Fixed X-ray Source Inspection for High-Speed Small Part Positioning
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Solution Overview
Problem
Conventional X-ray inspection apparatuses face challenges in performing high-speed inspections of numerous small parts due to the large and heavy X-ray source, which requires complex and time-consuming movement mechanisms, making precise positioning difficult and reducing production efficiency.
Innovation Solution
An X-ray inspection apparatus with a fixed X-ray source capable of emitting X-rays over a wide solid angle, combined with a simple planar movement mechanism for the inspection object, allowing for high-speed imaging without the need to move the X-ray source or rotate the object, using a transmission-type open X-ray tube and a two-dimensional array CCD detector for high precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional X-ray source is used, then X-ray images can be obtained, but the apparatus becomes large and heavy requiring complex movement mechanisms
Solution Approach 1:
Instead of moving the heavy X-ray source to capture images from multiple angles, the patent inverts the approach by keeping the X-ray source fixed and moving the inspection object on a lightweight X-Y stage to achieve the same imaging goals with reduced mechanical complexity
Solution Approach 2:
The patent extracts the movement requirement from the X-ray source system, separating the function of generating X-rays (fixed source) from the function of positioning (object stage), thereby eliminating the need for complex source movement mechanisms
2Adaptability or versatility
If a large and heavy X-ray source is moved to different positions, then multiple inspection angles can be achieved, but much time is required to finish movement
Solution Approach 1:
The patent inverts the traditional approach by keeping the X-ray source stationary and moving only the inspection object on a fast X-Y stage, achieving multiple inspection angles without the time-consuming movement of heavy source equipment
Solution Approach 2:
The patent segments the inspection system into a fixed X-ray source component and a movable object positioning component, allowing the lighter object stage to be moved quickly to achieve high-speed multi-angle inspection
3Adaptability or versatility
If a θ-table is disposed on an X-Y stage, then rotational inspection is enabled, but the mechanism becomes larger in scale and takes longer to complete movement
Solution Approach 1:
The patent extracts the rotational inspection capability from the heavy θ-table mechanism and achieves the same functionality by moving the inspection object on a standard X-Y stage, eliminating the need for large-scale rotational tables
Solution Approach 2:
Instead of rotating the X-ray source or using a θ-table to achieve different inspection angles, the patent inverts the approach by moving the inspection object in the X-Y plane to achieve the same angular coverage with a simpler, smaller mechanism
4Manufacturing precision
If high precision positioning is required for small parts like BGA, then the heavy mechanism must be precisely controlled, but this is difficult and time-consuming
Solution Approach 1:
The patent segments the positioning function from the heavy X-ray source system and assigns it to a dedicated lightweight X-Y stage, which can be precisely controlled at high speeds without the inertial constraints of moving large source equipment
Solution Approach 2:
The patent inverts the traditional approach by making the inspection object the movable component rather than the X-ray source, allowing precise positioning of small parts like BGA using a fast, lightweight stage while maintaining high inspection throughput
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 high-speed inspection of multiple objects with improved precision and reduced complexity, allowing for efficient inline processing and accurate positioning, enhancing production efficiency by eliminating the need for complex rotational mechanisms and large-scale movement.
Implementation Method 1
an X-ray source uses a high voltage to generate X-rays
Implementation Method 2
a two-dimensional array CCD detector for high precision and speed
Data Source
AI summary
In an inspection of an object of inspection with use of X-rays, X-rays are output from an X-ray source disposed fixedly into a range of a predetermined solid angle and, while the object of inspection is moved along a plane within the output range of the X-rays, the X-rays are detected, in positions included in the solid angle and at a plurality of revolved points around an axis oriented vertical to the plane along which the object of inspection is moved, with its detecting surface tilted down toward the axis. Thus, the object can be inspected based on the detected X-rays.