Metal Container Base Inspection Using X-Ray and Profile Correlation
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Solution Overview
Problem
Existing methods for inspecting the thickness and profile of metal container bases in manufacturing lines are inadequate, as they either fail to detect defects or require post-manufacturing inspection, leading to resource waste and potential structural integrity issues.
Innovation Solution
A combined process using X-ray equipment and a distance meter to inspect the base of metal containers in real-time during manufacturing, determining thickness and profile by correlating X-ray absorption data with distance measurements to ensure accurate detection of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If post-manufacturing inspection is performed with X-ray equipment, then thickness defects can be detected, but manufacturing time is increased and resources are wasted on completed containers
Solution Approach 1:
The X-ray inspection system is positioned to inspect the metal disc before it undergoes the complete extrusion and forming process. By performing the thickness measurement in advance, the system identifies defective discs before manufacturing resources are invested in creating the final container, thereby reducing waste and inspection time for completed products
Solution Approach 2:
The patent replaces traditional contact-based thickness measurement methods with non-contact X-ray inspection. This substitution allows for rapid, preliminary inspection of the metal disc without physical interference to the manufacturing flow, enabling quick identification of thickness defects before the extrusion process
2Measurement precision
If only X-ray equipment is used for inspection, then thickness can be measured, but profile and shape information is not obtained
Solution Approach 1:
The patent combines two inspection systems into a single integrated inspection station: an X-ray equipment for thickness measurement and a distance meter (laser profilometer) for profile and shape measurement. Both systems operate simultaneously on the metal disc or container, providing comprehensive inspection data including thickness, profile, and shape without requiring separate inspection processes
Solution Approach 2:
The inspection station is designed with multi-functional capabilities, where a single setup performs multiple measurement functions. The X-ray system measures thickness while the distance meter captures profile and shape information, both within the same inspection cycle, making the system universally applicable for comprehensive quality control
3Manufacturing precision
If inspection is performed after container completion, then all parameters can be checked, but defective containers have already been manufactured wasting resources
Solution Approach 1:
The inspection is performed at an early stage in the manufacturing process, specifically on the metal disc before or during the extrusion process. By identifying thickness defects and profile issues at this preliminary stage, the system prevents defective containers from being fully manufactured, thereby reducing material waste and resource consumption
Solution Approach 2:
The inspection system provides immediate feedback on the quality of the metal disc and extruded container. This real-time information allows for rapid identification of defects and can trigger automatic rejection or process adjustment, preventing further manufacturing of defective products and reducing overall material waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and precise determination of the base thickness and profile, allowing for immediate identification and rejection of defective containers, reducing waste and ensuring structural integrity.
Implementation Method 1
emitting an X-ray beam from the X-ray emitter towards the X-ray receiver through a first area of the base of the metal container, part of the X-ray intensity being absorbed by the base of the metal container
Implementation Method 2
emitting a light beam from the light emitter incident on at least one point of the base of the metal container and receiving the light reflected from the base at the light receiver
Data Source
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AI summary
Process for manufacturing and inspecting a metal container (10) and installation for carrying out said process, wherein the process comprises providing a metal disc (1), extruding the metal disc (1) to form the metal container (10), moving the metal container (10) in a forward direction (F), and inspecting the base (13) of the metal container (10), wherein said inspection comprises performing a first inspection of the base (13) with an X-ray equipment (210,211) to obtain a first set of points of the base (13) with thickness values (e) and performing a second inspection of the base (13) with a distance meter (220,221) to obtain a second set of points with distance values (d) with respect to the base (13), and relating both sets of points, such that for each of the points a thickness value (e) and a distance value (d) is obtained, such that a profile of the base (13) of the metal container (10) and the thickness of said profile is obtained.