Digital Twin of Intelligent Small Surface Defect Detection with Cyber-manufacturing Systems

With the remarkable technological development in cyber-physical systems, industry 4.0 has evolved by use of a significant concept named digital twin (DT). However, it is still difficult to construct a relationship between twin simulation and a real scenario considering dynamic variations, especially when dealing with small surface defect detection tasks with high performance and computation resource requirements. In this article, we aim to construct cyber-manufacturing systems to achieve a DT solution for small surface defect detection task. Focusing on DT-based solution, the proposed system consists of an Edge–Cloud architecture and a surface defect detection algorithm. Considering dynamic characteristics and real-time response requirement, Edge–Cloud architecture is built to achieve smart manufacturing by efficiently collecting, processing, analyzing, and storing data produced by factory. A deep learning–based algorithm is then constructed to detect surface defeats based on multi-modal data, i.e., imaging and depth data. Experiments show the proposed algorithm could achieve high accuracy and recall in small defeat detection task, thus constructing DT in cyber-manufacturing.