X-Ray Inspection Validation With Pseudo-Defect Images
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Solution Overview
Problem
Existing X-ray inspection systems require manual validation using test samples, which is labor-intensive and risks contaminating normal articles with defective ones, especially during production.
Innovation Solution
An X-ray inspection apparatus that generates pseudo-defect images by altering pixel values in inspection images to simulate defects, allowing automated validation without physical samples, and includes a control unit to manage sorting and conveyance based on these images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual validation using test samples is performed, then inspection validity can be checked, but worker workload increases and risk of defective articles混入 normal products increases
Solution Approach 1:
The patent creates a virtual copy of the inspection image by generating a pseudo-defect image that replicates the appearance of defective articles. This virtual copy allows the system to validate inspection capabilities without requiring physical test samples, thereby reducing worker workload while maintaining inspection validity checking
Solution Approach 2:
The patent introduces a pseudo-defect image as an intermediary between the inspection system and physical test samples. This intermediary enables validity verification through image processing and comparison algorithms, eliminating the need for manual handling of physical defective articles and reducing contamination risk
2Reliability
If manual validation using test samples is performed, then inspection validity can be checked, but risk of defective articles混入 normal products increases
Solution Approach 1:
By creating a virtual pseudo-defect image that mimics the appearance of actual defective articles, the system can validate inspection capabilities without physically handling defective products. This eliminates the risk of defective articles混入 normal product batches while maintaining the ability to verify inspection validity
Solution Approach 2:
The patent replaces the mechanical process of physically handling and running test samples through the production line with a digital image processing system. The control unit generates pseudo-defect images and compares them against inspection images using algorithms, eliminating mechanical contamination risk while maintaining validation functionality
3Ease of operation
If automated validation is implemented, then worker workload is reduced, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions: it generates pseudo-defect images, compares them with inspection images, and automates validity verification. By consolidating these functions into a single control unit, the system achieves automation to reduce worker workload without proportionally increasing overall system complexity
Solution Approach 2:
The system changes parameters of the inspection image by generating pseudo-defect images with modified pixel values that simulate defective conditions. This parameter transformation enables automated validation through image comparison algorithms, reducing manual intervention while managing system complexity through controlled image processing
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
Reduces the risk of defective articles being produced while minimizing worker workload by automating validation checks and ensuring accurate detection of defects.
Implementation Method 1
an irradiation unit that irradiates the article, which is conveyed by the conveying unit, with X-rays; a sensor unit that detects the X-rays that have transmitted through the article
Data Source
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AI summary
An X-ray inspection apparatus 1 includes a transport unit 5 that transports an article G; an irradiation unit 6 that irradiates the article G, which is transported by the transport unit 5, with X-rays; a sensor unit 7 that detects the X-rays; and a control unit 10 that generates an inspection image including the article G from a detection result of the X-rays by the sensor unit 7, and that inspects whether the article includes an abnormality, based on the inspection image. The control unit generates a pseudo-defect image including a virtual abnormality foreign object by changing pixel values of some of pixels constituting the inspection image generated when the article G is inspected, and checks a validity of the inspection based on the pseudo-defect image.