This work contributes to the recycling of technical black plastic particles, for example from the automotive or electronics industries. These plastics cannot yet be sorted with sufficient purity (up to 99.9%), which often makes economical recycling impossible. As a solution to this problem, imaging fluorescence spectroscopy with additional illumination in the near infrared spectral range in combination with classification by machine learning or deep learning classification algorithms is here investigated. The algorithms used are linear discriminant analysis (LDA), k-nearest neighbour classification (kNN), support vector machines (SVM), ensemble models with decision trees (ENSEMBLE), and convolutional neural networks (CNNs). The CNNs in particular attempt to increase overall classification accuracy by taking into account the shape of the plastic particles. In addition, the automatic optimization of the hyperparameters of the classification algorithms by the random search algorithm was investigated. The aim was to increase the accuracy of the classification models. About 400 particles each of 14 plastics from 12 plastic classes were examined. An attempt was made to train an overall model for the classification of all 12 plastics. The CNNs achieved the highest overall classification accuracy with 93.5%. Another attempt was made to classify 41 mixtures of industrially relevant plastics with a maximum of three plastic classes per mixture. The same average classification accuracy of 99.0% was achieved for the ENSEMBLE, SVM, and CNN algorithms. The target overall classification accuracy of 99.9% was achieved for 18 of the 41 compounds. The results show that the method presented is a promising approach for sorting black technical plastic waste.

A hyperspectral measurement system for the fast and large area measurement of Raman and fluorescence signals was developed, characterized and tested. This laser hyperspectral imaging system (Laser-HSI) can be used for sorting tasks and for continuous quality monitoring. The system uses a 532 nm Nd:YAG laser and a standard pushbroom HSI camera. Depending on the lens selected, it is possible to cover large areas (e.g., field of view (FOV) = 386 mm) or to achieve high spatial resolutions (e.g., 0.02 mm). The developed Laser-HSI was used for four exemplary experiments: (a) the measurement and classification of a mixture of sulphur and naphthalene; (b) the measurement of carotenoid distribution in a carrot slice; (c) the classification of black polymer particles; and, (d) the localization of impurities on a lead zirconate titanate (PZT) piezoelectric actuator. It could be shown that the measurement data obtained were in good agreement with reference measurements taken with a high-resolution Raman microscope. Furthermore, the suitability of the measurements for classification using machine learning algorithms was also demonstrated. The developed Laser-HSI could be used in the future for complex quality control or sorting tasks where conventional HSI systems fail.

Hyperspectral inspection using imaging systems is becoming more and more important for quality control tasks in several industries, replacing well trained operators or established machine vision systems based on RGB-systems. Hyperspectral imaging (HSI) on thin coated substrates is challenging due to the high reflectivity of the substrates. Nevertheless, the thin films contribute to the spectral data and can be evaluated. Therefore, the performance of inspection systems can be increased significantly. However, the large amount of data generated by HSI has to be processed and evaluated for quality information about the product. In this paper, thin aluminum oxide (Al₂O₃) layers on stainless steel foil are investigated by HSI. These substrates can be used for the growth of vertically aligned carbon nanotubes (VA-SWCNT) for battery electrodes. HSI and spectral ellipsometry in combination with Partial Least Squares regression (PLS) was used to estimate the thickness of the Al₂O₃ layers and to calculate quality parameters for a possible monitoring process. The PLS model shows a R²_CV of 0.979 and a RMSECV of 3.6.

To correctly assess the cleanliness of technical surfaces in a production process, corresponding online monitoring systems must provide sufficient data. A promising method for fast, large-area, and non-contact monitoring is hyperspectral imaging (HSI), which was used in this paper for the detection and quantification of organic surface contaminations. Depending on the cleaning parameter constellation, different levels of organic residues remained on the surface. Afterwards, the cleanliness was determined by the carbon content in the atom percent on the sample surfaces, characterized by XPS and AES. The HSI data and the XPS measurements were correlated, using machine learning methods, to generate a predictive model for the carbon content of the surface. The regression algorithms elastic net, random forest regression, and support vector machine regression were used. Overall, the developed method was able to quantify organic contaminations on technical surfaces. The best regression model found was a random forest model, which achieved an R² of 0.7 and an RMSE of 7.65 At.-% C. Due to the easy-to-use measurement and the fast evaluation by machine learning, the method seems suitable for an online monitoring system. However, the results also show that further experiments are necessary to improve the quality of the prediction models.

Electric vehicles are shaping the future of the automotive industry. The traction battery is one of the most important components of electric cars. To ensure that the battery operates safely, it is essential to physically and electrically separate the cells facing each other. Coating a cell with varnish helps achieve this goal. Current studies use a destructive method on a sampling basis, the cross-cut test, to investigate the coating quality. In this paper, we present a fast, nondestructive and inline alternative based on hyperspectral imaging and artificial intelligence. Therefore, battery cells are measured with hyperspectral cameras in the visible and near-infrared (VNIR and NIR) parts of the electromagnetic spectrum before and after cleaning then coated and finally subjected to cross-cut test to estimate coating adhesion. During the cross-cut test, the cell coating is destroyed. This work aims to replace cross-cut tests with hyperspectral imaging (HSI) and machine learning to achieve continuous quality control, protect the environment, and save costs. Therefore, machine learning models (logistic regression, random forest, and support vector machines) are used to predict cross-cut test results based on hyperspectral data. We show that it is possible to predict with an accuracy of ~75% whether problems with coating adhesion will occur. Hyperspectral measurements in the near-infrared part of the spectrum yielded the best results. The results show that the method is suitable for automated quality control and process control in battery cell coating, but still needs to be improved to achieve higher accuracies.

With the progressive replacement of metallic parts by high-performance fiber-reinforced plastic (FRP) components, typical properties of metals are required to be placed on the material’s surface. A metallic coating applied to the FRP surface by thermal spraying, for instance, can fulfill these requirements, including electrical conductivity. In this work, laser pre-treatments are utilized for increasing the bond strength of metallic coatings. However, due to the high-precision material removal using pulsed laser radiation, the production-related heterogeneous fiber distribution in FRP leads to variations in the structuring result and consequently to different qualities of the subsequent coating. In this study, hyperspectral imaging (HSI) technologies in conjunction with deep learning were applied to carbon fiber-reinforced plastics (CFRP) structured by nanosecond pulsed laser. HSI-based prediction models could be developed, which allow for reliable prediction, with an accuracy of around 80%, of which laser-treated areas will successfully be coated and which will not. By using this objective and automatic evaluation, it is possible to avoid large amounts of rejects before further processing the parts and also to optimize the adhesion of coatings. Spatially resolved data enables local reworking during the laser process, making it feasible for the manufacturing process to achieve zero waste.