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Edge Video AnalyticsReference design

Surface Defect Inspection

A camera inspection station for steel strip, coil, sheet or parts that gives a pass or fail verdict for every frame. The verdict goes to the PLC over Modbus TCP and to the MES over MQTT at the same time, with all processing on one edge host. It fits lines that already have reject or marking stations and want to add or retrofit vision checks.

Manufacturing

Talk to an engineer See the hardware

Power loom weaving striped fabric in a small textile workshop in Hooghly, West Bengal — Photo: Tarunsamanta, CC BY-SA 4.0, Wikimedia Commons. Shows the setting, not this installation.

9.3 ms: Median time from capture to PLC coil on J40 (public NEU-DET dataset, 290 images)
10.56 ms: Median capture to coil time on J30
11.61 ms: Median capture to coil time on Hailo-8
0.7577: mAP50 detection score on J40 and J30 (same public dataset)

Results reported by the design's authors on their own test setups. Yours depend on the site, so we confirm them in a pilot.

The problem

Why it matters.

Steel strip surface checks are manual or late, so defects are not caught at line speed.

The flow

From signal to action.

01SenseLine cameraA fixed RTSP camera captures the strip or part as it passes.
02DecideDefect checkThe edge host runs a defect detector and a pass or fail rule on each frame.
03ActPLC signalA Modbus TCP coil and registers tell the PLC to reject, mark or sound an alarm.
04ConnectMES feedOne JSON message per frame goes over MQTT with verdict, defect class, timings and boxes.
05PeoplePreview pageEngineers watch a read-only browser page with live video and events while commissioning.

Deployment architecture

How it is wired.

The devices on site, what carries their data, where the decision is made and where the result goes.

01SenseOn site

IP camera (RTSP)1 per line position

02ConnectCarries the data

RTSP

03DecideRuns the model

reComputer J4012 (J40 Series, Jetson Orin NX 16GB)1 per site
reComputer J3011 (J30 Series, Jetson Orin Nano 8GB)1 per site
reComputer Industrial J (Orin Nano 8GB / Orin NX 16GB)1 per site
reComputer Industrial R2035-121 per site
TensorRT
HailoRT

04Your systemsWhere results land

Modbus TCP
MQTT
HTTP
PLC
MES

05ActWhat happens next

PLC signal

How it works

Step by step.

01Fix the camera so the defect fills a good part of the frame and keep the lighting steady.
02Deploy the inspection software. On Orin hosts the model engine is built on first start.
03Each frame is checked and given a pass or fail verdict.
04The PLC reads the verdict coil over Modbus and acts, while the MES gets per-frame details over MQTT.
05Measure false alarms on clean material from your own line before relying on the verdict.

The hardware

What goes on site.

Items we stock can go straight in the bag. Everything else we source and quote with the installation.

reComputer J4012 (J40 Series, Jetson Orin NX 16GB)Inspection host with the most stream headroom1 per siteSourced on quote
reComputer J3011 (J30 Series, Jetson Orin Nano 8GB)Lower-cost Orin inspection host1 per siteSourced on quote
reComputer Industrial J (Orin Nano 8GB / Orin NX 16GB)Fanless inspection host for mounting inside a cabinet1 per siteSourced on quote
reComputer Industrial R2035-12Hailo-8 inspection host1 per siteSourced on quote
IP camera (RTSP)Fixed camera over the line1 per line positionSourced on quote

Before you install

A fixed camera whose framing does not change during a run.
Stable lighting. A new lamp, angle or surface finish is new to the model.
Defects large enough to fill a meaningful part of the frame, not a few pixels in a wide shot.
Direct network links from camera to host and from host to the PLC and MES.

Good to know

The model was trained on a public dataset whose licence is still being confirmed, so plan to retrain on your own images before using it in a delivered system.
The test set had a defect in every image, so there is no false alarm data on clean material.
Accuracy varies widely by defect type. Scratches score well, crazing scores poorly.
Load tests used synthetic 10 FPS video, so test with your real camera before sizing.

How we deliver it

Paper to site, one team.

01Site surveyWe walk the site, or review photos and drawings, and agree what to measure and where each device goes.
02PilotOne lane, one line or one room first. We tune it on your conditions and agree what good looks like.
03Roll outWe supply the hardware in India with GST invoices, install it, and connect it to the systems you already run.
04SupportSpares, remote checks and model updates, with one team to call when something changes.

Questions

Asked before buying.

Will it talk to our PLC?

Yes. It writes the verdict to a Modbus TCP coil and registers that any Modbus-capable PLC can read.

Does it need internet?

No. Nothing in the verdict path depends on an outside service.

Is it ready to use on our line out of the box?

Not fully. It was trained on public steel images, so expect to collect your own images, set thresholds and retrain.

Want this on your site?

Tell us the site and the problem. We come back with a pilot plan and a priced hardware list.

Book a call with an engineer Write to us

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