Claims:We claim:

1. A system (100) for sorting short length rebars (101) on a sorting platform (200), the system (100) comprising:
a first image capturing unit (1) and a second image capturing unit (2), each positioned orthogonally relative to a horizontal plane of the sorting platform (200),
wherein, the first image capturing unit (1) is positioned proximal to a first end (5) of the sorting platform (200) and the second image capturing unit (2) is positioned proximal to a second end (6) of the sorting platform (200), opposite to the first end (5), and wherein the first image capturing unit (1) and the second image capturing are configured to capture images of rebars (102) on the sorting platform (200) from each of the first end (5) and the second end (6), respectively; and
a control unit (3), communicatively coupled to the first image capturing unit (1) and the second image capturing unit (2), the control unit (3) is configured to:
operate, the first image capturing unit (1) and the second image capturing unit (2) to capture images of the rebars (102), upon receiving a trigger signal;
create, a projected image based on images of the rebars (102) from each of the first image capturing unit (1) and the second image capturing unit (2);
process, the projected image of the rebars (102) to identify void spaces between the rebars (102) on the sorting platform (200) to determine the short length rebars (101);
analyze, the void spaces in the processed images of the rebars (102) on the sorting platform (200) to filter location of the short length rebars (101); and
indicate, the short length rebars (101) on an indication unit (4), based on filtered locations of the short length rebars (101).

2. The system (100) as claimed in claim 1, wherein the first image capturing unit (1) and the second image capturing unit (2) are orthogonally oriented at a predefined angle ranging between 15 to 60, relative to the horizontal plane of the sorting platform (200).

3. The system (100) as claimed in claim 1, wherein the first image capturing unit (1) and the second image capturing unit (2) are positioned proximal to at least one corner of the first end (5) and the second end (6) of the sorting platform (200).

4. The system (100) as claimed in claim 1, wherein the projected image created by the control unit (3) is a top view of the sorting platform (200) including the rebars (102), based on images captured by the first image capturing unit (1) and the second image capturing unit (2) about orthogonal orientation relative to the horizontal plane of the sorting platform (200).

5. The system (100) as claimed in claim 1, wherein processing of the projected image of the rebars (102) to identify void spaces, by the control unit (3) includes:
binarizing the images captured by the first image capturing unit (1) and the second image capturing unit (2); and
morphing the binarized images to filter location of the short length rebars (101).

6. The system (100) as claimed in claim 5, wherein the control unit (3) is configured to binarize the projected image by comparing a preset adaptive threshold value of the rebars (102) on the sorting platform (200) with an adaptive threshold value of the rebars (102) in the projected image, to differentiate the rebars (102) from components of the sorting platform (200) appearing in the images captured by the first image capturing unit (1) and the second image capturing unit (2).

7. The system (100) as claimed in claim 6, wherein the binarized image is morphed by removing components of the sorting platform (200) from the rebars (102), based on comparison of dimensional ratio of the components of the sorting platform (200) with a preset dimensional ratio of the rebars (102).

8. The system (100) as claimed in claim 1, wherein the control unit (3) is configured to analyze the processed image by comparing length of void spaces in the processed image with at least one of a predefined length of the rebar and measuring average of the pixel intensities across neighborhood regions of the void space in the processed image, to filter location of the short length rebars (101).

9. The system (100) as claimed in claim 1, wherein the filtered image of the rebars (102) and the sorting platform (200) from each of the first image capturing unit (1) and the second image capturing unit (2) are stitched, to indicate filtered locations of the short length rebars (101) on the indication unit (4).

10. A method for sorting short length rebars (101) in a sorting platform (200), wherein the sorting platform (200) and a first image capturing unit (1) and a second image capturing unit (2), positioned orthogonally relative to a horizontal plane of the sorting platform (200), the method comprising:
operating, by a control unit (3), the first image capturing unit (1) and the second image capturing unit (2) to capture images of the rebars (102), the first image capturing unit (1) and the second image capturing unit (2) are communicatively coupled to the control unit (3) and are based on a trigger signal from the control unit (3);
creating, by the control unit (3), a projected image based on images of the rebars (102) from each of the first image capturing unit (1) and the second image capturing unit (2);
processing, by the control unit (3), the projected image of the rebars (102) to identify void spaces between the rebars (102) on the sorting platform (200) to determine the short length rebars (101);
analyzing, the void spaces in the processed images of the rebars (102) on the sorting platform (200) to filter location of the short length rebars (101); and
indicating, the short length rebars (101) on an indication unit (4), based on filtered locations of the short length rebars (101).

11. The method as claimed in claim 10, wherein creating, by the control unit (3), the projected image includes transforming an orthogonal view of the rebars (102) and the sorting platform (200) to a top view, based images captured by the first image capturing unit (1) and the second image capturing unit (2) about an orthogonal orientation relative to the horizontal plane of the sorting platform (200).

12. The method as claimed in claim 10, wherein processing of the projected image of the rebars (102) to identify void spaces, by the control unit (3) includes:
binarizing the images captured by the first image capturing unit (1) and the second image capturing unit (2); and
morphing the binarized images to filter location of the short length rebars (101).

13. The method as claimed in claim 12, wherein binarizing the projected image, by the control unit (3), includes comparing a preset adaptive threshold value of the rebars (102) on the sorting platform (200) with an adaptive threshold value of the rebars (102) in the projected image, to differentiate the rebars (102) from components of the sorting platform (200) captured by the first image capturing unit (1) and the second image capturing unit (2).

14. The method as claimed in claim 13, wherein morphing the binarized image, by the control unit (3), includes removing components of the sorting platform (200) from the rebars (102), based on comparison of dimensional ratio of the components of the sorting platform (200) with a preset dimensional ratio of the rebars (102).

15. The method as claimed in claim 10, wherein analyzing the processed image, by the control unit (3), includes comparing length of void spaces in the processed image with at least one of a predefined length of the rebar and measuring average of the pixel intensities across neighborhood regions of the void space in the processed image, to filter location of the short length rebars (101).

16. The method as claimed in claim 10, wherein indicating the short length rebars (101), by the control unit (3), includes stitching of the filtered image of the rebars (102) and the sorting platform (200) from each of the first image capturing unit (1) and the second image capturing, to indicate filtered locations of the short length rebars (101) on the indication unit (4).
, Description:TECHNICAL FIELD

The present disclosure relates to manufacturing. Particularly, but not exclusively, the present disclosure relates to monitoring and sorting of rebars. Further, embodiments of the present disclosure disclose a system for sorting short length rebars on a sorting platform.

BACKGROUND OF THE DISCLOSURE

In manufacturing plants, products including a myriad of dimensions and shapes, for example, billets, slabs, bars, rebars, pellets, briquettes, and the like, may be produced in batches, which may then be transported as either as raw material or products for use. Prior transportation, such products may generally be subjected to various qualitative and quantitative inspection, which may include inspection of chemical properties [for example, chemical composition, reaction to reagents, and the like] and physical properties [for example, microstructure, hardness, ductility, surface finishing, and the like].

Generally, physical properties of the products are defined with predetermined profiles such as, billets, rebars, pellets, and the like, may be subjected to inspection for precision in manufacturing by determining parameters including, but not limited to, dimensions, of such manufactured product. For example, rebars are generally elongated metallic bars including ribbed lattice, where such rebars are preset with a defined length for commercial use, per demand. Such rebars are generally inspected to determine defects and/or damages that may be induced during manufacturing, where such defects or damages may be due to molding defects or secondary manufacturing processes such as, but not limited to, cutting process.

Conventionally, rebars are manually inspected and sorted for quality, prior shipment. The inspection and sorting may be performed considering various parameters of the rebars including, but not limited to, length, radius, surface defects and any other parameter that may enable to manually differentiate defective rebars from remaining rebars. With such manual inspection, precision in sorting of the rebars may be affected due to human errors or such manual process being tedious. With advent of technology, various robotic assemblies have been developed for inspection of the rebars, in order to avoid human intervention and errors therefrom. Such robotic assemblies may be expensive in view of number of sensors and/or actuators being incorporated for inspection and sorting. Also, conventional robotic assemblies may require additional space and/or remote space for operation in view of traversing units in the manufacturing plant surrounding such inspection and sorting station, which inherently tends to increase costs associated process of inspection of the rebars.

The present disclosure is directed to overcome one or more limitations stated above.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional process are overcome by a system and a method as claimed and additional advantages are provided through the provision of such system and method as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure, a system for sorting short length rebars on a sorting platform is disclosed. The system includes a first image capturing unit and a second image capturing unit, each positioned orthogonally relative to a horizontal plane of the sorting platform. Further, the first image capturing unit is positioned proximal to a first end of the sorting platform and the second image capturing unit is positioned proximal to a second end of the sorting platform, opposite to the first end. The first image capturing unit and the second image capturing are configured to capture images of rebars on the sorting platform from each of the first end and the second end, respectively. The system further includes a control unit, which is communicatively coupled to the first image capturing unit and the second image capturing unit. The control unit is configured to operate, the first image capturing unit and the second image capturing unit to capture images of the rebars, upon receiving a trigger signal. The control unit then creates a projected image based on images of the rebars from each of the first image capturing unit and the second image capturing unit. For processing the projected image of the rebars, the control unit is configured to identify void spaces between the rebars on the sorting platform to determine the short length rebars. The control unit then analyzes the void spaces in the processed images of the rebars on the sorting platform to filter location of the short length rebars. Upon analyzing, the control unit is configured to indicate the short length rebars on an indication unit, based on filtered locations of the short length rebars.

In an embodiment of the present disclosure, the first image capturing unit and the second image capturing unit are orthogonally oriented at a predefined angle ranging between 15 to 60, relative to the horizontal plane of the sorting platform. Further, the first image capturing unit and the second image capturing unit are positioned proximal to at least one corner of the first end and the second end of the sorting platform.

In an embodiment of the present disclosure, the projected image created by the control unit is a top view of the sorting platform including the rebars, based on images captured by the first image capturing unit and the second image capturing unit about orthogonal orientation relative to the horizontal plane of the sorting platform.

In an embodiment of the present disclosure, the control unit is configured to process the projected image of the rebars to identify void spaces, by binarizing and morphing the images captured by the first image capturing unit and the second image capturing unit. On morphing, the binarized images is filtered to indicate location of the short length rebars.

In an embodiment of the present disclosure, the control unit is configured to binarize the projected image by comparing a preset adaptive threshold value of the rebars on the sorting platform with an adaptive threshold value of the rebars in the projected image. Such comparison differentiates the rebars from components of the sorting platform appearing in the images captured by the first image capturing unit and the second image capturing unit.

In an embodiment of the present disclosure, the binarized image is morphed by removing components of the sorting platform from the rebars, based on comparison of dimensional ratio of the components of the sorting platform with a preset dimensional ratio of the rebars.

In an embodiment of the present disclosure, the control unit is configured to analyze the processed image by comparing length of void spaces in the processed image with at least one of a predefined length of the rebar and measuring average of the pixel intensities across neighborhood regions of the void space in the processed image, to filter location of the short length rebars. Further, the filtered image of the rebars and the sorting platform from each of the first image capturing unit and the second image capturing unit are stitched, to indicate filtered locations of the short length rebars on the indication unit.

In an other non-limiting embodiment of the present disclosure, a method for sorting short length rebars in a sorting platform is disclosed. The sorting platform and a first image capturing unit and a second image capturing unit is positioned orthogonally relative to a horizontal plane of the sorting platform. The method includes steps of operating the first image capturing unit and the second image capturing unit by a control unit, to capture images of the rebars. The first image capturing unit and the second image capturing unit are communicatively coupled to the control unit and are operated based on a trigger signal from the control unit. The first image capturing unit and the second image capturing are configured to capture images of rebars on the sorting platform from each of the first end and the second end, respectively. The system further includes a control unit, which is communicatively coupled to the first image capturing unit and the second image capturing unit. The control unit is configured to operate, the first image capturing unit and the second image capturing unit to capture images of the rebars, upon receiving a trigger signal. The control unit then creates a projected image based on images of the rebars from each of the first image capturing unit and the second image capturing unit. For processing the projected image of the rebars, the control unit is configured to identify void spaces between the rebars on the sorting platform to determine the short length rebars. The control unit then analyzes the void spaces in the processed images of the rebars on the sorting platform to filter location of the short length rebars. Upon analyzing, the control unit is configured to indicate the short length rebars on an indication unit, based on filtered locations of the short length rebars.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

FIG.1 is a schematic representation of a sorting station for sorting short length rebars, in accordance with an embodiment of the present disclosure.

FIG.2 illustrates a schematic representation of position of a first and a second image capturing units in the sorting station of FIG.1.

FIG.3A illustrates orthogonal photographic view of the rebars in the sorting station captured by the second image capturing unit, in accordance with an embodiment of present disclosure.

FIG.3B illustrates a top projected view of FIG. 3A.

FIG.3C illustrates a binarized image of FIG. 3B.

FIG.3D illustrates a morphed image of FIG. 3C.

FIG.3E illustrates n analysed image of FIG. 3C.

FIG.3F illustrates a filtered image of FIG. 3D.

FIG.3G illustrates an indicative image highlighting short length rebars of the rebars in the sorting station captured by each of the first and the second image capturing units, in accordance with an embodiment of present disclosure.

FIG.4 is a flow chart illustrating a method for sorting short length rebars in the sorting platform, in accordance with an embodiment of present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent processes do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

Embodiments of the present disclosure discloses a system for sorting short length rebars on a sorting platform. The system includes a first image capturing unit and a second image capturing unit, each positioned orthogonally relative to a horizontal plane of the sorting platform. Further, the first image capturing unit is positioned proximal to a first end of the sorting platform and the second image capturing unit is positioned proximal to a second end of the sorting platform, opposite to the first end. The first image capturing unit and the second image capturing are configured to capture images of rebars on the sorting platform from each of the first end and the second end, respectively. The system further includes a control unit, which is communicatively coupled to the first image capturing unit and the second image capturing unit. The control unit is configured to operate, the first image capturing unit and the second image capturing unit to capture images of the rebars, upon receiving a trigger signal. The control unit then creates a projected image based on images of the rebars from each of the first image capturing unit and the second image capturing unit. For processing the projected image of the rebars, the control unit is configured to identify void spaces between the rebars on the sorting platform to determine the short length rebars. The control unit then analyzes the void spaces in the processed images of the rebars on the sorting platform to filter location of the short length rebars. Upon analyzing, the control unit is configured to indicate the short length rebars on an indication unit, based on filtered locations of the short length rebars. With such configuration, the system is configured to amalgamate human-machine interface for reducing costs associated with sorting and inspection, without having to compromise on quality of such sorting and inspection. Also, the system is configured to operate with minimum number of cameras, without having to use a myriad of sensors for sensing length of each rebar on the sorting platform.

The term “rebars” refers reinforcing bar), known when massed as reinforcing steel or reinforcement steel, is a steel bar or mesh of steel wires used as a tension device in reinforced concrete and reinforced masonry structures to strengthen and aid the concrete under tension. In an embodiment, the rebar may also be considered as a plurality of segments of an elongated bar made from metallic, non-metallic or carbon fiber material, and including ribs or predetermined pattern being defined on an outer surface of each of the plurality of segments, to impart required functional limitation. In an embodiment, the elongated bars may be hollow or solid in nature, based on requirement and/or application in which such segments of the elongated bars may be employed.

The term “short length rebars” may be referred to those rebars from the batch of rebars, whose length is lesser than a preset value. The short length rebars may be determined on inspection and required to be sorted from remaining rebars having the preset value of length.

The terms “comprises”, “comprising”, or any other variations thereof used in the specification, are intended to cover a non-exclusive inclusion, such that the system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or method. In other words, one or more elements in an assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system and the method of operating such system.

Henceforth, the present disclosure is explained with the help of one or more figures of exemplary embodiments. However, such exemplary embodiments should not be construed as limitation of the present disclosure. Also, reference to direction and orientation presented herein are relative to illustrative figure, while such direction and orientation may vary based on viewpoint of observation.

The following paragraphs describe the present disclosure with reference to FIGS.1 to 4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.

FIG.1 is an exemplary embodiment of the present disclosure illustrating a system (100) for sorting short length rebars (101) in a sorting platform (200). The sorting platform (200) may be configured to receive, hold and/or transport the rebars (102), while also allowing other secondary operations including, but not limited to, cutting, grinding, finishing, inspection, sorting, and other operations that may be required to be performed on the rebars (102). The sorting platform (200) may be a portion of a sorting station, where a plurality of sorting platforms may be progressively positioned, about which the rebars (102) may traverse for inspection and sorting of short length rebars (101). The sorting platform (200) may be a stationary base or a moveable tray, on which the rebars (102) may be positioned or traversed for bundling and/or packaging. In an embodiment, the sorting platform (200) may be enclosable in a housing [not shown in figures] for allowing the rebars (102) to be introduced for inspection and sorting. The sorting platform (200) includes a head section configured to receive the rebars (102) from the transport conveyer and a tail section further from the head section. The tail section may be configured to deliver the sorted rebars (101) to a delivery conveyer [not shown].

The system (100) of the present disclosure includes a first image capturing unit (1) and a second image capturing unit (2), for assisting an operator and/or a robot, capable of traversing about and along the sorting platform (200), to separate and/or segregate short length rebars (101) from the sorting platform (200). As best seen in Figure 2, the first image capturing unit (1) and the second image capturing unit (2) may be positioned orthogonally relative to a horizontal plane of the sorting platform (200), where the horizontal plane may be referred to as a plane on which the rebars (102) may be placed. In an embodiment, the first image capturing unit (1) and the second image capturing unit (2) may be orthogonally oriented at a predefined angle ranging between 15 to 60, relative to the horizontal plane of the sorting platform (200).

Further, to focus and capture broader field of the sorting platform (200) and in-turn the rebars (102), the first image capturing unit (1) may be positioned proximal to a first end (5) i.e., head section of the sorting platform (200), while the second image capturing unit (2) may be positioned proximal to a second end (6) i.e., tail section of the sorting platform (200), which is opposite to the first end (5). The first image capturing unit (1) and the second image capturing unit (2) may be positioned on same side or opposite sides or along diagonal section of the sorting platform (200). In the illustrative embodiment, the first image capturing unit (1) and the second image capturing unit (2) are positioned proximal to at least one corner of the first end (5) and the second end (6) of the sorting platform (200). It is to be understood that the first image capturing unit (1) and the second image capturing unit (2) may be aligned relative to the sorting platform (200) in such a way that, field of view of the first image capturing unit (1) may at least partially overlap with field of view of the second image capturing unit (2). Such configuration of the first image capturing unit (1) and the second image capturing unit (2) may allow to capture, process, and stitch of images of substantial length of the rebars (102) positioned on the sorting platform (200). Here, the phrase “substantial length of the rebars (102)” may be referred to as at least 90% of length of the rebars (102), being positioned on the sorting platform (200). For example, in the illustrative embodiment, each of the first image capturing unit (1) and the second image capturing unit (2) may be positioned orthogonal to the horizontal plane of the sorting platform (200) and be positioned at one side of the sorting platform (200), for capturing images of the rebars (102).

In an embodiment, the first image capturing unit (1) and the second image capturing unit (2) may be configured to focus on the sorting platform (200) and in-turn the rebars (102), for ensuring overlapping of the field of views of the first image capturing unit (1) and the second image capturing unit (2) from each of the first end (5) and the second end (6), respectively, of the sorting platform (200). Further, the first image capturing unit (1) and the second image capturing unit (2) may include at least one of RGB sensor and RGB-D sensor, to determining the short length rebars (101) on the sorting platform (200). In an embodiment, the first image capturing unit (1) and the second image capturing unit (2) may be a camera, which may be including but not limited to, high frame rate camera. It is understood that more than two image capturing units may be employed in the system (100).

Further, the system (100) includes a control unit (3), which may be communicatively coupled to the first image capturing unit (1) and the second image capturing unit (2). The control unit (3) may be configured to operate the first image capturing unit (1) and the second image capturing unit (2), either individually or simultaneously, to capture images of the rebars (102). The control unit (3) may be configured to operate the first image capturing unit (1) and the second image capturing unit (2), when a trigger signal from an operator or user may be received, on positioning and/or arrival of the rebars (102) on the sorting platform (200). In an embodiment, the control unit (3) may also be configured to operate the first image capturing unit (1) and the second image capturing unit (2), when the rebars (102) and/or the sorting platform (200) may be relatively positioned with respect to field of view of the first image capturing unit (1) and the second image capturing unit (2). The images captured by the first image capturing unit (1) and the second image capturing unit (2) may be configured to be processed by the control unit (3), to determine short length rebars (101) on the sorting platform (200).

For sake of simple understanding of the system (100), image of the rebars (102) captured by the second image capturing unit (2), from the second end (6) of the sorting platform (200), is detailed in Figure 3A, while processing of such image by the control unit (3) is detailed in Figures 3B to 3F. It is to be understood that, similar procedure and/or operations are to be considered as operation for the image captured by the first image capturing unit (1) from the first end (5) of the sorting platform (200), which is then stitched [i.e. optically attached in a frame of reference] to produce Figure 3G.

As can be best seen in Figure 3a, the second image capturing unit (2) is configured to capture and/or record images of the rebars (102) on the sorting platform (200), from the second end (6), where the second image capturing unit (2) is positioned proximal to the second end (6) of the sorting platform (200) and orthogonally oriented with respect to the horizontal plane and towards the first end of the sorting platform (200). Image of the rebars (102) and the sorting platform (200) captured by the second image capturing unit (2) indicates apparent length [also referred to as isometric and/or pseudo-length] of the rebars (102) on the sorting platform (200), where such image is transmitted to the control unit (3) for further processing.

The control unit (3) is configured to create a projected image of the image captured by the second image capturing unit (2). The projected image created by the control unit (3) may be a substantial top view of the rebars (102) [best shown in FIG. 3B] based on transformation from orthogonal view of capture by the second image capturing unit (2). The control unit (3) may include the first end (5) of the sorting platform (200) along with each side of the sorting platform (200) in the field of view of the second image capturing unit (2) as a reference for performing and/or projecting such transformation of the image to create the projected image. In an embodiment, the control unit (3) may also perform and/or project transformation of the image captured by the second image capturing unit (2), with respect to corners and edges of the sorting platform (200), in the field of view of the second image capturing unit (2).

The control unit (3) is configured to process the projected image of the rebars (102), to identify void spaces between the rebars (102) on the sorting platform (200) to determine the short length rebars (101). Further, the control unit (3) may be configured to process the projected images by binarizing and morphing, in order to enable analyzing the void spaces of the rebars (102) on the sorting platform (200). The control unit (3) is configured to binarize the projected image by comparing a preset adaptive threshold value of the rebars (102) on the sorting platform (200) with an adaptive threshold value of the rebars (102) in the projected image, as best seen in Figure 3C. Such processing of the projected image by the control unit (3), is configured to differentiate the rebars (102) from components of the sorting platform (200) appearing in the images captured by the first image capturing unit (1) and the second image capturing unit (2). By binarizing the projected image, the control unit (3) may be configured to compensate for fluctuations in lighting conditions [for example, by either inverting color spectra or converting the image captured by the second image capturing unit (2) into black-white] in and surrounding of the sorting platform (200) and in-turn the rebars (102). With such binarized image the components of the sorting platform (200) such as, but not limited to, portion of the sorting platform (200), conveyors, spacers, and any other element being captured by the second image capturing unit (2) along with the rebars (102), may be differentiated based on adaptive threshold of such components when compared with a preset adaptive threshold value of the rebars (102) on the sorting platform (200). Due to such comparison of adaptive threshold, the control unit (3) may be capable of determining dimensional ratio of the rebars (102) and that of the components of the sorting platform (200) for morphing.

In an embodiment, the control unit (3) may be configured to morph the binarized image by removing the components of the sorting platform (200) that may be seen in the projected image, where dimensional ratio and/or profile [either substantially or to a minimal extent] of the components that deviate away from a preset dimensional ratio of the rebars (102) may be removed, as best seen in Figure 3D. Such morphed image of the rebars (102), deduced from the binarized image, may enable in identifying and analyzing void spaces in the processed image for determining short length rebars (101) on the sorting platform (200). In an embodiment, the morphed image may include void spaces identified between the components of the sorting platform (200) and the rebars (102), to analyze variation in length of such void spaces with tat of the predefined length of the rebars (102).

From Figure 3D, the control unit (3) to avoid misrepresentation of an empty space on the sorting platform (200) with the void space between the rebars (102) to identify the short length rebars (101), may analyze each of the identified void spaces. Such analysis of the void spaces may be performed by the control unit (3), by comparing at least one of length of the void spaces in the processed image with at least one of a predefined length of the rebar and, measuring average of the pixel intensities across neighborhood regions of the void space in the processed image, to filter location of the short length rebars (101). In an example, the control unit (3) upon analyzing that the length of the void space compares with the predefined length of the rebar, then such void space may be filtered and/or neglected from identification. The control unit (3) may filter such identified void spaces to be equivalent to an empty space between the rebars (102) on the sorting platform (200).

Now referring to FIG. 3E, in which Blue box indicates a situation where length of the void space determined by the control unit (3) may be lesser than the predefined length of the rebar, then the control unit (3) is configured to analyze pixel intensities in the processed image. In an embodiment, for performing analysis by way of determining pixel intensities, the control unit (3) may be configured to either re-binarize or remove binarizing from the processed image, to identify morphed regions [that is, identified void spaces in the binarized image] on the projected image. The morphed regions may correspond to identified void spaces between the rebars (102), where the short length rebars (101) may include uniform pixel intensity at least two regions surrounding such morphed region. Such uniform pixel intensity is analyzed by the control unit (3) to identify that the void space surrounded by the rebars (102) having the predefined length may be indicative of the short length rebar. However, in a case where the measured average of the pixel intensities across and along the neighborhood regions of the void space is not comparable to the pixel intensity of the rebars (102), then the control unit (3) may filter such identified void spaces, as best seen in Figure 3F.

In the illustrative embodiment, the control unit (3) upon identifying the void spaces in an analyzed image produced from the second image capturing unit (2), may be configured to perform similar actions/operations for identifying the void spaces in the analyzed image produced from the first image capturing unit (1). The control unit (3) may then be configured to stitch [i.e. optically attached in a frame of reference] to produce Figure 3G, which may independently by the analyzed image from the first end (5) of the sorting platform (200) at the left hand side of Figure 3G and the analyzed image from the second end (6) of the sorting platform (200) at the right hand side of Figure 3G. The identified image may then be displayed on an indication unit (4) associated with the system (100) so that, the operator and/or the robot may suitably traverse about and along the sorting platform (200), to separate and/or segregate short length rebars (101) from the sorting platform (200).

In an embodiment, the control unit (3) may be a computing device including, but not limited to, a computer, laptop, a mobile phone and the like, and/or a centralized control unit (3) such as, but not limited to, a control panel of the sorting platform (200), a control module operable in the control panel of the sorting station, an electronic control chip dedicated to control the first image capturing unit (1) and the second image capturing unit (2) along with processing of images captured therefrom. The control unit (3) may be comprised of a processing unit. The processing unit may comprise at least one data processor for executing program components for executing user- or system-generated requests. The processing unit may be a specialized processing unit such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may include a microprocessor, such as AMD Athlon, Duron or Opteron, ARM’s application, embedded or secure processors, IBM PowerPC, Intel’s Core, Itanium, Xeon, Celeron or other line of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), etc.

The control unit (3) may be disposed in communication with one or more memory devices (e.g., RAM, ROM etc.) via a storage interface. The storage interface may connect to memory devices including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computing system (100) interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, etc.

Referring now to Figure 4 which is an exemplary embodiment of the present disclosure illustrating a flow chart of a method for sorting short length rebars (101) in the sorting platform (200), which includes the first image capturing unit (1) and the second image capturing unit (2), positioned orthogonally relative to the horizontal plane of the sorting platform (200).

Further, the order in which the method described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.

At block 301, the control unit (3) may be configured to receive the trigger signal for operating the first image capturing unit (1) and the second image capturing unit (2). In an embodiment, the trigger signal may be generated when position of the rebars (102) on the sorting platform (200) may be either manually or automatically detected by at least one sensor communicatively coupled to the control unit (3). In an embodiment, the control unit (3) may also be configured to operate the first image capturing unit (1) and the second image capturing unit (2), when the rebars (102) and/or the sorting platform (200) is relatively positioned with respect to field of view of the first image capturing unit (1) and the second image capturing unit (2). Based on the trigger signal, the control unit (3) is configured to operate the first image capturing unit (1) and the second image capturing unit (2) to capture the image of the rebars (102) on the sorting platform (200). Such image is then transmitted to the control unit (3) from the first image capturing unit (1) and the second image capturing unit (2) for processing, analyzing, and indicating the short length rebars (101).

At block 302, the control unit (3) is configured to transform the image captured by the first image capturing unit (1) and the second image capturing unit (2) to create the projected image, which may be transformation from orthogonal view to substantially a top view of the rebars (102). Transformation of the image to the projected image may be performed by the control unit (3) considering various factors including, but not limited to, lighting conditions, range of field of view, optical capacity of the first image capturing unit (1) and the second image capturing unit (2), references [such as number of edges, corners and/or sides] of the sorting platform (200) available in the image, and any other factor affecting pixel intensity of the image during transformation into the projected image.

Further, the control unit (3) is configured to process the projected image by binarizing and morphing, as at block 303. The projected image is binarized by comparing a preset adaptive threshold value of the rebars (102) on the sorting platform (200) with an adaptive threshold value of the rebars (102) in the projected image. The preset adaptive threshold value of the rebars (102) may be dependent on parameters including, but not limited to, color temperature of the rebars (102), contrast of the sorting platform (200), and any other parameter that may affect binarizing of the projected image.

The control unit (3) may process the binarized image by morphing the rebars (102) relative to components of the sorting platform (200), where the components of the sorting platform (200) may be differentiated based on the present adaptive threshold. Due to such differentiation of adaptive threshold, the control unit (3) may be capable of determining dimensional ratio of the rebars (102) and that of the components of the sorting platform (200) for morphing. Based on comparison of the dimensional ratio of the components of the sorting platform (200) with the preset dimensional ratio of the rebars (102), the control unit (3) may be configured to morph the binarized image by removing components of the sorting platform (200) from the rebars (102). With that, the morphed image includes only the rebars (102) and the void spaces defined due to the short length rebars (101), where such void spaces may then be analyzed by the control unit (3) to filter location of the short length rebars (101).

For analyzing the processed image, at block 304, the control unit (3) may be configured to compare the length of void spaces in the processed image with at least one of the predefined length of the rebar and measuring average of the pixel intensities across neighborhood regions of the void space in the processed image, to filter location of the short length rebars (101). For example, when the predefined length of the rebar is about 12m, then the control unit (3) may be configured to filter identified void spaces having length more than 0.5m and width greater than width of the rebars (102). Remaining identified void spaces from the morphed image may then be interpolated and/or layered on the projected image created by the control unit (3) for further analyzing locations of the void spaces based on pixel intensity of at least two regions surrounding each of the remaining identified void spaces. The pixel intensity analyzed by the control unit (3), may be uniform for the void space surrounded by the rebars (102) having the predefined length, whereas void spaces away from the rebars (102) are filtered.

With such analysis of the control unit (3), location of short length rebars (101) are indicated on the indication unit (4) for selectively removal from the sorting platform (200), as at block 305. The indication unit (4) may be including, but not limited to, a control panel, a display device, audio-visual unit, and any other device capable of indicating location of the void spaces and in-turn the short length rebars (101) from the sorting platform (200).

In an embodiment, the system (100) is configured to amalgamate human-machine interface for reducing costs associated with sorting and inspection, without having to compromise on quality of such sorting and inspection.

In an embodiment, the system (100) is configured to operate with minimum number of cameras, without having to use a myriad of sensors for sensing length of each rebar on the sorting platform (200).

In an embodiment, the system (100) may be readily incorporated any sorting platform (200), without requiring structural modifications/changes to layout of such sorting platform (200).

In view of the above description of the present disclosure, the system (100) may be employed in various fields of technology for sorting and inspection based on dimensional parameters of an article, and the present disclosure should nowhere be limited to determining and/or sorting short length rebars (101). For instance, the system (100) of the present disclosure can also be employed in other fields of technology including, but not limited to, manufacturing of pipes, cylinder, billets, and the like. Also, application of the system (100) may further be extended to determine surface defects on articles including, but not limited to, sheet metals, plyboards, and the like.

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:
Particulars Numeral
System 100
First image capturing unit 1
Second image capturing unit 2
Control unit 3
Indication unit 4
First end 5
Second end 6
Sorting platform 200
Short length rebars 101
Rebars 102