Dongkuk CM, a company that makes cold-rolled, plated, and color-coated steel, announced on January 30 that it has developed DK SDD, an AI technology to detect surface defects on steel sheets. This is a first in the industry.
Traditionally, inspecting defects on color-coated steel sheets relied on skilled workers visually checking each sheet. Since a single steel coil is about 5,000 meters long, inspectors had to manually check millions of tons of steel every year.
By utilizing AI for defect detection, Dongkuk CM can improve the quality of its steel sheets, prevent defects from recurring, as well as track quality over time. After about three years of research, the company has developed this technology and is preparing to file for a patent.
DK SDD stands out because it works on premium color-coated steel with uneven surfaces and over 20,000 colors. Previous technologies struggled with detecting defects on these complex surfaces, but Dongkuk CM’s AI technology can precisely recognize defects even on printed or structured steel.
The system integrates rule-based methods with deep learning. High-resolution cameras consistantly capture images of the steel during production, checking for defects in real time, even at high speeds of up to 130 meters per minute.
Dongkuk CM has already started using DK SDD at its Busan plant for making high-speed color-coated steel used in construction materials. It’s also testing the system for making steel used in home appliances. The company plans to fully roll out DK SDD later this year.
Next year, the system will be applied to all color-coated steel production lines at the Busan plant, and the inspection results will be linked to the Manufacturing Execution System (MES) to track and manage quality. Dongkuk CM expects this new system to optimize the workforce and reduce risks related to claims.
Executive Statement
According to Choi Woo-chan, had of Dongkuk CM’s Technology Research Institute, they have now set a new standard for the surface quality inspection of color-coated steel sheets. They will not stop at enhancing the product competitiveness of their color-coated steel sheets, but will continue to build a sustainable manufacturing environment through process automation and technological advancement, and will persistently pursue the realization of an AI-based intelligent factory.