The rebar counting machine has two basic functions: automatic rebar counting and separation, which will greatly improve the efficiency of the bar mill and relieve workers from this simple but hard work. This system uses machine vision technology for target recognition, target tracking, and automatic positioning, with high accuracy and stable states, and is an essential equipment for rebar production nowadays. DBM rebar counting machine has the following advantages:
1) The counting error is less than 2/10000.
2) The system could work 24 hours/day continuously, Increasing productivity.
3) The system could control the number/weight of every bundle, and decrease the production cost.
4) The system’s cost is very low, and the spare parts are also inexpensive.
5) It will achieve full automation, and enhance the plant’s image.
6) Fast installation and easy operation: It only needs 15 days to install and commission and 5 days to teach your worker how to operate.
7) The rebar counting machine could be installed on the stop time of the steel mill, not influencing the production.
8) One-year free warranty period, life-long free update of the system.
Adopting computer automatic counting technology, increases the speed and precision rate (error rate less that 0.02%) of steel bar counting.
Only need six months to recover the cost.
Improves the production efficiency greatly, and brings significant economic and social benefits to the user.
Reduces the worker's labor intensity.
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“Online automatic counting system” is an automatic bar counting device that uses machine vision for target recognition, target tracking, and automatic positioning technology. The system collects the image of the bar moving on the chain bed and transmits it to the host computer. After image recognition and target tracking, the real-time counting function of the bar production process is realized; when the count value of each bundle reaches the set value, the chain bed is controlled to stop, indicate the position of automatic steel splitting, guide or control the start and stop of the steel moving machine, and can be used to display the steel splitting position in real time to guide the steel splitting. The system enters the next working cycle.
The “Automatic Steel Bar Splitting System” is an automatic steel bar separation device that performs target recognition, target tracking, and automatic separation technology on the basis of accurate counting. When the count value of each bundle reaches the set value, the chain bed will be controlled to stop and indicate the position of automatic steel splitting. The system will decide the steel splitting action according to the feedback bar distribution information of the visual inspection module and select the appropriate steel splitting action.
The steel dividing control module controls the mechanical action of steel dividing to complete the automatic steel dividing work, and the system enters the next working cycle.
1) The automatic counting system collects the end-face images of moving bars from the side of the transfer chain, and realizes real-time counting after image detection, image recognition, and target tracking. When the bundle count value reaches the set value, it controls the start and stop of the transfer chain.
2) The automatic steel separation system will automatically stop the current transfer chain when the rated count of each bundle is full. The control module controls the mechanical action of steel splitting. In the process of steel separation, the visual feedback module tracks the movement of the bar in real-time, adjusts the steel separation strategy according to the change of the bar, accurately controls the separation of the bar at one end, and realizes the automation of counting and steel separation.
Specifications for bars above Φ12 (inclusive), the counting error is less than or equal to ±0.08‰.
For rebars stacked no more than 2 layers, the average separation time of the ends is ≤5s;
For rebars stacked more than 2 layers, the system has error correction function;
When the interleaving and stacking cannot be separated seriously, the system prompts an alarm for manual intervention.
The system automatically gives the steel line and prompts the position of the steel; arbitrarily set the count of each bundle, and support the measurement and packaging of the rated count.
1) Main control cabinet
2) Composite special lights
3) Special camera platform
4) Machine separation device.
1) Video signal capture
2) Video image information processing
3) Target tracking and counting
4) Determination of steel-splitting position
5) Mechanical steel-splitting, etc.
The rebar counting machine system consists of electrical main control cabinet, on-site operation box, far-infrared polarized noise and shadow light source, camera module, end extension, middle extension, etc. and completes video image acquisition, video image information processing, target tracking, counting, steel sorting, etc. The main function.
The state of the moving bar is dynamically monitored by using the graphics processor and machine vision technology with the visual signal image processor as the core of the image information processing, and the online counting of the bar and the action of steel separation are realized. Video image processing and target tracking are the core parts of the system, which are responsible for real-time processing of on-site video image information. Among them, the work of bar motion tracking detection, background separation, target position determination, target tracking and fault-tolerant counting, and dividing steel line calibration is completed by the computer software system.
The system utilizes international advanced machine vision technology to detect bar ends via high-speed image processing.
It performs real-time identification, marking, and tracking of each bar to eliminate human error.
For bars with a diameter of Φ12 or larger, the counting error is strictly ≤±0.08‰.
The system can even handle stacked bars; if bars are stacked up to 2 layers, it maintains high-speed precision, and for layers exceeding this, it utilizes an integrated error correction function.
When the count reaches the pre-set bundle value, the system automatically controls the start and stop of the transfer chain.
In cases of severe intertwining where the system cannot safely separate the bars, it triggers an alarm for manual intervention to ensure batch integrity.
The automatic bar separation system is designed for high-speed operation, with an average separation time of ≤5s for bars stacked up to 2 layers.
It uses a CANopen bus communication protocol to control high-precision servos for single-end or fully automatic separation.
The system dynamically adjusts its separation strategy based on real-time visual feedback, ensuring the flow remains synchronized with the rolling mill’s pace.
The hardware includes a specialized far-infrared polarized noise-reducing light source to ensure clear imaging regardless of ambient light interference.
The system components, including the end separator and middle separator, are industrial-grade and designed to operate reliably alongside the chain bed.
To maintain peak performance, the only major requirement is ensuring the camera lenses remain clean, and the counting area is not physically obstructed.
To maximize the system’s machine vision capabilities, bar ends should be aligned within a range of ±100mm.
Bar end curvature should not exceed 1x the diameter within the first 100mm of the bar.
The bars should be positioned at a right angle to the chain, with a tilt of no more than 10°.
Both starting and stopping of the transport mechanism should be smooth, with “drift” or “surge” kept under 50mm.