Abstract
Recent research has made significant progress in automated unmanned systems utilizing Artificial Intelligence (AI)-based image processing to optimize the rebar manufacturing process and minimize defects such as twisting during production. Despite various studies, including those employing data augmentation through Generative Adversarial Networks (GANs), the performance of rebar twist prediction has been limited due to image quality degradation caused by environmental noise, such as insufficient image quality and inconsistent lighting conditions in rebar processing environments. To address these challenges, we propose a novel approach for real-time rebar twist prediction in manufacturing processes. Our method involves restoring low-quality grayscale images to high resolution and employing an object detection model to identify and track rebar endpoints. We then apply regression analysis to the coordinates obtained from the bounding boxes to estimate the error rate of the rebar endpoint positions, thereby determining the occurrence of twisting. To achieve this, we first developed a Unified-Channel Attention (UCA) module that is robust to changes in intensity and contrast for grayscale images. The UCA can be integrated into image restoration models to more accurately detect rebar endpoint characteristics in object detection models. Furthermore, we introduce a method for predicting the future positions of rebar endpoints using various linear and non-linear regression models. The predicted positions are used to calculate the error rate in rebar endpoint locations, determined by the distance between the actual and predicted positions, which is then used to classify the presence of rebar twisting. Our experimental results demonstrate that integrating the UCA module with our image restoration model significantly improved existing models in Peak Signal-to-Noise Ratio (PSNR) and Structural Similarity Index Measure (SSIM) metrics. Moreover, employing regression models to predict future rebar endpoint positions enhances the F1 score for twist prediction. As a result, our approach offers a practical solution for rapid defect detection in rebar manufacturing processes.