X-Ray Foreign-Body Detection Sensitivity Using Virtual Test Specimens
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Solution Overview
Problem
The determination of detection sensitivity for foreign bodies in X-ray machines used for product inspection is labor-intensive and time-consuming, requiring manual placement and conveyance of test cards with test spheres of different materials and sizes, which complicates the process.
Innovation Solution
An automated method using stored attenuation values of test bodies simulates their effect on product images, eliminating the need for manual placement and conveyance, and determining detection sensitivity through software-based image analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual placement and conveyance of test cards with test spheres is used to determine detection sensitivity, then detection sensitivity can be determined, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent creates virtual copies of test spheres by generating synthetic attenuation patterns that replicate the X-ray attenuation characteristics of physical test spheres. These virtual test spheres are superimposed onto product images, eliminating the need for physical test cards while preserving the measurement function. The synthetic attenuation values are calculated based on known material properties and geometric parameters of the virtual test spheres.
Solution Approach 2:
The patent replaces the mechanical process of manually placing and conveying physical test cards through the X-ray system with a computational approach. Virtual test spheres are generated through software algorithms that calculate expected attenuation patterns, and these are processed digitally to determine detection sensitivity. This substitution eliminates manual labor and physical handling while maintaining measurement accuracy.
2Adaptability or versatility
If multiple test cards with different materials and sizes are used to determine detection sensitivity, then comprehensive sensitivity data is obtained, but the process becomes even more time-consuming
Solution Approach 1:
The patent creates a universal virtual test sphere system where a single software framework can generate test spheres of various materials, sizes, and configurations. By storing attenuation characteristics for multiple material types and generating virtual spheres of different diameters through parameter adjustment, the system achieves comprehensive coverage of foreign body variations without requiring separate physical test cards for each scenario.
Solution Approach 2:
The patent determines detection sensitivity across multiple foreign body parameters by systematically varying virtual test sphere parameters (material composition, diameter, shape) within the software. Attenuation values are calculated for different parameter combinations, enabling comprehensive sensitivity assessment for various foreign body types and sizes through computational parameter variation rather than physical test card changes.
3Measurement precision
If physical test cards with test spheres are used, then detection sensitivity can be measured, but manual intervention and complex procedures are required
Solution Approach 1:
The patent replaces physical test cards with virtual copies generated through software. Virtual test spheres are created by calculating attenuation patterns based on material properties and geometric parameters, then superimposing these synthetic patterns onto product images. This copying approach maintains measurement functionality while eliminating the need for physical test card handling, storage, and setup procedures.
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
This method allows for rapid, fully automated determination of detection sensitivity without test cards, enabling immediate sensitivity determination after product teaching, and facilitates quick adaptation to various test specimen materials and sizes.
Implementation Method 1
an X-ray device for determining foreign substances in products... whose detection signal of the product produces a detection image... As a product passes through the X-ray machine, a grayscale image is created that numerically expresses the attenuation of the X-ray beam by the product
Data Source
Figure 1~2
AI summary
The invention relates to a method for determining the detection sensitivity of an X-ray device for detecting foreign substances in a product, comprising a detector whose detection signal produces a detection image with a defined resolution, which is evaluated for foreign substance detection. The method includes the following separate steps: - in a test specimen analysis phase, which serves to define the parameters for product inspection, the attenuation of the detection signal in the product's detection image by a test specimen of defined material and size is recorded and stored in the form of attenuation values; - in the ongoing product inspection, the product's detection image (product gray value) is calculated at several positions using the stored attenuation values of the test specimen (resulting gray value) and used to determine the detection sensitivity.