Use of Artificial Intelligence to Monitor the Reliability of Removable Load-Handling Devices

Abstract

Introduction. The malfunction of removable load-handling devices (RLHD) poses significant production risks. That is why research in this field is relevant. The problem has often become a topic of scientific investigation. The authors propose using artificial intelligence more extensively to monitor the state of RLHD. This paper presents a study on how to improve the machine vision model to better identify the absence of locks on RLHD hooks. A probable occurrence of such an issue in production is noted. A storage and monitoring system for RLHD condition is proposed. The aim of this study is to demonstrate the potential for further training of neural networks to significantly enhance the efficiency of RLHD monitoring, ensuring their safe use.Materials and Methods. The work is based on the results of a survey conducted at the LLC “KZ Rostselmash” plant from 2022 to 2023, involving 144 RLHD. Mathematical statistics methods were used to process the data. A neural network model previously trained using the YOLO computer vision algorithm was studied. It was retrained taking into account the norms of the rejection of RLHD, specified in federal rules and standards. Images of RLHD with defects and missing parts were collected from these sources and used to create a training database. The database was expanded by augmentation. The Roboflow platform was used for work.Results. The array of images used for further training of the neural network was divided into three samples: training (88%), validation (8%) and test (4%). These samples were used to train and validate its results. The training was completed after 260 epochs, with a steady increase in accuracy. The neural network model of computer vision obtained in this way automatically detected a common defect in the RLHD hook — the absence of a lock. Its performance was assessed using three indicators: average accuracy (94%), prediction accuracy (88.8%) and response (89.2%). The neural network could receive images from a video camera in real-time and recognize hook defects. During the RLHD inspection at the Rostselmash plant, a grab for lifting engines was found to have all three hooks defective — without locks. To avoid such situations, at the end of work, it was recommended to place the RLHD on a special stand equipped with a microcontroller device that could monitor for a number of potential issues using radio frequency identification.Discussion and Conclusions. The main goal of this proposed solution is to detect and address signs of non-compliance with the established standards. This task can be implemented in facilities that use lifting equipment. In this case, the timely noticed RLHD defects will allow preventing production incidents. As a result, material damage can be reduced and injury statistics improved.