Modular X-Ray Scanner Modules for Fast Inspection Training
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing X-ray scanners are difficult to upgrade or adapt to new technologies, leading to obsolescence and costly replacements, and require time-consuming setups for specific product inspections.
Innovation Solution
A modular scanner design that allows interchangeable electromagnetic wave sources and detectors, combined with an automated application training method to optimize settings for various inspection applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fixed X-ray scanner design is used, then system stability is maintained, but adaptability to new technologies deteriorates
Solution Approach 1:
The X-ray scanner is divided into modular components: a base unit and interchangeable technology modules. Each module contains specific X-ray sources, detectors, or processing units that can be independently replaced or upgraded. This segmentation allows the system to adapt to new technologies by simply swapping modules rather than redesigning the entire system, thus improving adaptability while maintaining manageable complexity through standardized interfaces.
Solution Approach 2:
The base unit is designed with universal interfaces and mounting mechanisms that can accommodate multiple types of technology modules. The control system includes universal communication protocols and processing capabilities that work with different module types. This universality enables a single base unit to support various X-ray technologies and applications, improving adaptability without requiring multiple specialized systems.
2Reliability
If entire scanner is replaced when technology upgrades, then optimal performance is achieved, but cost and time loss increase
Solution Approach 1:
By segmenting the scanner into a reusable base unit and replaceable technology modules, the system allows selective upgrading of only the technology components that need improvement. The base unit with its control system, power supply, and structural framework can be retained and reused across multiple technology generations, significantly reducing replacement time and cost while still achieving optimal performance through module upgrades.
Solution Approach 2:
The module interfaces and mounting mechanisms are pre-designed and standardized in advance, allowing for quick connection and integration of new technology modules. Compatibility protocols and alignment features are established beforehand, enabling rapid deployment of upgraded modules without requiring extensive reconfiguration or calibration, thus minimizing downtime and replacement time.
3Measurement precision
If manual setup for each inspection application is performed, then inspection accuracy is optimized, but setup time increases
Solution Approach 1:
Optimal inspection parameters, algorithms, and detector settings are pre-configured within each technology module during its design and manufacturing process. When a module is installed, the control system automatically retrieves and applies these pre-optimized settings based on the module's identification, eliminating the need for manual setup while maintaining high inspection accuracy. This preliminary configuration enables rapid application switching without sacrificing measurement precision.
Solution Approach 2:
The control system continuously monitors inspection results and system performance, using feedback to automatically adjust parameters and optimize detection algorithms in real-time. This adaptive feedback mechanism allows the system to maintain high inspection accuracy across different applications without requiring manual intervention, as the system self-adjusts based on observed performance and contaminant detection requirements.
4Adaptability or versatility
If frequent reconfiguration for different products is done, then application versatility is improved, but system stability deteriorates
Solution Approach 1:
The system segregates stable, proven technology into the base unit while allowing configurable technology modules to handle application-specific variations. The base unit's control system, power supply, and structural framework remain stable and unchanged, providing a consistent foundation. Different technology modules can be swapped to accommodate various products and inspection requirements, achieving application versatility without compromising the stability of the core system components.
Solution Approach 2:
The control system is designed with universal processing capabilities and communication interfaces that can handle multiple application types through standardized protocols. This universality allows the stable base unit to support diverse inspection applications by working with different technology modules, achieving application versatility while maintaining system stability through consistent control architecture and processing logic across all configurations.
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 quick adaptation to new technologies and improved performance levels without replacing the entire scanner, reducing costs and time for setup and training.
Implementation Method 1
an electromagnetic wave source (102)... a detector (110) positioned to measure emissions from the electromagnetic wave source
Implementation Method 2
recording attenuated emissions that pass through the product
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A scanner comprises an electromagnetic wave source; and a detector positioned to measure emissions from the electromagnetic wave source, wherein the electromagnetic wave source comprises a first technology, and the electromagnetic wave source is interchangeable with a second electromagnetic wave source comprising a second technology and/or wherein the detector comprises a first technology, and the detector is interchangeable with a second detector comprising a second technology. The scanner can comprise a storage medium having instructions stored thereon to perform a method for training the scanner for an inspection application, the method comprising operating the electromagnetic wave source to generate electromagnetic wave emissions at a plurality of combinations of parameters; moving a conveyor belt to expose product having a plurality of contaminants of different sizes to the emissions generated at more than one combination of parameters; recording attenuated emissions that pass through the product at more than one combination of parameters; and selecting a combination of parameters to use when inspecting for the contaminant.