Hot rolled steel surface defect detection and classification using an automatic ensemble approach

Abstract

Abstract This study introduces an ensemble-based Deep Neural Network (DNN) model for detecting defects on steel surfaces. The method suggested in this study classifies steel surface conditions into six possible fault categories, namely, crazing, inclusion, rolled in, pitted surface, scratches, and patches. The images undergo preprocessing and extraction of features in spatial and frequency domains using image segmentation techniques such as grey level difference method (GLDM), fast Fourier Transform (FFT), grey level co-occurrence matrix (GLCM), texture analysis and discrete wavelet transform (DWT). The ensembling of image features into a fused feature pool is carried out after the preprocessing of input images that are provided as input to a light-weight neural network model for training and testing. The performance of the model is comprehensively evaluated via an ablation study both before and after ensembling. In addition, the model capability is effectively analyzed using receiver operating characteristics (ROC) curve, confusion matrix from which classification accuracy of the model could be obtained and other parameters including precision and f1-score. It was observed that the proposed deep learning network presents phenomenally high accuracy of 99.72% for detection and classification of steel surface faults. This result was found to be superior when compared with the performance of the same neural network over each feature type individually. This study also compares the classification results of the model built based on the ensembled feature set with the results of various other classification approaches available in literature. The ensemble-based model could potentially be integrated into existing inspection systems for real-time, efficient and robust condition monitoring of steel surfaces.