The traditional SIFT (Scale Invariant Feature Transform) registration algorithm is highly regarded in the field of image processing due to its scale invariance, rotation invariance, and robustness to noise. However, it faces challenges such as a large number of feature points, high computational demand, and poor real-time performance when dealing with large-scale images. A novel optimization method based on integral image technology and canny edge detection is presented in this paper, aiming to maintain the core advantages of the SIFT algorithm while reducing the complexity involved in image registration computations, enhancing the efficiency of the algorithm for real-time image processing, and better adaption to the needs of large-scale image handling. Firstly, Gaussian separation techniques were used to simplify Gaussian filtering, followed by the application of integral image techniques to accelerate the construction of the entire pyramid. Additionally, during the feature point detection phase, an innovative feature point filtering strategy was introduced by combining Canny edge detection with dilation operations alongside the traditional SIFT approach, aiming to reduce the number of feature points and thereby lessen the computational load. The method proposed in this paper takes 0.0134 s for Image type a, 0.0504 s for Image type b, and 0.0212 s for Image type c. In contrast, the traditional method takes 0.1452 s for Image type a, 0.5276 s for Image type b, and 0.2717 s for Image type c, resulting in reductions of 0.1318 s, 0.4772 s, and 0.2505 s, respectively. A series of comparative experiments showed that the time taken to construct the Gaussian pyramid using our proposed method was consistently lower than that required by the traditional method, indicating greater efficiency and stability regardless of image size or type.

Gear defect detection directly affects the operational reliability of critical equipment in fields such as automotive and aerospace. Gear defect detection technology based on machine vision, leveraging the advantages of non-contact measurement, high efficiency, and cost-effectiveness, has become a key support for quality control in intelligent manufacturing. However, it still faces challenges including difficulties in semantic alignment of multimodal data, the imbalance between real-time detection requirements and computational resources, and poor model generalization in few-shot scenarios. This paper takes the paradigm evolution of gear defect detection technology as the main line, systematically reviews its development from traditional image processing to deep learning, and focuses on the innovative application of intelligent algorithms. A research framework of “technical bottleneck-breakthrough path-application verification” is constructed: for the problem of multimodal fusion, the cross-modal feature alignment mechanism based on Transformer network is deeply analyzed, clarifying its technical path of realizing joint embedding of visual and vibration signals by establishing global correlation mapping; for resource constraints, the performance of lightweight models such as MobileNet and ShuffleNet is quantitatively compared, verifying that these models reduce Parameters by 40–60% while maintaining the mean Average Precision essentially unchanged; for small-sample scenarios, few-shot generation models based on contrastive learning are systematically organized, confirming that their accuracy in the 10-shot scenario can reach 90% of that of fully supervised models, thus enhancing generalization ability. Future research can focus on the collaboration between few-shot generation and physical simulation, edge-cloud dynamic scheduling, defect evolution modeling driven by multiphysics fields, and standardization of explainable artificial intelligence. It aims to construct a gear detection system with autonomous perception capabilities, promoting the development of industrial quality inspection toward high-precision, high-robustness, and low-cost intelligence.