11 V May 2023

https://doi.org/10.22214/ijraset.2023.51485
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Product Defect Identification System

Rutu1, Rakesh M R 2, Pooja L3, Hema C4
1, 2, 3
Student, Department of ECE, EWIT
4
Assistant Professor, Department of ECE, EWIT

Abstract: Some uncontrollable defects will occur on the surface of metal work pieces during processing. The existence of surface
defects not only affects the appearance of the finished product, but also affects the quality to a certain extent. Surface defect
detection of metal work pieces can effectively improve product quality and production efficiency, and is an important link in the
process of product quality control. This proposed system uses the convolutional neural network algorithm in deep learning to
classify and detect metal surface defects. The surface defect recognition accuracy and defect detection rate of metal work is
computed.
Keywords: Machine learning, CNN (Convolutional Neural Network)

I. INTRODUCTION
With the continuous improvement of science and technology, the intelligent, automated, and unmanned manufacturing industry will
be an inevitable trend in the future. China has also put forward the "Made in China 2025" strategy to become a powerful country in
science and technology to realize the transformation from a manufacturing country to a manufacturing country. As an important
form of metal materials, metal workpieces are widely used in daily life and industrial production by virtue of their excellent
mechanical and physical properties. In the production process of the product, due to the influence of equipment and technology,
different kinds of defects often appear on the surface of the product, such as scratches, holes, and cracks in the metal work piece.
The surface quality of metal workpieces not only affects the appearance and image of the product, but may also affect the functional
characteristics of the product and cause significant losses to the enterprise. Therefore, it is very necessary to detect the surface
defects of the product, and it is particularly important to design a real-time and effective surface defect detection method for metal
workpieces. Conventional non-destructive inspection methods for surface defects of metal workpieces include magnetic particle
inspection, penetrant inspection, infrared thermal imaging inspection, ultrasonic inspection, visual inspection, etc. Machine vision
inspection technology is constantly being used in inspections in various fields. Machine vision inspection mainly uses high-
resolution industrial cameras to obtain images of specimens to be inspected, and uses digital image processing inspection algorithms
to complete the inspection of defects. The visual inspection is a non-contact inspection, and it will not cause any damage to the
workpiece to be inspected during inspection. At the same time, the visual inspection has a high degree of automation, which can be
realized for a long time and work continuously and smoothly. In recent years, research on artificial intelligence technology has
continued to deepen, and machine learning and deep learning methods have been rapidly developed, and have been gradually
applied in various fields, providing a new method for solving the detection problem of metal work piece surface defects. Deep
learning can directly learn two-dimensional images, reducing image pre-processing, without manually extracting features, and can
automatically learn more appropriate features layer by layer, greatly reducing the impact of human factors. Quality management has
become a central concern for manufacturing organizations, as achieving good quality is necessary to remain competitive in the
market (Harik & Wuest, 2020). In addition to the establishment of international standards (European Committee for Standardization,
2015a, 2015b), different frameworks have been developed to aid organizations in establishing well-functioning quality management
systems, such as Total Quality Management and Six Sigma (Oakland, 2014). A prominent element within these larger quality
management frameworks is quality control, which is implemented for the expressed purpose of ensuring manufactured products
comply with quality requirements. It is also accepted that visual classification tasks with higher complexity require more data, larger
networks and more resource-intensive training of the neural network (Ameer& Maul, 2019). For quality inspection applications, this
complexity may increase when more product variants are introduced to the network, resulting in a wider range of, for example,
colours, materials, defect types and geometry.

A. Purpose
Defect detection during manufacturing processes is a vital step to ensure product quality. The timely detection of faults or defects
and taking appropriate actions are essential to reduce operational and quality-related costs. It is also efficient at inspecting large
production lines and spotting faults even on the smallest parts of a final product.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 459
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

B. Problem Statement
We'll look into whether deep learning models are appropriate for identifying steel product flaws. The key difficulty in this task is
developing a reliable system from a small number of samples. In order to categorise and compare the performance of various neural
network architectures and data augmentation strategies in addressing the key issues previously exposed, we will analyse the
performance of these different neural network architectures in this project.

C. Objectives
The aim of this work is to develop image processing algorithms for product identification, defect detection and grading. For the
purpose, it is also proposed to develop a specially designed product image acquisition setup. This aim is proposed to be achieved in
the study by the following objectives:
1) Design and develop a robust machine learning algorithm for product classification.
2) Design and develop a lab prototype system to acquire images of surface defects over the entire area of the product.
3) Develop texture feature descriptors to discriminate defective and non-defective regions of the product.
4) Evaluate and validate the performance of the feature extraction algorithm and classifier results for unseen test data sets.
5) Develop grading rules based on computation of effective cutting value of the product for objective product grading.

D. The Merits Of The Project

1) It improves the Manufacturing process and optimizes costs.
2) It minimizes the manufacturer's costs by identifying detects earlier and faster.
3) It also reduces scrap and improves employee productivity.

E. Scope
The project has a focus on improving the performance and accuracy of surface defect detection by applying the model of CNN. In
other words, the data will principally be assessed via the model of CNN and in contrast to the other two semantic segmentation
models called ResUnet and Deeplab v3 plus. Finally, according to the analysis, an improvement will be made to CNN model. The
dataset contains only steel surfaces from Kaggle competition as mentioned before.

II. METHODOLOGY
A. Block Diagram Of Product Defect Detection System
The manufacturing industries have been searching and developing new solutions to increase the product quality and to decrease the
time taken and costs of production. The defect in the products can be detected using pre- processing defect. This defect detection in
industrial applications produces high detection accuracy than the traditional methods acquired by the manufacturing industries for
examining defects. The defect is detected through image processing.
LCD DISPLAY

Rs Rw E P4 P5 P6 P7

CAMERA
8 Gnd 9 10 11 12 13 H-BRIDGE
USB
ARDUINO BUZZER
UNO
BOARD

MOTOR
LAPTOP

POWER SUPPLY CONVEYOR BELT

Fig 1: Block Diagram of Product Defect Detection System

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 460
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

B. Arduino Uno Board

Arduino UNO is based on an ATmega328P microcontroller. It is easy to use compared to other boards, such as the Arduino Mega
board, etc. The board consists of digital and analog Input/Output pins (I/O), shields, and other circuits. The Arduino UNO includes 6
analog pin inputs, 14 digital pins, a USB connector, a power jack, and an ICSP (In-Circuit Serial Programming) header. It is
programmed based on IDE, which stands for Integrated Development Environment. It can run on both online and offline platforms.

C. H-Bridge
An H bridge is an electronic circuit that switches the polarity of a voltage applied to a load. These circuits are often used in robotics
and other applications to allow DC motors to run forwards or backwards. The H-bridge arrangement is generally used to reverse the
polarity/direction of the motor, but can also be used to 'brake' the motor, where the motor comes to a sudden stop, as the motor's
terminals are shorted, or to let the motor 'free run' to a stop, as the motor is effectively disconnected from the circuit. An H Bridge is
a set of four switches that are assembled in such a way that an arbitrary load impedance is decoupled from a direct current (DC)
power rail and ground.

D. Motor
A DC motor is any of a class of rotary electrical machines that converts direct current electrical energy into mechanical energy. The
most common types rely on the forces produced by magnetic fields. Nearly all types of DC motors have some internal mechanism,
either electromechanical or electronic, to periodically change the direction of current flow in part of the motor.DC motors were the
first form of motor widely used, as they could be powered from existing direct- current lighting power distribution systems. A DC
motor's speed can be controlled over a wide range, using either a variable supply voltage or by changing the strength of current in its
field windings. Small DC motors are used in tools, toys, and appliances

E. Power Supply
A power supply is an electrical device that supplies electric power to an electrical load. The main purpose of a power supply is to
convert electric current from a source to the correct voltage, current, and frequency to power the load. As a result, power supplies
are sometimes referred to as electric power converters. Power is the backbone of any electronic system and the power supply is what
feeds the system. Power supplies are used in most electric equipment. Their applications cut across a wide spectrum of product
types, ranging from consumer appliances to industrial utilities, from milliwatts to megawatts, and from handheld tools to satellite
communications.

F. Buzzer
An audio signaling device like a beeper or buzzer may be electro mechanical or piezo electric or mechanical type. The main
function of this is to convert the signal from audio to sound. Generally, it is powered through DC voltage and used in timers, alarm
devices, printers, alarms, computers, etc. Based on the various designs, it can generate different sounds like alarm, music, bell &
siren.It includes two pins namely positive and negative. The positive terminal of this is represented with the ‘+’ symbol or a longer
terminal.

G. LCD Display
A liquid-crystal display (LCD) is a flat-panel display or other electronically modulated optical device that uses the light-modulating
properties of liquid crystals. Liquid crystals do not emit light directly, instead using a backlight or reflector to produce images in
color or monochrome. LCDs are available to display arbitrary images (as in a general-purpose computer display) or fixed images
with low information content, which can be displayed or hidden, such as preset words, digits, and 7-segment displays, as in a digital
clock. They use the same basic technology, except that arbitrary images are made up of a large number of small pixels, while other
displays have larger elements
III. IMPLEMENTTION
A. Process Of Defect Detection System
Detection of a defect by image processing broadly follows some of the basic steps which include feature extraction, edge detection,
morphological operators, and training of data..A real-time defect detection system is presented to help classify product quality
automatically based on the YOLO (You only look once) algorithm. The system can be integrated into factories and production lines,
helping to optimize efficiency and save operating costs.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 461
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Based on the YOLO algorithm , we trained a model to predict good and defected products during product manufacturing process in
the factory. Later on, with the trained model, we built a system to detect defective products in real-time. The system can be readily
installed and deployed at factories with existing infrastructure (CCTV cameras and connected computers).

B. The Proposed System For Detecting Defects In Real Time

1) YOLO Network: First of all, the outside images of the packaging boxes collected from the cameras will be labelled and
classified as defective/non-defective or damaged/intact through external appearance assessment. Then this module builds the
YOLO network as described and trains the network with annotated images to produce the trained model. After that, the model
will be put into the packaging defect detection system for detecting defects of boxes from the conveyor belts.
2) Real-time image receiving: This module collects data from the cameras mounted on the conveyor belts and transmits frames of
packages in real-time to the server. We utilize FFmpeg, a popular open-source, cross platform solution used in image processing
and streaming to support real-time frame processing.
3) Packaging defect detection: This module manages frames sent from the Real-time video receiving module in a queue. Each
frame in this queue will be resized and then put into the trained model to predict the probability values of which class the
packaging boxes belong to. Finally, the prediction results of this frame are transmitted to the Automatic classifier module.
4) Automatic classifier: Based on the probability values received from the Package defect detection module with a given
threshold, this module will automatically process the classification of packages, giving the decision whether a package is
defective or not. After that, information of defect package is sent to the robot arm to move the damaged package out of the
conveyor belt.

C. System Architecture

Fig 2: Architecture of the proposed system

A pre-trained model is a saved network that was previously trained on a large dataset, typically on a large-scale image-classification
task. Some highly optimized and extraordinarily efficient pre-trained models are available on the internet. Different models are used
to perform different tasks. Some of the pre-trained models are VGG-16, VGG-19, YOLOv5, YOLOv3, and ResNet 50.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 462
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

D. Flowchart

START

Data Collection

Data Pre-processing

Image Annotation

Splitting Dataset

Training with suitable

algorithm

Data Input & Model

Testing

No
Satisf Parameters
y Fixing

Ye

Model saving

STOP

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 463
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

The system consists of 3 main stages:

1) Stage1
Acquiring the image of the product
It involves the capturing of the images of the product using camera. In this system we collected the number of database of product
images that is good and bad quality images. These product image databases are helpful for more accurate result. So in this system
we collected the camera images as database 225 database and these images used as input images in this system.

2) Stage 2:
Detection process:
Choose an input image from collected database images. Product is detected by feature extraction process. The proposed
methodology in this paper, to perform the analysis for image features extracts using following steps
a) Capture input images using camera and collect number of images as a database images. It includes good as well as bad quality
images.
b) RGB image is converted to HSV color space. Then lower and upper ranges are defined. Then ranges of binary image are
defined. Then convert single channel mask back into 3 channels.
c) For extracts a colored object to detect the color, here we use HSV colorthresholder script to determine the lower/upper
thresholds. HSV color space is also give the information about the image that is, it either present or not in this system.
d) Using by this input image we obtain the mask images. In mask image we get black and white colored image.

3) Stage 3:
Detection of defective product:
Find out defective product is one of the most important preprocessing steps. The defective skin is calculated. A color image of the
product was used for the analysis. If the pixel value is less than the selected threshold value then it is considered as a part of
defective i.e. bad quality product..Any pixel value greater than the selected threshold value is a part of pure skin i.e. good quality
product.
The image is mask then pure part of the image indicated by black while the damaged ones white. Then the total number of white
pixels are calculated which will be equal to the total number of pixels corresponding to damaged part.
A pre-processing procedure is performed to enable more accurate classification as well as ensuring the image resolution corresponds
to the expected size of input images in the network. Image Processing for a more detailed description of the implemented image
processing algorithm. Once processed, the image is transferred to a classification network which attempts to determine if the
product is defective or not.

Fig 3 : Process of Detection

The framework allows for easy exchange of the classification network to test how different approaches perform in the same
conditions. Monolithic approaches, of which there are many architectures available for use, do not need any further design to
function and can be implemented as soon as they have been trained. However, the implementation of a modular network requires
additional steps, especially given how the very structure of modular networks can be tailored to specific use cases and specific sets
of data.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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IV. RESULT

Fig 4 : Complete Proposed System

The Setup of Product Defect Detection System is shown in the above figure. It segregates the defected and non defected products
as shown below figure.

Fig 5: Segregation process

The defected and non defected products are shown in below figure.

Fig 6: Identification of Defected product

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Fig 7: Identification of Good product

V. CONCLUSION
In this modern world, almost every sector is being enlightened by different technological innovations and findings. India is also
moving forward with these blessings although the most significant economic resource of our country. We believe this model can
play a very essential part in today's world. Industrialization is a fundamental aspect of modern civilization. With increasing
modernization and Industrialization, industrial growth and demand emerge as a massive factor in this. But this is lacking in using
new technologies of machine learning. As a result, our industry should be familiar with all of the latest machine learning and other
techniques. In this study, the image processing technique and application of image processing expertise for automatic inspection and
defect detection is discussed. Although lot of research carried by different researcher doing research in images processing, there is
scope to apply image processing techniques for quality control of industrial product. The image processing techniques are very
powerful tool for automatic, fast and easier defect detection and quality control of various types of products. Algorithm is proposed
for real time quality monitoring of manufactured product. This proposed system can replace manual inspection of industrial product.
Result will indicate product is defective or non-defective. Using this automatic inspection system cost of inspection will be reduced
also accuracy of inspection will increase.

VI. FUTURE SCOPE

We hope that in the future, this model will be implemented with a much more efficient dataset for a specific piece of product or
object that contains various information, and so on. So that no product or object is wasted by quality inspection and this system is
more productive. We want this model to be used all over the world to help the growth of the industrial sector. Both researchers and
entrepreneurs may be interested in this field. In the future, we hope to create a cloud platform for all of the industries that will be
using this model to share information all over the industries.

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ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

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