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Automatic anode rod inspection in aluminum smelters using deep-learning techniques: a case study
(2020)
Automatic fault detection using machine learning has become an exciting and promising area of research. This because it accurate and timely way to manage and classify with minimal human effort. In the computer vision community, deep-learning methods have become the most suitable approaches for this task. Anodes are large carbon blocks that are used to conduct electricity during the aluminum reduction process. The most basic function of anode rod inspection is to prevent a situation where the anode rod will not fit into the stub-holes of a new anode. It would be the case for a rod containing either severe toe-in, missing stubs, or a retained thimble on one or more stubs. In this work, to improve the accuracy of shape defect inspection for an anode rod, we use the Fast Region-based Convolutional Network method (Fast R-CNN), model. To train the detection model, we collect an image dataset composed of multi-class of anode rod defects with annotated labels. Our model is trained using a small number of samples, an essential requirement in the industry where the number of available defective samples is limited. It can simultaneously detect multi-class of defects of the anode rod in nearly real-time.
Development work within an experimental environment, in which certain properties are investigated and optimized, requires many test runs and is therefore often associated with long execution times, costs and risks. This can affect product, material and technology development in industry and research. New digital driver technologies offer the possibility to automate complex manual work steps in a cost-effective way, to increase the relevance of the results and to accelerate the processes many times over. In this context, this article presents a low-cost, modular and open-source machine vision system for test execution and evaluates it on the basis of a real industrial application. For this purpose a methodology for the automated execution of the load intervals, the process documentation and for the evaluation of the generated data by means of machine learning to classify wear levels. The software and the mechanical structure are designed to be adaptable to different conditions, components and for a variety of tasks in industry and research. The mechanical structure is required for tracking the test object and represents a motion platform with independent positioning by machine vision operators or machine learning. An evaluation of the state of the test object is performed by the transfer learning after the initial documentation run. The manual procedure for classifying the visually recorded data on the state of the test object is described for the training material. This leads to an increased resource efficiency on the material as well as on the personnel side since on the one hand the significance of the tests performed is increased by the continuous documentation and on the other hand the responsible experts can be assigned time efficiently. The presence and know-how of the experts are therefore only required for defined and decisive events during the execution of the experiments. Furthermore, the generated data are suitable for later use as an additional source of data for predictive maintenance of the developed object.
This work is a study about a comparison of survey tools and it should help developers in selecting a suited tool for application in an AAL environment. The first step was to identify the basic required functionality of the survey tools used for AAL technologies and to compare these tools by their functionality and assignments. The comparative study was derived from the data obtained, previous literature studies and further technical data. A list of requirements was stated and ordered in terms of relevance to the target application domain. With the help of an integrated assessment method, the calculation of a generalized estimate value was performed and the result is explained. Finally, the planned application of this tool in a running project is explained.
Cardiovascular diseases are directly or indirectly responsible for up to 38.5% of all deaths in Germany and thus represent the most frequent cause of death. At present, heart diseases are mainly discovered by chance during routine visits to the doctor or when acute symptoms occur. However, there is no practical method to proactively detect diseases or abnormalities of the heart in the daily environment and to take preventive measures for the person concerned. Long-term ECG devices, as currently used by physicians, are simply too expensive, impractical, and not widely available for everyday use. This work aims to develop an ECG device suitable for everyday use that can be worn directly on the body. For this purpose, an already existing hardware platform will be analyzed, and the corresponding potential for improvement will be identified. A precise picture of the existing data quality is obtained by metrological examination, and corresponding requirements are defined. Based on these identified optimization potentials, a new ECG device is developed. The revised ECG device is characterized by a high integration density and combines all components directly on one board except the battery and the ECG electrodes. The compact design allows the device to be attached directly to the chest. An integrated microcontroller allows digital signal processing without the need for an additional computer. Central features of the evaluation are a peak detection for detecting R-peaks and a calculation of the current heart rate based on the RR interval. To ensure the validity of the detected R-peaks, a model of the anatomical conditions is used. Thus, unrealistic RR-intervals can be excluded. The wireless interface allows continuous transmission of the calculated heart rate. Following the development of hardware and software, the results are verified, and appropriate conclusions about the data quality are drawn. As a result, a very compact and wearable ECG device with different wireless technologies, data storage, and evaluation of RR intervals was developed. Some tests yelled runtimes up to 24 hours with wireless Lan activated and streaming.