基于卷积神经网络X射线环焊缝缺陷检测

X-ray circumferential weld defect detection based on convolutional neural network

  • 摘要: 针对工业X射线焊缝图像对比度低、缺陷模糊且相对面积较小及难以识别的问题,设计了结合卷积神经网络的识别框架。根据缺陷图像特点,设计了对应的神经网络结构、卷积模板及池化模板的大小。在分析确定神经网络结构的基础上,卷积神经网络的灵敏度和训练算法也在文中一并给出。通过实例对神经网络结构进行了有效性的验证,缺陷检测准确率达97%,误报率仅为3%。同时,对适用于卷积神经网络进行识别的X射线焊缝图像进行了分析,发现灰度直方图有效信息跨度范围在50之上的卷积神经网络可以有效识别。文中所设计的神经络对X射线焊缝缺陷图像的识别可行、有效。创新点:(1)卷积神经网络结构设定为4级6层,卷积核大小尺寸为3×3,原始图像深度为1。经过第一次卷积操作后,有4个通道;经过3×3卷积核卷积后,有3个通道能够识别缺陷,则可以初步确认疑似缺陷区域。经过第二次卷积操作后,有16个通道;再次经过3×3卷积核卷积后,可以识别出缺陷图像。(2)通过对识别成功和识别失败图像灰度直方图进行分析,当灰度图跨度低于50时,图像检测目标与背景之间的对比度相对较低,卷积神经网络中卷积层难以提取目标特征,此时神经网络的识别失效,无法判定缺陷。当局部图像灰度直方图跨度高于50时,识别目标较背景突出,图像整体对比度较高,卷积层可以提取识别目标的特征,此时的卷积神经网络对焊缝图像有较好的识别效果。

     

    Abstract: Aiming at the problems of low contrast of industrial X-ray weld images, fuzzy defects and relatively small areas, and they were difficult to identify, a recognition framework combined with convolutional neural networks was designed.According to the characteristics of the defect image, the size of the corresponding neural network structure, convolution template and pooling template were designed.Based on the analysis and determination of the neural network structure, the sensitivity and training algorithm of the convolutional neural network were also given in the article.The effectiveness of the neural network structure was verified through examples, the defect detection accuracy rate was 97% and the false alarm rate was only 3%.At the same time, the X-ray weld image suitable for the recognition of the convolutional neural network was analyzed, it was found that the convolutional neural network with the effective information span of the gray histogram above 50 could be effectively identified.It showed that the neural network designed in this paper was feasible and effective in the recognition of X-ray weld defect images.Highlights:(1)The convolutional neural network structure was set to 4 level 6 layers, convolution kernel size was 3 ×3, the depth of the original image was 1.After first convolution operation, there were four channels.After 3×3 convolution kernels convolution, there were three channels to identify defects, and suspected defect area could be preliminarily confirmed.After the second convolution operation, there were 16 channels, and then after the convolution of 3×3 convolution kernel again, the defect image could be identified.(2)By analyzing the gray histogram of successfully recognized and failed recognized images, when the gray scale span was less than 50, the contrast between the image detection target and the background was relatively lower, and the convolution layer in the convolutional neural network was difficult to extract the target features.In this case, the recognition of the neural network fails and defects could not be determined.When the gray histogram span of the local image was higher than 50, the recognition target was more prominent than the background, the overall image contrast was higher, and the convolution layer could extract the features of the recognition target.In this case, the convolutional neural network had a good recognition effect on the weld image.

     

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