X-ray Container Flaw Detection with Central Source and Arc Detectors
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Solution Overview
Problem
Existing methods for detecting flaws in containers and their contents using x-ray radiation imaging suffer from low throughput and poor resolution, particularly in imaging the base of containers, due to limitations in x-ray source placement and material opacity.
Innovation Solution
An x-ray detection system with an arc-shaped transport path and x-ray source positioned on a central axis, surrounded by multiple imaging detectors, allows for improved coverage and magnification of container bases, enabling efficient detection of flaws with reduced distortion and increased throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single x-ray source and detector are used in prior art methods, then the device complexity is reduced, but the imaging coverage and resolution of container bases deteriorate
Solution Approach 1:
The patent divides the imaging system into multiple detectors arranged around the container at different positions and angles. Each detector captures a specific portion of the container base, and the results are combined to form a complete high-resolution image. This segmentation allows detailed imaging of the container base without requiring a single complex x-ray source configuration.
Solution Approach 2:
The patent transitions from a single-point x-ray imaging approach to a multi-dimensional imaging arrangement where detectors are positioned at various angles and distances around the container. This dimensional expansion enables comprehensive coverage of the container base from multiple perspectives, improving resolution and coverage simultaneously.
2Ease of operation
If the x-ray source is positioned at the level of the conveyor belt, then the setup is simplified, but the coverage of the container base deteriorates
Solution Approach 1:
The patent positions x-ray sources at multiple heights and angles around the container rather than at a single level. This multi-dimensional arrangement ensures that the container base is illuminated from various directions, achieving complete coverage including difficult-to-reach areas like the center of the base and edge regions.
Solution Approach 2:
The patent employs rotating or movable x-ray sources that change their position phase around the container during the imaging process. This dynamic positioning allows the x-ray beams to sweep across different portions of the container base, ensuring comprehensive coverage without requiring multiple fixed sources at different locations.
3Device complexity
If x-rays pass through the conveyor belt to image containers, then the imaging process is simplified, but the imaging quality deteriorates due to reduced x-ray intensity
Solution Approach 1:
The patent extracts the imaging function from the conveyor belt structure by positioning x-ray sources and detectors on separate, dedicated imaging platforms. This separation allows the x-ray beams to reach the container without passing through the conveyor belt material, preserving beam intensity and image quality while maintaining the conveyor's transport function.
Solution Approach 2:
The patent introduces intermediate imaging platforms and positioning mechanisms that facilitate the x-ray imaging process without requiring the x-rays to pass through the conveyor belt. These intermediaries enable precise positioning of sources and detectors while maintaining adequate x-ray intensity for high-quality imaging.
4Measurement precision
If multiple x-ray sources are used to improve imaging coverage, then the imaging quality improves, but the device complexity and cost increase
Solution Approach 1:
The patent combines multiple imaging functions into an integrated system where a single x-ray source can be positioned at different locations and angles, or where multiple detectors work together to capture complete images. This merging approach achieves comprehensive imaging coverage while reducing the total number of separate x-ray sources and detectors required.
Solution Approach 2:
The patent designs the imaging system with multi-functional components that can perform multiple imaging tasks. For example, a single x-ray source can image containers at different positions along the conveyor, and detectors can be configured to capture various portions of the container base. This universality reduces the overall complexity compared to having dedicated separate systems for each imaging function.
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 achieves accurate and efficient detection of flaws in containers and their contents, ensuring higher throughput and improved imaging quality, particularly at the critical base area, by optimizing the geometric arrangement of the x-ray source and detectors.
Implementation Method 1
x-ray radiation, which penetrate glass and plastic irrespective of its optical properties in the visible spectral range
Implementation Method 2
a thin section in a plastic container will absorb less x-ray radiation than a thicker section
Implementation Method 3
the discontinuity caused by the crack will reflect and/or refract the x-ray radiation
Data Source
AI summary
Method and system for x-ray detection of flaws in containers or their contents wherein containers are conveyed on a circular path around a central axis upon which an x-ray source is situated below the plane of the base of the containers. The x-ray source emits x-ray radiation obliquely upwards through the containers to a plurality of imaging x-ray detectors. Analysis of the images provided by these x-ray detectors determines the presence of a flaw in a container or its contents and is used to command a rejection mechanism to reject the container in question.