fulfills the industry’s requirement for automated inspection. The experiments confirmed the feasibility and effectiveness of this method in practical engineering applications, providing reliable technical support for the online inspection of automotive brake piston components. Moreover, this methodology can be extended to assess concentricity in other complex stepped shaft parts. Full article

Form deviation generated during the milling profile process challenges the precision and functionality of industrial fixtures and product manufacturing across various sectors. Inspecting contour profile quality relies on commonly employed contact methods for measuring form deviation. However, the methods employed frequently face limitations that can impact the reliability and overall accuracy of the inspection process. This paper introduces a novel approach, the novel intelligent inspection method (NIIM), developed to accurately inspect and categorize contour profiles in machined parts manufactured through the milling process by computer numerical control (CNC) machines. The NIIM integrates a calibration piece, a vision system ($RAM$-$Starlit{e}^{TM}$), and machine learning techniques to analyze the line profile and classify the quality of contour profile deformation generated during CNC milling. The calibration piece is specifically designed to identify form deviations in the contour profile during the milling process. The $RAM$-$Starlit{e}^{TM}$ vision system captures contour profile images corresponding to curves, lines, and slopes. An algorithm generates a profile signature, extracting Fourier descriptor features from the contour profile to analyze form deviations compared to an image reference. A feed-forward neural network is employed to classify contour profiles based on quality properties. Experimental evaluations involving 60 machined calibration pieces, resulting in 356 images for training and testing, demonstrate the accuracy and computational efficiency of the proposed NIIM for profile line tolerance inspection. The results demonstrate that the NIIM offers 96.99% accuracy, low computational requirements, 100% inspection capability, and valuable information to improve machining parameters, as well as quality classification. Full article

Thermal infrared imaging could detect hidden faults in various types of high-voltage power equipment, which is of great significance for power inspections. However, there are still certain issues with thermal-imaging-based abnormal heating detection methods due to varying appearances of abnormal regions and complex temperature interference from backgrounds. To solve these problems, a contour-based instance segmentation network is first proposed to utilize thermal (T) and visual (RGB) images, realizing high-accuracy segmentation against complex and changing environments. Specifically, modality-specific features are encoded via two-stream backbones and fused in spatial, channel, and frequency domains. In this way, modality differences are well handled, and effective complementary information is extracted for object detection and contour initialization. The transformer decoder is further utilized to explore the long-range relationships between contour points with background points, and to achieve the deformation of contour points. Then, the auto-encoder-based reconstruction network is developed to learn the distribution of power equipment using the proposed random argument strategy. Meanwhile, the UNet-like discriminative network directly explores the differences between the reconstructed and original image, capturing the deviation of poor reconstruction regions for abnormal heating detection. Many images are acquired in transformer substations with different weathers and day times to build the datasets with pixel-level annotation. Several extensive experiments are conducted for qualitative and quantitative evaluation, while the comparison results fully prove the effectiveness and robustness of the proposed instance segmentation method. The practicality and performance of the proposed abnormal heating detection method are evaluated on image patches with different kinds of insulators. Full article

Crack detection is significant to building repair and maintenance; however, conventional inspection is a labor-intensive and time-consuming process for field engineers. This paper proposes a three-step computer vision-based framework to quickly recognize concrete cracks and automatically identify their length, maximum width, and area in damage images. In step one, a region-based convolutional neural network (YOLOv8) is applied to train the crack localizing model. In step two, Gaussian filtering, Canny, and FindContours are integrated to extract the reference contour (a pre-designed seal) to obtain the conversion scale between pixels and millimeter-wise sizes. In step three, the recognized crack bounding box is cropped, and the ApproxPolyDP function and Hough transform are performed to quantify crack dimensions based on the conversion ratio. The developed framework was validated on a dataset of 4630 crack images, and the model training took 150 epochs. Results show that the average crack detection accuracy reaches 95.7%, and the precision of quantified dimensions is over 90%, while the error increases as the crack size grows smaller (increasing to 8% when the crack width is within 1 mm). The proposed method can help engineers to efficiently achieve crack information at building inspection sites, while the reference frame must be pre-marked near the crack, which may limit the scope of application scenarios. In addition, the robustness and accuracy of the developed image processing techniques-based crack quantification algorithm need to be further improved to meet the requirements in real cases when the crack is located within a complex background. Full article

The quality of underwater bridge piers significantly impacts bridge safety and long-term usability. To address limitations in conventional inspection methods, this paper presents a sonar-based technique for the three-dimensional (3D) reconstruction and visualization of underwater bridge piers. Advanced MS1000 scanning sonar is employed to detect and image bridge piers. Automated image preprocessing, including filtering, denoising, binarization, filling, and morphological operations, introduces an enhanced wavelet denoising method to accurately extract the foundation contour coordinates of bridge piers from sonar images. Using these coordinates, along with undamaged pier dimensions and sonar distances, a model-driven approach for a 3D pier reconstruction algorithm is developed. This algorithm leverages multiple sonar data points to reconstruct damaged piers through multiplication. The Visualization Toolkit (VTK) and surface contour methodology are utilized for 3D visualization, enabling interactive manipulation for enhanced observation and analysis. Experimental results indicate a relative error of 13.56% for the hole volume and 10.65% for the spalling volume, demonstrating accurate replication of bridge pier defect volumes by the reconstructed models. Experimental validation confirms the method’s accuracy and effectiveness in reconstructing underwater bridge piers in three dimensions, providing robust support for safety assessments and contributing significantly to bridge stability and long-term safety assurance. Full article

The accurate assessment of peanut seed plumpness is crucial for optimizing peanut production and quality. The current method is mainly manual and visual inspection, which is very time-consuming and causes seed deterioration. A novel imaging technique is used to enhance the detection of peanut seed fullness using a non-destructive soft X-ray, which is suitable for the analysis of the surface or a thin layer of a material. The overall grayscale of the peanut is similar to the background, and the edge of the peanut seed is blurred. The inaccuracy of peanut overall and peanut seed segmentation leads to low accuracy of seed plumpness detection. To improve accuracy in detecting the fullness of peanut seeds, a seed plumpness detection method based on level set and multi-threshold segmentation was proposed for peanut images. Firstly, the level set algorithm is used to extract the overall contour of peanuts. Secondly, the obtained binary image is processed by morphology to obtain the peanut pods (the peanut overall). Then, the multi-threshold OTSU algorithm is used for threshold segmentation. The threshold is selected to extract the peanut seed part. Finally, morphology is used to complete the cavity to achieve the segmentation of the peanut seed. Compared with optimization algorithms, in the segmentation of the peanut pods, average random index (RI), global consistency error (GCE) and variation of information (VI) were increased by 10.12% and decreased by 0.53% and 24.11%, respectively. Compared with existing algorithms, in the segmentation of the peanut seed, the average RI, VI and GCE were increased by 18.32% and decreased by 9.14% and 6.11%, respectively. The proposed method is stable, accurate and can meet the requirements of peanut image plumpness detection. It provides a feasible technical means and reference for scientific experimental breeding and testing grading service pricing. Full article

To achieve effective and accurate segmentation of photovoltaic panels in various working contexts, this paper proposes a comprehensive image segmentation strategy that integrates an improved Meanshift algorithm and an adaptive Shi-Tomasi algorithm. This approach effectively addresses the challenge of low precision in segmenting target regions and boundary contours in routine photovoltaic panel inspection. Firstly, based on the image information of photovoltaic panels collected under different environments by cameras, an improved Meanshift algorithm based on platform histogram optimization is used for preliminary processing, and images containing target information are cut out; then, the adaptive Shi-Tomasi algorithm is used to extract and screen feature points from the target area; finally, the extracted feature points generate the segmentation contour of the target photovoltaic panel, achieving accurate segmentation of the target area and boundary contour of the photovoltaic panel. Experiments verified that in photovoltaic panel images under different background environments, the method proposed in this paper enhances the accuracy of segmenting the target area and boundary contour of photovoltaic panels. Full article