Synthetic Defect Image Generation for Power Line Insulator Inspection Using Multimodal Large Language Models

The bottleneck in learning-based industrial defect detection is often limited not by model capacity, but by the scarcity of labeled defect data: defects are rare, annotations are expensive, and collecting balanced training sets is slow. We present an end-to-end pipeline for synthetic defect generation and annotation, combining Vision-Language-Model-based prompts, LoRA-adapted diffusion, mask-guided inpainting, and sample filtering with automatic label derivation, and demonstrates the potential of real data with realistic synthetic samples to overcome data scarcity. The evaluation is conducted on, a challenging dataset of pitting defects on ball screw drives, and then on a subset of the Mobile phone screen surface defect segmentation dataset (MSD) dataset to test cross-domain transfer. Beyond downstream detector performance, we analyze key stages of the pipeline, including prompt construction, LoRA selection, and sample filtering with DreamSim and CLIPScore, to understand which synthetic samples are both realistic and useful. Experiments with YOLOv26, YOLOX, and LW-DETR show that synthetic-only training does not replace real data. When combined with real data, synthetic defects can preserve performance and yield modest gains in selected BSData training regimes. The MSD transfer study shows that the overall pipeline structure carries over to a second industrial inspection domain, while also highlighting the importance of domain-specific adaptation and annotation-quality control. Overall, the paper provides an end-to-end assessment of diffusion-based industrial defect synthesis and shows that its strongest value lies in strengthening scarce real datasets rather than substituting for them.

Defect detection systems for industrial condition monitoring can only be relied upon if they are validated, yet defective samples are rare and, for a specific asset, often nonexistent. We present a framework that synthesizes severity-graded defects on real non-defective images without any defect references for the target asset, that can be used for model selection and validation. A defect taxonomy for common failure modes is distilled from literature into prescriptive prompts at varying defect severities. Regions of interest are cropped from in defect-free images and edited with a pre-trained image generation model ("FLUX.2 [klein]"). Color-matching and blending are employed to improve structural coherence with the original image. Generations are filtered out by a scorer and by estimated detection difficulty. Model selection experiments on MVTecAD show image AUROC choice regret over model selection can be nearly halved compared to the best fixed model chosen with access to test data. Experiments show the need for severity-graded anomaly synthesis. A case study investigates the proposed method for in-situ monitoring of Pelton turbine runners in hydropower, where real defect images are rare and expensive to collect. A PatchCorebased anomaly detection model is fit on Pelton turbine images and selected and validated using synthetic images, showing strong detection performance (94 % correct detection at optimal threshold and AUROC 0.97). The model reliably detects moderate and advanced defects, while early-stage defects remain challenging, indicating the synthetic data meaningfully stresses detector sensitivity.

Substation meters play a critical role in monitoring and ensuring the stable operation of power grids, yet their detection of cracks and other physical defects is often hampered by a severe scarcity of annotated samples. To address this few-shot generation challenge, we propose a novel framework that integrates Knowledge Embedding and Hypernetwork-Guided Conditional Control into a Stable Diffusion pipeline, enabling realistic and controllable synthesis of defect images from limited data. First, we bridge the substantial domain gap between natural-image pre-trained models and industrial equipment by fine-tuning a Stable Diffusion backbone using DreamBooth-style knowledge embedding. This process encodes the unique structural and textural priors of substation meters, ensuring generated images retain authentic meter characteristics. Second, we introduce a geometric crack modeling module that parameterizes defect attributes--such as location, length, curvature, and branching pattern--to produce spatially constrained control maps. These maps provide precise, pixel-level guidance during generation. Third, we design a lightweight hypernetwork that dynamically modulates the denoising process of the diffusion model in response to the control maps and high-level defect descriptors, achieving a flexible balance between generation fidelity and controllability. Extensive experiments on a real-world substation meter dataset demonstrate that our method substantially outperforms existing augmentation and generation baselines. It reduces Frechet Inception Distance (FID) by 32.7%, increases diversity metrics, and--most importantly--boosts the mAP of a downstream defect detector by 15.3% when trained on augmented data. The framework offers a practical, high-quality data synthesis solution for industrial inspection systems where defect samples are rare.