X-Ray Level Inspection Machine

I. Project Overview

Project Title

X-Ray Liquid Level Inspection and Automatic Rejection System

Project Scope

The system is designed to provide continuous, non-contact monitoring of liquid levels in bottles and cans during production. Containers that fall outside the specified filling range are automatically identified and accurately removed from the production line.

Maximum Throughput

Up to 72,000 containers per hour, depending on the selected high-speed equipment configuration.

Compatible Container Materials

The system can be applied to containers manufactured from a variety of materials, including:

• Aluminum

• Tinplate

• PE

• PET

• PP

• Glass

• Ceramics

• Other commonly used packaging materials

Applicable Product Range

• Container Volume: 200–2,000 mL

• Container Diameter: 30–90 mm

• Container Height: 50–200 mm

Equipment Type

X-Ray Liquid Level Inspection Machine

II. Environmental and Site Conditions

1. Installation Elevation

5–3,000 m above sea level

2. Operating Temperature

5°C–40°C

3. Relative Humidity

50%–65% RH

4. Factory and Installation Requirements

The installation site shall provide a stable, level, and sufficiently load-bearing foundation. Floor flatness and other relevant infrastructure conditions shall comply with applicable national standards to ensure reliable operation and long-term equipment stability.

5. Storage Requirements

After delivery, the equipment and all associated components shall be stored in an environment that meets applicable national requirements. Where equipment remains in storage prior to installation, appropriate lubrication, inspection, and preservation procedures shall be carried out to prevent corrosion, surface deterioration, deformation, or other damage that could affect installation, commissioning, or normal operation.

III. Utility and Production Requirements

1. Power Supply

220 VAC, 50 Hz, single-phase

The electrical supply shall be provided by the customer. Any special voltage or electrical requirements shall be confirmed before equipment design and manufacturing, as modifications may affect the technical configuration, delivery schedule, and equipment pricing.

2. Power Consumption

Approximately 1.0 kW

3. Control Voltage

24 VDC

4. Compressed Air

4–12 Pa

The customer shall provide the compressed-air pipeline and connection between the plant air source and the main equipment unit.

Note: The compressed-air specification should be verified before the final technical document is issued. 4–12 Pa is not a typical pneumatic working pressure; if the intended value is 4–12 bar or 0.4–1.2 MPa, the unit should be corrected.

IV. Equipment Configuration and Operation

1. Installation Arrangement

Recommended Position

The inspection machine shall be installed downstream of the filling machine, either before or after the inkjet coding station, depending on the actual production-line arrangement.

Conveyor Requirements

The unit shall be integrated into a single-row conveyor chain. A straight conveyor section of at least 2 meters shall be reserved at the installation position to provide sufficient space for stable inspection and rejection.

Installation Period

Standard on-site installation is expected to be completed within 24 hours, provided that the installation area and utilities are prepared in advance.

Conveyor Modification

A guide-rail opening of ≤150 mm shall be provided on the straight conveyor section to create sufficient clearance for the reject mechanism to discharge defective containers.

Major System Components

The complete system mainly comprises:

• X-ray liquid level inspection unit

• Automatic rejection mechanism

• Electrical distribution cabinet

• HMI operating panel

• Electronic control modules

• Mechanical structure and assemblies

Defective Product Collection

It is recommended that the purchaser install a rigid collection container at the reject outlet to receive and collect rejected products.

2. Inspection Functions

The equipment provides two liquid-level inspection modes:

• Low Liquid Level Detection — Standard

• High Liquid Level Detection — Auxiliary/Optional

Inspection thresholds can be configured according to the customer's product specifications and quality requirements.

3. Inspection Principle

The system determines the liquid level using X-ray transmission and attenuation characteristics.

When X-rays pass through a container, the amount of radiation reaching the detector varies according to the quantity and distribution of material inside the container. Different liquid levels therefore produce corresponding changes in the detected signal.

The acquired signals are converted into measurable values and evaluated against predefined reference parameters. If the detected liquid level falls outside the permitted range, the container is classified as non-conforming and the rejection system is activated to remove it from the production flow.

This non-contact measurement method allows liquid-level inspection without physically contacting or damaging the container.

4. Principal Features

Non-Contact Online Measurement

The system performs liquid-level inspection without physical contact with the product, eliminating the risk of mechanical damage during measurement.

Encoder-Based Container Tracking

An encoder connected to the synchronous drive system provides continuous container-position feedback. This enables accurate product tracking and rejection even when the production line experiences temporary stops or changes in conveying speed.

Dynamic Speed Adaptation

The inspection system is capable of operating at different conveyor speeds and automatically synchronizes its inspection and rejection timing with the actual production rate.

Electromagnetic Interference Protection

Inspection and control functions are arranged in separate electrical enclosures, helping reduce electromagnetic interference and improving overall system reliability.

Sealed Stainless-Steel Construction

The machine adopts a stainless-steel enclosure with a sealed structure, providing improved resistance to moisture, condensation, mist, and water droplets. This makes the equipment suitable for demanding production environments.

Automatic X-Ray Standby Function

During production-line idle periods, X-ray emission is automatically disabled, reducing unnecessary radiation generation and power consumption.

Embedded Control Architecture

The control system combines dedicated hardware circuitry with an embedded operating environment, providing stable long-term operation and reducing dependence on general-purpose computer systems.

Safety Alarm and Automatic Rejection

The system is equipped with an integrated audible and visual alarm system. When an abnormality is detected, the system provides an alarm and automatically activates the rejection mechanism for non-conforming containers.

V. Technical Specifications

* The final equipment configuration shall be selected according to the container diameter, material density, container geometry, and actual production requirements.

* Dynamic detection accuracy may be affected by foam, product agitation, liquid turbulence, or instability of the liquid surface.

Performance Summary

The X-ray inspection system combines non-contact liquid-level measurement, real-time container tracking, automatic defect classification, and high-precision rejection. With a maximum inspection rate of up to 400 containers per minute and a stated rejection accuracy of ≥99.99%, it is suitable for high-speed bottle and can production lines requiring continuous and automated fill-level quality control.