Abstract
During the production of web materials such as plastic, textiles or metal, where there are rolls involved in the production process, periodically generated defects may occur. If one of these rolls has some kind of flaw, it can generate a defect on the material surface each time it completes a full turn. This can cause the generation of a large number of surface defects, greatly degrading the product quality. For this reason, it is necessary to have a system that can detect these situations as soon as possible. This paper presents a vision-based sensor for the early detection of this kind of defects. It can be adapted to be used in the inspection of any web material, even when the input data are very noisy. To assess its performance, the sensor system was used to detect periodical defects in hot steel strips. A total of 36 strips produced in ArcelorMittal Avilés factory were used for this purpose, 18 to determine the optimal configuration of the proposed sensor using a full-factorial experimental design and the other 18 to verify the validity of the results. Next, they were compared with those provided by a commercial system used worldwide, showing a clear improvement.
Highlights
Quality control in industrial environments is an essential aspect, both to improve product quality and to reduce costs caused by discarded defective products
This study focuses on quality control during production of web materials using a computer vision system
This paper has presented a sensor system based on computer vision capable of detecting periodical defects in web materials during their production
Summary
Quality control in industrial environments is an essential aspect, both to improve product quality and to reduce costs caused by discarded defective products. The rolls that are in direct contact with the web material to be produced can be the source of serious defects In these cases, this situation is repeated until the defective roll is replaced. This situation is repeated until the defective roll is replaced For this reason, it is very important to make early detection of such defects during the production of web materials. The sooner this situation is detected, the sooner the defective roll may be replaced, greatly reducing the productivity loss
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