X-ray Foreign Material Detection Using Challenge Cards
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Solution Overview
Problem
Existing foreign material detection systems in production lines require manual intervention and mode changes, leading to inefficiencies and increased risk of product recalls due to the need for manual verification and interruptions in production.
Innovation Solution
A system that uses challenge cards with marking components and RFID tags to automatically detect foreign materials in X-ray images, allowing continuous production line operation and enhanced verification efficiency by maintaining the system in a singular mode and automating the verification procedure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual verification and mode changes are implemented for foreign material detection, then detection accuracy is improved, but production efficiency deteriorates due to line stoppages and manual intervention
Solution Approach 1:
The system automatically performs verification by detecting challenge cards with RFID tags and marking components, eliminating the need for manual intervention. The machine self-verifies its detection accuracy continuously during production without requiring operators to stop the line for manual checking
Solution Approach 2:
The detection system operates continuously in a single production mode without requiring mode changes or line stoppages. Challenge cards are automatically detected and verified during normal production flow, maintaining uninterrupted production while continuously verifying detection accuracy
2Reliability
If frequent verification testing is performed to maximize detection accuracy, then foreign material detection reliability is improved, but production interruptions increase
Solution Approach 1:
Challenge cards are pre-placed within products before they enter the detection system. This allows verification testing to be performed on products that are already prepared, eliminating the need to stop production to insert test objects and enabling continuous verification during normal operation
Solution Approach 2:
The system performs verification testing continuously during production by automatically detecting challenge cards as products move through the scanner. This eliminates periodic stoppages for manual verification and maintains both production flow and detection reliability
3Measurement precision
If challenge mode operation is used for verification, then detection accuracy is confirmed, but system complexity increases due to multiple operational modes
Solution Approach 1:
The detection system operates in a single production mode that simultaneously handles both normal product detection and verification testing. The same scanning and processing mechanisms detect both foreign materials in products and marking components on challenge cards, eliminating the need for separate challenge modes or operational configurations
Solution Approach 2:
The system combines foreign material detection and verification testing into a single integrated process. Challenge cards with RFID tags and marking components are detected using the same X-ray imaging and processing systems used for product inspection, merging two functions into one unified operational mode
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
The system enables frequent and accurate foreign material detection without stopping the production line, reducing the risk of recalls and increasing overall efficiency by automating the challenge procedure and maintaining continuous operation of the machinery.
Implementation Method 1
controlling an X-ray machine to capture an image of a good
Data Source
AI summary
Disclosed herein are systems and methods for detecting foreign material in a good. A system controls an X-ray machine to capture an image of a good. The system analyzes the image captured by the X-ray machine by applying one or more of a foreign material detection algorithm and a foreign material model to the image. The system determines whether the good includes a foreign material comprising a challenge card by detecting at least one marking component on the foreign material when analyzing the image, wherein the challenge card includes the at least one marking component and a challenge material.