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【2020 Application Example】 AOI fabric inspector lowers the false negative rate, and reduced the re-inspection volume by 70%

Low detection rate, slow speed, difficult recruitment and high personnel costs

The textile industry has always been a labor-intensive industry. At present, almost all textile companies worldwide still inspect fabrics manually. There are three major pain points in manual fabric inspection: Low detection rate, slow speed, difficulty in recruiting workers, and high personnel costs On average, a fabric inspector can find up to 200 defects in one hour with a defect detection rate of about 70%.

However, inspectors are only able to maintain their concentration for 20 to 30 minutes at most, and their fabric inspection speed is generally limited to 20 to 30cm/s. Fabric inspectors become fatigued if they exceed this time and speed.

Domestic and foreign AOI fabric inspection machines purchased by textile manufacturers have not yet been officially integrated into the production line. At the beginning, 10,000 suspected defects could be detected in one roll of fabric. The detection rate was high but the accuracy [screening] was low. The number of suspected defects has been reduced to 7000, but is still not at the level of experienced inspectors.

High-speed cameras capture defects and record defect locations

▲High-speed cameras capture defects and record their locations

The rule-based defect identification method currently used by manufacturers requires a lot of adjustment time (about 1 to 3 months) before the manufacturers (site) actually uses it, and there is currently no solution to automatically correct the identification model after use. As a result, manufacturers need to spend extra time to adjust parameters. Therefore, it requires considerable cost for both manufacturers and clients (sites).

Current manufacturers' grey cloth inspection process

▲Current grew fabric inspection process of manufacturers

The specific method used by the guidance team and cooperating manufacturers to implement AI identification technology and learning framework (for model retraining) into the defect inspection process is described below

1. AI-based defect identification model:

Utilizes the large amount of image data collected (including fabrics with and without defects) to construct the defect detection model through machine learning, such as SVM, or deep learning object detection methods, such as SSD or YOLOv3. This model is used to determine the condition of the surface of grey fabric and determine if it is a normal product or a defective product, thereby achieving defect identification.

2. Identification model retraining framework:

If there is an error in the judgment of the visual inspector, the image will be marked and the data will be used in the dataset for re-training. After a certain number of misjudged data is accumulated, the system will automatically start the identification model retraining function, and the new model that is generated will automatically replace the old recognition model, thereby achieving the purpose of model update.

Post-project implementation grey cloth defect inspection process

▲Grey fabric defect inspection process after the implementation of this project

Low false negative rate and solves the challenges of labor shortage and higher quality requirements in the industry

This project uses a deep learning network architecture to reclassify defects that are detected, including real defects and false defects, and can further classify real defects and false defects to lower the false negative rate of traditional AOI solutions. This is expected to reduce re-inspection volume by 70% and above for fabric inspectors, eliminate concerns about implementation in the current production line, accelerate the application of AI-based AOI solutions by textile manufacturers, and solve the challenges of labor shortage and higher quality requirements in the industry.

Recommend Cases

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Using Plant Growth Chambers as an Example - Standardizing Electronic Device Procedures Based on Imaging

In recent years, global climate change and environmental issues have become increasingly severe, causing major impacts on agricultural production Traditional agriculture heavily relies on weather conditions, facing challenges such as unstable crop quality, plummeting yields, and difficult pest control Particularly in Taiwan, agricultural biotech companies and farmers have suffered continuous losses, creating an urgent need for innovative solutions Meanwhile, Taiwan's plant factory industry faces many challenges high equipment and labor costs, an incomplete industrial chain diminishing international competitiveness, and a lack of cooperation among enterprises, all of which limit industry development Additionally, COVID-19the pandemic has highlighted the importance of remote monitoring and management Traditional manual inspections and data collection methods no longer meet the needs of modern agricultural production These issues collectively underline the urgent need for smart agricultural solutions, driving companies like Taiwan's HaiBoTe to develop innovative projects integrating IoT, cloud computing, and artificial intelligence technologies HaiBoTe Cloud Data Integration and Analysis Platform Facing these challenges, the agricultural sector urgently needs a system that can precisely control growth environments, improve resource efficiency, enable remote monitoring, and facilitate intelligent management Existing plant factory equipment often requires complete replacement, with poor compatibility with older equipment, and sensors and camera systems may require different interfaces, making them inconvenient to use Therefore, there is a need for a flexible solution that can integrate various equipment and technologies, providing real-time monitoring and data analysis, and automatically adjusting environmental parameters based on plant growth conditions This demand exists not only in Taiwan but is also a global trend in the development of smart agriculture By incorporating artificial intelligence, more scientific evaluation standards can be established, optimizing production processes, improving yield and quality, while reducing energy consumption and environmental impact Additionally, such smart solutions can attract more young people to participate in agricultural production, promoting industry upgrading and sustainable development Overall, the demand for smart agricultural solutions stems from the urgent requirements to address climate change, enhance production efficiency, reduce costs, and achieve precise management, and this is exactly the problem companies like Taiwan's HaiBoTe are striving to solve Taiwan's plant factory operators are facing a series of severe challenges, which are gradually eroding their competitiveness and survival space Firstly, the high cost of equipment and operations is their biggest burden Each electricity bill feels like a heavy blow, forcing them to balance between ensuring product quality and controlling costs Secondly, the unpredictability brought by climate change has become their nightmare Sudden extreme weather events can destroy their carefully nurtured crops in a short time, causing massive economic losses What's worse, they find themselves increasingly at a disadvantage in international market competition In contrast, large overseas plant factories, with their advanced automation technology and well-organized supply chains, can produce stable-quality agricultural products at lower costs, putting unprecedented pressure on Taiwan's operators On the technical level, they also face numerous challenges Compatibility issues between new and old equipment often put them in a bind, encountering various technical obstacles when trying to integrate different systems Lack of precise data analysis and forecasting capabilities also makes it difficult for them to make production decisions and accurately determine the best growth conditions for each crop Existing monitoring systems provide data that is often disorganized, difficult to interpret and apply Human resource challenges are also severe, with young people generally lacking interest in agricultural work, making it difficult for them to recruit employees with modern agricultural skills Even existing employees often feel exhausted from tedious manual operations and monitoring tasks These problems are intertwined, creating a complex dilemma that leaves plant factory operators confused and anxious They urgently need a comprehensive solution that can enhance factory operational efficiency, reduce costs, and improve product competitiveness, helping them overcome difficulties and regain their footing in the fierce market competition In facing the various challenges of plant factory operators, Taiwan's HaiBoTe company has demonstrated exceptional technical innovation and a flexible customer-oriented development strategy They deeply understand that the solution must be able to seamlessly integrate existing equipment while providing highly intelligent management functions To this end, HaiBoTe's RD team adopted a modular design approach to develop a system that can be flexibly configuredIoTIoT system The core of this system is a smart control hub that can communicate with various sensors and actuators During development, HaiBoTe worked closely with customers, deeply understanding their specific needs and operational environments They even dispatched engineers onsite to observe the daily operations of the plant factories, ensuring that the developed system actually solves practical problems This in-depth cooperation not only helped HaiBoTe optimize their product design but also established a close relationship with customers, laying the foundation for subsequent continuous improvements HaiBoTe's innovation is not just reflected in hardware design but also in their developed intelligent software system This system integrates advanced machine learning algorithms, capable of precise forecasts and optimal control of plant growth conditions based on large amounts of historical data and real-time monitoring information To help customers overcome technical barriers, HaiBoTe designed an intuitive and easy-to-use user interface, which even non-technical operators can master easily Additionally, they provide comprehensive training and tech support services, ensuring customers can fully utilize all functions of the system When facing challenges, HaiBoTe's technical team can quickly identify problems through remote diagnostics and provide solutions In one incident, during a serious equipment failure emergency faced by a customer, HaiBoTe's engineers guided the customer through system remote access, successfully instructing them on repairs and avoiding potential massive losses This full-range service not only solves customers' immediate difficulties but also strengthens their confidence in intelligent management, driving the entire industry toward more efficient and sustainable development HaiBoTe's developed smart agriculture solution not only brought revolutionary changes to plant factories but also painted an encouraging picture for the future of the entire agricultural industry The excellence of this system is evident in several aspects firstly, it achieves precise control of the plant growth environment, significantly improving crop yield and quality stability Through advanced artificial intelligence algorithms, the system can forecast and adjust optimum growth conditions based on historical data and real-time monitoring information, ensuring each plant grows in the ideal environment Secondly, it significantly reduces energy consumption and operational costs, improving resource efficiency The intelligent management system optimizes water, electricity, and nutrient supply, reducing waste and lowering manpower costs Additionally, the system's modular design and strong compatibility allow it to seamlessly integrate various new and old equipment, providing a flexible solution for gradual upgrades of plant factories Most importantly, the system injects a sense of technology and modernity into agricultural production, helping to attract the younger generation to the field and injecting new vitality into the industry Looking ahead, HaiBoTe's smart agriculture system has broad application prospects and expansion potential In addition to plant factories, this system can also be applied to traditional greenhouse cultivation, urban agriculture, and even home gardening In the field of aquaculture, similar technology can be used to monitor and optimize the breeding environments for fish or shrimp In the food processing industry, similar intelligent monitoring and forecasting systems can be used to optimize production processes and enhance food safety Even in the pharmaceutical industry, this type of precise environmental management system could be applied to drug research and production processes To further promote this system, HaiBoTe could adopt a multifaceted strategy Firstly, they could collaborate with agricultural colleges and research institutions to establish demonstration bases, allowing more people to experience the benefits of smart agriculture firsthand Secondly, they could develop customized solutions tailored to different scales and types of agricultural production, expanding the applicability of their products Furthermore, they could raise awareness and acceptance of smart agriculture within the industry by hosting forums, online seminars, and sharing success stories Lastly, they could explore collaborations with government departments to integrate this system into policies supporting the modernization and sustainable development of agriculture, thereby promoting the widespread adoption of smart agriculture on a larger scale Through these efforts, HaiBoTe not only can expand its market share but also make a significant contribution to the sustainable development of global agriculture, truly realizing the vision of technology empowering agriculture 「Translated content is generated by ChatGPT and is for reference only Translation date:2024-12-09」

【導入案例】維繫遊艇王國美譽 嘉信遊艇導入國內第一套FRP複材超音波智慧檢測
Maintaining the reputation of the “Kingdom of Yachts” - Kha Shing Enterprise introduces the first domestic FRP ultrasonic smart inspection of composite materials

The Kaohsiung-based Kha Shing Enterprise Co, Ltd was established over 40 years ago, and is Taiwan's largest customized yacht company with customers all over America, Europe, Asia, and Australia, earning Taiwan the reputation of the "Kingdom of Yachts" Current FRP hull inspection still relies on traditional methods, such as visual inspection and knocking sounds, which is time-consuming and labor-intensive Kha Shing has applied PAUT array ultrasonic inspection to hull FRP composite materials for the first time, and combined it with AI to interpret ultrasound images, develop complete intelligent solutions, and create emerging markets for inspection companies Kha Shing Enterprise Co, Ltd was formerly Kha Shing Wood Industry Co, Ltd, and was a factory specializing in wood import in Kaohsiung Linhai Industrial Park when it was first established It began to design, manufacture, and sell yachts in 1977 After the second-generation successor of the company, President Kung Chun-Hao entered the company, he made a breakthrough in the previous manufacturing model that relied mainly on the skills of master craftsmen, introduced digital manufacturing to accelerate shipbuilding, and began to make larger yachts, ranking in the top 20 manufacturers worldwide among manufacturers of large yachts over 24 feet It also set a record of delivering 94 yachts within one year, earning Taiwan the reputation of "Kingdom of Yachts" Defect detection ensures yacht quality, using AI to replace humans to achieve higher efficiency Defect detection is very important to ensuring yacht quality At present, the yacht industry still uses very traditional defect detection methods The hull structure is usually made by hand lay-up or the vacuum infusion process, using visual inspection or knocking and the frequency of the sound to determine defects It requires time-consuming manual inspection If there are any defects, they must be reworked and repaired, and a gel coat subsequently sprayed The hull must be constructed in sections to facilitate inspection For large yachts over 24 meters long, construction in sections is very time-consuming and labor-intensive To shorten the time of the yacht manufacturing process, Kha Shing Enterprise will first carry out the gel coating process for the hull, and then perform the hand lay-on process The hull manufacturing process has two types of composite material test specimen structures In terms of 54-foot yacht hulls, the hull contains gel coat, core material, fiber and resin, and the total thickness is about 32cmplusmn01cm, which is twice the total thickness of FRP hull without core material of about 16cmplusmn01cm Defects such as incomplete impregnation of glass fiber or residual air bubbles between glass fiber and resin occasionally occur during the manufacturing process The types of defects include insufficient resin, voids, and delamination Once defects occur, the supply of hull materials will be insufficient and yacht delivery will be delayed Schematic diagram of types of FRP hull In order to solve this problem, Kha Shing Enterprise has engaged in technical cooperated with the metal materials industry and the AI technology industry, combining the ultrasonic inspection expertise of the metal materials industry with AI technologies developed by the AI technology industry in recent years to help solve issues of Kha Shing Enterprise with defect detection The method uses PAUT on the composite material structure of yachts, conducts FRP ultrasonic evaluation to determine the thickness of the yacht hull and material properties, and evaluates the ultrasonic probe frequency applicable to the hull structure based on professional ultrasonic experience After testing, a frequency of 5MHz and a probe width of 45mm can successfully find the location and size of defects in the simulated defect test specimen The three parties jointly found defect detection solutions from array ultrasonic evaluation, AI technology model development, and actual application in yachts The image inspected is an ultrasound image The image displays different colors based on the ultrasonic feedback signal An AI model that automatically identifies defective parts is established through the YOLO algorithm If the amount of abnormal data collected is insufficient for training, the CNN-based Autoencoder algorithm is used to collect normal image data for training and construct an AI model for abnormality detection The object detection YOLO model is trained by inputting image data marked as having defects, while the abnormality detection model is trained by inputting image data without defects Simulated defective specimen corresponding to PAUT results Defect detection by and AI system can shorten the construction period by 15 months and speed up determination by 50 After the development of this AI system is completed, it will be validated on actual 54-foot yachts of Kha Shing Enterprise, and can effectively resolve issues with defects The application of AI technology in ultrasonic inspection for intelligent determination is expected to accelerate determination by approximately 50, and will also shortens the construction period by 15 months, effectively improving the speed and quality of the yacht manufacturing process As Taiwan develops larger and more refined yachts, it will create opportunities for industry optimization and transformation, as well as opportunities for the development of key technologies The application of an AI ultrasonic inspection solution for composite materials is the first of its kind in the yacht industry, and is expected to attract more yacht manufacturers with inspection needs The AI ultrasonic inspection solution for composite materials has three major competitive advantages 1 Professional inspection experience and digital database to facilitate process management and analysis 2 Automatic AI determination and identification quickly identifies defects and provides immediate feedback to process engineers 3 High-efficiency process inspection provides defect repair recommendations, reduces damage rate, and improves the strength and quality of composite materials The application of AI technology can optimize the yacht manufacturing process, reduce manual inspection, create added value through the application of AI in Taiwanrsquos yacht industry, increase international purchase orders, and allow Taiwan yachts to continue to enjoy a good reputation in the world Furthermore, this business model has also spread to fields of application related to composite materials, increasing cross-sector market usage It is estimated to contribute approximately NT14 to NT2 billion in economic benefits to Taiwan's equipment maintenance and non-destructive testing market

【導入案例】防患於未然 麗臺科技研發心臟衰竭AI辨識技術可及早發現病徵
Preventing Problems Before They Arise: Leadtek Research Develops AI Technology for Early Detection of Heart Failure Symptoms

With the increase in the elderly population, the incidence of various chronic diseases is rising daily Among these, heart failure is not only a silent killer it has a very long disease course with a high recurrence rate, leading to increased burden on healthcare personnel However, by using medically certified electrocardiography acoustics devices, coupled with AI predictive assessment of heart failure risk and remote care systems, diagnosis can be aided significantly, helping doctors make accurate diagnoses for subsequent patient medical care or referrals Heart failure has a lengthy course and medical expenditure is five times that of diabetes If you find yourself short of breath even with minimal movement, or if you wake up from sleep needing to sit up to feel comfortable, or if you have symptoms such as swollen lower limbs, anxiety, restlessness, fatigue, or a loss of appetite, be cautious These could be signs of heart failure According to statistics, there are about 60 million people with heart failure worldwide, with 5 million new cases every year In China, nearly 290 million people suffer from cardiovascular diseases, accounting for the second leading cause of death among urban residents around 12 million of these are heart failure patients, accounting for over 59 of cardiac-related deaths The disease course of heart failure is exceptionally long, and both its recurrence and rehospitalization rates are exceedingly high, resulting in medical costs that are twice that of hypertension and five times those of diabetes According to US research statistics, the 30-day mortality rates for patients with myocardial infarction and heart failure are respectively 166 and 111, and the rehospitalization rates within 30 days are 199 and 244 The symptoms of heart failure, because they are similar to those of other diseases such as chronic obstructive pulmonary disease and asthma, have an 185 misdiagnosis rate, which poses a challenging problem for healthcare institutions Leadtek, a major graphics card manufacturer, has been investing in the medical and healthcare sector since 2000 Following two heart attacks in 2011 and 2015 experienced by Chairman Lu Kunshan, Leadtek has focused on health big data, independently developing AI technology for heart failure recognition This AI application reads patients' electrocardiograms and phonocardiograms to perform anomaly detection and model prediction of heart failure risk, enabling early detection of disease symptoms Leadtek independently developed heart failure AI recognition technology to predict medical history and risk Leadtek's independently developed heart failure AI recognition technology has the following three judgment functions 1 Prediction of heart failure history Classifies electrocardiogram and phonocardiogram data into 'with hospitalization history of heart failure' and 'no history of heart failure' 2 Risk prediction of heart failure Provides a predictive risk value of heart failure occurrence based on the electrocardiogram and phonocardiogram data 3 Prediction of heart failure recurrence risk For patients with heart failure, it reads their phonocardiogram and electrocardiogram data, assessing the risk prediction of heart failure recurrence Leadtek states that the application of heart failure AI recognition technology can assist doctors in making more efficient and accurate diagnoses, facilitating subsequent medical treatment or referrals for patients As an instance, in studies of heart failure patients discharged from Taipei Veterans General Hospital, using the EMAT Electromechanical Activation Time index and SDI Systolic Dysfunction Index calculated by the synchronized electrocardiography-acoustic device as treatment guidelines resulted in a higher survival rate compared to those treated based on traditional symptoms This research has also been published in the authoritative international cardiology journal JACC, receiving recognition in the international market System manufacturers can apply heart failure AI recognition technology for other value-added applications Leadtek states that cooperating system manufacturers can choose to build their own heart failure AI risk prediction engine, uploading their system's electrocardiogram and phonocardiogram data to Leadtek's heart failure AI risk prediction engine, which then returns risk prediction values for integration by system manufacturers cooperating manufacturers as a value-added application input Not just for clinical use, the heart failure AI risk prediction engine can also be extended for use at home or in the workplace Additionally, this system can be extended to other applications, including One, hospital outpatient screening Doctors can use the electrocardiogram and phonocardiogram recorder along with the heart failure AI risk prediction model to conduct a 10-second rapid test in outpatient and emergency departments to assess a patient's cardiac history and heart failure risk Two, discharge risk assessment Doctors can use the electrocardiogram and phonocardiogram recorder along with the heart failure AI risk prediction model to assess the heart failure risk during a patient's hospital stay The test data can serve as a pre-discharge risk assessment and prognostic indicator Three, continuous home care Patients can use the electrocardiogram and phonocardiogram recorder, wearable electrocardiogram recorder, and transmit through a home transmission box gateway to measure electrocardiogram and phonocardiogram signals at home and upload them to the amor health cloud platform for heart failure AI risk prediction analysis Patients can manage their health autonomously via an APP, reviewing historical physiological trends disease management nurses can manage member health through the health management backend Web Four, home rehabilitation training Patients can wear a health bracelet to monitor activity, fatigue, circulation, and sleep, autonomously managing their health through the mobile APP and observing the risk of heart failure, engaging in exercise and rehabilitation training to aid in swift recovery The heart failure AI recognition technology system can also be extended to employee home care applications Additionally, in factories or offices, this system can also achieve employee health management goals, with applications including One, workplace safety units Provide employees with wearable electrocardiogram recorders before they start work duties Two, physiological monitoring for business executors While executing business duties or training, employees wear wearable electrocardiogram recorders for fatigue warnings, signaling whether physiological conditions allow continued execution of tasks Task segments can use data transmission boxes or apps to upload physiological monitoring information to the health management platform, assessing the heart failure risk for operations staff, with test data serving as an indicator for enterprise resource human units and public safety Three, workplace physiological monitoring center care The workplace physiological monitoring center can inspect and record employees' historicalphysiological trends through the health cloud platform Four, workplace nursing units Nursing units receiving instructions from the physiological monitoring center can provide health management advice based on employees' physiological trends nursing centers can manage employee health through the health management backend Web Five, employees can wear health bracelets to monitor activity, fatigue, circulation, and sleep, autonomously managing their health and observing the risk of heart failure through the mobile APP, engaging in exercise and rehabilitation training to aid in rapid recovery Workplace application of heart failure cloud care and big data center diagram「Translated content is generated by ChatGPT and is for reference only Translation date:2024-05-19」