Software and methods for automated pallet inspection and repair

A capture and analysis computer device for a pallet comprising a top deck and a bottom deck, with the top deck including top boards supported by bearer boards, the capture and analysis computer device comprising:

• at least one processor configured to perform the following:
• collect from a plurality of lasers three-dimensional data associated with geometry and topography of the pallet, with the data having x-, y- and z-coordinates;
• convert the collected data into a two-dimensional representation of the pallet by
• determining locations and heights of the bearer boards,
• establishing at least one filter plane offset from a surface of the top boards, with the at least one fitter plane corresponding to a threshold,
• comparing the collected data to the at least one filter plane, with the collected data above the at least one filter plane being identified as top boards and the collected data below the at least one filter plane being identified as bearer boards, and
• discarding the collected data having z-coordinates below the threshold so as to discard analysis of the bearer boards;
• identifying elements of the pallet by analyzing the two-dimensional representation;
• determining a pallet design based on size, number, and location of the elements;
• comparing the elements of the pallet against criteria selected from a database of pallet designs;
• and
• creating a repair recipe if the pallet fails the criteria.