X-ray Image Processing for Foreign Object Detection on Separator Rolls
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Solution Overview
Problem
Inspecting foreign objects on separator rolls using X-rays is challenging due to the difficulty in reducing the spot diameter of X-rays with lenses and the resulting longer exposure times, which can lead to positional changes and image blurring, making it hard to detect foreign objects accurately.
Innovation Solution
An image processing device that calculates and integrates pixel values of a group of pixels in a continuous region to reduce the impact of X-ray attenuation variations, allowing for more accurate detection of foreign objects by setting a background value and calculating relative densities, thereby enhancing detection accuracy and reducing the risk of failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If X-ray radiography is used to inspect foreign objects on separator rolls, then the ability to penetrate thick objects is improved, but the exposure time increases and image blurring occurs
Solution Approach 1:
The patent combines multiple pixels that are adjacent to each other in the X-ray image into a single integrated pixel. By merging the signal from multiple pixels, the system achieves better signal-to-noise ratio and reduces the impact of blurring, allowing for shorter exposure times while maintaining detection capability.
Solution Approach 2:
The patent segments the X-ray image into multiple adjacent pixels and processes each pixel's signal separately before integration. This segmentation allows for precise control of the integration process and enables the system to distinguish between actual foreign objects and blurring artifacts.
2Area of stationary object
If X-ray source emits from an area rather than a point, then the spot diameter cannot be reduced with lenses, but this causes image blurring
Solution Approach 1:
The patent merges signals from multiple adjacent pixels to compensate for the inherent blurring caused by the extended X-ray source area. By integrating the signals, the system recovers the foreign object signal that would otherwise be diluted across multiple pixels, improving measurement precision despite the large source area.
3Loss of information
If exposure time is extended to capture sufficient X-ray signal, then the signal-to-noise ratio improves, but positional changes and blurring increase
Solution Approach 1:
The patent combines signals from multiple adjacent pixels to achieve the necessary signal-to-noise ratio without requiring long exposure times. The integration process sums the X-ray attenuation signals across multiple pixels, maintaining detection sensitivity while minimizing the time during which positional changes and blurring can occur.
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 solution effectively reduces the risk of failing to detect foreign objects by improving image processing techniques for X-ray images, allowing for more accurate detection and potentially shortening exposure times compared to conventional methods.
Implementation Method 1
an X-ray image sensor to capture an image on the basis of an X ray emitted by an X-ray source and attenuated by a foreign object
Data Source
AI summary
An image processing device and method for reducing the risk of a failure to detect a foreign object provided. The image processing device is configured for processing an image based on an X ray having propagated through an inspection target having a foreign object. The image processing device includes a storage section configured to store respective first pixel values of a plurality of pixels that form the image; a pixel value computing section configured to calculate respective second pixel values of the plurality of pixels on a basis of the first pixel values; and a pixel value integrating section configured to integrate respective second pixel values of a group of pixels belonging in a continuous region. The method includes steps of storing the respective first pixel values, calculating the respective second pixel values, and integrating respective second pixel values of a group of pixels belonging in a continuous region.