X-Ray Bulk Material Detection With Flap and Blowing Removal
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Solution Overview
Problem
Existing bulk material foreign object detection systems face inefficiencies in removing multiple objects due to the need for high-pressure gas blowing, which can fail when pressure is distributed across multiple nozzles, leading to incomplete removal and increased costs with larger compressors.
Innovation Solution
A dual removal method using flap and blowing mechanisms, where flap removal is employed for large quantities or dense objects, and blowing removal for smaller or less dense objects, with sub-flaps for precise control and reduced co-removal ratios, and re-inspection for missed objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple nozzles are opened at the same time to remove multiple foreign objects, then the quantity of foreign objects that can be removed increases, but the gas pressure becomes lower and removal effectiveness decreases
Solution Approach 1:
The patent segments the foreign object removal process into two distinct methods: blowing removal (using gas pressure) and flap removal (using mechanical flaps). The system divides foreign objects into two categories based on quantity: single or few objects are removed by blowing, while multiple objects are removed by flaps. This segmentation resolves the contradiction by providing a specialized solution for each scenario rather than attempting to use a single method for all cases.
Solution Approach 2:
The patent changes the removal method parameter based on the quantity of foreign objects detected. When the quantity exceeds a threshold, the system switches from blowing removal to flap removal. This parameter change allows the system to maintain high removal effectiveness by selecting the appropriate method for the specific situation, avoiding the pressure loss that would occur from opening multiple nozzles simultaneously.
2Quantity of substance
If the capacity of the air compressor is increased to open more nozzles at the same time, then more foreign objects can be removed, but the cost and space occupation increase
Solution Approach 1:
The patent segments the removal capability into two independent systems: a blowing removal system with limited nozzle capacity and a flap removal system with high multi-object capacity. This segmentation allows the system to handle multiple foreign objects without requiring a high-capacity compressor, thus avoiding the increased cost and space occupation while still achieving the goal of removing multiple objects simultaneously.
Solution Approach 2:
The patent uses flap removal as an alternative copy of the blowing removal function. Instead of upgrading the compressor to handle multiple objects, the system introduces flaps that perform the same removal function through a different mechanism. This copying approach achieves multi-object removal capability without the need for increased compressor capacity.
3Measurement precision
If blowing removal is used for bulk material, then precise removal of individual objects is possible, but removal fails when gas pressure is distributed across multiple nozzles
Solution Approach 1:
The patent changes the removal method parameter based on the quantity of foreign objects detected. For single or few objects, blowing removal is used to maintain precision. For multiple objects, flap removal is activated to ensure reliability. This parameter change based on object quantity resolves the contradiction by matching the removal method to the specific situation.
Solution Approach 2:
The system uses X-ray detection to feedback the quantity and position of foreign objects, then selects the appropriate removal method based on this information. When multiple objects are detected, the system feedbacks to activate flap removal instead of blowing, ensuring reliable removal. This feedback mechanism resolves the contradiction by making the removal method selection adaptive to the actual situation.
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
Enhances foreign object removal accuracy by adaptively selecting removal methods based on object quantity, density, and proximity, reducing failure rates and operational costs.
Implementation Method 1
high-pressure gas is blown, and the bulk material changes its falling trajectory due to the gas pressure
Implementation Method 2
the bulk material falls freely forward and downward due to gravity and inertia
Implementation Method 3
Through X-ray transmission images, the internal structure and state of products can be clearly seen
Data Source
AI summary
The present application discloses a bulk material foreign object detection method, device and X-ray foreign object detection equipment. The method is applicable to the X-ray foreign object detection equipment with a bulk material foreign object detection device, a flap removal device and a blowing removal device, comprising: acquiring an X-ray image of the bulk material under detection; analyzing the X-ray image, and determining the quantity, position, size and density of foreign objects in the bulk material; when the quantity of foreign objects exceeds a preset quantity threshold, or size, density and position relationship are not suitable for blowing removal, they are removed by the flap removal device; when they are suitable for blowing removal, based on their positions, they are removed by corresponding nozzles of the blowing removal device. Accurate and complete removal of foreign objects is achieved.