Device and method for detecting the presence of abnormalities in a reel
A device for detecting the presence of abnormalities in a reel includes an image capturing module for capturing images of the reel including at least one camera, a displacer for displacing the reel in a field of view of the at least one camera, an analyzer for analyzing the images captured by the at least one camera and detecting the presence of abnormalities. The image capturing module including an upper capturer and lower capturer, the upper capturer fixed on a movable support arranged for being movable with respect to lower capturer, the upper capturer and/or the lower capturer including at least one three dimension camera arranged for providing a three dimension image of the reel.
1. A device configured to detect the presence of abnormalities on an external surface of a reel, the device comprising:
an image capturing module configured to capture images of the reel, the image capturing module comprising at least one camera;
a displacer configured to displace the reel in a field of view of the at least one camera;
an analyzer configured to analyze the images captured by the at least one camera and to detect the presence of abnormalities, wherein the abnormalities are configured to define failures on the external surface of the reel including misaligned core of the reel, reel core dimensions default, crushed reel core, reel width variation, reel diameter variation, irregular reel side, reel telescoping effect, waving of the reel, and color contamination of the reel;
wherein the image capturing module comprises an upper capturer configured to capture images of an upper face of the reel, and a lower capturer configured to capture images of the lower face of the reel, the upper capturer fixed on a movable support arranged for being vertically movable with respect to the lower capturer between a first vertical position and a second vertical position where the upper capturer is closer to the reel than when the movable support is in the first position, the upper capturer comprising at least one first camera that includes at least one three dimension (3D) camera arranged to provide a three dimension (3D) image of the reel and the lower capturer comprising at least one second camera; and
a computing arrangement configured to compute at least one parameter of the detected abnormality, including at least one dimension of the abnormality, wherein the computing arrangement is configured to determine if the reel should be rejected based upon the abnormality.
2. The device according to claim 1 , wherein the image capturing module further comprises an illuminator configured to illuminate while the image capturing module captures the images of the reel.
3. The device according to claim 1 , further comprising:
at least one actuator configured to actuate movement of the movable support.
4. The device according to claim 1 , wherein the at least one first camera comprises the at least one 3D camera and at least one 2D camera, and the at least one second camera comprises at least one 3D camera and at least one 2D camera.
5. The device according to claim 1 , further comprising:
at least one sensor module configured to activate and deactivate the image capturing module to control capture of the image depending on the position of the reel with respect to the at least one camera.
6. The device according to claim 1 , wherein the displacer includes at least a conveyor belt configured to convey the guiding of the reel through the field of view of the at least one 3D camera.
7. The device according to claim 6 , wherein the at least one conveyor belt includes a plurality of rollers, the rollers having a beveled surface arranged for contacting the reel.
8. The device according to claim 1 , further comprising:
a cleaning system configured to clean a lens of the at least one camera.
9. The device according to claim 8 , wherein the cleaning system includes a pneumatic system that includes at least one blow nozzle and at least one regulating valve configured to regulate the air flow to the at least one blow nozzle.
10. The device according to claim 1 , wherein the at least one dimension includes at least one of a width, a diameter, a height and a volume of the abnormality.
11. The device according to claim 1 , wherein the analyzer is arranged for stopping the displacer and is configured to issue an audible warning and/or sending a warning message to a user if one or more of the abnormalities are found.
12. A method for detecting one or more abnormalities on an external surface of a reel, the method comprising:
providing the device according to claim 1 ;
activating the displacer so as to place the reel between the upper capturer and the lower capturer;
actuating the movable support so as to place the reel in the field of view of the 3D camera;
capturing images of the reel; and
analyzing the captured images to detect the presence of the abnormalities.
13. The method according to claim 12 , further comprising:
providing a theoretical value of at least one parameter of the reel, wherein the at least one parameter includes width in cross-section of a diameter of the reel; and
moving the movable support depending on the theoretical value of the reel to adjust the position of the reel with respect to the 3D camera.
14. The method according to claim 13 , wherein the at least one parameter of the reel includes a width in cross-section of a diameter of the reel.
15. The method according to claim 12 , wherein the image capturing module comprises at least one 3D camera and at least one 2D camera, and wherein the method further comprises:
computing the captured 3D and the 2D images to generate a processed image; and
analyzing the processed image to detect the presence of abnormalities.
16. The device according to claim 1 , wherein the at least one first camera includes a camera positioned directly vertically above the reel and the at least one second camera includes a camera positioned directly vertically below the reel when the reel is in the field of view.