Patent Application
20250003892
The present invention relates to an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus, and particularly relates to an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus capable of generating an X-ray image appropriate for a purpose such as an article inspection based on transmission image data of X-rays of a plurality of different energy regions.
An X-ray inspection apparatus is known in which X-rays of a plurality of different energy regions are emitted to an article to acquire transmission image data having a brightness variation according to a distribution of a transmission amount, and a predetermined image process is performed to inspect a quality of the article with high accuracy by making a difference in brightness between portions such as containing foreign matter or packaging defects.
For example, in an X-ray inspection apparatus disclosed in Patent Document 1, a transmission image in which a foreign matter is emphasized is generated by a subtraction process, and the presence or absence of the foreign matter is inspected and displayed on a display unit, so that an operator can grasp an inspection situation.
In addition, as in Patent Document 2, a display unit can be provided at a work location for post-processing an article after an inspection, and can display a work instruction including a transmission image to an operator.
Meanwhile, in the X-ray inspection apparatus, the system, and the like in the related art, for example, as an image processing technique for increasing detection accuracy of a foreign matter contained in an article is advanced, a portion having a high possibility of the foreign matter is emphasized and a brightness is remarkable, and inspection performance of the foreign matter can be improved, but the brightness variation tends to be ambiguous in a portion having a low possibility of the foreign matter.
That is, an X-ray transmission image of the article itself obtained as a result of an image process for accurately detecting the foreign matter is not useful for an operator who performs additional inspection, processing, or the like because it is difficult to obtain information for visually grasping a situation of a target object even by careful observation.
For example, in a case where a removal work of a residue such as a bone remaining in the article is performed as the additional processing while checking a position of the residue by looking at the transmission image, in order to grasp in which part the residue remains, in some cases, it is not easy to grasp the position of the residue in the article only from the image in which the bone or the like is emphasized, and work efficiency of the removal work is significantly reduced.
The present invention is made in order to solve the problems described above in the related art, and an object of the present invention is to provide an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus s with which an operator easily and accurately grasps a situation of an inspection object related to an inspection or work while improving inspection performance such as foreign matter detection.
In order to achieve the object described above, according to a first aspect of the present invention, there is provided an X-ray inspection apparatus including: an inspection unit that detects X-rays transmitted through an inspection object in a plurality of energy regions, and inspects the inspection object by using a determination image generated by executing a predetermined image process on at least two pieces of X-ray transmission image data corresponding to at least two energy regions; display means for displaying an inspection result of the inspection unit; display image generation means for generating a display image by executing a display image process different from the image process for generating the determination image, on the X-ray transmission image data; and display control means for causing the display means to display the inspection result and the display image.
With this configuration, in the X-ray inspection apparatus according to the first aspect of the present invention, the display image is generated by the display image generation means such that an image brightness of the inspection object in the display image is different from an image brightness of the inspection object in the determination image, and is displayed on the display means together with the inspection result in a predetermined display mode. Therefore, an operator can easily and accurately grasp a situation of the inspection object corresponding to the inspection result of the inspection object and a situation of a particularly important inspection part or a target part for which an additional inspection or work may be required depending on the inspection result, from the display image suitable for visual observation at a glance, while ensuring required inspection performance by the determination image.
According to a second aspect of the present invention, in the X-ray inspection apparatus according to the first aspect, the determination image is a subtraction image obtained by performing a subtraction process on the transmission image data of the X-rays in the plurality of energy regions, which are transmitted through the inspection object, and the display image is an image in which an image brightness of the inspection object in the image has a higher contrast than an image brightness of the inspection object in the determination image.
In this manner, for the determination image which is a subtraction image, by adjusting the X-rays in the plurality of energy regions, a foreign matter, an unnecessary residue, a fault part, or the like, which have a different X-ray transmittance from the inspection object, can be reflected with a high contrast with respect to the inspection object, and for the display image of the inspection object which is generated separately from the determination image, the image of the article itself is a high contrast image with respect to the inspection object in the determination image, so that the situation of the particularly important inspection part or the target part for which the additional inspection or work may be required depending on the inspection result, can be easily and accurately grasped from the display image. The contrast referred to herein is a difference between a light level and dark level or a difference in brightness, and it is also conceivable to use a display mode in which the display image and the determination image can be compared and referred to.
According to a third aspect of the present invention, the X-ray inspection apparatus according to the first aspect, further includes: operation input means for inputting request information according to an operation input of a user, in which the display image generation means generates the display image as a plurality of different images in which the same target object is reflected, by executing a plurality of types of image processes set in advance on X-ray transmission image data of a specific energy region among the plurality of energy regions, based on the request information from the operation input means.
In this case, since the display image is generated as a plurality of different images in which the same inspection object is reflected, the operator can select the display image capable of easily and accurately grasping the situation of the inspection object and the situation of the particularly important inspection part or the target part for which the additional inspection or work may be required depending on the inspection result, by any one or a plurality of images among the plurality of different display images.
According to a fourth aspect of the present invention, in the X-ray inspection apparatus according to the third aspect, the display image generation means executes a plurality of types of image processes stored in advance to generate a total X-ray image corresponding to the X-ray transmission image data including the plurality of energy regions, and performs a subtraction process on the X-ray transmission image data of the plurality of energy regions under a plurality of different image processing conditions to generate a plurality of different types of subtraction images, and the operation input means performs an operation input of requesting a display output of any one image or a plurality of images among the total X-ray image and the plurality of different types of subtraction images and an operation input of requesting a change setting of the display output.
In this configuration, by generating the plurality of different types of subtraction images such that a thickness or a shape of the entire inspection object or a portion of interest is easily reflected in the total image and a defective part such as a foreign matter, an unnecessary residue, or a fault part in the inspection object is relatively easily reflected in the subtraction image, the subtraction image with which a specific portion of the inspection object including the defective part is easily grasped can be easily specified.
According to a fifth aspect of the present invention, in the X-ray inspection apparatus according to the fourth aspect, the plurality of different types of subtraction images are subtraction images in which article-affected brightness variation of the inspection object in the image are different from each other according to the plurality of different image processing conditions.
In this case, since the article-affected brightness variation of the inspection object in the plurality of different types of subtraction images are different from each other, the subtraction image with which a specific portion of interest of the inspection object including the defective part (for example, the thick portion or the thin portion) is easily grasped is further facilitated to be specified.
According to a sixth aspect of the present invention, there is provided an article inspection system including: the X-ray inspection apparatus according to the first aspect; a transport device that transports an article on a predetermined transport path; and a post-process booth disposed on a downstream side of the transport path, in which an inspection unit of the X-ray inspection apparatus has an X-ray detector that detects X-rays transmitted through the article on the transport path, and outputs a detection signal, and display image generation means of the X-ray inspection apparatus outputs a display image to post-process display means installed in the post-process booth.
With this configuration, in the article inspection system of the present invention, the display image is output to the post-process display means of the post-process booth, so that a target part for an additional inspection or work in the post-process booth can be easily and accurately grasped based on the display image at a glance, and processing efficiency in the post-process booth can be improved.
According to a seventh aspect of the present invention, there is provided an X-ray image forming apparatus including: a transmission image data generation unit to which a detection signal of X-rays transmitted through an article is input and which generates X-ray transmission image data in a plurality of different energy regions; an image processing unit that executes a predetermined image process on the X-ray transmission image data in the plurality of energy regions to generate at least a subtraction image of the X-ray transmission image data; and an image output unit that causes display means to output the image generated by the image processing unit, in which the image processing unit includes display image generation means for generating a total X-ray image corresponding to the X-ray transmission image data including the plurality of energy regions, and executing the predetermined image process on the X-ray transmission image data in the plurality of energy regions under a plurality of subtraction image processing conditions to generate a plurality of different types of subtraction images as the subtraction image, and the image output unit includes selection operation means for selecting and setting at least one image of the total X-ray image and the plurality of different types of subtraction images generated by the display image generation means in a switchable manner as an image to be displayed and output.
With this configuration, in the X-ray image forming apparatus of the present invention, the display image generation means of the image processing unit generates the total X-ray image corresponding to the X-ray transmission image data including the plurality of energy regions, and executes the predetermined image process on the X-ray transmission image data of the plurality of energy regions under the plurality of different image processing conditions to generate the plurality of different types of subtraction images. By the selection operation means of the image output unit, at least one image of the total X-ray image and the plurality of different types of subtraction images is selected and set in a switchable manner as an image to be displayed and output. Therefore, an operator can easily and accurately grasp a situation of the inspection object corresponding to the inspection result of the inspection object and a situation of a particularly important inspection part or a target part for which an additional inspection or work may be required depending on the inspection result, from the display image suitable for visual observation, while ensuring required inspection performance by the determination image.
According to an eighth aspect of the present invention, there is provided an article processing system including: the X-ray image forming apparatus according to the seventh aspect; a transport device that transports an article on a predetermined transport path; and a post-process booth disposed on a downstream side of the transport path, in which a transmission image data generation unit of the X-ray image forming apparatus has an X-ray detector that detects X-rays transmitted through the article on the transport path, and outputs a detection signal, and the post-process booth has post-process display means for displaying and outputting at least one of a total X-ray image and a plurality of different types of subtraction images, which are generated by the image processing unit and selected and set by the selection operation means.
With this configuration, in the article processing system according to the present invention, at least one image of the total X-ray image and the plurality of different types of subtraction images, which are generated by the image processing unit and are selected and set by the selection operation means, is displayed and output by the post-process display means of the post-process booth. Therefore, a user who operates the selection operation means can easily and accurately grasp the target part for the additional inspection or the work in the post-process booth based on the display image suitable for visual observation at a glance, and the processing efficiency in the post-process booth is improved.
According to a ninth aspect of the present invention, in the article processing system according to the eighth aspect, the post-process display means is configured to include a plurality of displays spaced apart from each other at least in a transport direction of the article, and the post-process booth is provided with sorting means for sorting the article transported on the transport path in an additional process space corresponding to any one of the plurality of displays, in a transport order.
In the article processing system according to the ninth aspect, since the plurality of displays of the post-process display means are spaced apart from each other at least in an article transport direction by the transport path, the article transported to a downstream side of the transport path can be sorted in the additional process space corresponding to any one of the plurality of displays by the sorting means, in the transport order. The plurality of displays may be alternately arranged on both sides in a transport path width direction while being spaced apart from each other in the article transport direction.
According to the present invention, it is possible to provide an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus with which an operator easily and accurately grasps a situation of an inspection object related to an inspection or work while improving inspection performance such as foreign matter detection.
Hereinafter, embodiments according to the present invention will be described with reference to the drawings.
First, a configuration thereof will be described.
An X-ray inspection apparatus 1 illustrated in
The article transport unit 10 transports an inspection object W (article) in a direction of an arrow Db in
The X-ray inspection unit 20 includes an X-ray generator 21 and an X-ray detector 22 that are disposed with the transport path 11a of the article transport unit 10 therebetween. The X-ray generator 21 and the X-ray detector 22 are disposed to face each other while being spaced apart from each other up and down in a vertical direction, for example, here, and may be disposed to be spaced apart from each other in both the vertical direction and a horizontal direction.
The X-ray generator 21 emits X-rays toward the transport path 11a side of the inspection object W by the article transport unit 10, and in the present embodiment, the inspection object W is irradiated with the X-rays downward from a vertically upward side. Meanwhile, the irradiation direction of the X-rays from the X-ray generator 21 is not limited to the downward direction, and may be another direction.
An X-ray source of the X-ray generator 21 is, for example, an X-ray tube with a thermal cathode incorporated therein, and may be a grid-controlled thermal cathode X-ray tube that controls an X-ray amount (for example, reduces the X-ray amount with a negative grid voltage) by controlling a grid voltage applied to a control grid.
The X-ray generator 21 applies a direct-current negative potential to a cathode of an X-ray tube (not illustrated), for example, emits electrons from a filament that is lit at a high temperature, and focuses electrons emitted from the filament using a focusing electrode to which a direct-current negative potential is while applying a direct-current positive potential to a target to accelerate the electrons emitted from the filament at a high voltage and cause the electrons to collide with the target, thereby generating X-rays from the target.
As illustrated in
Specifically, the X-ray detector 22 is configured with one line sensor in which the plurality of sensors 221 to 22N are integrally coupled, and is disposed on a lower side of the transport path 11a inside the loop-shaped transport belt 11 of the article transport unit 10. Here, for example, if each sensor width of the plurality of sensors 221 to 22N in the Da direction is 1 mm, a gap between the sensors is sufficiently small with respect to a sensor width, and a width of the transport path 11a for transporting the inspection object W in the Da direction is 200 mm, it is sufficient to use a line sensor having approximately 200 sensors. The X-ray detector 22 can output detection information for X-rays of a plurality of different energy regions, respectively. Details of this configuration will be described below.
As illustrated in
The inspection processing unit 30 is realized by a combination of hardware, such as a central processing unit (CPU) and a random access memory (RAM), and software, such as a program that exhibits various functions on the hardware without being illustrated in detail, and may include a field programmable gate array (FPGA), a digital signal processor (DSP), or the like, for example. The various functions referred to herein are functions of each means for generating the X-ray transmission image data, performing predetermined inspection control, display output control, and the like.
The transmission image data generation means 31 performs a predetermined signal process by dividing electric signals (detection information) in units of a scan time set in advance, which are respectively output from the plurality of sensors of the X-ray detector 22 while the inspection object W passes through between the X-ray generator 21 and the X-ray detector 22, detect information on a two-dimensional position defined in the Db direction, which is a transport direction of the inspection object W, and the Da direction in which the sensors 221 to 22N are arranged, and an image tone value according to a signal processing result for each position, and generate transmission image data of the inspection object W.
In addition, in response to the X-ray detector 22 outputting the detection information of each of a plurality of different energy regions, the transmission image data generation means 31 generates the transmission image data of the inspection object W, corresponding to each of the plurality of energy regions.
Specifically, the X-ray detector 22 outputs detection information of X-rays in a certain energy region, for example, a first energy region, and the transmission image data generation means 31 generates first X-ray transmission image data (Xza in
That is, in the present embodiment, energy of X-rays corresponding to a detection signal level of the X-ray detector 22 has a magnitude relationship of the “first energy region”< “second energy region”. In the example described above, the description is made in a state in which the first energy region is set to 20 keV to 40 keV and the second energy region is set to 50 keV to 70 keV, and these two energy regions are spaced apart from each other, and the embodiment is not limited thereto. The relationship between these two energy regions may be any of separation, adjacency, and partial overlap, and it is sufficient that a central value of each energy region satisfies the magnitude relationship described above. In addition, the number of energy regions is not limited to two, and may be three or more energy regions having different central values.
The transmission image data storage means 32 has an image memory function of sequentially taking transmission image data generated by the transmission image data generation means 31 in correspondence with each of the plurality of energy regions, that is, the transmission image data Xza and Xzb of the inspection object W generated based on two-dimensional position information of the inspection object W and a signal processing result for each position by executing a predetermined signal process for each scan time, as line image data for each scan time over a predetermined inspection time. In addition, each time a predetermined inspection time elapses, the transmission image data storage means 32 stores transmission image data Xia and Xib in which the entire inspection object W is reflected as transmission images of X-rays of the first and second energy regions (the plurality of different energy regions) such that the transmission image data Xia and Xib can be respectively read out. The predetermined inspection time is, for example, an X-ray inspection time of each inspection object W, which is set in accordance with a length and a transport speed of each inspection object W in the transport direction based on a timing of the transport of the inspection object W to the article transport unit 10, and is set as a time sufficient for each inspection object W to completely pass over the X-ray detector 22.
The determination means 33 executes, according to a determination processing condition set in advance and stored, and a condition additionally set by the condition setting means 36, an image process for determination of a predetermined image processing algorithm on each of at least two pieces of the transmission image data Xia and Xib corresponding to the same inspection object W among the plurality of pieces of the transmission image data of the X-rays of the plurality of energy regions stored in the transmission image data storage means 32, and execute a subtraction process known as an energy subtraction process between the processed transmission image data Xia and Xib to determine the presence or absence of a defective portion such as a foreign matter or a bone in the inspection object W based on transmission image data (hereinafter, also simply referred to as a subtraction image) Xsc obtained as a result of the subtraction process. The predetermined image processing algorithm here is a combination of, for example, a plurality of image processing filters and an image process for feature extraction.
In a case where the subtraction process as described above is performed, for example, by setting each energy region such that, among the X-rays of the plurality of energy regions, X-rays in any low-energy region are less likely to be transmitted through a defective portion such as a foreign matter or a bone, and X-rays in a high-energy region are relatively likely to be transmitted through the defective portion such as the foreign matter or the bone, transmission image data in which the defective portion such as the foreign matter or the bone is emphasized is obtained in the subtraction image as compared with an article-affected image that reflects the inspection object W itself, so that it is possible to increase determination accuracy of the determination means 33 that determines whether or not the defective portion in which the foreign matter is contained or the bone is left behind occurs in the inspection object W.
The determination result (a signal indicating the presence or absence of the defective portion described above) of the determination means 33 is used as a sorting command signal for controlling a latter-stage sorting device (not illustrated), and when the inspection object W determined to have the defective portion reaches the sorting device, the defective inspection object W is excluded to an outside from a transport path of a non-defective product extending on a downstream side of the sorting device in response to the sorting command signal.
The display image generation means 34 executes a predetermined display image process on the transmission image data Xia and Xib of the X-rays of the first and second energy regions stored in the transmission image data storage means 32 to generate a display image different from the determination image Xsc in which the subtraction process described above is performed on at least an image brightness of the inspection object W. Here, the predetermined display image process is executing of an image process of applying a predetermined image processing algorithm or the like to each of the transmission image data Xia and Xib of each energy region read out from the transmission image data storage means 32, and the predetermined image processing algorithm is a combination of, for example, a plurality of image processing filters and an image process for feature extraction.
Specifically, for the determination image obtained in the determination means 33, as described above, the subtraction image data Xsc obtained by performing the subtraction process on the X-ray transmission image data Xia and Xib of the plurality of energy regions is transmission image data in which the defective portion such as the foreign matter or the bone is emphasized, as compared with an X-ray image in which the inspection object W itself is an imaging target. Meanwhile, the display image generation means 34 generates image data of a display image Xip suitable for visual observation in which an image brightness of the inspection object W has a higher contrast than an image brightness of the inspection object W in the determination image Xsc as a plurality of types of candidate images different from each other. The contrast referred to herein is a difference between a light level and dark level or a difference in brightness.
For example, the display image generation means 34 generates a total X-ray image Xte (transmission image data of X-rays in a total energy region including the X-rays in the plurality of energy regions) obtained by adding up tone values of the X-ray transmission image data Xia and Xib in the plurality of energy regions as one candidate of the display image Xip. The total X-ray image Xte is obtained by adding the tone values of respective pixels of the high-energy image and the low-energy image, and may be used as an average value instead of adding the tone values of the respective pixels.
Further, the display image generation means 34 generates a plurality of different types of, visually distinctive, subtraction images Xs1, Xs2, and Xs3 in which an image brightness of the inspection object W has a higher contrast than the determination image Xsc by executing a plurality of types of subtraction processes in which each processing condition is different for the predetermined determination image process (filter process, feature extraction process, subtraction processes, or the like) of the determination means 33, and the processing conditions of the subtraction process in the display image generation means 34 are further different from each other. The subtraction images Xs1, Xs2, and Xs3 are displayed as other plurality of candidate images of the display image Xip than the total X-ray image Xte. The subtraction image referred to here is an energy subtraction image using a high-energy image and a low-energy image, and an image in which a low brightness portion or a high brightness portion is emphasized is used for at least one of the high-energy image or the low-energy image. When the plurality of different types of subtraction images Xs1, Xs2, and Xs3 are displayed as the candidate images of the display image Xip, it is also possible to consider displaying the determination image Xsc in a display mode in which the determination image Xsc can be compared and referred to.
The plurality of types of subtraction processes are processes of, for example, selecting X-ray detection signals in any two regions among a plurality of energy regions R1, R2, R3, and R4 illustrated in
The operation display unit 40 is, for example, a touch panel type display device configured with a liquid crystal display (LCD) or the like, and has a function of display means 41 and a function of operation means 42 (operation input means).
The function of the display means 41 is a function of displaying various types of information required for the X-ray inspection, such as an operation state or setting information of the X-ray inspection apparatus 1, on a display screen. In addition, the function of the operation means 42 is, for example, a function of performing various touch panel operations, such as a selection operation of a display screen, a mode switching operation of whether an operation mode is an inspection mode, a setting mode, or another mode, and a function of inputting request information according to an operation input of a user in an operation function of performing an operation of setting, inputting, or the like various parameters under the setting mode.
The operation display unit 40 is not limited to a touch panel integrated with the X-ray inspection apparatus 1, and may be provided in a form of a portable tablet type information terminal or the like, or may be additionally installed in a form of a display, an operation panel, or the like different from the touch panel integrated with the X-ray inspection apparatus 1.
The display control means 35 executes a predetermined display control process by taking an OK/NG signal (further, the determination image Xsc according to a display request) which is a determination result from the determination means 33, candidate image data of the display image Xip, which is generation image data of the display image generation means 34, for example, the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, and Xs3, a request operation input from the operation means 42, for example, a display control condition set by the condition setting means 36 according to a type selection operation of the inspection object W, and the like. The display control means 35 causes the display means 41 to display a result of the X-ray inspection and the display image Xip of the inspection object W, which is the inspection target, in a display mode set according to the type and other inspection conditions by the condition setting means 36.
For example, when the type of the inspection object W is set, the display control means 35 generates the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, and Xs3 for a sample of the inspection object W for the type setting, as candidates for the display image Xip displayed on the display means 41. The display control means 35 can generate, and display and output the candidate image data Xte, Xs1, Xs2, and Xs3 of the plurality of display images Xip as the candidates for the display image Xip appropriate for observation of each user who uses the operation display unit 40 in a scrollable, selectable, and operable manner by the display means 41 on a screen, in an inspection before state in which the type setting is completed, in an inspection stop state in which a switching request operation input of the display image Xip from the operation means 42 is performed, or in another non-inspection state. In a case where the display devices are installed at a plurality of locations as the display means 41, a selection setting of the display image Xip may be enabled for each of the display devices.
The display control means 35 also stores and holds a display control program and display screen information for displaying and expanding any of display screen groups stored in a stepwise-expandable manner from a main menu screen on the display means 41 in response to an operation input to the operation means 42, and displaying a first operation display screen 60 illustrated in
As illustrated in
In the first operation display screen 60, when a touch operation is performed on a setting and adjustment button 65a in the operation button display region 65, the condition setting means 36 of the inspection processing unit 30 can shift the X-ray inspection apparatus 1 to the inspection stop state, and can expand and display a function selection and setting operation window 66 in which a function such as an inspection setting, a sorting setting, a transport setting, a communication setting, an operation check request, a display screen setting, or the like can be selected and set above the operation unit image of the setting and adjustment button 65a.
Further, when the display screen setting in the function selection and setting operation window 66 is selected, the display control means 35 can shift the X-ray inspection apparatus 1 from the inspection stop state to the setting mode, and can cause the display means 41 to display and output a second operation display screen 70 as illustrated in
As illustrated in
In this case, the second operation display screen 70 is displayed by the display image selection function of the function selection and setting operation window 66, and if the supply of the inspection object W is stopped once to be shift to the inspection stop state or the like, the second operation display screen 70 can be displayed by the display means 41 by selecting a display image setting menu in the function selection and setting operation window 66.
In addition, if the display image setting menu is selected, a plurality of selection candidates of the display image Xip that can be displayed on the second operation display screen 70 are read out from a memory of the condition setting means 36, the number of display images is narrowed down according to a selection input in the selection input display region 74, and the display images are displayed as preview images (images 1 and 3 in
Alternatively, as illustrated in
Of course, in a case where an operation of selecting the function of the display screen setting is performed in a state in which the function selection and setting operation window 66 is displayed on the first operation display screen 60, a display control condition of whether to display the display image selection screen 70 or to pop-up display the display screen selection setting window 83 can be alternatively selected and determined by the condition setting means 36, and can be switched as necessary. Alternatively, it is also conceivable to switch whether to shift the function selection and setting operation window 66 to the display output of the display image selection screen 70 or to the pop-up display of the display screen selection setting window 83, by performing a touch operation input with different operation conditions.
Also in a case where the preview image display region 73 of the display image selection screen 70 or any of the display screen selection setting windows 83 that are pop-up displayed in the first operation display screen 60 is displayed, the display image generation means 34 executes a plurality of types of image processes (display image process) that are set in advance, on X-ray transmission image data in a specific energy region among the plurality of energy regions from request information from the operation means 42 to generate a plurality of candidate images (including the candidate images 83b, 83f, and the like that are outside the display screen selection setting window 83 in
For example, the display image generation means 34 generates the total X-ray image Xte corresponding to the X-ray transmission image data including the plurality of energy regions as some of the plurality of candidate images 83a, 83b, 83c, 83d, 83e, and 83f, by executing a plurality of types of image processes stored in advance in the memory as a predetermined image process for generating a display image, and generates the plurality of different types of subtraction images Xs1, Xs2, and Xs3 obtained by performing the subtraction process on the X-ray transmission image data of the plurality of energy regions under a plurality of different processing conditions. As described above, the plurality of types of subtraction processes are processes of selecting X-ray detection signals in any two regions among the plurality of energy regions R1, R2, R3, R4, and the like and executing the image processing filter or the feature extraction process on each of the X-ray detection signals, and then performing the subtraction process on X-ray transmission image data of the two regions of each set, and may include the determination image Xsc.
Examples of the image type of the display image Xip include a subtraction image in which a light portion (for example, a thick portion of the inspection object W) of the X-ray transmission image on a high-energy region side is emphasized, in addition to the total X-ray image Xte described above and a simple subtraction image corresponding to the determination image Xsc, a subtraction image in which a dark portion (for example, a portion of a foreign matter or an unnecessary residue) of the X-ray transmission image on a low-energy region side is emphasized, a subtraction image in which a dark portion (for example, the portion of the foreign matter or the unnecessary residue) of the X-ray transmission image on the high-energy region side is emphasized, a subtraction image in which a light portion (for example, a thin portion of the inspection object W) of the X-ray transmission image on the low-energy region side is emphasized, and the like. Meanwhile, the candidates for the display image are not necessarily limited to these, and a selection list of the display image Xip can be displayed to be set and changed or scrollable such that the X-ray transmission image on the high-energy region side, the X-ray transmission image on the low-energy region side, and the X-ray transmission image before the subtraction process in which the emphasis process is performed can be selected.
Also in the preview image display region 73 of the display image selection screen 70 and also in the display screen selection setting window 83 that is displayed in a pop-up manner in the first operation display screen 60, the number of display modes that can be switched is, for example, three or more, and it is needless to say that the number of display modes that can be switched may be two, or four or more. In addition, if a grayscale display can be performed, the grayscale display may be performed, but only a screen frame and an option that is a candidate for the display image Xip may be displayed. Only the selected image may be preview-displayed as a display image selected by the display frame of the thick frame.
In the display screen selection setting window 83 illustrated in
In this manner, the operation means 42 (operation input means) is capable of an operation input for requesting a display output in a state in which any one image or a plurality of images of the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like are selected and set, and an operation input for requesting a change setting of such display output, and in
As illustrated in
Next, a detailed configuration of the X-ray inspection unit 20 illustrated in
As illustrated in
The article transport unit 10 and the X-ray inspection unit 20 in
When describing the X-ray detector 22 in more detail, the X-ray detector 22 is configured with a line sensor in which N pieces of photon detection type sensors that output a pulse signal having a wave peak value corresponding to energy of a photon as detection information each time the photon of the X-ray transmitted through the inspection object W is input to the photon detection type sensor are arranged in a transport width direction as the plurality of sensors 221 to 22N. Therefore, the transmission image data generated by the transmission image data generation means 31 represents a brightness of a transmission image corresponding to the number of pulses output by each of the sensors 221 to 22N per unit time.
The sensors 221 to 22N output one pulse signal having a wave peak value corresponding to energy of a photon for one input of the photon. Since the X-ray generator 21 emits X-rays in which photons of X-rays having different energies (wavelengths) are mixed, the pulse signals output from each of the sensors 221 to 22N have variations in wave peak values.
If it is determined which of a plurality of different signal level sections constituting the entire output range of the wave peak value in advance, for example, the plurality of energy regions R1, R2, R3, and R4 illustrated in
In addition, in order to generate the plurality of pieces of transmission image data having different ranges of the X-ray transmission energy, the transmission image data generation means 31 converts the output signal of each of the sensors 221 to 22N associated with the positions in the Da direction which is the transport width direction into a digital data string by the A/D conversion units 511 to 51N, and inputs the digital data string to the wave peak value detection units 521 to 52N.
Each of the wave peak value detection units 521 to 52N is for detecting a wave peak value of a pulse signal from the input data string, and for example, performs a differentiation process on the input data string, detects a zero-cross timing at which a differentiation value (a slope of the signal) is switched from a positive value equal to or more than a predetermined value to a negative value equal to or less than the predetermined value, detects a data value at the zero-cross timing as the wave peak value of the pulse signal, and outputs the data value to the region determination units 531 to 53N, respectively.
The region determination units 531 to 53N compare the region boundary values L1 to LM−1 in which an output range of a wave peak value is divided into M (a plurality of) regions R1 to RM with the wave peak value detected by the wave peak value detection units 521 to 52N, determine in which region the wave peak value enters, and output a region identification signal representing the region in which the wave peak value enters to the region-by-region accumulation units 541 to 54N.
Each of the region-by-region accumulation units 541 to 54N receives the region identification signal output from each of the region determination units 531 to 53N within the scan time, accumulates the number of inputs of the region identification signals indicating the same region, and sequentially outputs the cumulative number for each region within the scan time. The cumulative number of the region identification signals is the cumulative number of pulse signals among pulse signals output from one sensor within the scan time, having the same region in which the wave peak value enters.
The transmission image data output unit 55 sets the cumulative number of region identification signals output from the respective region-by-region accumulation units 541 to 54N for each scan time to data arranged in parallel and in time series, and outputs the data as transmission image data for the inspection object W in each region.
The way to divide the region of the wave peak value described above is not unique, and as one example, the region may be divided evenly into a plurality of regions between a wave peak value of a pulse signal output by a sensor with respect to the maximum value of the energy of the photon of the X-rays emitted from the X-ray generator 21 (a theoretical value depending on an acceleration voltage of an electron in a case of an X-ray tube) and a predetermined reference value (for example, 0). In addition, the number of regions is also any number of two or more, and transmission image data may be generated in a large number of regions first, and transmission image data appropriate for each of the detection of the foreign matter or the mass measurement may be selected and used from the transmission image data.
For example, transmission image data may be generated in each region with an initial number of regions set to 10, and a first region counted from a region having the highest energy may be assigned to the region R1, a third region may be selectively assigned to the region R2 described above, and the like, from the initial region to the final region, and the transmission image data of the assigned region may be used. In addition, transmission image data of a plurality of regions in an initial state may be combined to obtain transmission image data of one region in a final state, and the combined transmission image data may be used. Specifically, transmission image data of the first and second regions counted from a region having the highest energy may be combined to obtain transmission image data of the region R1 described above, and transmission image data of the third and fourth regions may be combined to obtain transmission image data of the region R2 described above.
In the specific example illustrated here, the transmission image data is generated only for the number of initial regions, and the region is assigned and the transmission image data is combined according to the combination of the transmission image data optimum for the detection of the foreign matter or the like. Meanwhile, in a case where the combination of the transmission image data optimum for detection of a foreign matter or the like is known for the inspection object W, only the transmission image data for the assigned region need be generated, and instead of combining the plurality of transmission image data, the cumulative number of region identification signals of the plurality of regions may be added up to generate one transmission image data (total X-ray image). Thus, it is possible to save a storage region of the transmission image data storage means 32.
The plurality of pulse signal level regions R1 to RM can be a plurality of different X-ray energy regions. That is, by using the photon detection type sensor, the X-ray transmission image data in the plurality of different energy regions, including the first X-ray transmission image data Xza and the second X-ray transmission image data Xzb described above, are obtained. For example, the determination means 33 or the display image generation means 34 may perform the necessary image process by using the transmission image data in the energy region R4 as the first X-ray transmission image data Xza and using the transmission image data in the region R2 having X-ray energy higher than X-ray energy in the energy region R4 as the second X-ray transmission image data Xzb.
In this manner, in the configuration using the photon detection type sensor and the transmission image data generation means 31 corresponding to the photon detection type sensor, it is possible to easily acquire X-ray transmission image data in a desired energy region, and it is possible to provide an X-ray inspection apparatus having an appropriate X-ray inspection function based on the X-ray transmission image data in the energy region appropriate for detecting a contained foreign matter, or an unnecessary residue such as a bone. In such an apparatus configuration, as described above, the display switching in the operation display unit 40 is executed after the X-ray inspection is temporarily stopped, and the operation display unit 40 displays an option of the display image that is selectable by the user. In addition, one or more of the options can be selected, and when being selected, the selected option is preview-displayed as a candidate image and/or a selected image. In this case, if a plurality of options are selected, the options are displayed side by side. In addition, it is also possible to read out the transmission image data, execute different image processes on one transmission image data, and generate a plurality of types of display images Xip.
Next, operations will be described.
In the X-ray inspection apparatus 1 according to the present embodiment configured as described above, an X-ray inspection mode in which an X-ray inspection can be executed and other modes, for example, a setting mode in which various settings can be performed are switched by the condition setting means 36 according to an operation input of a mode selection to the operation means 42 of the operation display unit 40.
When the X-ray inspection is executed in the inspection mode of the X-ray inspection apparatus 1, the X-ray generator 21 of the X-ray inspection unit 20 emits X-rays to the inspection object W transported in the transport direction, that is, the Db direction by the article transport unit 10, the X-rays transmitted through the inspection object W are detected by the X-ray detector 22 and input to the transmission image data generation means 31, and transmission image data of the inspection object v corresponding to each of a plurality of energy regions, for example, the X-ray transmission image data Xza and Xzb of first and second energy regions are generated.
Further, the X-ray transmission image data Xza and Xzb of the inspection object W from the transmission image data generation means 31 are sequentially taken in by the transmission image data storage means 32 as line image data for each scan time over a predetermined inspection time, and can be respectively read as the transmission image data Xia and Xib in which the entire inspection object W is reflected.
The determination means 33 generates the determination image Xsc that is a subtraction image by an image process and a subtraction process of a predetermined image processing algorithm on the transmission image data read out from the transmission image data storage means 32, for example, the two pieces of transmission image data and Xib corresponding to the same inspection object W, and determines the presence or absence of a defective portion such as a foreign matter or a bone in the inspection object W based on the determination image Xsc.
On the other hand, when the X-ray inspection in such an inspection mode is executed, the display control means 35 takes an OK/NG signal or the determination image Xsc which is a determination result from the determination means 33, the total X-ray image Xte and the different types of subtraction images Xs1, Xs2, Xs3, and the like, which are generation image data of the display image generation means 34, a request operation input from the operation means 42, and the like, and displays a result of the X-ray inspection and the display image Xip of the inspection target in a display mode set according to a type and other inspection conditions by the condition setting means 36, on the image display region 63 and the inspection information display region 64 of the first operation display screen 60.
An X-ray transmission image of the inspection object W as an inspection target generated by the same image process as any type of image selected and set in advance is displayed in the image display region 63 of the first operation display screen 60, when selecting the type of the display image, the function selection and setting operation window 66 is displayed in the first operation display screen 60, when selecting the display image setting function, the second operation display screen 70 is displayed, and a selection candidate for the display image Xip, for example, the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like are displayed as selectable candidate images.
If an image type to be displayed is selected among a plurality of candidate images displayed in the preview image display region 73 of the second operation display screen 70, the display image Xip in which the same image process as the selected type of image is executed is generated based on the latest transmission image data, and preview-displayed by, for example, emphasizing the display frame. Further, by shifting to a management mode in which an access is restricted by an input of a passcode from the operation means 42, the display candidate is changed or added.
Alternatively, according to a setting condition of the condition setting means 36, instead of the preview image display region 73 of the display image selection screen 70, the display screen selection setting window 83 is pop-up displayed, the plurality of candidate images 83a, 83b, 83c, and the like for specifying a type of the display image Xip are aligned and displayed in a scrollable, and selectable, and settable manner, and an operation of selecting and setting a specific type of display image Xip is performed.
Next, actions of the present embodiment will be described.
In the present embodiment, the display image generation means 34 generates the display image Xip such that an image brightness of the inspection object W is different from an image brightness of the determination image Xsc, and the display image Xip is displayed on the display means 41 together with a result of the inspection in a display mode set in advance. Therefore, required inspection performance is ensured by the determination image Xsc, and an operator who monitors an inspection situation by the display means 41 can easily and accurately grasp a situation of the inspection object W corresponding to an inspection result of the inspection object W and a situation of a particularly important inspection part or a target part for which an additional inspection or work may be required depending on the inspection result, from the display image Xip displayed in the preview image display region 73 of the display image selection screen 70.
In addition, in the present embodiment, for the determination image Xsc that is a subtraction image, by adjusting the X-rays in the plurality of energy regions such that the inspection object W itself has a low contrast, a foreign matter, an unnecessary residue, a fault part, and the like, which have an X-ray transmittance different from an X-ray transmittance of the inspection object W, are reflected with a high contrast with respect to the inspection object W, and required inspection accuracy can be ensured. On the other hand, the candidate images Xte, Xs1, Xs2, Xs3, and the like of the display image of the inspection object W generated separately from the determination image Xsc are images in which the image brightness of the inspection object W itself has a high contrast with respect to the image brightness of the inspection object W in the determination image Xsc, so that in a case where an additional inspection or work is to be performed on a downstream side or a latter stage side of the X-ray inspection apparatus 1, a target part of the additional inspection or the processing can be easily and accurately grasped from the display image Xip.
In the present embodiment, since the display images Xip is generated as the plurality of different candidate images Xte, Xsc, Xs1, Xs2, Xs3, and the like in which the inspection object W of the same target is reflected, based on the X-ray transmission image data in the specific energy region among the plurality of energy regions, the operator can easily and accurately grasp a situation of the inspection object W and a situation of a particularly important inspection part or a target part for which an additional inspection or work may be required depending on the inspection result, by using any one or a plurality of images among the plurality of different display images Xip.
In addition, in the present embodiment, a display output of any one image or a plurality of images among the total X-ray image Xte including the plurality of energy regions, and the plurality of different types of subtraction images Xs1, Xs2, Xs3 can be easily changed and set to a display output mode to be requested according to a request operation input from the operation means 42. In addition, since the entire thickness or shape of the inspection object W is easily reflected in the total X-ray image Xte, and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like are displayed, a defective part such as a foreign matter, an unnecessary residue, or a fault part of the inspection object W is relatively easily reflected, and a subtraction image in which a specific portion of the inspection object W including the defective part is easily grasped can be selected.
In addition, in the present embodiment, since the plurality of different types of subtraction images Xs1, Xs2, and Xs3 are subtraction images in which the article-affected brightness variation of the inspection object W are different from each other, the subtraction image in which the specific portion of the inspection object W including the defective part is easily grasped is further facilitated to be specified.
In this manner, according to the present embodiment, the X-ray image forming apparatus is provided in which the total X-ray image corresponding to the transmission image data Xia and Xib of the X-rays including the plurality of energy regions is generated by the transmission image data generation means 31 and the transmission image data storage means 32 of the image processing block 30A of the inspection processing unit 30, and the plurality of different types of subtraction images Xs1, Xs2, and Xs3 are generated by executing the predetermined image process with the plurality of different image processing conditions based on the transmission image data Xia, Xib of the X-rays in the plurality of energy regions. By the operation means 42 of the inspection processing unit 30, at least one image of the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, and Xs3 is selected and set in a switchable manner as an image to be displayed and output. Therefore, the operator can easily and accurately grasp the situation of the inspection object W corresponding to the inspection result of the inspection object W and the situation of the particularly important inspection part or the target part for which an additional inspection or work may be required depending on the inspection result, from the display image Xip, while ensuring the required inspection performance by the determination image Xsc.
As a result, it is possible to provide an X-ray inspection apparatus 1, an article inspection system, and an X-ray image forming apparatus, which have excellent inspection performance and workability.
The article inspection and processing system 100 according to the present embodiment is provided with a front-stage conveyor 91 and a latter-stage conveyor 92 in front of and behind the X-ray inspection apparatus 1, which is an X-ray image forming apparatus, of the first embodiment described above, and is provided with a plurality of work booths 93A, 93B, 93C, and 93D along the latter-stage conveyor 92, and is an article processing system that is also an article inspection system and that can perform a post-process such as an additional inspection and processing.
That is, as illustrated in
In the article inspection and processing system 100, the inspection processing unit 30, which is an X-ray image forming apparatus, of X-ray inspection apparatus 1 includes the image processing block 30A that generates X-ray transmission image data, and the control block 30B that executes predetermined inspection control, display output control, and the like based on the X-ray transmission image data from the image processing block 30A.
In addition, although not illustrated in
The post-process booths 93A, 93B, 93C, and 93D include post-process display means 94A, 94B, 94C, and 94D including a plurality of displays, which can display and output at least one image among the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like generated by the image processing block 30A and selected and set by the operation means 42 of the operation display unit 40. In addition, in the vicinity of each of the post-process booths 93A, 93B, 93C, and 93D, sorting means capable of sorting and discharging the inspection object W on the latter-stage conveyor 92 into any of the post-process booths 93A, 93B, 93C, or 93D corresponding to each of sorting positions b1, b2, b3, or b4, for example, a plurality of flipper-type sorting devices 95A, 95B, 95C, and 95D (only main portions are illustrated) are provided.
In the present embodiment, in addition to the control block 30B that outputs the display image Xip of the inspection target, which is at least one image among the inspection result OK/NG of the X-ray inspection unit 20, the total X-ray image Xte, the determination image Xsc, the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like, the inspection processing unit 30 of the X-ray inspection apparatus 1 is provided with a sorting control block 30C that selects and sets an output destination of the display image Xip of the inspection object W, and executes an operation of alternatively sorting and discharging the inspection object W to any one of the plurality of sorting devices 95A to 95D, according to a progress situation of the additional inspection and/or the additional processing (for example, remaining bone removal work) in the post-process booths 93A to 93D.
For example, when the inspection object W is sorted to the corresponding post-process booths 93A, 93B, 93C, or 93D by any of the sorting devices 95A to 95D, the sorting control block 30C measures a processing time until it is detected that the inspection object W after the processing, such as the additional inspection and/or the processing, is manually returned to the original sorting position b1, b2, b3, or b4, by a sensor, a switch, or the like (not illustrated) for detecting completion of work provided in each of the post-process booths 93A, 93B, 93C, or 93D. For example, the output destination of the display image Xip of the inspection object W is selected and set according to a start time and a time length of the processing time, and the sorting and discharge operation is selectively executed by any of the plurality of sorting devices 95A to 95D.
In the article processing system of the present embodiment, at least one image of the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like, which are generated by the image processing block 30A of the inspection processing unit 30 and selected and set by the operation means 42, are selectively displayed and output by the post-process display means 94A to 94D of the post-process booths 93A to 93D. Therefore, a user who operates the operation means 42 can easily and accurately grasp a target part of the additional inspection or work in any of the corresponding post-process booths 93A to 93D based on the display image Xip at a glance, and processing efficiency is improved.
In addition, corresponding to any one of the post-process display means 94A to 94D including the plurality of displays spaced apart from each other at least in the transport direction of the inspection object W, the inspection object W transported by the article transport unit 10 and a transport path of the latter-stage conveyor 92 is sorted in a space (additional process space) on a worktable of any one of the plurality of displays in the post-process booth 93A to 93D, in a transport order, by any one of the plurality of sorting devices 95A to 95D. Therefore, in the article inspection system of the present embodiment, since the total X-ray image Xte and the plurality of different types of subtraction images Xs1, Xs2, Xs3, and the like are output as the display images Xip to the post-process display means 94A to 94D of the post-process booths 93A to 93D, the target part of the additional inspection or the work in the post-process booths 93A to 93D can be easily and accurately grasped based on the display images Xip, and the processing efficiency in the post-process booths 93A to 93D can be improved.
Further, in the article processing system, since the plurality of displays of the post-process display means 94A to 94D are spaced apart from each other at least in the article transport direction, the inspection object W that is determined to require the additional inspection or the processing (for example, a dedicated inspector visually inspects for any small bones, and if any remain, the inspector removes the bones for work) by the determination means 33 on the transport path passing from the article transport unit 10 to the latter-stage conveyor 92 is sorted and transported to any of the post-process booths 93A to 93D, it is possible to secure a sufficient processing time for the additional inspection or processing and to execute the stable additional inspection or processing.
In this manner, in the present embodiment, in the X-ray inspection apparatus 1 having the function of the X-ray image forming apparatus, it is possible to enable the operator to easily and accurately grasp the situation of the inspection object related to the inspection or the work while improving the inspection performance such as the foreign matter detection, and it is possible to realize the article processing system having high processing efficiency.
In the first embodiment described above, the X-ray inspection apparatus 1 is described as the X-ray image forming apparatus according to the present invention and the article inspection system including the sorting device at the latter stage of the X-ray inspection apparatus 1, and in the second embodiment, the article processing system including the plurality of work booths 93A to 93D provided with the plurality of sorting devices 95A to 95D as sorting means at the latter stage of the X-ray inspection apparatus 1 is described, and a form or disposition of the post-process work booth is optional.
In addition, the conditions for the control of the display output of the display image Xip or the sorting and discharge of the inspection object W to the plurality of work booths 93A to 93D are also optional, and as the conditions for such control, for example, as described in JP-A-2017-138193, a sorting rule including a work code, a work time, the number of works, and the like of the user may be managed, maintained, and updated in a memory table format.
As described above, the X-ray inspection apparatus, the article inspection system, and the X-ray image forming apparatus according to the present invention can provide an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus with which an operator easily and accurately grasps a situation of an inspection object related to an inspection or work while improving inspection performance such as foreign matter detection. The present invention is useful for an X-ray inspection apparatus, an article inspection system, and an X-ray image forming apparatus in general, capable of generating an X-ray image appropriate for a purpose such as an article inspection based on transmission image data of X-rays in a plurality of different energy regions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2023-106878 | Jun 2023 | JP | national |
