Abstract
Aluminum is extensively utilized in the aerospace, aviation, automotive, and other industries. The presence of surface defects on aluminum has a significant impact on product quality. However, traditional detection methods fail to meet the efficiency and accuracy requirements of industrial practices. In this study, we propose an innovative aluminum surface defect detection method based on an optimized two-stage Faster R-CNN network. A 2D camera serves as the image sensor, capturing high-resolution images in real time. Optimized lighting and focus ensure that defect features are clearly visible. After preprocessing, the images are fed into a deep learning network incorporated with a multi-scale feature pyramid structure, which effectively enhances defect recognition accuracy by integrating high-level semantic information with location details. Additionally, we introduced an optimized Convolutional Block Attention Module (CBAM) to further enhance network efficiency. Furthermore, we employed the genetic K-means algorithm to optimize prior region selection, and a lightweight Ghost model to reduce network complexity by 14.3%, demonstrating the superior performance of the Ghost model in terms of loss function optimization during training and validation as well as in terms of detection accuracy, speed, and stability. The network was trained on a dataset of 3200 images captured by the image sensor, split in an 8:1:1 ratio for training, validation, and testing, respectively. The experimental results show a mean Average Precision (mAP) of 94.25%, with individual Average Precision (AP) values exceeding 80%, meeting industrial standards for defect detection.