X-ray inspection equipment

Abstract

The present invention provides an X-ray inspection device that allows for easy, rapid, and accurate setting and adjustment of the sorting operation timing without the need to use defective product samples or simulated defective products for each inspection item. [Solution] An X-ray inspection apparatus comprising an image processing unit 33 that performs predetermined image processing on an X-ray inspection image Dpx of an item P and outputs quality judgment data, a judgment unit 35 that makes a good or bad judgment based on the judgment data, and a sorting unit 70 that sorts the item P in a sorting direction according to the judgment result, further comprising a sorting information setting unit 47 that sets the sorting direction according to the judgment result, a sorting operation control unit 45 that, when operated using a sorting confirmation sample, causes the sorting unit 70 to perform a sorting operation based on the judgment result of the judgment unit 35 at a predetermined sorting timing, and a sorting confirmation image generation unit 40 that generates a pseudo-NG image Dps for sorting confirmation so that the judgment result of the judgment unit 35 based on the judgment data is to be sorted in the sorting direction set by the sorting information setting unit 47.

Description

Technical Field

[0001] The present invention relates to an X-ray inspection apparatus, and more particularly to an X-ray inspection apparatus including an inspection unit that performs X-ray inspection by processing an X-ray image of an article obtained by X-ray imaging, and a sorting unit that executes a sorting operation in a sorting direction according to the inspection result.

Background Art

[0002] Conventionally, an inspection unit that inspects the presence or absence of foreign matters, missing parts, shape defects, biting of a packaging seal part, etc. in a conveyed article based on an X-ray image of the article, and a sorting unit that sorts inspected articles in a sorting direction according to the inspection result on the downstream side in the conveyance direction of the inspection unit are provided. An X-ray inspection apparatus is widely used.

[0003] In such an X-ray inspection apparatus, usually, in consideration of the conveyance speed and sorting ability of the sorting unit, the conveyance speed of the article is set so that stable inspection and sorting are performed. For example, the sorting delay time obtained by adding up the time required for inspection in the inspection unit and the time from the output of the inspection measurement result to the start of the sorting operation is used to set the waiting time from the detection of the entry of each article to the start of sorting, and the sorting operation is executed after waiting for the elapse of that time.

[0004] As this type of conventional X-ray inspection apparatus, for example, when all NGs (defects) are counted when the same article is judged as NG in a plurality of inspection items, the number of NG products obtained by subtracting the number of non-defective products from the total number of inspected articles does not match the total NG count number, and the inspection result display becomes difficult to understand. In order to solve this problem, there is one that integrates the number of sorting times of articles for each sorting direction so that the number of articles for each sorting direction can be accurately grasped (for example, see Patent Document 1).

[0005] Furthermore, other conventional X-ray inspection devices are known that, for example, use the results of a defect determination based on whether the weight of the conveyed items is excessive or insufficient, and the detection output of a sensor that detects whether the items sorted and excluded according to the defect determination have passed through a predetermined exclusion path corresponding to the type of defect, to confirm whether the defective items have passed through a predetermined exclusion path during the exclusion drive period of the sorting machine for the defective items, or during a predetermined period synchronized with the exclusion drive period (see, for example, Patent Document 2). [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2011-206710 [Patent Document 2] Japanese Patent Application Publication No. 05-322634 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] However, with the conventional X-ray inspection equipment described above, the time required for image processing and judgment processing for item inspection varied greatly depending on the required item transport speed and differences in item types. In addition, the time required for item detection and operation verification during sorting and its control could also vary significantly. As a result, there was a problem in that setting and adjusting the timing of the sorting operation took a considerable amount of time.

[0008] In other words, if the sorting delay time from the detection of incoming inspection items to the start of sorting, and the sorting operation time required for the sorting operation after that delay time, are fixed to predetermined times, it may not be possible to complete accurate image processing and judgment processing for all inspection items within those set times, resulting in judgment errors. Therefore, in order to avoid such judgment errors, when the operating conditions were changed according to the items to be inspected and the inspection items, it was necessary to prepare defective product samples or simulated defective products for each inspection item, and then feed them into the production line incorporating the X-ray inspection device to adjust the sorting delay time and sorting operation time to a suitable level each time.

[0009] Moreover, such adjustment work requires understanding the sorting timing according to the shape of the items, especially the length and speed in the transport direction, and setting the necessary sorting operation time for each sorting direction. Furthermore, since the operation timing differs depending on the type of sorting mechanism used, it is necessary to verify the operation for each type of item under conditions equivalent to inspection, by actually transporting samples of defective products or simulated defective products, which made the adjustment work time-consuming.

[0010] Furthermore, when there are few inspection items, the sorting operation can be started earlier, allowing for a longer sorting period. However, when there are many inspection items, the image processing time for the X-ray images of the items increases as the number of inspection items increases. This necessitates a very strict setting with no margin for error in the sorting delay time that defines the start timing of the sorting operation and the sorting operation time required for the subsequent sorting operation. As a result, it takes time to set and adjust the timing to ensure that the sorting operation is executed reliably.

[0011] The present invention aims to solve the conventional problems described above and to provide an X-ray inspection device that can easily, quickly, and accurately set and adjust the timing of sorting operations without using defective product samples or simulated defective products for each inspection item. [Means for solving the problem]

[0012] The X-ray inspection apparatus according to the present invention, in order to achieve the above objective, is characterized by comprising: (1) an image processing unit that performs predetermined image processing on an X-ray inspection image obtained by an operation that irradiates an article being transported with X-rays and detects the X-rays that have passed through the article with an X-ray detector and outputs determination data indicating the quality state of the article; (2) a determination unit that determines whether the article is good or bad based on the determination data; and (3) a sorting unit that sorts the article in a sorting direction according to the determination result of the determination unit, wherein the X-ray inspection apparatus further comprises: a sorting information setting unit that sets the sorting direction according to the determination result; (4) a sorting operation control unit that, when the operation is performed using a sorting confirmation sample as the article, performs a sorting operation on the sorting confirmation sample at a predetermined sorting timing based on the determination result of the determination unit; and (5) a sorting confirmation image generation unit that, when predetermined image processing is performed on a sample inspection image based on an X-ray inspection image of the sorting confirmation sample, generates a pseudo-image for sorting confirmation to make the determination result of the determination unit based on the determination data a target for sorting in the sorting direction set by the sorting information setting unit.

[0013] With this configuration, in the present invention, when judgment data for the judgment unit is obtained from the X-ray inspection image of a sample for sorting and confirming good products through predetermined image processing in the image processing unit, a pseudo-image for sorting and confirming is generated as a sample inspection image so that the judgment result in the judgment unit based on that judgment data is judged as defective in the sorting direction set in the sorting information setting unit. Therefore, regardless of the number of sorting directions set in the sorting information setting unit, there is no need to prepare defective product samples or pseudo-NG products for each inspection item, and the timing of the sorting operation can be easily, quickly, and accurately set for the sorting direction for each inspection item.

[0014] In a preferred embodiment of the present invention, (2) the sorting confirmation image generation unit may be configured to include an NG image storage unit that stores images of predetermined defective parts that are determined to be sorted in the sorting direction, and an NG image generation unit that generates a pseudo-sorting confirmation image by adding the images of predetermined defective parts stored in the NG image storage unit to the X-ray inspection image of the sorting confirmation sample of the good product image.

[0015] In this way, by simply feeding in good samples in the same way as during normal inspection operation, a pseudo-image for sorting confirmation is generated for each inspection item, indicating that the judgment result from the judgment unit will be used to sort the items in the pre-set sorting direction. This makes it possible to easily, quickly, and accurately set the timing of the sorting operation.

[0016] In a preferred embodiment of the present invention, (3) in addition to setting the sorting direction, the sorting information setting unit can also set the sorting timing, and the sorting operation control unit can be configured to perform sorting operations based on the sorting timing set in the sorting information setting unit.

[0017] In this case, a sorting timing corresponding to the sorting direction can be set, allowing for more accurate sorting operations based on that timing.

[0018] In a preferred embodiment of the present invention, (4) the sorting unit provides a product recognition means (such as a light emitter) for recognizing an article when the article has been sorted in a predetermined sorting direction, and the sorting operation control unit causes the sorting unit to perform a sorting operation at a provisional sorting timing based on the transport speed when the article was transported, and when the product recognition means recognizes that the sorting has been performed correctly in the predetermined sorting direction, the sorting information setting unit is configured to set the provisional sorting timing as the sorting timing.

[0019] In this case, when the product recognition means recognizes that the articles sorted in a predetermined sorting direction have been correctly sorted in that sorting direction, a provisional sorting timing based on the article conveyance speed is set as the sorting timing, so that a more reliable operation check can be performed.

Advantages of the Invention

[0020] According to the present invention, it is possible to provide an X-ray inspection apparatus that can easily, quickly, and accurately set and adjust the timing of the sorting operation without using defective product samples or pseudo-NG products for each inspection item.

Brief Description of the Drawings

[0021] [Figure 1] It is a schematic configuration diagram of an X-ray inspection apparatus according to an embodiment of the present invention. [Figure 2] (a) is a schematic plan view showing the arrangement of a plurality of types of sensors in an X-ray inspection apparatus according to an embodiment of the present invention, and (b) is a schematic configuration diagram of a drive control system of a sorting unit in an X-ray inspection apparatus according to an embodiment of the present invention. [Figure 3] It is an explanatory diagram of an example of a pseudo-image for sorting confirmation in which images of a plurality of types of defective parts corresponding to a plurality of inspection items in an inspection unit of an X-ray inspection apparatus according to an embodiment of the present invention are added to an X-ray image of a non-defective product sample. [Figure 4] It is a timing chart showing the relationship between a sorting delay time T3 from the loading of an article into an inspection unit of an X-ray inspection apparatus according to an embodiment of the present invention until a sorting operation by sorting in a sorting unit is started according to a determination result in the inspection unit, a sorting operation time T4 executed after the elapse of the sorting delay time T3, a sorting check delay time T7 which is a standby time for checking the success or failure of the sorting operation for operation confirmation, and a sorting check operation time T9 required for the sorting check. [Figure 5] It is an explanatory diagram of a sorting timing setting screen for setting a sorting delay time and a sorting operation time for each inspection item in an X-ray inspection apparatus according to an embodiment of the present invention. [Figure 6]It is a flowchart showing a control procedure for setting and operation confirmation of the sorting delay time and sorting operation time for each inspection item in an X-ray inspection apparatus according to an embodiment of the present invention.

Embodiment for Carrying Out the Invention

[0022] Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

[0023] FIGS. 1 to 6 show an X-ray inspection apparatus according to an embodiment of the present invention.

[0024] First, the configuration will be described.

[0025] As shown in FIGS. 1 and 2, the X-ray inspection apparatus 1 of the present embodiment includes a conveyance unit 10 that conveys an article P to be inspected along a predetermined conveyance path, an inspection unit 20 that performs predetermined image processing on an X-ray image (X-ray inspection image) of the article obtained by imaging each article P in the conveyance path to inspect the quality state of the article P, a sorting unit 70 that operates in response to a sorting command signal RJ corresponding to the inspection result of the quality state and sorts the inspected articles P inspected by the inspection unit 20 in a sorting direction according to the inspection result, and a control unit 30 that controls the conveyance unit 10, the inspection unit 20, and the sorting unit 70.

[0026] In the present embodiment, the X-ray inspection apparatus 1 in which the sorting unit 70 is arranged immediately after the inspection unit 20 is illustrated as an example. Needless to say, the inspection unit 20 and the sorting unit 70 may be configured as an X-ray inspection system in which other inspection apparatuses, conveyors, etc. are interposed therebetween and they are separated from each other and configured as independent inspection apparatuses and sorting apparatuses. In that case, the inspection apparatus in the X-ray inspection system is the inspection unit referred to in the present invention, and the sorting apparatus in the X-ray inspection system is the sorting unit referred to in the present invention.

[0027] The transport unit 10 consists of a front conveyor 11, an inspection conveyor 12, and a sorting conveyor 13 arranged in a line in the left-right direction in Figure 1, and their transport drive means. Although not shown in detail, each is a belt conveyor that can sequentially transport items P to the right in Figure 1 by supporting a loop-shaped conveyor belt with parallel drive and driven rollers. The transport drive means for the inspection conveyor 12 and the sorting conveyor 13 include transport drive motors M1 and M2, and speed detection encoders (not shown), and the control unit 30 controls the transport to achieve a transport speed set for each type of item P.

[0028] The inspection unit 20 is an X-ray inspection unit that includes an X-ray generator 21 (X-ray source) that generates X-rays in a predetermined energy band that penetrate the articles P transported by the transport unit 10, and an X-ray detector 23 positioned directly below the belt-top section 12a of the inspection conveyor 12.

[0029] The X-ray generator 21 generates X-rays of wavelength and intensity corresponding to the tube current and tube voltage using a known X-ray tube 22, and is configured to irradiate articles P in a predetermined inspection section on the inspection conveyor 12 with fan-beam-shaped X-rays that spread in a direction perpendicular to the article transport direction of the transport unit 10, i.e., in the scanning direction of the X-ray detector 23, through the X-ray window of an enclosure (not shown).

[0030] The X-ray detector 23, although not shown in detail, is, for example, an indirect conversion type X-ray line sensor using a scintillator. Multiple photodiodes or CCDs (charge-coupled devices) that receive the scintillation light are arranged in an array at a predetermined pitch in the width direction of the transport path of the transport unit 10 to perform X-ray detection at a predetermined resolution. Note that the X-ray detector may also use a direct conversion type semiconductor element.

[0031] The X-ray detector 23 is positioned at a predetermined location in the transport direction corresponding to the X-ray irradiation position from the X-ray generator 21. That is, the X-ray detector 23 detects the X-rays irradiated from the X-ray generator 21 and transmitted through the article P for each predetermined transmission region corresponding to the detection element, converts the amount of X-ray transmission into an electrical signal corresponding to the amount of X-ray transmission, and outputs an X-ray detection signal Lx for generating an X-ray transmission image in which the direction of X-ray transmission is the observation direction.

[0032] Furthermore, the X-ray detector 23 is configured to perform line scanning in the width direction according to the transport speed of the inspection conveyor 12. When the pre-inspection item detection sensor 26 detects that an item P has been placed on the inspection conveyor 12, the control unit 30 causes the X-ray detector 23 to repeat line scanning for at least the duration of the X-ray imaging period of the item P (transport direction length / transport speed), and captures the X-ray detection signal Lx for each scanning line. The pre-inspection item detection sensor 26 is, for example, composed of a photoelectric sensor having an optical axis at a predetermined position in the transport direction on the inspection conveyor 12 and being shielded by the transported item P.

[0033] The control unit 30 is an inspection control means that controls the X-ray irradiation intensity and irradiation period in the inspection unit 20, as well as the line scanning period of the X-ray detector 23 and the detection period for each item P according to the transport speed of the items P. It is also a sorting control means that variably sets and controls the output conditions of the sorting command signal RJ according to the inspection results of the inspection unit 20 and the sorting operation conditions in the sorting unit 70 according to the type of sorting command signal RJ and the type of item P.

[0034] Although the detailed configuration of this control unit 30 is not shown, it is realized by a combination of hardware such as a microcomputer (processor) having a CPU, ROM, RAM, and I / O interface, and software such as programs that perform various functions on that hardware. The hardware referred to here may include FPGA (Field Programmable Gate Array), DSP (Digital Signal Processor), GPU (Graphics Processing Unit), etc. Furthermore, the various functions referred to here are multiple functions for acquiring and outputting detection data capable of generating an X-ray image of item P, generating inspection image data, predetermined image processing, inspection judgment processing, and display output control, and also include software management functions and timer functions for reading control programs and program modules for performing each function in ROM, auxiliary storage devices, or other recording media, or for downloading them from other computers via data communication.

[0035] Specifically, the control unit 30 has, among the multiple functional units that perform the aforementioned functions, an inspection image acquisition unit 31, an inspection processing unit 32, and an image processing algorithm storage unit 34, which are functional units for performing inspections based on X-ray images of the item P.

[0036] The inspection image acquisition unit 31 sequentially captures and stores the X-ray detection signal Lx from the X-ray detector 23 as a line scan image, and can generate X-ray image data Dpx (hereinafter also referred to as imaging data Dpx) for inspection processing that corresponds to the dose distribution of X-rays transmitted through the object P.

[0037] Specifically, the inspection image acquisition unit 31 performs A / D conversion on the X-ray detection signals Lx from multiple detection elements for each line scan of the X-ray detector 23, and sequentially stores the cumulative transmission amount data for each unit time for all n detection element regions (where n is an integer greater than 1, for example, 640) in the image memory as digital data that can be displayed in multi-level densities from 0 to 1023, thereby generating imaging data Dpx.

[0038] The inspection processing unit 32 is configured to perform a predetermined item inspection based on the imaging data Dpx of each item P from the inspection image acquisition unit 31. It includes an image processing unit 33 that takes in the imaging data Dpx output from the inspection image acquisition unit 31 and performs predetermined image processing, such as one or more predetermined filter processing to enable the extraction of image features and feature measurement to determine the feature quantities of the extracted image features, and a determination unit 35 that performs a determination process to determine whether or not an item P is in a predetermined quality state based on the feature quantity data extracted and measured by the image processing unit 33, such as determining whether or not there are foreign objects mixed in, whether or not there are missing items, the shape of the contents, the size, or the packaging condition is acceptable or unacceptable.

[0039] The image processing algorithm storage unit 34 stores multiple image processing algorithms Pgm, each usable by the inspection processing unit 32, in the form of control programs or program modules that can be incorporated into the inspection processing unit 32, each associated with a corresponding type of item P. Furthermore, the image processing algorithm storage unit 34 is connected to the inspection processing unit 32 via data transmission, allowing for the updating of at least the image processing algorithms used in the image processing unit 33 (which may include the judgment processing algorithms used in the judgment unit 35) to newer versions or changes to algorithms with different functions.

[0040] Furthermore, the inspection processing unit 32 outputs the judgment result from the judgment unit 35 to the display unit 51 (display), and the control unit 30, when it receives an operation input from the operation unit 52, which is provided together with the display unit 51, requesting the selection or switching of a product type, can request the image processing algorithm storage unit 34 to embed a specific image processing algorithm Pgm corresponding to the requested product type from the operation unit 52, including the necessary download work from an external source. The display unit 51 and the operation unit 52 may be provided as a single unit in the form of a touch panel or the like, or a tablet terminal or the like may be provided separately.

[0041] The image processing unit 33 of the inspection processing unit 32 stores a predetermined image processing algorithm Pgm, which combines image processing filters and the like, in an updatable and switchable manner, for performing a predetermined item inspection based on the imaging data Dpx of the item P acquired from the inspection image acquisition unit 31.

[0042] The image processing filter included in the image processing algorithm Pgm of the image processing unit 33 is a processing program for extracting image features (e.g., edges, lines, corners, regions, grayscale, texture) necessary for a predetermined item inspection based on the image data Dpx of the item P. If the image processing algorithm Pgm includes a filter for foreign object detection, it may have a feature extraction filter that performs edge detection processing to emphasize the contours of foreign objects in the item P, or a differential filter such as a Sobel filter, which emphasizes the edges of foreign objects by applying differential processing based on a predetermined calculation formula to the neighborhood region of the pixel of interest. Note that "image processing filter, etc." means that pre-processing such as grayscale correction and noise reduction is included for the image data Dpx from the inspection image acquisition unit 31 in order to improve the accuracy of the image feature detection processing.

[0043] Furthermore, the image feature measurement performed by the image processing unit 33 is a process that calculates the feature quantities necessary for the judgment process in the judgment unit 35 by performing necessary preprocessing and image processing on the image data Dpx of the item P acquired from the inspection image acquisition unit 31, and then performing calculations such as calculating attributes related to grayscale features, color features, shape features, etc. (feature quantities that characterize edges, regions, distances, positions, shapes, etc.), calculating feature quantities that represent the spatial relationships between such features, or calculating texture feature quantities related to spatial frequency distribution and directional components.

[0044] The determination unit 35, based on the feature quantities extracted and feature-measured by the image processing unit 33, detects feature shapes and foreign objects detected in the item P, and compares the feature quantities such as the area, contour length, and density sum of the detected object with a predetermined judgment criterion limit to determine whether or not a local feature shape corresponding to a foreign object or defective part that satisfies the judgment conditions for defect detection is contained within the item P.

[0045] The inspection processing unit 32 applies a predetermined image processing algorithm Pgm, which combines multiple filtering processes, to the imaging data Dpx of a predetermined type of item P, or to the image data obtained by adding necessary pre-processing and image processing, in order to generate an image capable of determining a predetermined quality state of the item P.

[0046] Furthermore, the image processing algorithm storage unit 34 has in advance multiple image processing algorithms (which may further include judgment processing algorithms usable by the judgment unit 35) that can be used by the image processing unit 33 and perform predetermined image processing. The image processing unit 33 and the image processing algorithm storage unit 34 of the inspection processing unit 32 have the function of updating or switching the image processing algorithm Pgm currently used by the inspection processing unit 32 to a specific image processing algorithm Pgm corresponding to the newly set product when the inspection processing unit 32 requests a switch or update to a different product based on a product selection or switching operation from the operation unit 52.

[0047] On the other hand, the sorting section 70 comprises a support frame 71 that supports the sorting conveyor 13, a pair of sorting members, such as flipper arms 73A and 73B, that are rotatably supported on the support frame 71 so as to be located on both sides in the width direction of the transport path of the sorting conveyor 13, a discharge mechanism 72 having a pair of air cylinders CYL1 and CYL2, lever members 74a and 74b, and valves V1 and V2 (not shown in detail), and a drive circuit 75 thereof.

[0048] When the valves V1 and V2 are electromagnetically operated by the drive circuit 75, the discharge mechanism 72 can perform a sorting operation to a first sorting position, for example, the item removal position shown by the dashed line in Figure 2(b), in which the rotational position of any one of the flipper arms 73A and 73B is positioned on the inspection conveyor 12, in accordance with the electromagnetic operation input, or it can return to a second sorting position, for example, the standby position parallel to the transport direction, as shown by the solid line in Figure 2(b), in which either of the flipper arms 73A and 73B in the first sorting position is retracted from the inspection conveyor 12.

[0049] The drive circuit 75 selectively supplies operation signals SOL1 and SOL2 (see Figure 2(b)) corresponding to the type of sorting command signal RJ to each valve V1 and V2, for example, supply and discharge control valves (which may also be directional control valves and speed control valves) that control the supply and discharge of air (compressed air). This allows independent control of the extension and retraction of a pair of air cylinders CYL1 and CYL2 via valves V1 and V2. By controlling the flipper arms 73A and 73B via the discharge mechanism 72 to their relative positions according to the type of sorting command signal RJ or the sorting start timing, the discharge direction of the articles W can be divided into three different sorting directions: discharge to the left side facing the transport direction of articles P, distribution to the right side, or passing straight through.

[0050] The sorting unit 70 is also equipped with a pre-sorting item detection sensor 76 located at a predetermined value in the transport direction near the entrance of the sorting conveyor 13, product recognition means for recognizing the passage of items P in each sorting direction, such as a good item passage detection sensor 77 that detects the passage of good items (OK items) near the exit of the sorting conveyor 13, and a defective item removal detection sensor 78 that detects defective items P that have been removed from the transport path when the flipper arm 73B is in the item removal position (the inclined position shown in Figure 2(a)).

[0051] These pre-sorting item detection sensors 76, good item passage detection sensors 77, and defective item removal detection sensors 78 are each composed of photoelectric sensors having optical axes as shown by dotted lines in Figure 2(a), similar to the pre-inspection item detection sensor 26. The pre-sorting item detection sensor 76 detects items P that have reached the sorting area when they are obscured by items P that have been brought onto the sorting conveyor 13. The good item passage detection sensor 77 detects the passage of good items when they are obscured by items P that have been judged as good and have passed through the sorting area. The defective item removal detection sensor 78 detects the passage of defective items when they are obscured by defective items P that have been removed from the transport path by the flipper arm 73B.

[0052] The control unit 30, among the multiple functional units described above, controls the sorting operation in the sorting unit 70 and also has a sorting confirmation image generation unit 40, an operation control unit 45, an operation confirmation determination unit 46, and a sorting information setting unit 47 as functional units for performing operation confirmation of the inspection unit 20 and the sorting unit 70.

[0053] The sorting confirmation image generation unit 40 generates a pseudo-image for sorting confirmation based on the imaging data Dpx of a good product sorting confirmation sample Ps, in order to confirm whether there are any abnormalities in the sorting operation of the inspection unit 20 in each sorting direction.

[0054] Specifically, the sorting and verification image generation unit 40 includes an NG image storage unit 41 that stores typical NG feature images for each type of defect that have the characteristics of a predetermined defective part that is determined to be sorted in the sorting direction, and an NG image generation unit 42 that generates a pseudo-NG image Dps(1) for sorting and verification by combining and adding NG feature images of predetermined defect types stored in the NG image storage unit 41 to a sample image of a good product, for example, the good product sample image Dps(0) shown in Figure 3.

[0055] In other words, when the sorting confirmation image generation unit 40 obtains an X-ray transmission image Dps(0) shown in the upper part of Figure 3 as an overall image of the sorting confirmation sample Ps based on the imaging data Dpx(OK) (see Figure 1) of the sorting confirmation sample Ps of good products, the sorting confirmation image generation unit 40 synthesizes and adds a partial NG feature image, which has been stored in advance in the NG image storage unit 41 of the sorting confirmation image generation unit 40, to the X-ray transmission image Dps(0). This generates a pseudo-NG image Dps(1) for sorting confirmation, which has overall image features similar to the X-ray transmission image Dps(0) of the sorting confirmation sample Ps, but also partially possesses defective features corresponding to the NG feature image.

[0056] Furthermore, as shown in Figure 3, the sorting confirmation image generation unit 40 synthesizes and adds some of the NG feature images from multiple types pre-stored in the NG image storage unit 41 to the X-ray transmission image Dps(0) of the sorting confirmation sample Ps of good products of item P. This creates a pseudo-NG image Dps(1) for sorting confirmation that has multiple inspection items that can be simultaneously applied to the selected item P, each having the respective NG feature images Ci and Cj (where C is an NG feature, and i and j are mutually distinct arbitrary natural numbers) for each type. For example, in the upper diagram of Figure 3 (X-ray transmission image Dps(0)), the solid circle frame indicates that the partial image feature Q1 of good quality item P of the sorting variety is included. In the lower diagram (pseudo-NG image Dps(1) for sorting confirmation), the dotted circle frame indicates that the NG feature image C1, which shows a defective condition such as jamming, misalignment of the seal, or contamination of foreign matter in the seal portion of the flexible packaging, is included. The dotted circle frame also indicates that the NG feature image C2 is obtained by subtracting a partial image of the contents of the flexible packaging product to an arbitrary shape or ratio suitable for the sorting variety, and that the dotted circle frame indicates that the NG feature image C3 of an arbitrary foreign matter sample or test piece that may be mixed into item P is included. Then, a pseudo-NG image Dps(1) for sorting confirmation can be generated that combines these NG feature images and partial images of good quality products.

[0057] Of course, when multiple sorting directions are set for multiple inspection items that can be applied simultaneously to the selected item P, the sorting confirmation image generation unit 40 can also generate a pseudo sorting confirmation image Dps(2) (see Figure 1) having an NG feature image Ci or Cj of any of the multiple types pre-stored in the NG image storage unit 41 for each sorting direction, by selectively combining and adding an X-ray transmission image Dps(0) of the good product sorting confirmation sample Ps of the selected item P each time an X-ray transmission image Dps(0) is acquired, for each sorting direction, thereby generating a pseudo sorting confirmation image Dps(2) (see Figure 1) having an NG feature image Ci or Cj of any of the one inspection item that can be applied to the selected item P, or a pseudo sorting confirmation image Dps(2) for good products. It is also possible to generate multiple pseudo sorting confirmation images Dps(2) corresponding to multiple types of inspection items when multiple good product sorting confirmation samples Ps of the selected item P are fed in or pass through the inspection unit 20 multiple times.

[0058] The control unit 30 can switch between a normal inspection operation mode in which imaging data Dpx output from the inspection image acquisition unit 31 is directly taken into the inspection processing unit 32, and an operation confirmation mode (which may be a test mode or maintenance mode that allows for operation confirmation of inspection and sorting) in which imaging data Dpx output from the inspection image acquisition unit 31 is taken in as a pseudo-NG image Dps(1) for sorting confirmation via the sorting confirmation image generation unit 40.

[0059] Furthermore, in operation confirmation mode, the control unit 30 sets the images output from the sorting confirmation image generation unit 40 according to the selected product type to at least one sorting confirmation pseudo-NG image Dps(1) and / or multiple sorting confirmation pseudo-images Dps(2), based on the number of sorting directions set in the sorting unit 70 according to the type of defect of the item P. In addition, the number of sorting directions set in the sorting unit 70 is further configured to include a sorting direction that removes item P from the normal product transport line if the start timing of the sorting operation does not fall within the time range in which normal operation is possible (this point will be described later).

[0060] The operation control unit 45 has the function of variably controlling the speed of motors M1 and M2 for driving the inspection conveyor 12 and sorting conveyor 13 according to the type of item P and the inspection items, and the function of selectively outputting the aforementioned operation signals SOL1 and SOL2 to the drive circuit 75 or not outputting either, depending on the type of sorting command signal RJ from the inspection processing unit 32 and the appropriateness of the sorting start timing. Here, the type of sorting command signal RJ is, for example, the type of defect of the defective product corresponding to one of the aforementioned NG feature images C1, C2, and C3.

[0061] Furthermore, the operation control unit 45 is equipped with an operation confirmation and determination unit 46. This operation confirmation and determination unit 46 determines whether the timing of the determination result output is appropriate, prior to outputting the determination result (OK / NG) to the display unit 51 and outputting the sorting command signal RJ, when the leading edge of the item P brought onto the inspection conveyor 12 is detected by the item detection sensor 26 before inspection, and just before the sorting delay time T3 has elapsed, for example, when the determination time Tj has elapsed until the time t3 when the determination processing in the determination unit 35 is completed. For this reason, the operation control unit 45 receives detection signals from the item detection sensor 26 before inspection, the item detection sensor 76 before sorting, the good item passage detection sensor 77, and the defective item exclusion detection sensor 78.

[0062] The appropriateness of the sorting start timing referred to here depends on whether or not a sorting command signal RJ is output from the inspection processing unit 32 between the detection of the arrival of item P by the item detection sensor 26 before inspection and the elapsed of a predetermined sorting delay time T3. In other words, if the output timing of the sorting command signal RJ for item P to be inspected is appropriate, sufficient sorting operation time T4 can be secured to redirect the flipper arm 73B for removing defective products from a position parallel to the other flipper arms 73A to an item removal position (the inclined position shown by the dotted line in Figure 2(b)) and remove item P as a defective product. On the other hand, if the output timing of the sorting command signal RJ for item P to be inspected is not appropriate, it means that sufficient sorting operation time T4 cannot be secured to redirect the flipper arm 73B for removing defective products from a position parallel to the other flipper arms 73A to an item removal position and remove item P as a defective product.

[0063] The sorting operation signal SOL1 is generated by the drive circuit 75 in response to the sorting command signal RJ1 output from the operation control unit 45 when the timing of the sorting command signal RJ output from the inspection processing unit 32 is after a predetermined sorting delay time T3 has elapsed from the detection of an item by the item detection sensor 26 before inspection. This sorting operation signal SOL1 switches the connection between the supply pressure (○) and drain (×) of the primary side control pressure port of the electromagnetically operated valve V1 and the control pressure port of the secondary side air cylinder CYL1, thereby switching the air supply and discharge state to the pair of air supply and discharge ports of the air cylinder CYL1 to the cylinder contraction side (the side for removing items that are not suitable for transport).

[0064] On the other hand, the sorting operation signal SOL2 is generated by the drive circuit 75 in response to the sorting command signal RJ2 selectively output from the operation control unit 45 when the timing of the sorting command signal RJ output from the inspection processing unit 32 is before the predetermined sorting delay time T3 has elapsed from the detection of the item by the item detection sensor 26 before inspection. In other words, the sorting operation signal SOL2 is generated when the inspection processing unit 32 instructs the sorting and discharge (removal) of defective products by the sorting command signal RJ, and the timing of the output of the sorting command signal RJ for the item P to be inspected is appropriate. This sorting operation signal SOL2 switches the connection between the supply pressure (○) and drain (×) of the primary side control pressure port of the electromagnetically operated valve V2 and the control pressure port of the secondary side cylinder CYL2, thereby switching the air supply and discharge state to the pair of air supply and discharge ports of the air cylinder CYL2 to the cylinder contraction side (defective product sorting and removal side).

[0065] If the determination result in the determination unit 35 is OK within a predetermined sorting delay time T3 from the detection of an item by the item detection sensor 26 before inspection, and the sorting command signal RJ is not output from the inspection processing unit 32, the operation control unit 45 outputs the sorting command signal RJ3 during the period in which the item P to be sorted passes. At that time, neither the sorting operation signals SOL1 nor SOL2 are output by the drive circuit 75. In this case, for example, if the air cylinders CYL1 and CYL2 are single-acting, the flipper arms 73A and 73B can be returned to a parallel standby position by the return springs built into them. Alternatively, if the air cylinders CYL1 and CYL2 are not single-acting, the flipper arms 73A and 73B can be returned to a parallel standby position (a position that allows good items to pass) by, for example, providing a centering spring in each and providing a neutral position in the directional control valves V1 and V2.

[0066] The sorting information setting unit 47 also functions as a setting value memory within the operation control unit 45. This sorting information setting unit 47 stores sorting information, which associates the identification code of each inspection item with the sorting operation direction when a defective product of that inspection item is found in the sorting unit 70, based on operation input from the operation unit 52 or data communication input to the control unit 30. This information is stored in the form of a table or similar. In addition to setting the sorting direction, the sorting information setting unit 47 also sets the sorting timing for each type of item P as a sorting delay time T3 and a sorting operation time T4. The sorting operation control unit 45 then executes the sorting operation in the sorting unit 70 based on the sorting timing set in the sorting information setting unit 47. The term "type" here includes the type name and code that identify the type of item P to be inspected, as well as the identification codes of one or more applicable inspection items and the setting value of the transport speed.

[0067] Furthermore, in the operation control unit 45, the sorting check delay time T7 and the sorting check operation time T9 are set to be updatable and stored in the sorting information setting unit 47. Depending on the sorting command outputs RJ2 and RJ3 output from the operation control unit 45, when good items P move straight along the sorting conveyor 13 and when defective items are sorted and removed by the sorting unit 70, the passage of items P in each sorting direction is detected by the good item passage detection sensor 77 and the defective item removal detection sensor 78, making it possible to determine whether the corresponding sorting operation was successfully executed in the predetermined sorting direction.

[0068] Figure 4 shows the changes in sensor signals and timer operation when the control unit 30 operates the operation control unit 45 and the operation confirmation and determination unit 46 as described above.

[0069] (Normal inspection operation mode) As shown in Figure 4, when the leading edge of an item P being brought onto the inspection conveyor 12 is detected by the item detection sensor 26 before inspection, a timer measurement for a predetermined sorting delay time T3 is started from the detection time t0. After the timer measurement for the sorting delay time T3 has finished (time has elapsed), the timer measurement for the sorting operation time T4 by the sorting unit 70 is started.

[0070] Here, the predetermined sorting delay time T3 is stored in the setting value memory of the inspection processing unit 32 as a timer setting value for each item, for example, when setting the item type or switching between item types, and is also stored in the adjustment memory of the operation control unit 45 in a rewritable manner.

[0071] This predetermined sorting delay time T3 is the waiting time required from the time the inspection image acquisition unit 31 acquires imaging data Dpx of the item P, the image processing unit 33 performs predetermined image processing such as filtering and image analysis processing such as feature measurement, the execution of a determination process to determine whether or not the item P is in a predetermined quality state based on the results of these predetermined image processing and image analysis processes, until the sorting command signal RJ corresponding to the determination result is output.

[0072] Specifically, as shown in an example in Figure 4, the predetermined sorting delay time T3 is primarily the time required for determination Tj, which is from the detection of the leading edge of the item P by the item detection sensor 26 before inspection, to the time t1 when the imaging data Dpx of the item P is acquired by the inspection image acquisition unit 31, and then to the time t2 when the predetermined image processing and image analysis processing in the image processing unit 33 is completed, until the time t3 when the determination processing in the determination unit 35 is completed. The timer measurement for the sorting delay time T3 expires at the time t4 when the sorting command signal RJ corresponding to the determination processing result in the determination unit 35 is output.

[0073] During the timer measurement of the sorting operation time T4, which starts from the output time t4 of the sorting command signal RJ, the sorting unit 70 executes the sorting operation in accordance with the sorting command signal RJ from the inspection processing unit 32. Therefore, in a normal inspection operation where the operation timing has been adjusted in advance, the sorting operation is completed normally during the sorting operation time T4.

[0074] When the timer measurement for the sorting operation time T4 expires, a timer measurement for a predetermined sorting check delay time T7 to confirm the success or failure of the sorting operation starts from that point t6. When the timer measurement for the sorting check delay time T7 expires, a timer measurement for the sorting check operation time T9 starts from that point t7.

[0075] During the sorting check operation time T9, the optical axis of the defective product exclusion detection sensor 78 is blocked by the defective product P that has been removed from the transport path by the flipper arm 73B, and when the passage of a defective product in the exclusion direction is detected, it is possible to confirm whether the product inspection based on the X-ray image in the inspection unit 20 and the result of that inspection have been determined to be defective, and whether the sorting operation in the sorting unit 70 has been completed successfully.

[0076] (Operation check mode) On the other hand, if the operation is performed in the normal inspection operation mode after the operation input for registering or switching the type of item P is made by the operation unit 52, the number of inspection items may be large, and the processing time for the predetermined image processing for them may be longer than usual. In that case, as shown as an abnormal timing in Figure 4, the judgment processing in the judgment unit 35 cannot be completed by the time the judgment required time Tj has elapsed, and the sorting command signal RJ corresponding to the judgment processing result in the judgment unit 35 cannot be output by the time t4 when the timer measurement of the sorting delay time T3 has expired.

[0077] Therefore, in this embodiment, after the operation input for registering or switching the type of item P, a sample Ps for sorting and confirming good products of that type is passed through the inspection unit 20 and X-ray imaged. At this time, the sorting and confirmation image generation unit 40 generates a pseudo-NG image Dps(1) for sorting and confirmation, which has overall image characteristics similar to the X-ray transmission image Dps(0) of the sorting and confirmation sample Ps, but also partially possesses defective characteristics corresponding to an NG characteristic image.

[0078] Furthermore, regarding the pseudo-NG image Dps(1) for sorting confirmation, if multiple types of inspection items that take time to process are required, and the processing time becomes longer than usual, the operation control unit 45 determines at the time t3 when the judgment time Tj has elapsed that it cannot output the sorting command signal RJ by the time t4 when the timer measurement of the sorting delay time T3 has expired.

[0079] In this case, the control unit 30 outputs, for example, the sorting timing setting operation screen 60 shown in Figure 5, to the display unit 51.

[0080] This operation screen 60 includes an operation status display area 61 that shows the operating status of the X-ray inspection device 1, a setting information display area 62 that displays multiple types of setting value information related to the sorting timing for the current product type with their respective parameter names and set values, a selection operation display area 63 that displays options, operation explanations, and operation input elements according to the operation input, and an operation button display area 64 that displays images of multiple operation buttons and other operation parts in an orderly manner and functions as part of the operation unit 52. The operation button display area 64 displays an operation button 65 for selecting the sorting direction for which operation confirmation is to be performed, and a setting / adjustment operation button 66 that allows input of the transport speed of the item P and the setting time for each timer measurement.

[0081] On this operation screen 60, when the operation button 65 for selecting the sorting direction is touched, the sorting directions (RJ1, RJ2, RJ3 in Figure 5) are displayed in an optional manner, and it is possible to confirm operation in the selected sorting direction. In addition, when the operation button 66 for setting and adjustment is touched, any parameter from the transport speed of the inspection conveyor 12 (main conveyor speed [m / s] in the same figure), the transport speed of the sorting conveyor 13 (sorting machine conveyor speed [m / s] in the same figure), sorting delay time T3, and sorting operation time T4 can be set and entered as a set value.

[0082] The operation control unit 45 executes an operation confirmation process using the parameters set on the operation screen 60 for the transported sorting confirmation sample Ps, and displays the sorting confirmation result (e.g., OK) in operation confirmation mode. Furthermore, if the sorting delay time T3 is displayed as part of the parameters set on the operation screen 60, and no input to change the sorting delay time T3 is made within a predetermined time, the system may set the delay time expiration time t4' to a predetermined adjustment unit time after the timer measurement expiration time t4 of the sorting delay time T3, for example, as the sorting delay time at which the sorting command signal RJ can be output. In addition, the sorting delay time T3 is calculated as a waiting time corresponding to the type of sorting command signal RJ based on the transport direction length and transport speed of the newly selected item P, and the candidate value for the parameter setting may be highlighted in the setting information display area 62 or supplementary explanation may be displayed in the selection operation display area 63.

[0083] In that case, the sorting command signal RJ can be output by the time the delay time expires t4', and the timer measurement of the sorting operation time T4 can be started from that time t4' or the immediately following start time t5. In addition, the operation control unit 45 overwrites the value of the sorting delay time T3 stored in the built-in adjustment memory with the time value from the time t0 when the tip of the item P is detected by the item detection sensor 26 before inspection to the reset delay time expiration time t4'.

[0084] The operation control unit 45 also outputs a sorting command signal RJ1 to the drive circuit 75 of the sorting unit 70, requesting a sorting operation signal SOL1 by the end of the delay time t4', when the timing of the output of the sorting command signal RJ from the inspection processing unit 32 is after the sorting delay time T3 has elapsed. At this time, the sorting operation signal SOL1 from the drive circuit 75 operates the electromagnetically operated valve V1, and the air supply and discharge state to the air cylinder CYL1 is switched to the cylinder contraction side, so that the flipper arm 73A is driven to the article exclusion position shown by the dashed line in Figure 2(b), and good product sorting confirmation samples Ps are discharged. The sorting command signal RJ1 may also be output when the sorting confirmation samples Ps, which are the articles P to be sorted, have come too close to the sorting unit 70 and have been detected by the article detection sensor 76 before sorting, before the output of the sorting command signal RJ.

[0085] When the operator passes the sample Ps for sorting and confirming good products through the inspection unit 20 again, it is X-ray imaged again and an X-ray transmission image Dps(0) is obtained, and a pseudo-NG image Dps(1) for sorting and confirmation is generated in the sorting and confirmation image generation unit 40. However, since the sorting and confirmation pseudo-NG image Dps(1) requires multiple types of inspection items that take time to process, the processing time is longer than usual. Nevertheless, if it is determined at the time t3, when the judgment time Tj has elapsed, that the sorting command signal RJ can be output before the timer measurement of the sorting delay time T3 expires at t4', then the time value from the time t0, when the tip of the product P is detected by the product detection sensor 26 before inspection, to the reset delay time expiration time t4' is determined as the value of the sorting delay time T3.

[0086] Then, if it is determined that the sorting command signal RJ can not be output by the timer measurement expiration time t4', the sorting confirmation result will be displayed as NG, and the above operation confirmation work using the good product sorting confirmation sample Ps will be requested again, and the timer measurement expiration time t4' will be changed to a time value or setting input value that is further later by a predetermined adjustment unit time.

[0087] On the other hand, even if the sorting delay time T3 is appropriate, the sorting operation by distribution in the sorting unit 70 may not be executed properly if the sorting operation time T4 immediately following it is not appropriate.

[0088] Therefore, in the operation confirmation mode, first, while the timer for the sorting operation time T4 is being measured, the sorting unit 70 performs sorting operations in accordance with the sorting command signal RJ from the inspection processing unit 32.

[0089] At this time, if the sorting operation is completed successfully during the sorting operation time T4, the sorting operation time T4 can be determined. To make this determination, once the timer measurement for the sorting operation time T4 has expired, a timer measurement for a predetermined sorting check delay time T7 to confirm the success or failure of the sorting operation is started from that point t6. Once the timer measurement for the sorting check delay time T7 has expired, a timer measurement for the sorting check operation time T9 is started from that point t7.

[0090] Then, during the sorting check operation time T9, the optical axis of the defective product exclusion detection sensor 78 is blocked by the defective product P that has been removed from the transport path by the flipper arm 73B, and when the passage of a defective product in the exclusion direction is detected, it can be confirmed that the product inspection based on the X-ray image in the inspection unit 20 and the result of that inspection are determined to be defective, and that the sorting operation in the sorting unit 70 has been completed successfully.

[0091] On the other hand, if, during the sorting check operation time T9, no passage of defective products in the rejection direction is detected, and the item inspection result based on the X-ray image in the inspection unit 20 is determined to be defective, but the sorting operation in the sorting unit 70 is not completed normally, the operation control unit 45 changes the timer measurement expiration time t6 to the operation time expiration time t6' which is a predetermined adjustment unit time later, or calculates the sorting operation time T4 as a waiting time corresponding to the type of sorting command signal RJ based on the transport direction length of the newly selected item P and the transport speed of the sorting conveyor 13. In addition, candidate values ​​for parameter settings may be highlighted in the setting information display area 62 or supplementary explanations may be displayed in the selection operation display area 63.

[0092] Then, if the sorting operation is completed successfully during the sorting operation time T4, the sorting operation time T4 can be determined. Note that the expiration time t6 of the timer measurement for the sorting operation time T4 will be t6', which is delayed by the aforementioned adjustment unit time. However, the sorting check delay time T7 can be shortened by the aforementioned adjustment unit time without delaying the start timing of its timer measurement from the original expiration time t6 of the sorting operation time T4. If the sorted items pass through within the sorting check operation time T9, it can be set to be shortened in this way. Otherwise, the delay can be corrected by the aforementioned adjustment unit time.

[0093] Once the sorting delay time T3 and sorting operation time T4 have been adjusted, the sorting operation in the sorting unit 70 and the discharge in the sorting direction can be confirmed by, for example, transporting and inspecting good items P for the number of inspection items, while sequentially generating pseudo-images Dps(2) for sorting confirmation that have NG characteristic images Ci or Cj of different types of defects in different sorting directions.

[0094] Alternatively, while transporting and inspecting multiple good items P in each sorting direction, the sorting operation in the sorting unit 70 and the discharge in the sorting direction can be confirmed.

[0095] Next, I will explain the mechanism of action.

[0096] In the X-ray inspection apparatus 1 of this embodiment, when registering a product type or switching the product type settings, the control unit 30 executes a control program for operation verification and timing adjustment work in the processing procedure shown in Figure 6.

[0097] First, the product type and a predetermined number of inspection items (C1-Cm) are set by operation input from the operation unit 52 (step S11). Then, the inspection conditions for each inspection item, namely the length Lw of the item P, the transport speed Vc of the inspection conveyor 12, and the transport speed Vr of the sorting conveyor 13, are set. Based on these, the sorting delay time T3 and sorting operation time T4, which define the standard sorting timing of the sorting unit 70, are calculated. Furthermore, according to the inspection items (C1-Cm), the necessary image processing algorithm Pgm stored in the image processing algorithm storage unit 34 and associated with the current product type is extracted and incorporated into the inspection processing unit 32 (step S12).

[0098] Next, the conditions for synthesizing NG images and other inspection conditions in the sorting confirmation image generation unit 40 are set according to the set number of inspection items and the number of sorting directions of the sorting unit 70 (step S13).

[0099] Next, a sample Ps for sorting and confirming good products is passed through the inspection unit 20. After the item detection by the item detection sensor 26 before inspection (step S14), once the judgment time Tj has elapsed until imaging, image synthesis, and judgment processing are performed (step S15), the appropriateness of the signal output timing (OK / NG) is determined at this stage based on whether or not it is possible to output the sort command signal RJ before the timer measurement of the sort delay time T3 expires (step S16). If the timing is appropriate (if OK in step S16), the sort command signal RJ is then output (step S17). If the timing is not appropriate (if NG in step S16), the expiration timing of the timer measurement of the sort delay time T3 is delayed from time t4 to time t4' by a predetermined adjustment unit time, or it is delayed to the value of the sort delay time T3 that has been input as a set value (step S18).

[0100] Then, immediately after the sorting command signal RJ is output at the end of the delayed-corrected timer measurement time t4', the timer measurement for the sorting operation time T4 begins, and the sorting operation by the sorting unit 70 is executed. The suitability of the sorting operation time T4 is determined (step S20), and if the timing is appropriate (if OK in step S20), it is then determined whether the number of samples Ps used for sorting confirmation of good products or the number of uses i has been reached (step S22). If the number of samples used or the number of uses i has not been reached, that number i is incremented (step S23), and the timing adjustment process from step S14 onwards is repeatedly executed.

[0101] On the other hand, if the sorting operation time T4 is not appropriate (if NO in step S20), then the timer measurement completion timing for the sorting operation time T4 is delayed by a predetermined adjustment unit time from time t6 to time t6' or by another predetermined adjustment unit time, or it is delayed by the value of the sorting operation time T4 entered as a set value (step S21).

[0102] Thus, in the X-ray inspection apparatus 1 of this embodiment, when the determination unit 35 obtains determination data Img such as the presence or absence of defects and the type of defect from the sample inspection image Dps(0) of the sample inspection image Ps for sorting and confirming good products based on the predetermined image processing results in the image processing unit 33, the determination unit 35 determines the determination result (OK / NG) based on the determination data Img as a defect (NG) for the sorting direction set in the sorting information setting unit 47, and pseudo-NG images Dps(1) and Dps(2) for sorting and confirming are generated as sample inspection images. Therefore, regardless of the number of sorting directions set in the sorting information setting unit 47, there is no need to prepare defective product samples or pseudo-NG products for each inspection item, and the timing of the sorting operation can be easily, quickly, and accurately set for the sorting direction for each inspection item.

[0103] Furthermore, in this embodiment, a pseudo-NG image Dps(1) or Dps(2) for sorting confirmation is generated by adding predetermined defective part images C1, C2, and C3 stored in the NG image storage unit 41 to the good product sorting confirmation sample image Dps(0). Therefore, by simply feeding in the good product sorting confirmation sample Ps in the same way as during normal inspection operation, a pseudo-NG image Dps(1) or Dps(2) for sorting confirmation is generated that will be used to sort each inspection item in the sorting direction determined by the judgment result in the judgment unit 35, and the timing of the sorting operation can be set easily, quickly, and accurately.

[0104] Furthermore, in addition to setting the sorting direction, the sorting information setting unit 47 sets the sorting timing using the sorting delay time T3 and the sorting operation time T4, and the sorting operation control unit 45 causes the sorting unit 70 to perform sorting operations based on the sorting timing set in the sorting information setting unit 47. Therefore, since the sorting timing corresponding to the sorting direction can be set, sorting can be performed by more accurate sorting operations based on that sorting timing.

[0105] In addition, in this embodiment, when an item P is sorted by the sorting unit 70 in a distribution direction such that good items proceed in a straight line and defective items are sorted and removed according to the inspection result of its quality status, a good item passage detection sensor 77 and a defective item removal detection sensor 78, which consist of a photoelectric sensor or the like, are provided as product recognition means for recognizing the item P. The sorting operation control unit 45 causes the sorting unit 70 to perform a distribution operation at a provisional sorting timing (time t4) based on the item transport speed or a sorting timing that has been delayed and corrected considering the transport timing (delayed and corrected time t4'). When the good item passage detection sensor 77 and the defective item removal detection sensor 78 recognize that the corresponding sorting operation has been performed correctly in the predetermined distribution direction, the sorting information setting unit 47 and the inspection processing unit 32 are instructed to set the provisional sorting timing as the sorting timing. Therefore, when the good product passage detection sensor 77 and the defective product rejection detection sensor 78 recognize that the items P sorted in a predetermined sorting direction have been correctly sorted in that direction, a provisional sorting timing based on the transport speed is set as the sorting timing in the sorting information setting unit 47, enabling more reliable operation verification.

[0106] As described above, the present invention provides an X-ray inspection apparatus 1 that can easily, quickly, and accurately set and adjust the timing of the sorting operation without using defective product samples or pseudo-NG products for each inspection item.

[0107] In this embodiment, the sorting unit 70 is a flipper sorting system using flipper arms 73A and 73B. However, the sorting unit 70 may also be a pusher system that pushes the items P in a direction perpendicular to the transport direction after they reach the transport position detected by the item detection sensor 76 before sorting, an air sorting system that pushes or blows away the items P in a direction perpendicular to the transport direction using wind pressure load from compressed air, or any other sorting system that allows for the discharge of NG items outside the transport path. In such cases, the main setting parameters may also change. Furthermore, if the parameter settings are insufficient within the normal adjustment range, it is of course possible to move the installation position of the sorting unit 70 downstream or change the sorting machine of the sorting unit 70 to a different type. Moreover, when a fluid-pressure operated cylinder is used in the sorting unit 70 as in one embodiment, it goes without saying that a rotary type can be used instead of a linear type, or an electric type can be used instead of a fluid-pressure operated type.

[0108] Furthermore, in this embodiment, the sorting unit 70 sorts and removes defective products on one side of the sorting conveyor 13, but it may be configured to sort and remove products on both sides, multiple sorting units 70 discharging in the same direction may be arranged at different positions in the direction of product transport, or multiple sorting units of other sorting methods may be installed in the transport direction to perform sorting operations corresponding to multiple judgment results at different positions in the transport direction.

[0109] As described above, the present invention provides an X-ray inspection apparatus that can easily, quickly, and accurately set and adjust the timing of sorting operations without using defective product samples or pseudo-NG products for each inspection item. The present invention is useful for X-ray inspection apparatuses in general that include an inspection unit that performs X-ray inspection by processing the X-ray image of an X-ray imaged article and a sorting unit that performs sorting operations in a sorting direction according to the inspection results. [Explanation of Symbols]

[0110] 1. X-ray inspection device 10 Conveying section 11 Front Conveyor 12 Inspection conveyor 12a Belt running section 13. Sorting conveyor 20. Inspection Department 21 X-ray generator 22 X-ray tube 23 X-ray detector 26. Item detection sensor before inspection 30 Control Unit 31. Inspection Image Acquisition Unit 32 Inspection Processing Unit 33 Image Processing Unit 34 Image processing algorithm memory unit 35 Judgment section 40. Image generation unit for sorting and confirmation. 41 NG Image Storage Unit 42 NG Image Generation Unit 45. Operation Control Unit (Sorting Operation Control Unit) 46 Operation Confirmation Judgment Unit 47. Distribution Information Setting Unit (Information Setting Unit) 51 Display section 52 Operation section 60 Operation screen 61 Operating status display area 62 Setting information display area 63 Display area for selection operation 64 Operation button display area 65 Operation buttons (operation buttons for selecting sorting direction) 66 Operation buttons (operation buttons for settings and adjustments) 70 Sorting Department 71 Support Slots 72 Ejection mechanism 73A, 73B Flipper Arm 75 Drive Circuit 76. Item detection sensor before sorting. 77. Good product passage detection sensor (product recognition means) 78. Defective product rejection detection sensor (product recognition means) C1, C2, C3 NG Feature Images CYL1, CYL2 Air Cylinders DPS sorting confirmation pseudo-image Dps(0) Good product sample image Dps(1) Pseudo-NG image for sorting and verification (a pseudo-image for sorting and verification created by combining images of multiple types of NG features) Dps(2) Pseudo-NG image for sorting and verification (a pseudo-image for sorting and verification created by combining various NG feature images) Dpx imaging data Dpx(OK) Imaging data of a sample used for sorting and confirming good quality products. M1, M2 motors P Goods Ps Sample for sorting and checking good quality products Q1. Partial image characteristics of a good product RJ1 sorting command signal (sorting direction for transport failure) RJ2 sorting command signal (direction for sorting and removing defective products) RJ3 sorting command signal (permitted direction for good products to pass) SOL1, SOL2 operation signal Time t0 (the point at which the tip of the item is detected before inspection) t1 time (imaging time) t2 time point (image processing and image analysis time) t3 (Time when the judgment process is completed) t4 time point (time when the timer measurement for the sorting delay time expires, time when the delay time expires, time when the sorting command signal is output) t4' (Time when the selection delay time for delay correction has expired) t5 point (start of timer measurement for sorting operation time when sorting delay time correction is applied) t6 (Time when the timer for sorting operation time expires, time when the operation time expires) t6' (the end of the timer measurement for the selection operation time during delay correction) t7 (Time when the timer for sorting check delay time expires) t8 (Time of rejection detection by the defective product rejection sensor) t9 (Time when the timer for the sorting check operation expires) T3 sorting delay time T4 sorting operation time T7 sorting check delay time T9 Sorting check operation time Tj Required judgment time V1, V2 valves (supply / exhaust control valves, directional control valves)

Claims

1. An image processing unit (33) performs predetermined image processing on an X-ray inspection image (Dpx) obtained by an operation that irradiates an item (P) being transported with X-rays and detects the X-rays that have passed through the item with an X-ray detector (23), and outputs determination data (Img) indicating the quality status of the item. A determination unit (35) that determines whether the article is good or bad based on the determination data, An X-ray inspection apparatus comprising a sorting unit (70) that sorts the aforementioned articles in a sorting direction according to the determination result of the determination unit, A distribution information setting unit (47) sets the distribution direction according to the determination result, When the aforementioned operation is performed using a sorting confirmation sample as the aforementioned item, a sorting operation control unit (45) sorts the sorting confirmation sample at a predetermined sorting timing based on the determination result of the determination unit, An X-ray inspection apparatus further comprising: a selection confirmation image generation unit (40) that generates a selection confirmation pseudo-image (Dps) for sorting in the sorting direction set by the sorting information setting unit, when the predetermined image processing is performed on a sample inspection image based on the X-ray inspection image of the selection confirmation sample, the determination result in the determination unit based on the determination data is to be sorted in the sorting direction set by the sorting information setting unit.

2. The X-ray inspection apparatus according to claim 1, wherein the sorting and confirmation image generation unit comprises an NG image storage unit (41) that stores images of predetermined defective parts that are determined to be sorted in the sorting direction, and an NG image generation unit (42) that generates a pseudo-image for sorting and confirmation by adding the images of predetermined defective parts stored in the NG image storage unit to the X-ray inspection image of the sorting and confirmation sample of the good product image.

3. The X-ray inspection apparatus according to claim 1 or 2, characterized in that, in addition to setting the sorting direction, the sorting timing is further set in the sorting information setting unit, and the sorting operation control unit performs sorting operations based on the sorting timing set in the sorting information setting unit.

4. When the articles are sorted in a predetermined sorting direction by the sorting unit, the system includes product recognition means (77, 78) for recognizing the articles, The X-ray inspection apparatus according to claim 3, characterized in that the sorting operation control unit causes the sorting unit to perform a sorting operation at a provisional sorting timing based on the transport speed when the articles are transported, and when the product recognition means recognizes that the sorting has been performed correctly in the predetermined sorting direction, it causes the sorting information setting unit to set the provisional sorting timing as the sorting timing.

Images