There are several types of steel products, such as wire rods, cold-rolled coils, hot-rolled coils, thick plates, and electrical sheets. Surface stains on cold-rolled coils are considered defects. However, surface stains on thick plates are not considered defects. A conventional optical structure is composed of a camera and lighting module. A defect inspection system that uses a dual lighting structure to distinguish uneven defects and color changes by surface noise is proposed. In addition, an image processing algorithm that can be used to detect defects is presented in this paper. The algorithm consists of a Gabor filter that detects the switching pattern and employs the binarization method to extract the shape of the defect. The optics module and detection algorithm optimized using a simulator were installed at a real plant, and the experimental results conducted on thick steel plate images obtained from the steel production line show the effectiveness of the proposed method.
Defective rollers in rolling plants often create spatially periodic defects on the product surface. It is essential for operators to receive early warnings of such periodic defects and take appropriate action to avoid a large quantity of defective products. We present a robust and efficient real-time method for inspecting periodic defects in continuous steel wire rods. The proposed inspection method consists of two parts: (1) an algorithm for detecting all defect candidates and (2) an algorithm to detect periodicities in the detected defect candidates and to determine their periods. The first algorithm exploits the translation-invariant property of the Haar undecimated discrete wavelet transform to improve the signal-to-noise ratio of the surface image. The second algorithm is based on analysis of the frequency spectrum of defect candidate positions. It identifies periodicities of the defect candidates by finding repeating impulse-like spectra. The inspection system using the proposed method is applied to a real production line and detects periodic defects in real time and identifies their periodicities with high accuracy.
For the shape measurement of the cold rolled strips, the new rectangular fringe shift method is introduced. The image saturation always occurs in the image center because of the total specular reflection of the strip surface. The central area saturation is reduced by using the circular gaussian density filter. Least-square fitting is used to find out the phase information of the strip. Phase map is obtained from the eight quasi-rectangular strip patterns and the shape of the object surface can be expressed by unwrapped phase map of 256 gray levels.
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