Database creation method for can body foreign object detection

Abstract

The application provides a database establishment method for detecting foreign matters in a tank body, which comprises the following steps: preparing a plurality of groups of test tank body samples; performing single sample testing on the plurality of groups of test tank body samples by using an X-ray machine to obtain a first database, wherein the single sample elimination effect testing is performed by testing a single test tank body sample by using the X-ray machine; performing continuous testing on the plurality of groups of test tank body samples by using the X-ray machine to obtain a second database, wherein the continuous elimination effect testing is performed by testing a plurality of test tank body samples continuously conveyed by using the X-ray machine; and obtaining a third database according to the data of the first database and the data of the second database. The technical scheme of the application effectively solves the problem of the large randomness of the X-ray machine in detecting foreign matters in a tank body and the problem of easy omission in the related art.

Description

[0001] Related applications

[0002] This application claims priority to Chinese patent application filed on August 18, 2022, with application number 202210994016.3, entitled "Database Establishment Method for Foreign Object Detection in Tanks", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to the field of foreign object detection technology in canned food, and more specifically, to a method for establishing a database for foreign object detection in cans. Background Technology

[0004] X-ray machines primarily utilize the penetrating power of X-rays, combining optoelectronic technology with computer and digital signal processing technologies. Through vision and pattern recognition, they differentiate, extract, and identify information from images, ultimately achieving foreign object removal. Essentially, an X-ray system is a scanning device. When a product passes through an X-ray beam at a constant speed, the signal gradually accumulates to form an image of the entire package. Once the entire image of the package is acquired, software inspection tools check for anomalies. However, this process requires the computer to test a large number of abnormal samples with standardized test materials under simulated real-world production conditions, continuously adjusting the threshold until the required accuracy is met. If the accuracy is too high, the false rejection rate will be high, affecting production efficiency; if the accuracy is too low, abnormal products will not be detected. Therefore, the detection accuracy of the equipment is crucial.

[0005] Currently, X-ray machines generally adopt a design method of inserting standardized test cards into the product for testing. However, this design method lacks standardized simulated test samples, has a high degree of randomness, and is prone to ignoring difficult-to-detect points inside the product. It cannot simulate the real production state, cannot achieve accurate effectiveness testing and equipment precision calibration, and the entire debugging cycle is very long. Summary of the Invention

[0006] The main objective of this invention is to provide a database establishment method for foreign object detection in tanks, in order to solve the problem that the randomness of foreign object detection in tanks by X-ray machines in related technologies is relatively large, and it is easy to miss detection.

[0007] To achieve the above objectives, the present invention provides a method for establishing a database for foreign object detection in tanks, comprising:

[0008] Prepare multiple sets of test tank samples;

[0009] The first database is obtained by conducting single-sample tests on multiple sets of test tank samples and X-ray machines. The single-sample test is the test of a single test tank sample using an X-ray machine.

[0010] A second database is obtained by continuously testing multiple sets of test tank samples and X-ray machines. The continuous testing involves testing multiple test tank samples that are continuously transported by X-ray machine.

[0011] The third database is derived from the data in the first database and the data in the second database.

[0012] Furthermore, the steps for preparing multiple sets of test tank samples include: dividing the area between the bottom wall and the side wall of the test tank sample into a first area, and placing foreign objects in the first area to obtain a first set of test tank samples; dividing the weld seam of the side wall of the test tank sample into a second area, and placing foreign objects in the second area to obtain a second set of test tank samples; dividing the connection between the side wall and the bottom wall of the test tank sample into a third area, and placing foreign objects in the third area to obtain a third set of test tank samples; and dividing the bottom wall of the test tank sample into a fourth area, and placing foreign objects in the fourth area to obtain a fourth set of test tank samples.

[0013] Further, the steps for obtaining the first set of test tank samples include: dividing the area between the bottom wall and the side wall of the test tank sample into a first region, and placing foreign object cards containing 316 stainless steel balls, glass foreign object cards, and rubber foreign object cards respectively within the first region to obtain the first set of test tank samples; the steps for obtaining the second set of test tank samples include: dividing the weld seam of the side wall of the test tank sample into a second region, and placing foreign object balls containing 316 stainless steel balls, glass foreign object balls, and rubber foreign object balls respectively within the second region to obtain the second set of test tank samples. The steps for obtaining the third set of test tank samples include: dividing the connection between the side wall and the bottom wall of the test tank sample into a third region, and placing the foreign object ball, glass foreign object ball, and rubber foreign object ball containing 316 stainless steel balls into the third region respectively to obtain the third set of test tank samples; the steps for obtaining the fourth set of test tank samples include: dividing the bottom wall of the test tank sample into a fourth region, and placing the foreign object ball, glass foreign object ball, and rubber foreign object ball containing 316 stainless steel balls into the fourth region respectively to obtain the fourth set of test tank samples.

[0014] Furthermore, the step of obtaining the first database by performing single-sample testing using multiple sets of test canister samples and an X-ray machine includes: testing multiple test canister samples containing foreign objects of different materials in the first set of test canister samples, and performing multiple tests on each test canister sample in the first set of test canister samples, with each test canister sample placed at a different angle during the multiple tests; testing multiple test canister samples containing foreign objects of different materials in the second set of test canister samples, and performing multiple tests on each test canister sample in the second set of test canister samples, with each test canister sample placed at a different angle during the multiple tests; and testing multiple test canister samples containing foreign objects of different materials in the third set of test canister samples, and performing multiple tests on each test canister sample in the third set of test canister samples. Each test can sample in the test can group was tested multiple times, with each sample placed at a different angle during the multiple tests. Multiple test can samples containing foreign objects of different materials in the fourth group were tested separately, and each sample in the fourth group was tested multiple times, with each sample placed at a different angle during the multiple tests. The number of tests performed on each sample in the first, second, third, and fourth groups was greater than 3.

[0015] Further, the step of continuously testing multiple sets of test canister samples and using an X-ray machine to obtain a second database includes: continuously testing multiple test canister samples containing 316 stainless steel foreign object cards in the first set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing glass foreign object cards in the first set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing rubber foreign object cards in the first set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing 316 stainless steel foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing glass foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing rubber foreign object cards in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing 316 stainless steel foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing 316 stainless steel foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing 316 stainless steel foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing glass foreign object balls in the second set of test canister samples using an X-ray machine; continuously testing multiple test canister samples containing rubber ... Multiple test canister samples containing foreign matter spheres were continuously tested using an X-ray machine. The third group of test canister samples containing 316 stainless steel foreign matter spheres, the third group of test canister samples containing glass foreign matter spheres, the third group of test canister samples containing rubber foreign matter spheres, the fourth group of test canister samples containing 316 stainless steel foreign matter spheres, the fourth group of test canister samples containing glass foreign matter spheres, and the fourth group of test canister samples containing rubber foreign matter spheres were all continuously tested using an X-ray machine. In each group of test canister samples, the X-ray machine performed more than 30 consecutive tests on foreign matter of the same material.

[0016] Furthermore, the step of continuously testing the foreign object detection device of the tank through multiple sets of test tank samples to obtain the second database includes: when continuously testing through multiple sets of test tank samples and an X-ray machine, the latter test tank sample of two adjacent test tank samples is rotated by a preset angle relative to the former test tank sample.

[0017] Furthermore, with a preset angle of 60°, the six test tank samples are combined into a test set, and the rotation angle of the first test tank sample in each test set is different.

[0018] Furthermore, the step of obtaining a first database by performing single-sample testing with multiple sets of test tank samples and an X-ray machine includes: recording image data of all rejected test tank samples using an X-ray machine, and obtaining the first database based on the image data of all rejected test tank samples; the step of obtaining a second database by performing continuous testing with multiple sets of test tank samples and an X-ray machine includes: recording image data of all rejected test tank samples using an X-ray machine, and obtaining the second database based on the image data of all rejected test tank samples.

[0019] Further, the step of obtaining a first database by performing single-sample testing using multiple sets of test canister samples and an X-ray machine includes: recording image data of all rejected test canister samples using an X-ray machine; when there are test canister samples that have not been rejected, testing the unrejected test canister samples again, and controlling the X-ray machine to record image data of the unrejected test canister samples; obtaining the first database based on the image data of all rejected test canister samples and the image data of the unrejected test canister samples; the step of obtaining a second database by performing continuous testing using multiple sets of test canister samples and an X-ray machine includes: recording image data of all rejected test canister samples using an X-ray machine; when there are test canister samples that have not been rejected, testing the unrejected test canister samples again, and controlling the X-ray machine to record image data of the unrejected test canister samples; obtaining the second database based on the image data of all rejected test canister samples and the image data of the unrejected test canister samples.

[0020] Furthermore, after obtaining the third database based on the data from the first database and the data from the second database, the method further includes: setting intervals between the test tank samples and qualified tanks, and inspecting them using an X-ray machine to verify the integrity of the third database.

[0021] By applying the technical solution of this invention, multiple sets of test tank samples are first prepared, and then single-sample tests are performed using these multiple sets of test tank samples and an X-ray machine to obtain a first database. Specifically, the multiple sets of test tank samples are each passed through an X-ray machine to enable the X-ray machine to scan the test tank samples. During single-sample testing, only one test tank sample is passed through the X-ray machine at a time. After the X-ray machine scans, another test tank sample is passed through the X-ray machine, and this process is repeated sequentially. Single-sample testing is the initial test, has lower detection difficulty, and can provide preliminary data to the X-ray machine for reference in subsequent accurate detection. After single-sample testing, continuous testing is performed. Specifically, multiple test canister samples from multiple groups of test canister samples are sequentially passed through an X-ray machine, allowing the X-ray machine to inspect the test canister samples. The X-ray machine performs detection based on the scanning of the test canister samples and obtains a second database. The second database is more comprehensive than the first database. Combining the second and first databases yields a third database. The third database improves the accuracy of subsequent X-ray machine inspections, and comparison with the first database helps avoid missed detections. Therefore, the technical solution of this application effectively solves the problem of high randomness and easy missed detections in the X-ray machine inspection of foreign objects in canisters in related technologies. Attached Figure Description

[0022] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0023] Figure 1 A flowchart illustrating the overall steps of an embodiment of the database establishment method for foreign object detection in a tank according to the present invention is shown.

[0024] Figure 2 It shows Figure 1 A detailed flowchart of steps S10 of the method for establishing a database for foreign object detection in tanks;

[0025] Figure 3 It shows Figure 1 A detailed flowchart of steps S20 of the method for establishing a database for foreign object detection in tanks;

[0026] Figure 4 It shows Figure 1 The detailed flowchart of step S30 of the method for establishing a database for foreign object detection in tanks;

[0027] Figure 5 It shows Figure 1 A schematic diagram of the three-dimensional structure of a test tank sample for establishing a database for foreign object detection in tanks;

[0028] Figure 6 It shows Figure 1 A schematic diagram of the overall structure of an X-ray machine for establishing a database for foreign object detection in tanks.

[0029] The above figures include the following reference numerals:

[0030] 10. Test tank sample; 11. First area; 12. Second area; 13. Third area; 14. Fourth area; 20. X-ray machine. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0033] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0034] like Figures 1 to 6 As shown, in this embodiment, the method for establishing a database for foreign object detection in the tank includes:

[0035] Step S10: Prepare multiple sets of test tank samples;

[0036] Step S20: Perform single-sample testing using multiple sets of test tank samples and X-ray machine 20 to obtain the first database, wherein the single-sample testing is performed by testing a single test tank sample using X-ray machine 20;

[0037] Step S30: Continuous testing is performed on multiple sets of test tank samples and X-ray machine 20 to obtain a second database. The continuous testing involves testing multiple test sample tanks that are continuously transported by X-ray machine 20.

[0038] Step S40: Obtain the third database based on the data from the first database and the data from the second database.

[0039] Applying the technical solution of this embodiment, multiple sets of test tank samples are first prepared, and then single-sample tests are performed using the multiple sets of test tank samples and the X-ray machine 20 to obtain a first database. Specifically, the multiple sets of test tank samples are passed through the X-ray machine 20 respectively, enabling the X-ray machine 20 to scan the test tank samples. During single-sample testing, only one test tank sample is passed through the X-ray machine 20 at a time. After the X-ray machine 20 scans, another test tank sample is passed through the X-ray machine 20, and this process is repeated sequentially. Single-sample testing is the initial test, has a lower detection difficulty, and can provide preliminary data to the X-ray machine 20 for reference in subsequent accurate testing. After single-sample testing, continuous testing is performed. Specifically, multiple test canister samples from multiple groups of test canister samples are sequentially passed through X-ray machine 20, allowing X-ray machine 20 to inspect the test canister samples. X-ray machine 20 performs inspection based on the scanning of the test canister samples and obtains a second database. The second database is more comprehensive than the first database. Combining the second and first databases yields a third database. The third database improves the accuracy of subsequent X-ray machine 20 inspections, and comparison with the third database helps avoid missed detections. Therefore, the technical solution of this embodiment effectively solves the problem of high randomness and easy missed detections in the detection of foreign objects in canisters by X-ray machine 20 in related technologies.

[0040] Specifically, single-sample testing is performed first, followed by continuous testing. This enables machine learning of the X-ray machine 20, meaning that the first database is obtained during continuous testing, which improves the accuracy of detection.

[0041] like Figure 6 As shown in the figure, a three-dimensional structural diagram of the test tank sample 10 and the entire test device is presented, that is, the test tank sample is referred to by the serial number 10.

[0042] like Figures 1 to 6 As shown, the X-ray machine 20 in this embodiment uses threshold image analysis and comparative image analysis. Threshold image analysis is the most basic method for determining the threshold for foreign object detection. This method records the region with the highest density in the image (the darkest pixel with the lowest gray value), mainly used to detect foreign objects with a density significantly higher than the product. It is adaptive in determining the threshold, which changes according to the product signal. The comparative image analysis method works by comparing each pixel value with its neighboring pixel values, then analyzing each pixel value and performing a truth table calculation (the "truth table" lists all possible combinations of true values). A good X-ray system will provide multiple detection programs or "tools" running simultaneously. Each program or tool will look for foreign objects of different sizes or shapes. Multiple tools help improve detection accuracy and safety levels.

[0043] like Figures 1 to 6 As shown, specifically, the detection rate = (number of rejected samples / total number of tested samples) × 100%; the false rejection rate = (number of false rejections / total number of tested samples) × 100%.

[0044] like Figures 1 to 6 As shown, in this embodiment, step S10: the step of making multiple sets of test tank samples includes: step S11: dividing the area between the bottom wall and the side wall of the test tank sample into a first area 11, and placing foreign objects in the first area 11 to obtain a first set of test tank samples; step S12: dividing the weld seam of the side wall of the test tank sample into a second area 12, and placing foreign objects in the second area 12 to obtain a second set of test tank samples; step S13: dividing the connection between the side wall and the bottom wall of the test tank sample into a third area 13, and placing foreign objects in the third area 13 to obtain a third set of test tank samples; step S14: dividing the bottom wall of the test tank sample into a fourth area 14, and placing foreign objects in the fourth area 14 to obtain a fourth set of test tank samples. Region 11 is the majority of the test tank sample, accounting for 98% of the entire sample. Region 12 is the weld area, accounting for 0.5% of the sample. Region 13 is the corner area, accounting for 0.25% of the sample. Region 14 is the bottom wall area, accounting for 1.25% of the sample. Region 12 contains welds, which can affect the accuracy of X-ray machine 20 detection; therefore, it needs to be tested separately. Region 13 tests the connection between the bottom and side walls. This connection, located at a corner, also increases testing difficulty, as it may be obstructed during X-ray machine scanning. Therefore, dividing the sample into Region 11, Region 12, Region 13, and Region 14 allows for better detection. Specific detection results are shown in Tables 1 to 3.

[0045] Table 1

[0046]

[0047] Table 2

[0048]

[0049]

[0050] Table 3

[0051]

[0052] like Figures 1 to 6As shown, in this embodiment, step S11, obtaining the first set of test tank samples, includes: dividing the area between the bottom wall and the side wall of the test tank sample into a first region 11, and placing foreign object cards containing 316 stainless steel balls, glass foreign object cards, and rubber foreign object cards respectively in the first region 11 to obtain the first set of test tank samples; step S12, obtaining the second set of test tank samples, includes: dividing the weld seam of the side wall of the test tank sample into a second region 12, and placing foreign object balls containing 316 stainless steel balls, glass foreign object balls, and rubber foreign object balls respectively in the second region 12 to obtain the second set of test tank samples. Step S13, obtaining the third set of test tank samples, includes: dividing the connection between the side wall and the bottom wall of the test tank sample into a third region 13, and placing foreign object balls containing 316 stainless steel balls, glass foreign object balls, and rubber foreign object balls respectively in the third region 13 to obtain the third set of test tank samples. Step S14: The step of obtaining the fourth set of test tank samples includes: dividing the bottom wall of the test tank sample into a fourth region 14, and placing a foreign object ball containing a 316 stainless steel ball, a glass foreign object ball, and a rubber foreign object ball in the fourth region 14 respectively to obtain the fourth set of test tank samples. In actual production processes, foreign objects may include metal, glass, or even rubber. To more realistically simulate this, the technical solution of this embodiment uses a 316 stainless steel ball foreign object ball, a glass foreign object ball, a rubber foreign object ball, a 316 stainless steel ball foreign object card, a glass foreign object card, and a rubber foreign object card. Specifically, placing the 316 stainless steel ball foreign object card, the glass foreign object card, and the rubber foreign object card in the first region 11 makes their positions more stable. Foreign object balls are used in other regions because these regions are smaller, and masking tape is used to adhere the foreign objects, which helps to stabilize their positions and enriches the sample for testing.

[0053] like Figures 1 to 6As shown, in this embodiment, in step S20: the step of obtaining the first database by performing single-sample tests on multiple sets of test tank samples and the X-ray machine 20 includes: respectively testing multiple test tank samples containing foreign objects of different materials in the first set of test tank samples, and performing multiple tests on each test tank sample in the first set of test tank samples, with different placement angles for each test tank sample in the multiple tests. Respectively testing multiple test tank samples containing foreign objects of different materials in the second set of test tank samples, and performing multiple tests on each test tank sample in the second set of test tank samples, with different placement angles for each test tank sample in the multiple tests. Respectively testing multiple test tank samples containing foreign objects of different materials in the third set of test tank samples, and performing multiple tests on each test tank sample in the third set of test tank samples, with different placement angles for each test tank sample in the multiple tests. Respectively testing multiple test tank samples containing foreign objects of different materials in the fourth set of test tank samples, and performing multiple tests on each test tank sample in the fourth set of test tank samples, with different placement angles for each test tank sample in the multiple tests. Among them, the number of tests performed on each test tank sample in the first set of test tank samples, the number of tests performed on each test tank sample in the second set of test tank samples, the number of tests performed on each test tank sample in the third set of test tank samples, and the number of tests performed on each test tank sample in the fourth set of test tank samples are all greater than 3. The above settings can better simulate real detection. Specifically, each time a test is performed, it is necessary to rotate 60° clockwise along the axial direction of the test tank sample. If all are normally removed, it is judged as qualified, otherwise it is considered that the test fails.

[0054] For the first region 11, the foreign objects are respectively arranged at the upper, middle, and lower parts of the first region 11, but it is necessary to ensure that the foreign objects are at least 1 mm below the top layer of the milk powder. For the second region 12, the foreign objects are pasted on the second region 12 through masking tape. For the third region 13, the foreign objects are pasted on the third region 13 through masking tape. For the fourth region 14, the foreign objects are pasted on the fourth region 14 through masking tape.

[0055] As Figures 1 to 6As shown, in this embodiment, step S30: continuously testing multiple sets of test canister samples and X-ray machine 20 to obtain a second database includes: continuously testing multiple test canister samples containing 316 stainless steel foreign object cards in the first set of test canister samples using X-ray machine 20; continuously testing multiple test canister samples containing glass foreign object cards in the first set of test canister samples using X-ray machine 20; continuously testing multiple test canister samples containing rubber foreign object cards in the first set of test canister samples using X-ray machine 20; continuously testing multiple test canister samples containing 316 stainless steel foreign object balls in the second set of test canister samples using X-ray machine 20; continuously testing multiple test canister samples containing glass foreign object balls in the second set of test canister samples using X-ray machine 20; and continuously testing multiple test canister samples containing rubber foreign object balls in the second set of test canister samples using X-ray machine 20. Multiple test canister samples containing 316 stainless steel foreign object balls in the third group of test canister samples were continuously tested using X-ray machine 20. Multiple test canister samples containing glass foreign object balls in the third group of test canister samples were also continuously tested using X-ray machine 20. Multiple test canister samples containing rubber foreign object balls in the third group of test canister samples were also continuously tested using X-ray machine 20. Multiple test canister samples containing 316 stainless steel foreign object balls in the fourth group of test canister samples were also continuously tested using X-ray machine 20. Multiple test canister samples containing glass foreign object balls in the fourth group of test canister samples were also continuously tested using X-ray machine 20. Multiple test canister samples containing rubber foreign object balls in the fourth group of test canister samples were also continuously tested using X-ray machine 20. In each group of test canister samples, the X-ray machine 20 performed more than 30 consecutive tests on foreign objects of the same material. This setup further enriches the second database.

[0056] For the first region 11, foreign matter balls of different materials are selected and placed in different areas of the upper, middle and lower parts of the first region 11. Each type of test is performed at least 30 times (each time rotating 60 degrees clockwise along the axis). It is necessary to ensure that the foreign matter balls are located at least 1 mm below the top layer of milk powder.

[0057] For the second region 12, select different types of target foreign object balls and use masking tape to stick them on any area of ​​the weld in the second region 12. The test process should cover the upper, middle and lower parts of the weld. Each type of test should be performed at least 30 times (each time rotating 60 degrees clockwise along the axis). It is necessary to ensure that the foreign object ball is located at least 1 mm below the top layer of the powder.

[0058] For the third region 13, select different types of target foreign objects and use masking tape to stick them to any area of ​​the corner where the ribs and bottom cover of the can are overlapped. Each type of test should be performed at least 30 times (each time rotating 60 degrees clockwise along the axis). It is necessary to ensure that the foreign object is located at least 1 mm below the top layer of milk powder.

[0059] For the fourth region 14, select different types of target foreign object balls and use masking tape to stick them to any area of ​​the bottom cover recess of the fourth region 14. Each type of test should be performed at least 30 times (each time rotating 60 degrees clockwise along the axis).

[0060] like Figures 1 to 6 As shown, in this embodiment, step S30, the step of continuously testing the foreign object detection device of the container with multiple sets of test container samples to obtain the second database, includes: when continuously testing with multiple sets of test container samples and the X-ray machine 20, the latter test container sample of two adjacent test container samples is rotated by a preset angle relative to the former test container sample. This setting places higher demands on the detection accuracy of the X-ray machine 20, thereby ensuring the accuracy of the detection.

[0061] like Figures 1 to 6 As shown, in this embodiment, the preset angle is 60°, and six test tank samples are arranged into a test set. The rotation angle of the first test tank sample in each test set is different. The above settings can simulate more realistically, thereby enriching the second database.

[0062] like Figures 1 to 6 As shown, in this embodiment, step S20, the step of obtaining a first database by performing single-sample testing using multiple sets of test tank samples and X-ray machine 20, includes: recording image data of all rejected test tank samples using X-ray machine 20, and obtaining the first database based on the image data of all rejected test tank samples. Step S30, the step of obtaining a second database by performing continuous testing using multiple sets of test tank samples and X-ray machine 20, includes: recording image data of all rejected test tank samples using X-ray machine 20, and obtaining the second database based on the image data of all rejected test tank samples. The above settings allow for a larger sample size in both the first and second databases, which not only improves the accuracy of subsequent detections but also ensures the quality and speed of the detection.

[0063] like Figures 1 to 6As shown, in this embodiment, step S20: The step of obtaining the first database by performing single-sample tests on multiple groups of test tank samples and the X-ray machine 20 includes: Step S21: The X-ray machine 20 records the image data of all the rejected test tank samples. Step S22: When there are test tank samples that have not been rejected, the non-rejected test tank samples are tested again, and the X-ray machine 20 is controlled to record the image data of the non-rejected test tank samples. Step S23: The first database is obtained based on the image data of all the rejected test tank samples and the image data of the non-rejected test tank samples. Step S30: The step of obtaining the second database by performing continuous tests on multiple groups of test tank samples and the X-ray machine 20 includes. Step S31: The X-ray machine 20 records the image data of all the rejected test tank samples. Step S32: When there are test tank samples that have not been rejected, the non-rejected test tank samples are tested again, and the X-ray machine 20 is controlled to record the image data of the non-rejected test tank samples. Step S33: The second database is obtained based on the image data of all the rejected test tank samples and the image data of the non-rejected test tank samples. The above settings can further ensure that the sample sizes of the first database and the second database are large enough.

[0064] As Figures 1 to 6 shown, in this embodiment, after step S40: The step of obtaining the third database based on the data of the first database and the data of the second database, it further includes: The test tank samples and the qualified tanks are arranged at intervals, and the X-ray machine 20 is used for detection to verify the integrity of the third database. The above settings can achieve verification, and after verification, it can be checked whether the X-ray machine 20 can perform detection quickly and accurately.

[0065] Finally, for the detection rate and the false rejection rate, use the specified standardized test samples to perform intermittent rejection tests on the samples (intermittent, that is, the abnormal cans and the normal cans are placed alternately or with one tank position interval between them, and the abnormal cans cannot be placed continuously for more than 2 cans). Each type of test is performed at least 30 times (each time it is rotated 60 degrees clockwise along the axis). If the detection rates of all types reach 100%, it is determined to be qualified, otherwise it is regarded as the test fails. The rejection test is carried out under simulated or normal production conditions, at least 10,000 times of tests (continuously). If the false rejection rate ≤ 0.05%, it is determined to be qualified, otherwise it is regarded as the test fails.

[0066] As Figures 1 to 6 shown, specifically, in this embodiment, it further includes the installation inspection of the equipment host; the steps of the installation inspection of the equipment host include:

[0067] 1. Check and confirm whether the overall appearance of the machine is flat and smooth, without burrs, sharp edges, and rust;

[0068] 2. Check and confirm whether the equipment installation location meets the requirements of the drawings and the needs of operation and maintenance. The equipment should be installed in a location where there are no obstructions on all sides, so as to:

[0069] Cleaning: air conditioning filters, conveyor belts, conveyor devices, rejection receivers, and the floor around the machines;

[0070] Maintenance: Electrical cabinets, pneumatic controllers, and conveyor systems;

[0071] Operation: Ensure the touchscreen interface is secure, the receiver is removed, general entrances and exits are open, and there is sufficient cooling space;

[0072] 3. Ensure that the X-ray machine 20 is installed in or around an area that will not be affected by vibration and mechanical impact. Securely fix the machine's support to the workshop floor, level the entire machine, and do not use casters or wheels.

[0073] 4. Avoid electromagnetic interference. Radiated electrical noise from surrounding electrical installations may adversely affect system performance and may even cause malfunctions such as incorrect rejection. The frequency converter (VFD) located near the X-ray machine 20 should be installed according to the supplier's instructions. Anti-static conveyor belts should be used whenever possible. Cables and speed drives on the inverter should be shielded and should not be located near detector assembly groups or detector cables.

[0074] 5. Clean power supply must be used. Significant changes in the load of the power grid supplying the system can generate cable noise. Therefore, standard practice is to install current suppressors / filters on the production line to clean the power supply. This is especially important for X-ray machines 20 that use encoder or tachometer motor signals.

[0075] 6. The conveyor belt should be kept horizontal, and the horizontal deviation should be ≤2.0mm. Unevenness of the conveyor chain and non-horizontal alignment with the bottom of the tank will cause accidental kicking.

[0076] 7. Check and confirm that all assembly components are securely connected;

[0077] 8. Check and confirm that all electrical connections of the equipment are sealed and externally insulated;

[0078] 9. Check and confirm that the Ethernet cable, remote debugging network card, testing software, remote support software, etc. have been installed.

[0079] 10. Check and confirm that the compressed air pressure of the non-conforming product rejection system is within the normal range of 4-6 bar;

[0080] The purpose of equipment operation status testing is to prove that the equipment, system, and their various technical parameters meet the design and production process requirements, and whether the operating effect meets the design requirements. Simultaneously, a comprehensive inspection of each trial standard operating procedure is conducted, and any deficiencies should be supplemented and modified accordingly. The operation of each component of the equipment and the monitoring of various technical parameters are determined through visual inspection or the application of appropriate equipment and tools to assess whether the equipment meets the design requirements.

[0081] like Figures 1 to 6 As shown, specifically in this embodiment, the X-ray machine 20 consists of three main components: an X-ray generator, a detector, and a control system. In X-ray systems used in the food and pharmaceutical industries, X-rays pass in a funnel shape through a collimator, a mechanical device used to narrow the X-ray beam. The collimator is positioned at the window of the X-ray generator. Only X-rays emitted in a specific direction can pass through the collimator. The collimator is integrated into the X-ray system because it is impossible to focus such short-wavelength radiation using lenses. Since the X-ray generator is typically mounted on top of the cabinet, the X-ray beam passes downwards through the product to be inspected and the conveyor belt carrying the product, aided by the collimator. The X-ray beam then strikes the detector downwards. The beam, propagating along the conveyor direction, is approximately 2 mm wide and triangular in shape. Starting from a small point in the X-ray source, the beam diverges outwards through the collimator to the widest point of the conveyor belt across the surface of the conveyor belt and below the detector. The X-ray detection surface is made of a scintillating material that converts X-rays into visible light. The scintillating surface is located below a small window on the top surface of the X-ray chamber. The window and the scintillating material extend to the width of the conveyor belt. The more X-rays that enter a scintillator, the brighter the emitted light. This is because the output of the scintillator is proportional to the amount of radiation entering. Below the scintillator strip is a row of photodiodes. These diodes are very sensitive to light, meaning that as light increases, the diode resistance decreases, and as light decreases, the resistance increases. A common commercial application of photodiodes is the automatic activation of streetlights and garden lights at dusk.

[0082] A diode is defined as a two-electrode electronic component that presents low resistance to current flowing in one direction and high resistance to current flowing in the opposite direction. Its most common function is to allow current to flow in one direction while blocking current flowing in the opposite direction.

[0083] A conventional X-ray system is equipped with a detector consisting of multiple independent diodes that convert the detected X-ray energy into an electrical signal. The system's electronics scan this signal and then sequentially transmit a "row" of data representing each diode to the built-in control system.

[0084] The diodes are identically adjusted or configured to operate in the same manner, forming an array in the detector. Various diode spacings are available; standard spacings are 0.4 mm, 0.8 mm, and 1.5 mm.

[0085] The control system uses diodes optically coupled to the scintillator to convert visible light levels into electrical signals, which are then transmitted back to the device's built-in control system. The control system then edits the inspected product into a "grayscale" X-ray image (i.e., a monochrome image displayed in gray, black, and white shades), which is then analyzed by the control system software. The software accepts or rejects the image (and the product packaging it represents) based on pre-set acceptance criteria. For rejected X-ray images, a signal is sent to the automatic rejection system, and the defective packaging is removed from the production line.

[0086] The X-ray energy absorbed when an X-ray beam passes through a product is determined by the product's thickness, density, and atomic mass number. Absorption is a linear attenuation coefficient. When packaging or a product passes through an X-ray beam, the beam is absorbed by the packaging or product, and only residual energy reaches the detector. Measuring the difference in X-ray absorption between a product and a foreign object is the basis of X-ray detection.

[0087] Generally, the compounds contained in food are composed of elements with an atomic mass of 16 or less – primarily H (hydrogen), C (carbon), and O (oxygen). The amount of X-rays absorbed by food containing low-mass elements is directly proportional to its density and thickness. In other words, the thicker or denser the product, the more X-rays it absorbs. If a potential foreign object has a high atomic mass (a characteristic usually related to the density of the foreign object), it can be detected by an X-ray system. Some foreign objects (such as stones or glass) may contain trace amounts of elements with very high atomic numbers. These elements have a multiplicative effect on the amount of X-rays absorbed by the foreign object.

[0088] Furthermore, the proximity of the foreign object to the X-ray source or the detector affects the detection accuracy. When the foreign object is closer to the source, the effective area projected by the detector (the X-ray shadow) is magnified. However, this magnification also means the image of the foreign object will be slightly blurred due to reduced edge sharpness. When the foreign object (or test card) is closer to the detector, the image is clearer, making it easier to detect using comparative image analysis tools. The location of the foreign object is relative to deeper packaging, but its impact also depends on the size of the detector diodes and the comparative image analysis method used. Defining an optimal test location for all applications is difficult because many variables (product, packaging, and inspection machine) affect the final result. Since food generally contains elements with low atomic mass and low density, while foreign objects contain elements with high atomic mass and high density, density is a convenient benchmark for foreign object detection. In short, foreign objects can only be detected if they have a greater density (i.e., a higher specific gravity) than the product they are incorporated into. Essentially, an X-ray system is a scanning device. The system captures an image of the entire package as the product passes through the X-ray beam at a constant speed. To ensure the correct aspect ratio (i.e., the correct image scale), the X-ray system automatically correlates the detector scanning speed with the product conveyor speed. If the product speed changes, an external encoder input must be specified to synchronize the detector scanning speed with the conveyor belt speed. Using 0.8 mm detector diodes, a new line of image data is acquired every 0.8 mm of product movement along the direction of travel. Once the data is compressed and corrected, all pixel values ​​are within the range of 0 (black) to 255 (white). Typically, the product is represented using grayscale values ​​in the range of 50 to 200. These lines are gradually accumulated to form the complete image of the package. Once the complete image of the package is acquired, the software inspection tool checks for anomalies. Generally, a specific number and characteristics of products should be used to perform the learning process to "teach" the software what to look for. Once acceptable samples have passed through the system, the software sets all inspection algorithms for these acceptance criteria, along with a built-in offset to account for the sample group.

[0089] like Figures 1 to 6 As shown, the technical solution of this embodiment establishes a complete set of methods for manufacturing standard test sample cans, which can completely simulate the product characteristics under real production conditions and is widely applicable to different cans. Complete standardized testing methods are established for different test samples. The combination of standard test samples and standardized testing methods can quickly complete the effectiveness verification and accuracy calibration of the equipment, enhancing timeliness, greatly optimizing the equipment's detection accuracy, improving the detection rate, and reducing the false rejection rate.

[0090] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0091] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0092] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0093] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for establishing a database for foreign object detection in tanks, characterized in that, include: Prepare multiple sets of test tank samples; The first database is obtained by performing single-sample testing on the multiple sets of test tank samples and the X-ray machine (20), wherein the single-sample testing is to test a single test tank sample by the X-ray machine (20); A second database is obtained by continuously testing the multiple sets of test tank samples and the X-ray machine (20), wherein the continuous testing is to test the multiple test tank samples that are continuously transported by the X-ray machine (20); A third database is obtained based on the data from the first database and the data from the second database; The steps for preparing multiple sets of test tank samples include: The area between the bottom wall and the side wall of the test tank sample is divided into a first region (11), and foreign objects are placed in the first region (11) to obtain a first set of test tank samples. The weld seam on the side wall of the test tank sample is divided into a second region (12), and foreign objects are placed in the second region (12) to obtain a second set of test tank samples. The connection between the side wall and the bottom wall of the test tank sample is divided into a third region (13), and foreign objects are placed in the third region (13) to obtain a third set of test tank samples. The bottom wall of the test tank sample is divided into a fourth region (14), and foreign objects are placed in the fourth region (14) to obtain a fourth set of test tank samples. After the step of obtaining the third database based on the data from the first database and the data from the second database, the following is also included: The test tank sample and the qualified tank are set at intervals and inspected by the X-ray machine (20) to verify the integrity of the third database; The steps of continuously testing the multiple sets of test tank samples and the X-ray machine (20) to obtain a second database include: When the multiple test tank samples and the X-ray machine (20) are continuously tested, the latter test tank sample of two adjacent test tank samples is rotated by a preset angle relative to the former test tank sample.

2. The method for establishing a database for foreign object detection in tanks according to claim 1, characterized in that, The steps to obtain the first set of test tank samples include: The area between the bottom wall and the side wall of the test tank sample is divided into a first area (11). The foreign object cards containing 316 stainless steel balls, glass and rubber are placed in the first area (11) to obtain the first set of test tank samples. The steps to obtain the second set of test tank samples include: The weld seam on the side wall of the test tank sample is divided into a second region (12). Foreign objects containing 316 stainless steel balls, glass foreign objects, and rubber foreign objects are placed in the second region (12) to obtain a second set of test tank samples. The steps to obtain the third set of test tank samples include: The connection between the side wall and the bottom wall of the test tank sample is divided into a third region (13). Foreign objects containing 316 stainless steel balls, glass foreign objects, and rubber foreign objects are placed in the third region (13) to obtain a third set of test tank samples. The steps to obtain the fourth set of test tank samples include: The bottom wall of the test tank sample is divided into a fourth region (14). Foreign objects containing 316 stainless steel balls, glass foreign objects, and rubber foreign objects are placed in the fourth region (14) to obtain the fourth set of test tank samples.

3. The method for establishing a database for foreign object detection in tanks according to claim 2, characterized in that, The steps of obtaining the first database by performing single-sample testing using the multiple sets of test tank samples and the X-ray machine (20) include: The first group of test tank samples containing foreign objects of different materials were tested separately, and each of the test tank samples in the first group of test tank samples was tested multiple times, with each test tank sample placed at a different angle in the multiple tests. The second group of test tank samples containing foreign objects of different materials were tested separately, and each of the test tank samples in the second group of test tank samples was tested multiple times, with each test tank sample placed at a different angle in the multiple tests. The third group of test tank samples containing foreign objects of different materials were tested separately, and each test tank sample in the third group of test tank samples was tested multiple times, with each test tank sample placed at a different angle in the multiple tests. The fourth group of test tank samples containing foreign objects of different materials were tested separately, and each test tank sample in the fourth group of test tank samples was tested multiple times, with each test tank sample placed at a different angle in the multiple tests. The number of times each test tank sample in the first group of test tank samples, the number of times each test tank sample in the second group of test tank samples, the number of times each test tank sample in the third group of test tank samples, and the number of times each test tank sample in the fourth group of test tank samples are tested are all greater than 3.

4. The method for establishing a database for foreign object detection in tanks according to claim 2, characterized in that, The steps of obtaining a second database by continuously testing the multiple sets of test tank samples and the X-ray machine (20) include: The X-ray machine (20) continuously tests multiple test tank samples containing 316 stainless steel foreign object cards in the first group of test tank samples. The X-ray machine (20) is used to continuously test multiple test tank samples containing glass foreign object cards in the first group of test tank samples; The X-ray machine (20) is used to continuously test multiple test tank samples containing rubber foreign object cards in the first group of test tank samples; The X-ray machine (20) was used to continuously test multiple test tank samples containing 316 stainless steel foreign object balls in the second group of test tank samples. The X-ray machine (20) is used to continuously test multiple test tank samples containing glass foreign matter spheres in the second group of test tank samples; The X-ray machine (20) is used to continuously test multiple test tank samples containing rubber foreign matter balls in the second group of test tank samples; The X-ray machine (20) was used to continuously test multiple test tank samples containing 316 stainless steel foreign object balls in the third group of test tank samples. The X-ray machine (20) is used to continuously test multiple test tank samples containing glass foreign matter spheres in the third group of test tank samples; The X-ray machine (20) is used to continuously test multiple test tank samples containing rubber foreign matter balls in the third group of test tank samples; The X-ray machine (20) was used to continuously test multiple test tank samples containing 316 stainless steel foreign object balls in the fourth group of test tank samples. The X-ray machine (20) is used to continuously test multiple test tank samples containing glass foreign matter spheres in the fourth group of test tank samples. The X-ray machine (20) is used to continuously test multiple test tank samples containing rubber foreign matter balls in the fourth group of test tank samples; The X-ray machine (20) performs more than 30 consecutive tests on foreign objects of the same material in each test tank sample.

5. The method for establishing a database for foreign object detection in tanks according to claim 1, characterized in that, The preset angle is 60°, and the six test tank samples are formed into a test set, with the first test tank sample in each test set having a different rotation angle.

6. The method for establishing a database for foreign object detection in tanks according to claim 1, characterized in that, The steps of obtaining the first database by performing single-sample testing using the multiple sets of test tank samples and the X-ray machine (20) include: The X-ray machine (20) records the image data of all rejected test tank samples, and the first database is obtained based on the image data of all rejected test tank samples. If a test tank is rejected normally, it is determined to be qualified. The steps of obtaining a second database by continuously testing the multiple sets of test tank samples and the X-ray machine (20) include: The X-ray machine (20) records image data of all rejected test tank samples, and the second database is obtained based on the image data of all rejected test tank samples.

7. The method for establishing a database for foreign object detection in tanks according to claim 6, characterized in that, The steps of obtaining the first database by performing single-sample testing using the multiple sets of test tank samples and the X-ray machine (20) include: The X-ray machine (20) records image data of all rejected test tank samples; When there are test tank samples that are not rejected, the test tank samples that are not rejected are tested again, and the X-ray machine (20) is controlled to record the image data of the test tank samples that are not rejected. The first database is obtained based on the image data of all rejected test tank samples and the image data of the test tank samples that were not rejected; The steps of obtaining a second database by continuously testing the multiple sets of test tank samples and the X-ray machine (20) include: The X-ray machine (20) records image data of all rejected test tank samples; When there are test tank samples that are not rejected, the test tank samples that are not rejected are tested again, and the X-ray machine (20) is controlled to record the image data of the test tank samples that are not rejected. The second database is obtained based on the image data of all rejected test tank samples and the image data of the test tank samples that were not rejected.

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