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GJ‐XF series X‐ray Inspection Machine Operation Manual

GJ-XF SERIES X-RAY INSPECTION


MACHINE

OPERATION MANUAL

Shanghai Gaojing Detection Technology Co., Ltd.

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GJ‐XF series X‐ray Inspection Machine Operation Manual

Contents
Chapter 1: General Overview………………………………………...3
1.1 Applications of X-ray Inspection machine………………………………...4
1.2 Principle Theory of X-ray Inspection machine………………………………….4
1.3 Main specifications………………………………………………………………5
1.4 Installation Guidance…………………………………………………………….6
1.5 Introduction of machine structure and all button functions…………………...…7

Chapter 2: Basic Operation…………………………………………...9


2.1 Software Setting………………………………………………………….……...10
2.1.1 IP Address Setting…………………………………………………………………………..10
2.1.2 Database ODBC Setting……………………………………………………………………10
2.2 Software Use…………………………………………………………………….11
2.2.1 System Initialization………………………………………………………………………...11
2.2.2 Image Analysis………………………………………………………………………………12
2.2.3 Parameter Setting for Bagged Food…………………………………………………..…13
2.2.4 Parameter Setting for Canned Food……………………………………………………..15
2.2.5 Parameter Reset…………………………………………………………………………….16
2.2.6 Other Image Processing Functions……………………………………………………....18
2.3 Operation of Image Database…………………………………………………...20
2.4 System Function Setting…………………………………………………….…..23
2.5 System Exit……………………………………………………………………...29

Chapter 3: Maintenance……………………………………………....31
3.1 Regular Maintenance…………………………………………………………….32
3.2 Notice of Repositioning the machine…………………………………………….32
3.3 Other Matters Needing Attention…………………………………………...……32

Chapter 4: Service Manual……………………………………………34


4.1 FAQs…………………………………………………………………...…………35
4.2 Contact Information of Gaojing Service Center………………………...………..36

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GJ‐XF series X‐ray Inspection Machine Operation Manual

Chapter 1

General Overview

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1.1 Applications of X-ray Inspection machine

In the process of food production industry, there are chances some


harmful impurity(metal, glass, stone, bone,etc) will be mixed in the
food products. If the producer does not take any measure to detect and
remove these impurity from the food before leaving the factory, these
unqualified products will be circulated into the hands of customers,
resulting in harmful effect to the health of consumers or more serious
consequence of threat to life. Under such circumstance, X-ray Inspection
machine is offering an effective solution to detect all those harmful
impurities during production process, ensuring food safety for all
consumers. X-ray Inspection machine has already become a
indispensable tool for all responsible food producers all over the world.

X-ray Inspection machine is utilizing X-ray penetration, integrated with


photoelectric, computer, digital signal processing technology to
distinguish/extract/identify the image information, can finally realize the
detection of foreign body mixed in products. The machine is capable of
detecting foreign objects of various kinds(including metal, glass,
ceramics, stone, bone, plastic and so on) from meat, fruits, vegetables,
additives, milk powder, chocolate, etc. Widely used in food industry;
pharmaceutical industry, textile industry, and other industrial sectors.

At the same time, the machine also has the function to detect product
defect, such as the packaging crack, bubble, content defects to achieve
detection for complete finished product.

1.2 Principle Theory of X-ray Inspection machine

The principle theory of X-ray Inspection machine can be summarized by


two "conversions". X-rays penetrate the metal material, to be received by
image intensifier. The image intensifier converts invisible X-ray detection
signal to visible image, we call this "photoelectric conversion". In the
terms of information nature, visual image is analog quantity, which can
not be identified by computer. The analog quantity has to be converted to
digital signal so that it can be input into computer for processing. The
specific method is to use high-definition television camera to pick up
visual image, input it into computer so as to convert to digital image.
After computer processing, the digital image will be displayed on
computer screen to show the status(size, feature, position) of
impurity/defection in interior materials, then the software will conduct
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GJ‐XF series X‐ray Inspection Machine Operation Manual

analysis and make assessment of detection result to achieve the purpose


of detection. The basic technical principle can be referred to Figure 1

Figure 1

1.3 Main specifications of GJ-XF series


型号
GJ-XF-2512 GJ-XF-4015
Model
金属球 Metal Ball:Φ0.3mm
检测灵敏度
金属丝 Metal Wire:Φ0.2×2mm
Sensitivity
玻璃珠 Glass Ball:Φ2.0mm
X 射线输出, 电压
200w(Standard), 400w(Optional)
X-ray Power,Voltage
单次检查剂量
Single Inspecting Dose <0.8μSv/h
Rate
X 射线传感器 光电二极管阵列探测器
X-ray Sensor Photodiode array detector
射线束方向 顶照射
Beam direction From top to the bottom
冷却/工作周期 油冷加风冷/100%
Cooling & Running cycle Oil and wind cooling/100%
操作方式 17 寸 LCD 液晶触摸屏幕
Operating mode 17 "LCD touch screen
操作系统
Windows
Operating system
通道尺寸
250(W)×120(H)mm 400(W)×150(H)mm
Tunnel size
传输带速度/负荷 20 米/分钟 m/min 20 米/分钟 m/min
Conveyor speed/lord 最大 Max.5 kg 最大 Max.10 kg
报警方式 自动停机或排斥(可选)
Alarm Method Auto stop or reject system(Optional)

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工作电压
220VAC(±10%) 单相 Signal phase 50±3Hz 1kVA
Power Supply
单机重量
420kg 450kg
Weight
工作温度/湿度
Working temperature 0℃~40℃ / 30~80%(无结霜 non-condensing)
/Humidity
保护等级 传输带部分:IP66 标准;其它部分:IP42 标准;
Waterproof grade IP66 for conveyer; IP42 for others;
主体材料 不锈钢
Main Material stainless steel
Sensitivity refers to the result that the standard test block of Gao Jing is
备注 detected on the empty running conveyor. Actual detection sensitivity will
Remark depend on the type, shape of product, position of mixed impurity, and
environment factors etc.

1.4 Installation Guidance

(1) The machine is packed by wooden case, unload the machine with a
forklift, and then remove out of the case according to the guidance of
Gaojing service technician on site;
(2) Electrical parts requires to be connected by Gaojing service technician
on site;
(3) The machine must be positioned and installed on flat ground, no tilt;

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1.5 Introduction of machine structure and all button functions

Indication Lamp Emergency Stop Button


LCD Touch Screen
X‐ray Switch Key

Upper Cabinet Box

Power Switch

Shield Door Shield Cover

Conveyor

Motor

Torsion Spring
Hinge

Foot rack

Figure2

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Air‐Conditioner

Emergency Stop
Button

Figure3

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Chapter 2

Basic Operation

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GJ‐XF series X‐ray Inspection Machine Operation Manual

2.1 Software Setting

2.1.1 IP Address Setting

Network properties of operating system should be set before using the software.
Open the dialog box Internet Protocol (TCP/IP) Properties in Windows operating
system, as shown in Figure 4.
(1) Set IP address to 192.168.1.8
(2) Set subnet mask to 255.255.255.0

Figure 4 IP address setting

2.1.2 Database ODBC Setting

Open the dialog box ODBC Data Source Administrator in Control Panel of
Windows platform and set database parameters as follows:
(1) Database source: xfilenameb
(2) Database path: D:\ Img250mm\xfilenameb.mdb
Required hard drive configuration for the software system is 80G. Default directory of
image database is disk D. Users should manage and backup image files regularly.

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Figure 5 ODBC setting

2.2 Software Use

Procedures to start up the machine:


(1) Plug into 220V socket (ground protection should be guaranteed).
(2) Rotate emergency switch and ensure it has not been pushed down.
(3) Rotate spanner switch located on the right of the machine’s lower part in a
clockwise direction till red light above the spanner switch is on.
(4) Turning the key to switch on the power of the X‐ray, and the yellow indicating
lamp on the panel will be lightened.
(5) Push down the green button system power. X‐PR software will be loaded
automatically.

2.2.1 System Initialization

After running X‐PR software, a dialog box (see Figure 6) will pop up to remind users
of ensuring whether there isn’t any object in passage. Click on the button Calibration.
Software system finishes starting up when progress bar is running to the rightmost

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position. Use button and to adjust voltage and current values.

Figure 6 system initialization

Click button to start detecting.

Click button to stop the system.

Button is used just for moving the belt, not for checking.

2.2.2 Image Analysis

Before starting the detection, several complete samples of the product needs to be
prepared. Software system will analyze X‐ray images of these samples, acquiring
characteristics of the product. Samples are placed on the conveyor belt at the
entrance of the tunnel.

Note: If the canned product has pull‐ring, the operator need to take notes of the
direction of the pull‐ring, the feeding should follow this direction in the future. If the

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product is cylindrical can, two rails of rack need to be adjusted, until the can product
to be gripped properly , while ensuring cans to pass smoothly. Better try to position
the canned products at the center of the belt, so that the thickness of the upper and
lower edges of the image will keep same as much as possible.

Choose Product Type according to product’s feature. The default setting of the
system is “Bagged Product ”. Click “Start” button, the machine will run the product to
as self‐ learning. After the product go through the tunnel, the screen will display the
image of the product, meanwhile the conveyor belt stops. If it doesn’t stop, please
check the length of the detected product. Normally, we suggest that the product
length needs to be smaller than the width of machine tunnel. In addition, if the
motor speed is too low, it might cause the length of image to be longer than real
product. In such case, the operator should increase the motor speed, but not too fast,
otherwise the image will be narrower than real product, and detecting sensitivity will
be affected. Therefore, it’s necessary to make fine adjustment of the motor speed to
make sure the length‐width ratio of the image is close to real product. Our
recommended ideal conveyor speed is 19‐20 meters/minute.

2.2.3 Parameter Setting for Bagged Food

First, select Bagged in Product Type. Put the product on the conveyor and do
self‐learning first. After self‐learning, a reference sensitivity will automatically show
in Gray Value. Use button and to set the actual sensitivity. Normally, the
actual sensitivity is 5 to 10 smaller than the referenced one. Let the product sample
without foreign object pass through passage several times. If it passed without
alarming, use samples with foreign objects to test whether system can detect FOs. If
it can, parameter setting is finished. Otherwise decrease/increase actual parameter
to an appropriate value, repeat above steps till the whole system can work properly.

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Figure 7 parameter setting for bagged food

Figure 8 draw the outline of product

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2.2.4 Parameter Setting for Canned Food

Figure 9 parameter setting for canned food

First, select Canned in Product Type. Then, set FieldProc using button and
. X‐ray image of product will be analyzed automatically. No‐detection area will be
displayed in green (see Figure 9).
Next step is setting the FieldSize and FieldSense. Usually, the larger the region
tolerance value (FieldSense), the smaller the detection sensitivity. The detection
sensitivity increases when the region tolerance decreases, false detection rate rising
slightly under such circumstance. Parameter FieldSize is always set to 10. The bigger
this value, the larger the detection blind zone. Users can increase FieldSize in order
to avoid false detection around image edge.
Let the product samples without foreign object pass through passage several times in
order to evaluate learning effect. If they can all pass without alarm, use samples with
foreign objects to test whether system can detect FOs. If it can, parameter setting is
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finished. Otherwise decrease/increase the parameters to an appropriate value,


repeat above steps till the whole system can work properly.
After setting parameters and learning process, users can start testing.
(1) If it is a product without foreign objects, system will not ring the alarm and belt
will not stop.
(2) If it is a product with foreign objects, system will ring the alarm and display the
X‐ray image containing foreign objects (marked in green).
(3) Each time product passes passage, the software will count automatically and
show the total number of products and the number of products with FOs. Click Clear,
reset the count.

If it is a ring‐pull can, operator should pay attention to the placement, that is, if
you let the side with ring enters into passage first when training, you must let it go
first when testing.

If users find the system is not sensitive to foreign object, or detection blind
zone is much larger, image analysis should be done again. Sometimes, users should
make a best tradeoff between detection precision and false detection rate.

2.2.5 Parameter Reset


If the parameter is not appropriate, please restart the self‐learning, the procedure is
as below:
(1)Click button P.Reset, all the parameters return to default settings.
(2)Place the products again, press Start
(3)After the alarm is triggered and machine stopped, please reset the parameters of
"Edge Shield", "Detection Threshold", " Area Extraction", "Area Tolerance", "Area
Dimension" or "Detecting sensitivity", etc.
(4)Click button P.Save
(5)Place same kind of product to evaluate the result of self‐learing

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When qualified products (without foreign objects) pass the tunnel without triggering
alarm, while unqualified products (with foreign objects) pass the tunnel to trigger
alarm. To do this procedure several times and all results are correct, it means the
self‐learning is correct, now you can start the official detection. Otherwise, please
repeat the process of self‐learning, until the results meet the above standard.

In the process of detection, if any unqualified products (with foreign objects) pass the
tunnel, the alarm will be triggered, and the image of foreign objects will be displayed
on the screen in green color(see figure 10). When any products pass through the
tunnel, the software will do counting automatically and show the total number of
products and the number of products with FOs. Click Clear, reset the count.

Figure 10 mark of foreign objects

Please be advised if users find the system is not sensitive to foreign object, or
detection blind zone is larger, please conduct image analysis again, try to lower
"Detection Threshold", "Area Tolerance", "Area Dimension" a little bit to achieve
better detecting result. On the other hand, such adjustment will lead to more
chances of false alarms. Thus, sometimes the operator has to make a best tradeoff

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between detection precision and false alarm rate.

2.2.6 Other Image Processing Functions


For those images that contain foreign objects, a series image processing
techniques can be used to help the operator to make final judgement. For example,
(1) Click Zoom, image is enlarged. Meanwhile, users can also see the whole image
in reduced form on the right of screen (See Figure 11).
(2) Click Inverse, negative image is showed (See Figure12).
(3) Benefit from touch screen technique, the operator can see every part of image
that he interested in only by clicking button and dragging image using his fingers
(4) Click Restore, return to the initial state of an image.
(5) Click SaveImg, current image will be stored in database.
(6) Users can retrieve scanned image by clicking and .

(7) Users can use button to move image.

Figure 11 image zoom

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Figure 12 image negative

Figure 13 color image

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Figure 14 open image

2.3 Operation of Image Database

Click property page Database on top left corner of screen, see Figure15. History
images can be searched according to search conditions set by users. Image data can
be saved as bitmap format. Unwanted image files can also be deleted from database
when you click button delete.

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Figure 15 GUI of image database

Image files are named according to the time when it is created, which ensures
uniqueness of each file.
(1) Users can search image files by setting search condition in Database property.
(2) Users can set search condition by a numeric keyboard that appears on screen
when you click combo box Year, Month, Day, Hour and Minute.

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Figure 16 database query

(3) Once you click Search button, software system will query image files that meet
the condition which you have set earlier in database and list them all. For example, if
you set Year to 2007, system will list all the image files that created in 2007.
(4) Select image filename you need, corresponding image will be displayed on the
screen.
(5) Users can delete unwanted image files by click Delete button. A reminding
dialog box appears to confirm whether you really want to delete the image. If you
choose Yes, the image file will be deleted from the database. Otherwise, the
manipulation will be canceled, see Figure17.
(6) Click Image Save As JPG button to save image as JPG format.
A filename same as the one in database is provided by default. Users only need to
click save after choose save directory.

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Figure 17 delete image file from database

2.4 System Function Setting

A series of values can be set in System Setting property page, see Figure18. Users
can control IO device manually by click function button on this page. Functions here
are mainly used to diagnose system.
● ConfigFile —— Set parameters in configure file. Click ReloadConf can help
you return to factory settings.
● KeyBoard —— Pop up a keyboard.

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GJ‐XF series X‐ray Inspection Machine Operation Manual

Figure 18 system setting property page

Figure 19 order test

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● Order Test —— Pop up Order Test interface, see Figure 19.


(1) MotoOn and MotoOff are two belt control buttons.
(2) Button X‐ray On and X‐ray Off are used to control the X‐ray source.
(3) Button AlarmTest are used to test the Alarm lamp.
(4) Function Boot is used to burn the programs which control the X‐ray detector.
◆First, select the file *.out according to your software system,
see Figure 20.
◆Second, input the IP address 192.168.1.216, see Figure 21.
◆Third, click Execute to begin the process.

Figure 20 open file *.out

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Figure 21 input IP address

(5) Create Report


Users can create a report to record product information including goods
description, style of goods, quantity, NG quantity, label number, brand name,
operator and so on.

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Figure 22 create report

(6) Search Report


Display reports list. Users can choose the report to see the details.

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Figure 23 search report

(7) DSP Reset —— Recover hardware system when a black line appears.

Figure 24 DSP Reset

● Map Control —— Used to adjust the gray level of an image.


● Max Calib —— Calibrate the system.
● Rate set —— Set the sampling frequency.
● Test Mode Setting —— Two testing mode can be selected.
Alarm & Stop: the system will give an alarm when detecting foreign objects and
the belt stops so that the operator can deal with it.
Alarm & Reject: the system will give an alarm when detecting foreign objects
and the defective goods will be rejected by the reject equipment
automatically.
Delay times are two parameters used to control reject equipment.
● Language Settings —— Choose English or Chinese.
● Other Settings —— Save Auto & Big Scr.

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Save Auto: Save X‐ray images automatically while testing.


Big Scr: Helps users see pictures more clearly when testing, see Figure 25.

Figure 25 convert to large image mode

Click button and uncheck Big Scr to return to the ordinary mode.

Functions above are highly recommended to be used under the instruction of


technicians.

2.5 System Exit

After click button, a dialog box pops up to let users choose Shut off or

Cancel, see Figure 26.


(1) If users choose Shut off, software interface will exit and FO detector will be
turned off.

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(2) If Cancel is selected, users can continue their operation.


If you choose Shut off, remember to push down System power to shut off
computer power supply and turn key switch in anticlockwise direction to turn off
X‐ray power. Next, rotate spanner switch located at right lower of the machine in an
anticlockwise direction to shut off the machine. Finally, remember to pull out the
attaching plug.

Figure 26 system exit

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Chapter 3

Maintenance

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3.1 Regular Maintenance

(1) Conveyor belt needs to be cleaned regularly according to the type of food to be
detected;
(2) The conveyor belt needs to be replaced after wear and tear;
(3) To check the conveyor motor and roller regularly, normal status is running
smoothly, no special noise;
(4) If the machine won’t be used for long period, need to cover the machine by dust
cover, booting the machine one time a week is advised;
(5) The machine requires to be stopped for a while for maintenance every day after
running, the exact period of maintenance depends on working condition,
temperature, humidity of the environment, etc.

3.2 Notice of Repositioning the machine

(1) Keep the balance of the machine, not tilted or contorted


(2) Use a forklift to move the machine in gentle way
(3) The forklift to lift the whole machine as per correct direction, only the frame parts
can be scooped by forklift

3.3 Other Matters Needing Attention

(1) The red switch on panel is only used to control motor. While button Start on
touch screen can not only control motor, but also control X‐ray expositions. Once you
start belt by the way of pushing down the red switch, you should stop the belt as the
same way. If you use Start button to run the belt, use Stop button on touch screen to
stop it.
(2) Turn off key switch when you stop testing products.
(3) Each time you begin to analyze image or change product type, be sure to click

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on the button P. Reset first.


(4) Users can adjust Map Control value in system setting property page to change
contrast of image. For thick sheet iron can, the mapping value is always set to
3000‐5000; for other ordinary food product, this value is usually set to 12000.
(5) Some products have requirement of position, be sure to place these kinds of
products at the same position each time, otherwise detection precision will decrease
and false detection rate will rise.
(6) In order to prolong life span of touch screen, please touch it gently.
(7)When using in continuous detection testing mode, space between products
should be about 8cm.
(8) Don’t put your hands into passage when the machine is in the state of running.
(9) Don’t open lead curtain when machine is not in power off state.
(10)Don’t open protection door when machine is not in power off state.
(11)Be sure to close protection door whenever finishing examine and repair.
(12)Pull out the attaching plug each time you shut off the machine. Time interval
should be more than 5 minutes if you turn it on again.
(13)In order to prolong service life, the X‐ray foreign object detector should avoid
working continuously for a long time. Moreover, it should be in a drafty workplace. It
is recommended to be turned off every four hours.

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Chapter 4

Service Manual

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4.1 FAQs

No Description Solution
1 black line appear in the whole Select DSP reset in software system setting
screen, from left to right, across page, restart the computer after reset to do
horizontal direction initialization.
After initialization, the black line disappears,
the fault has been ruled out.
After initialization the black line remains,
please contact Gaojing service center.
2 black line appear in the whole X‐ray tube fault, please contact Gaojing service
screen, from top to bottom center for repair
3 Can not do self‐learning for a. Check the length of the product if exceeds
product the valid detecting range or not.
b. black lines appears, please refer to No 1.
c. There is shadow at the top/bottom edge of
the screen, the shadow obviously not belong
to the image part, then increase the value of
the corresponding parameter, the fault can be
solved
4 No image is generated a. restart X‐ray tube
b. do DSP reset, restart the computer after
reset to do initialization.
After initialization, the image can be generated
in the screen, the fault has been ruled out.
Otherwise, please contact Gaojing service
center.
5 Computer can not be started Re‐plug memory stick, check if the graphic
card has problem. If still can not start the
computer, please contact Gaojing service
center for repair
6 Touch screen no response Re‐plug USB connection port of touch screen,
reinstall touch screen driving program, and do
calibration after re‐installation.
7 No power for whole machine a. Check if the emergency button has been
pressed down.
b. Check if the power switch is turned on.
c. Check the fuse in the machine box.
d. Check if the spanner switch is turned on.
8 Motor can not run intermittently a. Replace the relay.
b. Check wiring.

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9 Motor can not run a. Check if the belt is blocked, can not rotate
b. Check the power supply.
c. Check the fuse in the box.
d. Replace the relay.
e. Check if the terminals connectors are loose
f. Check the speed controller
g. Check if the motor is damaged
10 Messy black/while lines appears Check if the X‐ray source is turned on, if the
wiring of X‐ray source is loose. Do DSP reset
and system initialization. If the problem
remains, please contact Gaojing service center.
11 Network is not connected a. Check if the IP address is set correctly.
b. Check if both ends of the network cable is
connected. One end is connected to the
computer and the other end is connected to
the detector inside the machine. Re‐plug
them separately.
c. Check if the detector power cable is
connected properly.
d. Check if the network cable is damaged
12 "Exit" dialog pops up immediately a. Check if the network is connected, refer to
after starting detection, indicating No 11.
the shield door is opened b. Check if the safety switch of shield door is
normal.

4.2 Contact Information of Gaojing Service Center

Head Office:Zone A, 1st floor, No.128 XiangYin road, Shanghai, China


Plant: No.1288 Boxue Road, jiading Industrial Zone. Jiading District, Shanghai, China
Tel:+86‐21‐65688831
Fax:+86‐21‐65685250
E-mail: export@gaojing.com.cn

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