Methods, apparatuses, and systems for image-based measurement and inspection of pre-engineered structural components

• US 8,718,371 B2
• Filed: 03/04/2012
• Issued: 05/06/2014
• Est. Priority Date: 01/31/2007
• Status: Active Grant

• Current Assignee: Building Component Verification Systems, Inc.
• Original Assignee: Building Component Verification Systems, Inc.
• Inventors: Thompson, Cyril Robert, Corley, Steven
• Primary Examiner(s): Rahmjoo, Mike
• Application Number:
  US13/411,601
• Publication Number:
  US 20120163673A1
• Time in Patent Office: 793 Days
• Field of Search: 382/181, 382/100, 382/232, 356/430, 356/431, 356/429, 493/374
• US Class Current: 382/181
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: G06V 10/10 Image acquisition document image scanning and transmission H04N1/00; control of digital cameras H04N23/60
• CPC Class Codes: G06V 2201/06 Recognition of objects for industrial automation

Abstract

Methods, apparatuses, and systems for image-based measurement and inspection of pre-engineered structural components, such as building trusses and wall panels. A system can include: a light source; a camera; a first memory storage; a second memory storage; and a processing unit configured to (i) detect a characteristic of the structural component, (ii) compare the characteristic to a corresponding characteristic of at least one reference data, and (iii) indicate a result of the comparison. A method can include: causing a light source to illuminate a portion of the structural component, receiving a reflection of the light source from the illuminated portion of the structural component, and storing data corresponding to the intensity of the reflection; comparing the stored data to at least one reference data; and indicating a result of the comparison.

Claims

1. A method for inspecting a pre-engineered structural component, comprising:

a) passing said pre-engineered structural component through an inspection apparatus;

b) capturing at least one image with a camera of said inspection apparatus, said at least one image being from at least one side of said pre-engineered structural component, said pre-engineered structural component comprising two or more pieces of lumber and at least one support plate;

c) sending said at least one image to a processing unit of said inspection apparatus;

d) identifying a pre-engineered structural component design of said pre-engineered structural component using a digital image processing algorithm on at least a portion of at least one support plate in said image;

e) selecting a reference array that corresponds to said identified pre-engineered structural component design from a plurality of reference arrays stored in an internal memory of said inspection apparatus;

f) said processing unit performing the steps of (1) detecting one or more characteristics of said pre-engineered structural component contained in said at least one image, including at least one of the presence of a piece of lumber, the relative position of a piece of lumber, the presence of said at least one support plate, and relative position of said at least one support plate, and (2) comparing said one or more characteristics of said pre-engineered structural component with corresponding characteristics in said selected reference array;

g) measuring at least one dimension of said pre-engineered structural component contained in said at least one image;

h) comparing said at least one dimension to a corresponding dimension in said reference array; and

i) reporting a result of the comparison.

2. The method of claim 1, wherein said step of reporting comprises graphically displaying a result of said comparison superimposed over said images.

3. The method of claim 1 comprising the further step of compressing said at least one image.

4. The method of claim 3 comprising the further step of storing said compressed image.

5. The method of claim 1, further comprising the step of moving said pre-engineered structural component from a first position to a second position by at least one mechanized roller of said inspection apparatus.

6. The method of claim 1, wherein said step of capturing said at least one image comprises:

a) first, detecting a leading edge of said pre-engineered structural component;

b) upon such first detection, beginning capturing said at least one image of said pre-engineered structural component;

c) then detecting a trailing edge of said pre-engineered structural component; and

d) upon such second detection, stopping capturing said at least on image.

7. The method of claim 1, further comprising capturing at least two computer readable images of said pre-engineered structural component.

8. The method of claim 7, further comprising the step of said processing unit correlating said at least two computer readable images.

9. The method of claim 8 wherein said correlating step comprises the sub-steps of:

a) locating a first feature in a first of said at least two computer readable images;

b) locating a second feature in a second of said at least two computer readable images, wherein said second feature corresponds to said first feature; and

c) using a normalized cross correlation algorithm to correlate said first computer readable image and said second computer readable image about said first and said second features, respectively.

10. The method of claim 8, wherein the step of correlating said at least two computer readable images produces a composite image of an entire side of said pre-engineered structural component.

11. The method of claim 1 wherein the step of identifying said pre-engineered structural component design comprises determining the presence of an identification device in said at least one image.

12. The method of claim 11, wherein said step of determining the presence of said identification device comprises searching for a known identification device pattern in said at least one camera image.

13. The method of claim 11, wherein said step of identifying a pre-engineered structural component design of said pre-engineered structural component comprises receiving an input from a human interface device.

14. The method of claim 1, wherein the step of identifying said pre-engineered structural component design comprises determining the presence of said at least one support plate in said at least one image.

15. The method of claim 14, wherein the step of identifying said pre-engineered structural component design further comprises:

a) selecting a portion of at least one support plate;

b) computing the power cepstrum of said selected portion of said at least one support plate; and

c) identifying from said power cepstrum said at least one support plate.

16. The method of claim 1, wherein said at least one image of said pre-engineered structural component is a computer readable image.

17. The method of claim 1, wherein the step of identifying said pre-engineered structural component design is based on at least one identifying characteristic of said pre-engineered structural component in said camera image.

18. The method of claim 1, wherein said pre-engineered structural component design is a truss design.

19. A method for inspecting a pre-engineered structural component, comprising:

a) inserting said pre-engineered structural component into a first end of an inspection apparatus;

b) capturing at least one computer readable image of said pre-engineered structural component with a camera of said inspection apparatus, wherein said pre-engineered structural component comprises one or more pieces of lumber and at least one support plate;

c) sending said at least one computer readable image to a processing unit of said inspection apparatus;

d) said processing unit selecting a reference array from a plurality of reference arrays stored in an internal memory of said inspection apparatus by

(1) detecting at least one characteristic of said pre-engineered structural component contained in said at least one computer readable image, including at least one of the presence of a piece of lumber, the relative position of a piece of lumber, the presence of a support plate, and the relative position of a support plate, and

(2) identifying a reference array corresponding to said at least one detected characteristic; and

e) said processing unit performing the steps of (1) detecting at least one characteristic of said pre-engineered structural component contained in said at least one computer readable image, including at least one of the presence of a piece of lumber, the relative position of a piece of lumber, the presence of a support plate, and the relative position of a support plate, and (2) comparing said at least one characteristic of said pre-engineered structural component with a corresponding characteristic in said selected reference array.

20. The method of claim 19, further comprising reporting a result of the comparison.

21. The method of claim 20, wherein said step of reporting comprises graphically displaying a result of said comparison superimposed over said images.

22. The method of claim 19, comprising the further step of compressing said at least one computer readable image.

23. The method of claim 22, comprising the further step of storing said compressed image in a memory of said processing unit.

24. The method of claim 19, further comprising the step of moving said pre-engineered structural component from a first position to a second position by at least one mechanized roller of said inspection apparatus.

25. The method of claim 19, wherein said step of capturing said at least one computer readable image comprises:

a) first, detecting a leading edge of said pre-engineered structural component;

b) upon such first detection, beginning capturing said at least one computer readable image of said pre-engineered structural component;

c) then detecting a trailing edge of said pre-engineered structural component; and

d) upon such second detection, stopping capturing said at least one computer readable image.

26. The method of claim 19, further comprising capturing at least two computer readable images of said pre-engineered structural component.

27. The method of claim 26, further comprising the step of said processing unit correlating said at least two computer readable images.

28. The method of claim 27, wherein said correlating step comprises the sub-steps of:

a) locating a first feature in a first of said at least two computer readable images;

b) locating a second feature in a second of said at least two computer readable images, wherein said second feature corresponds to said first feature; and

c) using a normalized cross correlation algorithm to correlate said first computer readable image and said second computer readable image about said first and said second features, respectively.

29. The method of claim 27, wherein the step of correlating said at least two computer readable images produces a composite image of an entire side of said pre-engineered structural component.

30. The method of claim 19, wherein the step of identifying said pre-engineered structural component design comprises determining the presence of an identification device in said at least one image.

31. The method of claim 30, wherein said step of determining the presence of said identification device comprises searching for a known identification device pattern within said at least one image.

32. The method of claim 30, wherein said step of identifying said pre-engineered structural component design comprises receiving an input from a human interface device in communication with said processing unit.

33. The method of claim 19, wherein the step of identifying said pre-engineered structural component design comprises determining the presence of said at least one support plate in said at least one image.

34. The method of claim 33, wherein the step of identifying said pre-engineered structural component design further comprises:

a) selecting a portion of said at least one support plate;

b) computing the power cepstrum of said selected portion of said at least one support plate; and

c) identifying from said power cepstrum said at least one support plate.

35. The method of claim 19, wherein said pre-engineered structural component design is a truss design.

36. A method for inspecting a pre-engineered structural component, comprising:

a) inserting said pre-engineered structural component into a first end of an inspection apparatus;

b) capturing at least one computer readable image of said pre-engineered structural component with a camera of said inspection apparatus, wherein said pre-engineered structural component comprises one or more pieces of lumber and at least one support plate;

c) sending said at least one computer readable image to a processing unit of said inspection apparatus;

d) said processing unit selecting a reference array from a plurality of reference arrays stored in an internal memory of said inspection apparatus corresponding to at least one characteristic of a support plate of said pre-engineered structural component by

(1) determining the presence of said at least one support plate in said at least one computer readable image, and

(2) identifying a reference image corresponding to said pre-engineered structural component based on said at least one characteristic of said at least one support plate;

e) measuring at least one dimension of said pre-engineered structural component contained in said at least one computer readable image; and

f) comparing said at least one dimension to a corresponding dimension in said selected reference image.

37. The method of claim 36, wherein the step of determining the presence of said at least one support plate in said at least one computer readable image comprises:

a) selecting a portion of said at least one support plate;

b) computing the power cepstrum of said selected portion of said at least one support plate; and

c) identifying from said power cepstrum said at least one support plate.

38. The method of claim 37, wherein said at least one characteristic of said at least one support plate includes said power cepstrum said at least one support plate.

39. The method of claim 36, further comprising reporting a result of the comparison.

40. The method of claim 39, wherein said step of reporting comprises graphically displaying a result of said comparison superimposed over said images.

41. The method of claim 36, comprising the further step of compressing said at least one computer readable image.

42. The method of claim 36, comprising the further step of storing said compressed image in a memory of said processing unit.

43. The method of claim 36, further comprising the step of moving said pre-engineered structural component from a first position to a second position by at least one mechanized roller of said inspection apparatus.

44. The method of claim 36, wherein said step of capturing said at least one computer readable image comprises:

a) first, detecting a leading edge of said pre-engineered structural component;

b) upon such first detection, beginning capturing said at least one computer readable image of said pre-engineered structural component;

c) then detecting a trailing edge of said pre-engineered structural component; and

d) upon such second detection, stopping capturing said at least one computer readable image.

45. The method of claim 36, further comprising capturing at least two computer readable images of said pre-engineered structural component.

46. The method of claim 45, further comprising the step of said processing unit correlating said at least two computer readable images.

47. The method of claim 46, wherein said correlating step comprises the sub-steps of:

a) locating a first feature in a first of said at least two computer readable images;

b) locating a second feature in a second of said at least two computer readable images, wherein said second feature corresponds to said first feature; and

c) using a normalized cross correlation algorithm to correlate said first computer readable image and said second computer readable image about said first and said second features, respectively.

48. The method of claim 46, wherein the step of correlating said at least two computer readable images produces a composite image of an entire side of said pre-engineered structural component.

49. The method of claim 36, wherein said at least one characteristic of said at least one support plate includes at least one of a bar code, a label, printed text, and a machine readable pattern on said at least one support plate.