The invention relates generally to x-ray systems and particularly to apparatus and methods for absorption imaging of product advancing continuously on a conveyor belt.
Damage to modular plastic conveyor belts used in the meat, poultry, and other food industries often causes shards of plastic to contaminate the conveyed product. Besides the costs of belt repair or replacement and interruption in production, the food processor must also deal with possible contamination of the conveyed food product by the shards.
One version of apparatus for detecting materials on a conveyor belt comprises a conveyor belt conveying product in a conveying direction, an x-ray source, and a spectroscopic x-ray detector. The x-ray source directs a beam of x-rays having a source intensity distributed across a source spectrum through the thickness of the conveyor belt along an x-ray path. The spectroscopic x-ray detector comprises one or more pixels on the opposite side of the conveyor belt from the x-ray source that receive the x-rays that are attenuated as they pass through the conveyor belt, the conveyed product, and any foreign object advancing with the conveyed product on the conveyor belt at discrete pixel positions across the width of the conveyor belt. The one or more pixels define a corresponding field of view at each pixel position and determine a received intensity distributed across a received spectrum of the attenuated x-rays in its corresponding field of view at each pixel position. A processing system relates the received spectrum at each pixel position to the source spectrum to determine a measured attenuation of the x-rays and relates the measured attenuation to an x-ray attenuation model that includes attenuation coefficients of a set of preselected constituent materials including materials constituting the product, materials constituting the conveyor belt, and materials constituting foreign objects suspected as possible contaminants to determine the thickness of those materials in the fields of view at each pixel position.
One version of a method for detecting materials on a conveyor belt comprises:
(a) conveying product on a conveying surface in a conveying direction; (b) directing source x-rays having a source intensity distributed across a source x-ray spectrum along an x-ray path through the conveying surface and the product along a line across the width of the conveying surface; (c) detecting the x-rays attenuated on passing through the conveying surface at a plurality of pixel positions along the line with a spectroscopic x-ray detector comprising one or more pixels; (d) measuring the intensity of the attenuated x-rays in contiguous energy bins at each of the pixel positions to produce a received x-ray spectrum at each of the pixel positions; (e) relating the received x-ray spectrum to the source x-ray spectrum to determine a measured x-ray attenuation; and (f) relating the measured x-ray attenuation to an x-ray attenuation model that includes attenuation coefficients of a set of preselected constituent materials including materials constituting the product, materials constituting the conveyor belt, and materials constituting foreign objects suspected as possible contaminants to determine the thickness of those materials in the fields of view of each pixel in the line.
One version of an x-ray imaging apparatus embodying features of the invention is shown in
The spectroscopic x-ray detector 18 comprises a linear array of individual static x-ray-detecting pixels 20 that extend across the width of the belt 14. As one example, the pixels 20 can be solid-state cadmium telluride (CdTe) detectors. Each pixel 20 produces a received energy spectrum binned in contiguous fixed-width bins, such as 1 keV-wide bins, at each pixel position across the width of the belt 14. Thus, the array of pixels 20 represents a line scan that measures the received x-ray intensity distributed across a received x-ray spectrum. The received x-ray spectra are sent to a processing system 22 that includes a programmable computer running software programs such as a two-dimensional (2D) imager, an x-ray source controller, and a user-interface controller. The x-ray source controller pulses the x-ray source 10 in synchrony with the sampling of the spectroscopic x-ray detector 18. An alternative x-ray detector 18′, shown in dashed lines in
As shown in
The received x-ray spectrum at every pixel position is fitted to an x-ray attenuation model based on the Beer-Lambert Law, which models the received x-ray intensity Ir in each energy bin at the pixel position as the product of the source x-ray intensity Is and an exponentially decaying term: Ir(E)=Is(E)·e−Σi[μ(E)·d]
As shown in
The attenuation model is represented by a system of equations given in matrix form as:
where n is the number of energy bins used in the attenuation model; N is the number of preselected constituent materials in the attenuation model; μi(Ej) is the attenuation coefficient of preselected constituent material i in energy bin j; and di is the thickness of preselected constituent material i. All the μi(Ej) attenuation coefficients are known and stored in the processing system's memory or calculated algorithmically by the processing system. Likewise, the source intensity ME)) is known for each energy bin Ej. The received intensity Ir(Ej) for each energy bin is measured by the spectroscopic x-ray detector each sample time. The ratio of the received intensity to the source intensity is the measured attenuation. The processing system solves the system of equations by regression to determine the thicknesses di of each of the preselected constituent materials. The processing system uses a nonlinear regression, such as a least-squares regression. The Levenberg-Marquardt algorithm is one example of such a regression. The regression finds the best fit of the data to the attenuation model by minimizing the residuals of the di material thickness terms. The resulting di terms define the thickness of each of the preselected constituent materials for each pixel and, together with the calculated thicknesses for other samples, represent an image of the conveyor belt and the product and any other of the preselected constituent materials on the conveyor belt.
For example, to detect shards 42 of a conveyor belt 14 contaminating a piece of meat M as in
As shown in
As previously described in reference to
The flowchart of
With the x-ray detector calibrated and the belt pattern saved, the processing system runs the acquisition process 90 on the conveyor belt running loaded with product. The process first starts the conveyor belt at step 92 and pulses the x-ray source at step 94. The energy spectrum at each pixel position is recorded at step 96. The system of equations representing the attenuation model for the selected constituent materials is solved for a line scan after the calibration terms 74 are applied to the energy spectra at step 98 to construct a 2D image of a frame consisting of consecutive line images at step 100. The 2D image is stored at step 102. The stored 2D image 104 is available for display. If the belt speed has changed from the time when the empty belt pattern was stored by the initialization process 66, the frame image of the loaded belt is adjusted to match the frame length of the stored belt pattern or vice versa. And the loaded belt frame is synchronized, or aligned, with the empty belt pattern. Once that is done at step 106, the belt-pattern frame is subtracted from the loaded belt frame at step 108. The resulting difference provides the thicknesses of each of the preselected constituent materials at each pixel position in the frame. If any of the thicknesses exceeds an alarm threshold, a foreign-object-detection (FOD) alarm is sounded or other action is taken at step 110. If the belt is stopped at step 112, the acquisition process is exited. If the belt continues running, the process resumes in a regular repetitive fashion by pulsing the x-ray source again at step 94.
Although the processing system's initialization 66 and acquisition 90 processes can be implemented to run as individual sequential processes with program loops and delays to achieve the proper timing, the processes can alternatively be implemented more consistent with realtime multi-tasking programming using interrupt service routines and a task manager routine. As just one example, in the case of the acquisition process, the periodic pulsing of the x-ray source 94 and recording of the received energy spectra 96 could be implemented as an interrupt-service routine (ISR) scheduled to run at a preselected sampling rate. After all the spectra are recorded, the ISR could then bid the 2D imager task scheduled by the task manager to solve the system of equations 98, construct the 2D image 100, and store it 102 so that it can be displayed by a user-interface controller task. The 2D imager task could also synchronize the image with belt speed 106, subtract the stored empty belt pattern from the computed image 108, and generate FOD alarms 110. But those steps could alternatively be run in a separate task bid to run upon construction of the 2D image.
Although the attenuation model was described as using fixed-width energy bins, it is possible to combine energy bins to form effectively wider energy bins than those automatically produced by the pixels. Because the attenuation of x-rays is greater at lower energy levels, the pixels' energy bins at lower energy levels could be combined to form wider energy bins to be used in the attenuation model. At the higher energies, the energy bins used in the system of equations need not be as wide as those at the lower energies. But because the attenuation curve is much steeper at low energies, wider bins increase the error in the estimates of the attenuation values to be assigned to wide low-energy bins. To maintain the stability of the regression solution of the attenuation model, the widths of the bins are optimized so that the error term due to statistics (i.e., the count rate in an energy bin) and the estimation error in attenuation coefficient due to the steepness of the curve are approximately equal in magnitude.
Although the x-ray imaging apparatus has been described mainly in reference to detecting contaminants, especially shards of conveyor belt, it can also be used to detect belt features, such as thickened portions of the belt, which the processing system could use as positional references to measure belt elongation or belt speed or to determine the location of contaminants on the belt. And if a longitudinal lane of the belt is maintained clear of product, pixels under that lane could be used to measure the source x-ray intensity and spectrum in real time.
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