Real-time detection of surface cracking defects for large-sized stamped parts

Abstract

This study presents a framework for the real-time detection of surface cracking in large-sized stamped metal parts. The framework aims to address the challenges of low detection efficiency and high error rates associated with manual cracking detection. Within this framework, a novel network, SNF-YOLOv8, is proposed to efficiently detect cracking while ensuring that the detection speed matches the production speed. The network incorporates a convolutional spatial-to-depth module to enhance the detection of small-sized cracking and mitigate surface interference during inspections. Furthermore, a visual self-attention mechanism is introduced to improve feature extraction. A combination of standard convolutional and depth-wise separable convolutional layers in the neck network enhances speed without compromising accuracy. Experimental validation conducted using a dataset from actual production lines, in collaboration with a multi-national corporation, demonstrates that SNF-YOLOv8 achieves an average precision of 85.2% at a detection speed of 164 frames per second. The framework achieves an accuracy rate of 98.8% in detecting large-sized cracking and 96.4% in detecting small-sized cracking, meeting the requirements for high-precision and real-time detection applications.