X-ray Inspection Apparatus for Real-time Material Flow Control
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Solution Overview
Problem
In production lines, inconsistencies in the amount of raw materials conveyed can lead to decreased inspection accuracy, processing failures, and reduced manufacturing capacity, necessitating a solution to adjust the material flow appropriately.
Innovation Solution
An X-ray inspection apparatus is integrated with a conveyance unit, X-ray irradiation and detection units, an image generation unit, and a calculation unit to generate X-ray transmission images and calculate the total amount of articles conveyed per unit time, providing real-time feedback on material flow and enabling adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the amount of raw materials conveyed is increased, then manufacturing capacity is improved, but inspection accuracy deteriorates due to greater overlap of raw materials
Solution Approach 1:
The system implements feedback by using the X-ray inspection apparatus to detect the actual amount of raw materials conveyed, then providing this information back to the article handling apparatus upstream. This closed-loop feedback enables dynamic adjustment of material flow to maintain optimal inspection accuracy while maximizing manufacturing capacity.
Solution Approach 2:
The patent replaces manual monitoring and adjustment of material flow with an automated X-ray based detection and control system. The X-ray inspection apparatus automatically measures the amount of raw materials and triggers appropriate control actions, eliminating the need for manual intervention and enabling more precise control.
2Measurement precision
If the amount of raw materials conveyed is decreased, then inspection accuracy is improved, but manufacturing capacity is reduced
Solution Approach 1:
The system dynamically adjusts the amount of raw materials conveyed based on real-time detection results. Rather than using a fixed material flow rate, the article handling apparatus upstream can vary the conveyance amount according to actual inspection requirements, enabling optimal balance between inspection accuracy and manufacturing capacity under different operating conditions.
Solution Approach 2:
The system changes the parameter of material flow quantity dynamically based on detected conditions. When inspection accuracy requires lower material amounts, the system reduces conveyance; when capacity is prioritized and conditions permit, it increases conveyance. This parameter adjustment resolves the contradiction by making material flow adaptive rather than static.
3Measurement precision
If manual monitoring of raw material amounts is implemented, then inspection accuracy can be maintained, but labor requirements and operational complexity increase
Solution Approach 1:
The X-ray inspection apparatus performs self-service by automatically detecting and calculating the amount of raw materials conveyed without requiring external manual intervention. The system autonomously provides measurement data and can trigger control actions, eliminating the need for human operators to manually monitor and adjust material flow, thus maintaining inspection accuracy while reducing operational complexity.
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 effectively informs workers about the appropriateness of raw material amounts, allowing for timely adjustments to prevent inspection accuracy issues and processing failures, thereby enhancing production efficiency and accuracy.
Implementation Method 1
an X-ray irradiation unit configured to irradiate the articles conveyed by the conveyance unit with X-rays
Implementation Method 2
an X-ray detection unit configured to detect X-rays transmitted through the articles
Data Source
AI summary
An X-ray inspection apparatus includes a conveyance unit configured to convey articles, an X-ray irradiation unit configured to irradiate the articles conveyed by the conveyance unit with X-rays, an X-ray detection unit configured to detect X-rays transmitted through the articles, an image generation unit configured to generate an X-ray transmission image based on a detection result by the X-ray detection unit, and a calculation unit configured to calculate, based on the X-ray transmission image, the total amount of the articles conveyed per predetermined time by the conveyance unit.