Adversarial Model Training for Background-Robust Defect Detection

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Solution Overview

Problem

Conventional machine learning models for defect detection and feature identification struggle with reduced accuracy due to overrepresentation of certain defect and background combinations in training data, leading to reliance on background information rather than defect detection, and are not robust against differences in backgrounds or features.

Innovation Solution

A model generation apparatus that employs a three-step adversarial learning process involving a coder and two estimators to convert input data into feature amounts, where the first estimator focuses on the primary feature while the second estimator is trained to fail on secondary features, ensuring the model is robust against background variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If training data includes all combinations of defect type and background type, then estimation accuracy is improved, but data collection cost and time increase significantly

Engineering Contradiction:
Improveestimation accuracyVSAvoiddata collection time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-processing training data to extract and separate defect information from background information before model training. This allows the model to learn defect characteristics without being confounded by background variations, achieving high accuracy without needing all possible defect-background combinations in the training set.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent extracts defect information from training images by separating it from background information. The defect extraction unit identifies and extracts defect regions, while the background extraction unit identifies background regions. This separation allows the model to focus on defect characteristics independently of background variations, resolving the contradiction between accuracy and data collection requirements.

Inventive Principle:
Principle #2Taking out (Extraction)

2Reliability

If training data includes diverse background types, then model robustness improves, but the model may rely on background information rather than defect information for estimation

Engineering Contradiction:
Improvemodel robustnessVSAvoiddefect detection capability
Core Design Contradiction:
ReliabilityVSLoss of information

Solution Approach 1:

The patent extracts defect information from training images by separating it from background information. The defect extraction unit identifies and extracts defect regions, while the background extraction unit identifies background regions. This separation allows the model to focus on defect characteristics independently of background variations, resolving the contradiction between accuracy and data collection requirements.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies preliminary anti-action by deliberately reducing the estimation performance of the initial model on background information through adversarial training. The adversarial training unit trains the initial model to minimize background estimation accuracy, forcing the model to rely on defect information rather than background information for defect detection, thereby preventing background reliance before it becomes a problem.

Inventive Principle:
Principle #9Preliminary anti-action

3Productivity

If machine learning is performed with limited training data, then processing time is reduced, but estimation accuracy deteriorates due to unseen defect-background combinations

Engineering Contradiction:
Improvemodel training speedVSAvoidestimation accuracy
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies preliminary action by pre-processing training data to extract and separate defect information from background information before model training. This allows the model to learn defect characteristics without being confounded by background variations, achieving high accuracy without needing all possible defect-background combinations in the training set.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary defect extraction unit that processes training images to extract defect information separately from background information. This intermediary processing step creates purified defect data that can be used for training, allowing the model to achieve high accuracy on unseen defect-background combinations without requiring extensive training data coverage.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Productivity

If training data overrepresents certain defect-background combinations, then training convergence is faster, but the model fails to generalize to underrepresented combinations

Engineering Contradiction:
Improvetraining efficiencyVSAvoidgeneralization capability
Core Design Contradiction:
ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent extracts defect information from training images by separating it from background information. The defect extraction unit identifies and extracts defect regions, while the background extraction unit identifies background regions. This separation allows the model to focus on defect characteristics independently of background variations, resolving the contradiction between accuracy and data collection requirements.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the parameter representation by separating defect and background information into distinct features. Instead of training on raw images where defect and background are mixed, the system extracts defect features and background features separately, then trains the model to estimate defect information from defect features alone. This parameter separation allows the model to generalize across different background types without being biased by overrepresented combinations.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12444176B2Model generation apparatus, estimation apparatus, model generation method, and computer-readable storage medium storing a model generation program including training a model by converting training data to deliberately reduce estimation performance for improved defect detection and feature identification
Publication Date: 2025.10.14 OMRON CORP
  • US12444176B2 patent drawing
  • US12444176B2 patent drawing
  • US12444176B2 patent drawing

AI summary

A model generation apparatus according to one or more embodiments executes operations, with respect to each of learning data sets. The operations includes training a second estimator so that an estimation result obtained from a second estimator conforms to second correct answer data; training a coder so that an estimation result obtained from the second estimator does not conform to the second correct answer data; and training the coder and the first estimator so that an estimation result obtained from a first estimator conforms to first correct answer data. The model generation apparatus executes operation of the training the second estimator and the training the coder alternately and repeatedly.