OffNominal
PhD Candidate, University of Houston / Founder, OffNominal Vision

Chad Weatherly

Through OffNominal Vision, I build software for industrial automation: machine vision and inspection, PLC integration, part traceability, and the operations software manufacturers run on. In the Continual Edge AI Lab under Dr. Sen Lin, I research anomaly detection for industrial inspection: models that stay reliable as production changes and run on edge hardware.

Chad Weatherly
Houston, Texas

01 / Research

Continual Learning

Anomaly detection under drift

Inspection models are usually evaluated on a fixed test set, but production lines drift: tools wear, materials change, lighting shifts. This work benchmarks which approaches stay reliable as conditions change. Published at ECCV 2026.

Self-Supervised Learning

Learning what normal looks like

Defects are rare and labeled data is expensive. I train representations on normal production images so that anything unusual stands out, including logical errors such as missing or misplaced parts.

Edge AI

Inspection at the edge

Inspection has to run where the parts are. I design compact models that run on embedded hardware at line speed, with no dependence on a data center.

Pre-prints

Published Work

Rethinking Continual Anomaly Detection on the Edge: Benchmarking Under Realistic Industrial Conditions

Weatherly C, Lin S.

Computer Vision – ECCV 2026, Lecture Notes in Computer Science, vol 17078. Springer, Cham, 2026; pp 55–73.

DOI: 10.1007/978-3-032-37393-9_5

The MET Project: Distinguishing Multisystem Inflammatory Syndrome in Children from Typhus Using Artificial Intelligence

Chun A, Bautista A, Weatherly C, Osuna I, Nasto K, Munoz FM, Schutze G, Devaraj S, Muscal E, Sexson Tejtel K, Vogel T, Kakadiaris I.

Open Forum Infectious Diseases, 2022;9(Suppl 2):ofac492.916.

DOI: 10.1093/ofid/ofac492.916

02 / Industry Work

OffNominal Vision is my engineering practice. I build software for industrial automation, specializing in manufacturing.

What I build

Machine Vision

Vision and inspection systems

Automated inspection with deep learning and classical vision: X-ray, 2D and 3D cameras, barcode and QR reading. Experience with Cognex In-Sight, LMI Gocator, Luxonis OAK-D and production X-ray platforms.

Controls

PLC and controls integration

Connecting vision and software to the line: PLC logic and I/O on Allen-Bradley and Phoenix Contact PLCnext, Modbus and industrial Ethernet, interlocks and pass/fail handshakes with machine controllers.

Traceability

Part and operator tracking

UHF RFID and barcode tracking from the reader hardware to the database, so every part carries its history: who worked it, where, and when.

Operations Software

Scheduling, orders and shop-floor displays

Production scheduling, quoting and order management, and live shop-floor boards, integrated with ERP and accounting systems.

Edge Deployment

Software that runs on the floor

Applications in Python and Rust on Raspberry Pi, NVIDIA Jetson and industrial PCs, built to run unattended and recover on their own.

Infrastructure

Servers, data and connectivity

The servers, databases, APIs and secure remote access that tie stations together and get results to the people who need them.

Selected work

Manufacturing2025 – present

Operations and traceability for an oilfield equipment manufacturer

For a Houston-area manufacturer and its machine shop: RFID operator stations on the production floor, X-ray images filed by part identity, and a scheduling and order management system that is taking over from an off-the-shelf ERP.

Energy Components2023 – 2025

Deep-learning X-ray inspection

Replaced a rule-based vision system on a production X-ray line with a deep-learning pipeline that grades every part, integrated with the machine's recipe software and controls. Also built multi-camera QR tracking for parts trays.

03 / Technical Skills

Languages
Python, Rust, C/C++, C#, SQL
Machine Learning & Vision
PyTorch, OpenCV, timm
Systems & Backend
Flask, Axum / Tokio, REST APIs, SQLite, Linux, systemd
Industrial Automation
PLCs (Allen-Bradley, Phoenix Contact PLCnext), Modbus, machine vision (Cognex In-Sight, LMI Gocator), UHF RFID, X-ray inspection
Hardware
NVIDIA Jetson, Raspberry Pi, industrial PCs, Luxonis OAK-D and industrial cameras
Research Areas
Anomaly detection, self-supervised learning, continual learning, edge AI

04 / Contact

Work with OffNominal

Email is the best way to reach me, about research, a project, or both.

[email protected]