AI Driven Pop-up Manufacturing Made Possible with PowerEdge XR7620
Read the ReportThu, 14 Mar 2024 16:47:06 -0000
|Read Time: 0 minutes
| Executive Summary
As traditional manufacturing processes are being gradually replaced by advanced technology, deep learning, 3D printing, and open programmable robotics offer an unprecedented opportunity to accelerate this transformation and deliver high quality, personalized products more affordably.
To demonstrate this opportunity we took on a challenge to showcase AI pop-up manufacturing by 3D printing orthopaedic components, specifically acetabular liners used in hip replacement surgeries and running them through a robotic arm & AI quality inspection and a sorting process, with worker safety embedded within.
This solution was both developed and deployed on Dell™ PowerEdge™ XR7620 purpose built for the edge with NVIDIA® A100 tensor core GPUs, including the custom acetabular liner defect detection model.
The proof of concept resulting in a live demo was completed within a quarter from the AI development, to the mechanical work to create a custom gripper, to the robotic arm assembly programming and AI integration. The live demo was successfully set-up and deployed in a day and ran for three days.
- 1 50% saving in engineering time to reach targeted 1.2 second latency across application with Dell™ PowerEdge™ XR7620
- Three AI models running on Dell™ PowerEdge™ XR7620 to enable Industrial Transformation
We trained our defect defection model for acetabular liners on Dell™ PowerEdge™ XR7620 and deployed it on the same system at the edge. We also ran our worker safety model and segment anything model, all in the compact rugged edge form factor.
- Steen Graham, CEO at Scalers AI™
| Industry Challenge
The American Academy of Orthopedic Surgeons reports more than 300,000 hip replacements are performed annually. Defective hip implants can lead to complications and high-cost revision surgeries. According to the FDA, over 500,000 people in the United States have been injured by defective hip implants. A study published in the Journal of Bone and Joint Surgery found that patients with defective hip implants were 3.5 times more likely to need revision surgery. The same study found that patients with defective hip implants were 2.5 times more likely to experience series complications such as infection, dislocation, and fracture.
Further, the cost of the artificial hip and liner can range into the thousands with the overall surgery range from $20,000 to $45,000 according to the American Academy of Orthopaedic Surgeons, with revision surgery even higher.
| Solution Architecture
| The Concept
Demonstrate how we can improve production and quality inspection with the latest techniques in deep learning to reduce the likelihood of defective hip implants, while lowering the manufacturing cost. Ultimately, showing how modern techniques in AI, 3D printing, and robotics can improve patient safety and reduce costs.
Note: ~50% time savings estimated based on engineering resources applied in development (~2000 hours) and estimated incremental time required to label, train, custom API development, and post training optimization (~2000 hours).
| Robotics
A 7-axis robotic arm and custom gripper was developed specifically for the demo to pick up acetabular liners within a few months. The robot controller is integrated with the AI APIs to pick up the liners and run defect detection. The robotic arm picks up the liners and rotates them under the camera to enable the defect detection. Then, the robot places the liners in different buckets based on whether they pass or fail the quality inspection.
The NexCOBOT robotic controller and 7-axis robotic arm were integrated with Scalers AI™ APIs and run on Dell™ PowerEdge™ XR7620 server.
| Deep Learning Models
The deep learning model involves three Neural Networks (NNs), including the latest Segment Anything model (SAM) for object detection, and a custom model built specifically to detect defects in acetabular liners, as well as a workers safety model. The custom model showcases the ability to build high-performance models using modest-sized datasets.
| Demo
Dashboards | Defect Detection
Quality Inspection Process
- During the quality control, no defects have been detected on the liner picked up. The robot arm will then place it in the bucket dedicated to non defective hip implants.
- Three defects have been detected on this acetabular liner. The robot arm will place it in the bucket for hip implants who did not pass the quality inspection.
Dashboards | Worker Safety
- One worker has been detected in the hazard zone triggering a worker safety notification.
| Integration of Dell™ PowerEdge™ XR7620 Server
Dell™ PowerEdge™ XR7620 server, designed to withstand harsh industrial conditions, houses two Intel® Xeon® Scalable Processors and two NVIDIA® A100 Tensor Core GPUs and KIOXIA SSDs within its 472mm chassis. Its ruggedized design, combined with NVIDIA® A100 GPUs offer powerful parallel processing capabilities, enables real-time analysis of 3D-printed components and rapid defect detection.
| Developed time saving on Dell™ PowerEdge™ XR7620 Server
By selecting the powerful Dell™ PowerEdge™ XR7620 server we are able to make this demonstration possible within a few months. Selecting a CPU or entry level GPU edge platform would have resulted in ~50% increase in development time for additional data labeling, training, custom API development, and post training optimization. This all would be required to reach our minimum latency requirement of sub 1.2 seconds for the object detection and defect detection models.
Note: ~50% time savings estimated based on engineering resources applied in development (~2000 hours) and estimated incremental time required to label, train, custom API development, and post training optimization (~2000 hours).
| Dell Technology™ World 23’
AI Driven Pop-Up Manufaturing Demo
| Conclusion
Our demo has potential implications in revolutionizing orthopedic implant manufacturing. The amalgamation of 3D printing, deep learning, and open programmable robots may provide a flexible, efficient, and affordable manufacturing solution for orthopedic components. The incorporation of Dell™ ruggedized PowerEdge™ XR7620 server and NVIDIA® powerful GPUs ensures reliable and real-time defect detection, proving essential in reducing production delays.
As our proof of concept gains further refinement, we anticipate its adoption in various other manufacturing domains, bringing in a new era of efficiency and precision.
About Scalers AI™
Scalers AI™ specializes in creating end-to-end artificial intelligence (AI) solutions for a wide range of industries, including retail, smart cities, manufacturing, and healthcare. The company is dedicated to helping organizations leverage the power of AI for their digital transformation. Scalers AI™ has a team of experienced AI developers and data scientists who are skilled in creating custom AI solutions for a variety of use cases, including predictive analytics, chatbots, image and speech recognition, and natural language processing.
As a full stack AI solutions company with solutions ranging from the cloud to the edge, our customers often need versatile common off the shelf (COTS) hardware that works well across a range of workloads. Additionally, we also need advanced visualization libraries including the ability to render video in modern web application architectures.
| Fast track development with access to the solution code
Save hundreds of hours of development with the solution code. As part of this effort Scalers AI™ is making the solution code available.
Reach out to your Dell™ representative or contact Scalers AI™ at contact@scalers.ai for access.
Resources
- Reach out to your Dell™ representative or contact Scalers AI™ for access to the code!
This project was commissioned by Dell Technologies™ and conducted by Scalers AI, Inc.
Scalers AI™and Scalers AI™ logos are trademarks of Scalers AI, Inc.
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Author:
Steen Graham CEO at Scalers AI™
Chetan Gadgil CTO at Scalers AI™
Delmar Hernandez, Server Technologist at Dell Technologies™
Manya Rastogi, Server Technologist at Dell Technologies™