Automatic X-ray Reel Counter
Working Principle
Our Advantages
- 80kV X-ray tube with extended lifetime and maintenance-free operation
- Super definition 17" digital flat panel detector (FPD)
- Ultrafast counting with top speed of 12 seconds per reel
- Supports maximum 17" (430mm) reel or tray with moisture barrier bags
- Permanently updated AI deep learning algorithm with free updates
- Integration with MES, ERP, WMS and other management systems
- Manual mode for special cases (small quantities, overweight/oversize reels, packaged reels)
- AGV docking support for fully automated counting process
- Work order number functionality with counting record query & statistics
Hardware Parameters
X-ray Source
| Type | Microfocus |
| Max tube voltage | 80kV |
| Max tube current | 700μA |
| Focal spot size | 30μm |
Flat Panel Detector
| Type | Super definition digital FPD |
| Effective area | 430mm * 430mm |
| Pixel size | 139μm |
| Resolution | 3072 * 3072 |
Reel/Tray Counting
| Max size | Auto mode 15" (380mm), manual mode 17" (430mm) |
| Max thickness | Auto mode 50mm, Manual mode 80mm |
| Min parts size | 01005 |
| Speed | 12-15s |
| Accuracy | 01005 ≥ 99.98%, 0201 & above ≥ 99.99% |
| Media type | Reel materials, tray materials with moisture-proof bag |
Equipment Specifications
| Dimensions | 2700mm (L) * 1400mm (W) * 1900mm (H) |
| Weight | 3000kg |
| Power supply | AC110-220V 50/60HZ |
| Max power | 4800W |
| Industrial PC | I7 CPU, 16G RAM, 256G SSD+4T HDD |
| Displayer | 24" HDMI LCD |
| Management system connection | MES, ERP, etc. |
Workflow
| Loading | Automatic manipulator loading for 7 to 15 inch reels |
| Max loading quantity | 200 reels (7" with 8mm thickness) |
| Barcode scanning | Supports barcode and QR code scanning |
| Reel transfer | Automatic belt transfer system |
| Labelling | Automatic label printing and application with data upload |
| Unloading | Automatic manipulator unloading to reel vehicle |
Safety Features
| Radiation leakage | No leakage (≤1μSv/h, international standard) |
| Back door safety interlock | X-ray tube powers off immediately when door opens |
| Emergency stop | Front-mounted emergency stop button |
Speed and Accuracy
| Reel size | Parts size | Quantity | Accuracy | Speed |
| 7" (180mm) | 01005 | 10000 | 99.98% | 12-13s |
| 7" (180mm) | 0201 | 10000 | 99.99% | 11-12s |
| 7" (180mm) | 0402 | 10000 | 99.99% | 11-12s |
| 7" (180mm) | 0603 | 5000 | 99.99% | 10-11s |
| 10" (254mm) | 1206 | 5000 | 99.99% | 10-11s |
| 15" (380mm) | 1206 | 10000 | 99.99% | 11-12s |
Artificial Intelligence Deep Learning Algorithm
Our counting software utilizes a powerful AI deep learning algorithm that automatically identifies components without manual binding. The algorithm learns from counted component data including:
- Aspect ratio
- Corner angles of each component
- Slope between components from inside to outside
- Image deformation patterns from inside to outside
Counting accuracy improves with increased usage. The system easily handles similar components or larger trays as the algorithm evolves.
Cloud Database
Every Wellman X-ray counter connects to our cloud database. Machine data and images upload to the cloud while automatically downloading the latest database updates. Our engineers optimize algorithms based on collected data and regularly update customer systems.
Over time, counting accuracy approaches 100% with expanding component type coverage. When encountering new components, the system leverages existing database matches for higher efficiency and accuracy.
Sample Images
