Best method to detect cracks on wire rod surfaces

[[Jo...]]

Dear all,

I am currently working on surface inspection of wire rods and would like to detect potential cracks. In the attached photo, I am specifically interested in identifying the line-shaped feature highlighted within the circle as a crack.

I have attempted to use the surface defect inspection function for this purpose. However, the results are not very clear—rather than isolating the crack, the output mainly shows general surface roughness represented in a color map.

 

 

 

 

Could you kindly advise which function, method, or analysis approach would be more effective for reliably detecting cracks on the surface of wire rods? Any insights or recommendations would be greatly appreciated.

Thank you in advance for your support.

[[Na...]]

Hello Jonghan,

it is important to set the defect size to the correct value. The direction should be across the lines you want to detect. After the creation of the defect map, you can filter defects https://techguide.zeiss.com/en/zeiss-inspect-2025/article/cmd_inspection_inspect_create_surface_defect_element.html 

These defects seems to be long, so you could try to filter them by width/length ratio. 

If you need further help I think it would be best to contact the support with the concrete project.

 

Nanno

[[Jo...]]

 

After checking the surface defect, I try to put the restriction condition, but it doesn't work like the picture above.

[[Na...]]

Hello,

I think the direction was correct in your first post, if the defects are as shown on the outer area right on the second picture. 

You have to check the actual surface defect map with I-Inspect for "Surface defect comparison against nominal" first, then use the left symbol for defect analysis on the created inspection element in the explorer category "Surface defect comparison on actual". When applying the filter, please chose a correct value for "Tolerance", otherwise all defects are filtered out.

The correct defect filters can be estimated by a simple two-point distance for example.

There are other possibilities to detect specific defects, but this would be out of the scope of a forum. So please contact support with the project ideally to find the best solution.

Nanno