X-ray Inspection Apparatus for Foreign Matter Detection
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Solution Overview
Problem
Conventional X-ray inspection methods struggle to visualize foreign matter within objects at high resolution, particularly for fine pieces (about 0.3 mm) due to limitations in resolution differences among tomographic planes and difficulties in detecting foreign matter in three-dimensional spaces.
Innovation Solution
An X-ray inspection apparatus and method that generate frame data for multiple tomographic planes, calculate edge information, and create a composite image by combining pixels with maximum edge values, enhancing the visualization of foreign matter with improved resolution and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional X-ray inspection methods are used to detect foreign matter, then the inspection can be performed on assembled products, but the resolution is insufficient for fine foreign matter (about 0.3 mm) due to resolution differences among tomographic planes
Solution Approach 1:
The patent transitions from two-dimensional projection imaging to three-dimensional tomographic imaging by acquiring multiple images at different X-ray source positions and reconstructing tomographic planes. This dimensional change enables depth resolution and eliminates superposition of structures, achieving reliable detection of fine foreign matter at 0.3 mm resolution.
Solution Approach 2:
The patent divides the three-dimensional inspection space into multiple tomographic planes and processes each plane separately. By segmenting the volume into discrete slices and applying resolution correction for each plane, the system achieves consistent high-resolution detection throughout the entire inspection volume without degradation from depth-related blurring.
2Productivity
If the conveyor belt speed is increased for high productivity, then more products can be inspected per unit time, but the frame rate requirement increases making it difficult to achieve stable inspection
Solution Approach 1:
The patent performs resolution correction and image reconstruction in advance during the data processing stage, before final inspection decisions are made. By pre-processing the tomographic data to correct for resolution variations, the system enables high-speed conveyor operation without compromising detection stability, as the correction is already embedded in the reconstructed images.
3Reliability
If multiple tomographic planes are generated and processed, then three-dimensional detection capability is improved, but the data processing load increases making it difficult to achieve high frame rates
Solution Approach 1:
The patent extracts only the essential information needed for foreign matter detection from the multiple tomographic planes. By identifying and processing only the relevant features and differences between planes rather than handling all raw data, the system achieves three-dimensional detection capability while keeping processing complexity manageable and frame rates high.
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 approach allows for high-resolution visualization and reliable detection of foreign matter within objects, reducing data processing load and increasing frame rates, enabling more accurate inspection of objects in various applications.
Implementation Method 1
an X-ray tube that radiates X-rays and a detector that detects X-rays
Implementation Method 2
a detector that absorbs low-energy X-rays and a detector that absorbs high-energy X-rays
Data Source
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AI summary
Foreign matter present inside an object and the like are detected with higher resolution and higher reliability. Frame data of a plurality of tomographic planes that are parallel in the scan direction and set in a space between an X-ray tube (31 and an X-ray detecting unit (22) is generated based on detected frame data. The generation of frame data is performed based on the fan-shaped spreading of an X-ray beam and the differences in position in a height direction between the plurality of tomographic planes from a detection surface. Tomographic images are respectively generated from the frame data of the plurality of tomographic planes based on a laminography technique. Edge information based on the changes in pixel values in each tomographic image is calculated for each pixel. A three-dimensional distribution of the edge information is generated. A search is performed on the edge information in a direction passing through the plurality of tomographic planes. As a result of the search, pixels indicating a maximum value in the edge information are detected. Only pixels in the plurality of tomographic images that positionally correspond to the detected pixels are combined into a single composite image.