基于无监督学习的智能皮带缺陷检测方法
Intelligent Belt Defect Detection Method Based on Unsupervised Learning
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摘要: 皮带的实时检测是工业现场安全生产中重要的一环,针对现有输送带缺陷数据不足、缺陷检测模型训练效果不理想等问题,提出了一种基于生成对抗网络(Generative Adversarial Network ,GAN)改进的无监督皮带缺陷检测模型,模型地训练仅依赖易于获取的正常皮带图像,解决了皮带缺陷数据获取、标注困难的问题。为将生成对抗网络适用于皮带缺陷检测,做如下改进:为解决重构图片与输入图片的不对齐问题,将生成器改进为端到端的自编码器(Autoencoder,AE)结构;为增强生成器对于未知无规则缺陷的重建修复能力及缓解恒等映射问题,对训练图片添加柏林噪声制造的无规则模拟缺陷,将生成器损失函数改进为多种损失函数的加权和;为增强模型对于微小缺陷的检测能力,使用预训练的块判别器替换原有判别器结构,使用原始图像与重构图像在判别器潜在空间的差异计算异常分数。实验结果表明,所设计的模型使ROC-AUC达到0.999,PR-AUC达到0.997,单张图片检测时间为13.51ms。与结构相似性自编码器(Structural Similarity Index Measure – AutoEncoder,SSIM-AE)快速异常生成对抗网络(Fast-Anomaly Generative Adversarial Network,F-AnoGAN)、生成对抗异常检测(GANormaly)、全频道选择重构生成对抗网络(Omni-frequency Channel-selection Reconstruction Generative Adversarial Network,OCR-GAN)等方法相比,ROC-AUC提高4.5%,PR-AUC提高8%。检测时间满足现场皮带3m/s速度要求,同时正负例样本异常分数分布差异更加明显,在实际应用中拥有更高的鲁棒性和准确性。Abstract: Real-time monitoring of conveyor belts is a crucial aspect of safety in industrial production settings. Addressing the issues of insufficient existing conveyor belt defect data and the inadequate per-formance of defect detection models, this study proposes an unsupervised belt defect detection model based on an improved Generative Adversarial Network (GAN). The model's training relies solely on easily accessible images of normal belts, effectively circumventing the challenges in obtaining and labeling defect data for belts. To tailor the GAN for belt defect detection, several enhancements were implemented: the generator was modified into an end-to-end Autoencoder (AE) structure to address misalignment between reconstructed and input images; to enhance the gener-ator's ability to reconstruct and repair unknown irregular defects and alleviate identity mapping issues, we introduced irregular simulated defects using Perlin noise into the training images, and the generator loss function was refined into a weighted sum of multiple loss functions. Furthermore, to bolster the model's capability in detecting minute defects, a pre-trained block discriminator replaced the original discriminator structure. The anomaly score is determined by the highest block anomaly score and the difference in the latent space of the discriminator between the original and recon-structed images. Experimental results indicate that the proposed model achieved an ROC-AUC of 0.999 and PR-AUC of 0.997, with a detection time of 13.51ms per image. Compared to other methods such as Structural Similarity Index Measure – AutoEncoder(SSIM-AE),Fast-Anomaly GAN (F-AnoGAN), GANomaly, and Omni-frequency Channel-selection Reconstruction GAN (OCR-GAN), our model shows a 4.5% increase in ROC-AUC and an 8% increase in PR-AUC. It satisfies the real-time detection requirement for conveyor belts moving at 3 m/s. Furthermore, the model demonstrates a more distinct distribution difference in anomaly scores between positive and negative examples, offering robustness and accuracy in practical applications.
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