Intelligent Steel Surface Defect Segmentation for Edge-Oriented IIoT Quality Control

Abstract

Automated surface defect detection in hot-rolled steel is a prerequisite for real-time quality control, yet most deployed inspection systems operate in isolation from Industrial Internet of Things (IIoT) infrastructure. This paper reports a laboratory-scale proof of concept with two contributions. The first is a segmentation study on the Severstal dataset using a leakage-free, defect-stratified split of 1886 test images. Because a trivial all-background predictor already attains 96.66% pixel accuracy, performance is reported through Dice, IoU, precision, recall, and F1 with 95% confidence intervals. A compact from-scratch U-Net (0.49 M parameters) reaches a Dice of 0.416 at 38.6 ms per image, an ImageNet-pretrained DeepLabV3+ model reaches 0.677 at 46.3 ms and 37 times the parameters, and a classical Otsu baseline reaches 0.060, bracketing an explicit accuracy-versus-footprint design space rather than a single recommended model. The second contribution is architectural: a three-layer IIoT architecture whose messaging layer is empirically characterized on a Raspberry Pi broker over 158,500 messages. A factorial experiment isolates the transport configuration of the broker, rather than that of the publisher, as the determinant of end-to-end latency, yielding a seventeen-fold reduction. The layer sustains 1920 messages per second without loss, and a deliberate broker outage shows that MQTT delivery guarantees are semantic rather than temporal, motivating an application-level message-expiry policy. Embedded inference deployment is identified as the primary next step.