X-ray Inspection Calibration via Conveyor Position Histogram Analysis
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Solution Overview
Problem
Conventional X-ray inspection apparatuses face challenges in achieving accurate calibration due to deteriorated or damaged transport conveyors, leading to inappropriate X-ray absorption and bright X-ray images, which can result in inaccurate inspections.
Innovation Solution
The X-ray inspection apparatus includes a determination unit that identifies appropriate positions for calibration by analyzing X-ray detection results from a line sensor, allowing for precise calibration by avoiding deteriorated or damaged conveyor sections, and a control unit that adjusts the conveyor to prevent target objects from being inspected over these areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If calibration is performed using detection data from all conveyor positions including deteriorated portions, then calibration can be completed using available data, but the resulting X-ray images become too bright and inspection accuracy deteriorates
Solution Approach 1:
The patent extracts and removes data from deteriorated conveyor portions before performing calibration. The determination unit identifies inappropriate positions where the conveyor is deteriorated or damaged, and the calibrating unit excludes these positions when calculating calibration parameters. This separation allows calibration to proceed using only valid data from healthy conveyor sections, preventing the bright image artifact while maintaining calibration completion.
Solution Approach 2:
The patent applies different quality standards to different conveyor positions. Instead of treating all positions uniformly, the system evaluates each position's suitability for calibration based on local conditions (deterioration, damage). Positions meeting quality criteria are used for calibration, while those failing criteria are excluded. This local quality assessment ensures high-quality calibration data is used without wasting available valid data.
2Quantity of substance
If calibration is performed using data from deteriorated conveyor portions, then all available detection data is utilized, but the calibration accuracy and X-ray image quality deteriorate
Solution Approach 1:
The system extracts only the useful subset of detection data from healthy conveyor portions, excluding data from deteriorated portions. This selective extraction maintains high data utilization of valid data while eliminating harmful data that would degrade calibration accuracy. The determination unit identifies which positions provide reliable calibration data based on local conveyor conditions.
3Productivity
If the conveyor is operated continuously without stopping at inappropriate positions, then productivity is maintained, but inspection accuracy over deteriorated portions cannot be ensured
Solution Approach 1:
The patent performs preliminary identification of inappropriate conveyor positions before actual inspection occurs. The determination unit pre-maps which conveyor positions are suitable for inspection based on conveyor condition data. During continuous operation, the system uses this pre-established knowledge to ensure objects are only inspected when the conveyor is in an appropriate state, maintaining both productivity and accuracy without requiring continuous stopping.
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
This approach enables highly precise calibration and inspection by ensuring accurate X-ray detection and image processing, even with deteriorated or damaged conveyors, thereby preventing false positives from conveyor issues.
Implementation Method 1
the line sensor includes a plurality of pixels for detecting X-rays from the X-ray irradiation unit via the transport conveyor
Implementation Method 2
X-rays are absorbed in such deteriorated portions, damaged portions, and joint portions
Data Source
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AI summary
An X-ray inspection apparatus and an X-ray inspection program capable of performing a highly accurate calibration to accurately inspect a target object regardless of the condition of a transport conveyor are provided. An X-ray inspection apparatus (10) is a device that detects, by an X-ray line sensor (14), X-rays used to irradiate a product (G) placed on a conveyor (12) and transmitted therethrough in order to detect the presence of foreign matter contained in the product (G). When performing a calibration of a plurality of pixels (14a) in the X-ray line sensor (14), an appropriate position of the conveyor (12) for the calibration is searched by various control blocks such as a determination unit (20a), a calibrating unit (20b), and the like formed in a control computer (20) installed in the X-ray inspection apparatus (10), and the calibration is performed based on the result detected by the X-ray line sensor (14) at the position.