Aolong X-Ray Real-Time Imaging System for Industrial In-Line Inspection

Overview

The Aolong X-Ray Real-Time Imaging System is an industrial-grade, in-line non-destructive testing (NDT) platform engineered for high-throughput, high-fidelity internal inspection of manufactured components. Based on digital radiography (DR) principles, the system utilizes a microfocus or minifocus X-ray source coupled with high-resolution flat-panel detectors to generate real-time, dynamic radiographic images with spatial resolution down to sub-100 µm levels—enabling detection of voids, porosity, inclusions, cracks, and assembly defects without physical sectioning. Designed for integration into automated production lines, it supports continuous scanning at line speeds up to several meters per minute, depending on geometry and required image quality. The system operates within regulated radiation safety frameworks compliant with IEC 61331-1 and GBZ 138–2022, incorporating interlocked shielding and dose monitoring to ensure ALARA (As Low As Reasonably Achievable) exposure levels for operators and surrounding infrastructure.

Key Features

• Modular architecture supporting customizable configurations for diverse industrial inspection workflows—including wheel hub, welded pipe, pressure vessel, and semiconductor packaging applications.
• Integrated radiation shielding infrastructure: lead-lined enclosures (≥5 mm Pb equivalent), automatic door interlocks, and ambient dose rate monitoring aligned with national occupational safety standards.
• Digital image acquisition with frame rates up to 30 fps, enabling motion-compensated imaging of rotating or translating parts.
• Real-time contrast enhancement, edge sharpening, and noise reduction algorithms implemented directly in the imaging processing unit.
• Programmable logic controller (PLC)-based automation interface compatible with Siemens S7, Allen-Bradley ControlLogix, and Mitsubishi Q-series systems for synchronized part indexing and exposure triggering.
• Multi-layered system redundancy: dual power supplies, backup image buffers, and fail-safe beam shutdown protocols meeting SIL2 functional safety requirements.

Sample Compatibility & Compliance

The system accommodates samples ranging from small electronic components (<50 mm diameter) to large structural assemblies (up to Ø1200 mm × 3000 mm L). It supports metallic (aluminum, steel, titanium, copper alloys), composite (CFRP, GFRP), ceramic, and polymer-based materials. Compliant with ISO 17025–accredited laboratory practices when deployed in QA/QC environments; supports audit-ready documentation for GLP/GMP-regulated industries including aerospace (AS9100), automotive (IATF 16949), and medical device manufacturing (ISO 13485). Radiation safety design conforms to national regulatory frameworks (China’s HJ 1157–2021) and international guidance (IAEA Safety Standards Series No. SSG-11).

Software & Data Management

The proprietary Aolong iRIS™ software suite provides DICOM-compliant image acquisition, annotation, measurement, and report generation. All image metadata—including exposure parameters (kV, mA, pulse width), geometric magnification, detector gain settings, and timestamped operator log entries—are embedded and cryptographically signed to satisfy FDA 21 CFR Part 11 requirements for electronic records and signatures. Automated defect classification via rule-based thresholds (e.g., ASTM E2737–20 for castings) is supported, with optional AI-assisted anomaly detection modules available as validated add-ons. Raw data export supports TIFF, PNG, and vendor-neutral HDF5 formats; long-term archival complies with ISO 14721 (OAIS) reference models.

Applications

• Automotive: In-line inspection of aluminum wheel hubs, brake calipers, engine blocks, and tire cord integrity verification.
• Energy Infrastructure: Seamless weld inspection of boiler tubes, LNG storage tanks, and long-distance pipeline girth welds.
• Aerospace & Defense: In-situ inspection of turbine blades, landing gear assemblies, and munition casings (including live-round compatibility per MIL-STD-883H Method 2010).
• Electronics & Batteries: Internal electrode alignment, separator integrity, and dendrite detection in Li-ion pouch and cylindrical cells.
• Foundry & Casting: Porosity mapping in low-pressure die-cast aluminum housings and investment-cast superalloy components.
• Food & Pharma: Foreign object detection (metal, stone, glass) in sealed packaging; density uniformity assessment of tablet coatings.
• Cultural Heritage: Non-invasive structural analysis of archaeological artifacts, bronze vessels, and wooden relics.

FAQ

What radiation safety certifications does this system meet?
The system meets Chinese national standards GBZ 138–2022 and HJ 1157–2021, and its shielding design aligns with IEC 61331-1 for diagnostic X-ray equipment.
Can the system be integrated with existing factory MES or SCADA platforms?
Yes—it provides OPC UA and Modbus TCP interfaces for bidirectional communication with enterprise-level manufacturing execution systems and supervisory control networks.
Is remote diagnostics and software update support available?
Aolong offers secure TLS-encrypted remote maintenance access via dedicated service channels, with version-controlled firmware updates traceable to ISO/IEC 17025–accredited validation reports.
Does the system support automated pass/fail decision logic based on user-defined criteria?
Yes—threshold-based defect scoring and configurable acceptance rules are embedded in the iRIS™ software, with full audit trail logging for compliance review.
What is the typical lead time for a custom-configured in-line system?
Standard configurations ship within 12–16 weeks; complex integrations involving custom mechanical handling or regulatory validation may require 20–24 weeks from PO issuance.