SOFTWARE AND HARDWARE AUTOMATED SYSTEM OF CASTS DEFECTS NON-DESTRUCTIVE MONITORING
Authors: Knyazev S. V. , Skopich D. V. , Fat’yanova E. A. , Usol’tsev A. A. , Kutsenko A. I. 
Published: March 2019

Introduction of the “Automated system for operational control of casts production (OCCP AS)” makes the basis of an integrated automated production control system (APCS). It performs three main tasks: control and recording (production, products, materials, etc.), improving quality of casts and operational management of technological processes. Solution of these tasks was accomplished through automating data collection in real time for all production operations, recording material flows, creating operational communication channels, as well as centralized collection, processing and representation of data by the process information server. The next step in building an effective automated control system is to stabilize product quality in changing external conditions, for example, quality of materials, and to optimize production (technology change in order to reduce costs for constant or higher product quality). The second stage is based on mathematical processing and analysis of data coming from OCCP AS, it allows to determine optimal ranges of parameters of technological processes  – “Automated system for optimization and analysis of production progress (OAPP AS)”. OAPP AS consists of two subsystems: quality analysis and technology management. The first solves the problem of data analysis and modeling, the second – calculation of real-time optimal process parameters and real time prediction. The stages tasks compete for access to different hardware resources. The most critical parameter for OCCP AS is performance of server disk arrays, for OAPP AS it is processor performance. In either case, system scaling is effectively solved by parallelizing operations across different servers, forming a cluster, and across different processors (cores) on the same server. To process defect images and to obtain cause-and-effect characteristics, you can use OpenCV software package, which is an open source computer vision library. In course of processing, Sobel operator, Gauss filter and binarization were used. They are based on processing pixels using matrices. Operations on pixels are independent and can be performed in parallel. The task of clustering is reduced to definition of an expert method or using various mathematical algorithms for defects belonging to a specific cluster (data block) through a set of values of dependent factors. Thus, data blocks are formed by the criterion of the defect cause. Calculation of a data block to which a product defect belongs can be very resource-intensive operation. To increase efficiency of image recognition systems and parallelization ofsearch operations, it makes sense to place data clusters on different servers. As a result, there is a need for a distributed database. This is a special class of DBMS, which requires appropriate software. Generation of OAPPAS based on a multi-node cluster with ApacheCassandra DBMS installed and using Nvidia video cards supporting CUDA technology on each node will be the cheapest and most effective solution. Video card is selected based on required number of graphics processors on the node.