Systems and methods for counting and processing pliable objects

A method of processing pliable objects comprising:

• populating a package with a plurality of pliable objects according to a desired number of pliable objects, wherein each of the pliable objects of the plurality of pliable objects has a thickness and a length;
• passing the package under a camera such that the plurality of pliable objects are within a field of view of the camera;
• illuminating the package and the plurality of pliable objects;
• capturing an inspection image of the plurality of pliable objects using the camera, wherein:
• the inspection image is a top view of the plurality of pliable objects;
• a non-uniform gap is present between adjacent pliable objects of the plurality of pliable objects;
• and
• each non-uniform gap is substantially represented by a first luminance value range and each pliable object is substantially represented by a second luminance value range in the inspection image;
• partitioning, by a processor, the inspection image into a plurality of windows traversing the inspection image;
• preparing the inspection image for image analysis by setting a background luminance value of the inspection image to within the second luminance value range that substantially represents the pliable objects;
• for each individual window of the plurality of windows, performing a blob extraction process to determine a plurality of blobs corresponding to regions within the inspection image having substantially the second luminance value range such that the plurality of blobs correspond to the plurality of pliable objects;
• counting a number of blobs within each window of the plurality of windows;
• and
• determining a number of windows of the plurality of windows having a number of blobs that is equal to a target count;
• and
• accepting the plurality of pliable objects when the number of windows is equal to or greater than a threshold value.

A system for counting pliable objects comprising:

• a camera;
• a light source for illuminating the plurality of pliable objects;
• a controller comprising a processor and a non-transitory memory device communicatively coupled to the processor, the non-transitory memory device storing machine-executable instructions that, when executed by the processor, causes the controller to:
• provide an image capture signal to the camera that causes the camera to capture an inspection image of a top view of the plurality of pliable objects, wherein a non-uniform gap is present between adjacent pliable objects of the plurality of pliable objects, and each non-uniform gap is substantially represented by a first luminance value range and each pliable object is substantially represented by a second luminance value range in the inspection image;
• partition the inspection image into a plurality of windows traversing the inspection image;
• set a background luminance value of the inspection image to within the second luminance value range that substantially represents the pliable objects;
• for each individual window of the plurality of windows, perform a blob extraction process to determine a plurality of blobs corresponding to regions within the inspection image having substantially the second luminance value range such that the plurality of blobs correspond to the plurality of pliable objects;
• count a number of blobs within each widow of the plurality of windows;
• and
• provide a signal rejecting or accepting the plurality of pliable objects based at least in part on the number of blobs that are counted in one or more windows.