BT Master SC: Testing and sorting concrete blocks

The BT Master SC is the further development of the successful BT-Master stone and coarse ceramic inspection system that has been tested in some of the most advanced brick and concrete plants in Europe. The system consists of a scanner unit, an evaluation unit and a sorting unit. The scanner unit is placed above the existing conveyor system. Accordingly, no complex conversion work is required. The scanner is fitted with all necessary cameras, lighting systems and, depending on the design, with other components as well.

The BT Master SC scans ongoing production and, in the process, produces a 2D color image and a 3D vertical profile of all blocks on the board and determines their quality and length. For applications in the wet area, weighing cells can also be installed to determine density.

Quality can be determined for various error criteria:

Voids,

Cracks,

Broken edges,

Color deviations,

Protrusions,

Texture deviations,

Soiling and 

Other anomalies.

The evaluation unit is integrated into a dust-protected and climate-controlled PC cabinet. Due to the modular design and the use of up-to-date camera and AI-supported software, for example, spalling or cracks can also be detected in embossed surfaces.

Module I:   2D camera for optical inspection of the surface and color measurement;

Module II: 3D module for monitoring geometric requirements;

Module III: Sorting by a 5-axis robot;

Module IV: Weighing module (optional).

Image processing and robot systems from a single source

Module I

Module I consists of a proven AI surface test procedure performed with one or several BW or color-line cameras. The surface is scanned in passing or with a processing  scanner and is compared with matching reference samples.

Module II

The 3D measuring module consists of a high-resolution 3D camera and a high-performance laser that create a 3D image of the products by laser cutting. The image  serves to check dimensional accuracy and angularity. Here, the length, width and height as well as the spatial angle are measured. In this way, the system detects various block heights. The measurement of lengths, width and angles is measured with a precision of 0.1 mm and/or 0.5°.

Module III

The data determined by Modules I and II are passed by PLC to the optional robot system that controls the 5-axle sorting robot. The non-conforming blocks are recorded, removed and replaced by blocks from ongoing production.

The robot is fitted with a vacuum gripper that contains a vacuum matrix for blocks of various formats.  Small concrete crumbs are vacuumed off by the gripper to ensure a stable vacuum.

Module IV

Module IV, moreover, can determine the weight of the entire board, with calculation of the density.