Fast 3D Radiography Using an X-ray Flexible Curved Panel Detector with a Motion-Compensated Multiple Pulse X-ray Source

Abstract

The present invention provides an X-ray imaging system using a plurality of pulsed X-ray sources in motion for performing efficient and ultrafast 3D radiography using an X-ray flexible curved panel detector. There are a plurality of pulsed X-ray sources mounted on a structure in motion to form a source array. The sources move simultaneously relative to an object at a constant speed as a group along a predefined arcuate trajectory. Each individual X-ray source can move a small distance around its static position. The individual source is activated when it has a speed equal to the group speed but has an opposite direction of movement. This allows the source to remain relatively stationary during activation. The operation results in a reduced source travel distance for each individual source. 3D radiography image data can be acquired in a much shorter time with a much wider sweep angle, and image analysis can also be performed in real time.

Description

[0001] This invention claims priority to the following applications: Provisional Application Serial No. 63182426, filed on April 30, 2021; Provisional Application Serial No. 63226508, filed on July 28, 2021; Provisional Application Serial No. 63170288, filed on April 2, 2021; Provisional Application Serial No. 63175952, filed on April 16, 2021; Provisional Application Serial No. 63194071, filed on May 27, 2021; Provisional Application Serial No. 63188919, filed on May 14, 2021; Provisional Application Serial No. 63225194, filed on July 23, 2021; Provisional Application Serial No. 63209498, filed on June 11, 2021; Provisional Application Serial No. 63214913, filed on June 25, 2021; Provisional Application Serial No. 63220924, filed on July 12, 2021; Provisional Application Serial No. 63222847, filed on July 16, 2021; Provisional Application Serial No. 63224521, filed on July 22, 2021; and U.S. Application Serial 17149133, filed on January 24, 2021, which in turn claims priority to Provisional Serial 62967325, filed on January 29, 2020, the contents of which are incorporated by reference. Technical Field

[0002] This patent specification pertains to the field of 3D X-ray radiography systems and methods, and more particularly to the use of pulsed X-ray sources and large field-of-view digital flexible panel X-ray detectors. Background Art

[0003] There is a type of digital X-ray 3D radiography, such as mammography; digital tomosynthesis (DTS) is a method for performing high-resolution limited-angle tomography at radiation dose levels comparable to those of conventional radiography. These digital tomosynthesis systems typically use an X-ray source mounted at one end of a rotatable assembly and a digital flat panel detector mounted at the other end. There is a device for compressing and fixing the breast between the X-ray source and the detector. Compression of the breast is necessary to reduce scattered X-rays, reduce radiation dose, make the optical density across the detector more uniform, and improve the visualization of anatomical structures. Tomosynthesis can be used to screen for early signs of breast cancer in asymptomatic women. This type of imaging can also be used as a diagnostic tool for women with symptoms of breast cancer. Tomosynthesis is an advanced type of mammography. Compared to 2D mammography, digital breast tomosynthesis (DBT) detects more cancers and has fewer false positive recalls and more precise lesion localization. When performing tomosynthesis, the X-ray source will need to move in an arc around the breast.

[0004] While the X-ray source moves around the breast, a series of low-dose X-ray images are acquired at different angles. The collected data set allows for the reconstruction of parallel planes. Each plane is clearly visible, and the images of tissues outside those planes are blurred. Generally, a wider sweep angle will generate more data projections and result in better 3D resolution, but it takes longer. Data processing is manufacturer-specific because different reconstruction algorithms may be used. It should be emphasized that these kinds of digital tomosynthesis systems and methods can also be applied to other X-ray 3D radiography applications, such as X-ray 3D chest diagnostic systems for COVID, X-ray 3D non-destructive testing (NDT) systems, and X-ray 3D security inspection systems. There is prior art that performs X-ray 3D radiography using a single X-ray source and a single flat panel.

[0005] However, there are drawbacks in the prior art. The main drawback is that a single X-ray source takes a long time to acquire good data projections. The second drawback is that it is difficult to perform real-time reconstruction because the whole process is slow. The third drawback is that using a rigid X-ray flat panel detector has more serious geometric distortion. Due to the rapid development of technology, today's electronic devices can be made flexible, faster, more compact, and more efficient. Just like flexible solar panel chargers, X-ray detectors can also be made flexible. A typical modern X-ray flat panel detector includes a thin film transistor (TFT), an X-ray scintillator layer, and readout electronics, etc. Although the readout electronics board cannot be made flexible with current technology, using a flexible substrate can make the TFT-based detector flexible. Scintillation materials or scintillator layers (such as Gd2O2S:Tb (GOS or GADOX)) have been made flexible to a certain extent decades ago to be attached to a flexible film for X-ray imaging purposes. Summary of the Invention

[0006] In a first aspect, a system for providing fast 3D radiography using a plurality of pulsed X-ray sources in motion, the system comprising: a primary motorized table that moves freely on an arcuate rail with a predetermined shape; a primary motor coupled to the primary motorized table and controlling the speed of the primary motorized table; a plurality of secondary motorized tables coupled to the primary motorized table and moving along the direction of the arcuate rail; a plurality of secondary motors, each secondary motor engaging a secondary motorized table and controlling the speed of the secondary motorized table; a plurality of X-ray sources, each X-ray source being moved by a secondary motorized table; a support frame structure that provides a housing for the primary motorized table and the secondary motorized tables; and a flexible curved panel detector for receiving X-ray imaging data.

[0007] In a second aspect, a method of fast 3D radiography using multiple pulsed X-ray sources in motion, the method comprising: positioning a primary motorized table and one or more secondary motorized tables to a predetermined initial position; sweeping the primary motorized table at a predetermined constant speed by the primary motor; oscillating each of the secondary motorized tables in the secondary motorized tables in a predetermined order by a corresponding secondary motor; electrically activating the X-ray source and the flexible curved panel detector when the secondary motorized table moves in a direction opposite to that of the primary motorized table and at a selected speed of the primary motorized table; and acquiring image data from the X-ray source using the flexible curved panel detector.

[0008] In another aspect, an X-ray imaging system for performing ultrafast, efficient 3D radiography using multiple pulsed X-ray sources in motion is presented. In the system, multiple pulsed X-ray sources are mounted on a structure in motion to form a source array. The multiple X-ray sources move simultaneously around an object at a constant speed as a group on a predefined arcuate orbit. Each individual X-ray source can also move a small distance rapidly around its static position. When an individual X-ray source has a speed equal to the group speed but in the opposite direction of movement, the individual X-ray source is triggered by an external exposure control unit. This arrangement allows the X-ray sources to remain relatively stationary during the X-ray pulse-triggered exposure duration. The multiple X-ray sources result in a greatly reduced source travel distance for each individual X-ray source. The X-ray receiver is an X-ray flexible curved panel detector. 3D radiography image projection data can be acquired in a much shorter period with a much wider overall sweep. Image analysis can also be performed in real time while scanning is being carried out.

[0009] In another aspect, an X-ray imaging system for performing efficient and ultrafast 3D radiography using multiple pulsed X-ray sources in motion includes multiple pulsed X-ray sources that are mounted on a structure in motion to form a source array. The multiple X-ray sources move simultaneously relative to an object at a constant speed as a group on a predefined arcuate orbit. Each individual X-ray source can also move a small distance rapidly around its static position. When an individual X-ray source has a speed equal to the group speed but has an opposite direction of movement, the individual X-ray source and the X-ray detector are activated by an external exposure control unit. This arrangement allows the X-ray sources to remain relatively stationary during X-ray source activation and X-ray detector exposure. The X-ray receiver is an X-ray flexible curved panel detector. The multiple X-ray sources in motion result in a greatly reduced source travel distance for each individual X-ray source. 3D radiography image data can be acquired in a shorter time with an overall wider sweep angle, and image analysis can also be performed in real time while scanning is being carried out.

[0010] On the other hand, an X-ray flexible curved panel detector allows for a curved surface geometry to minimize distortion. In a specific implementation, a random firing scheme can also be used to randomly activate X-rays from one of any sources in the array. The results of each and cumulative analysis determine the next X-ray source and exposure conditions. The 3D X-ray radiography image is reconstructed based on each image with an angled geometry of the X-ray exposure source. Much broader applications include: 3D mammography or tomosynthesis, chest 3D radiography for COVID or rapid 3D NDT, rapid 3D X-ray security inspection.

[0011] The advantages of the above system may include one or more of the following. Various embodiments of multiple X-ray sources in motion are used in a novel ultrafast five 3D radiography system. The first advantage is that the overall system speed is several times faster. Each X-ray source will only need to mechanically travel a small portion of the entire distance in an arc trajectory. This greatly reduces the amount of data acquisition time required by the patient at the X-ray diagnostic machine. The second advantage is that image analysis can also be done in real time while the scan is in progress. The judgment of the captured image will affect the X-ray source position for the next shot. There is no need to wait until the entire image acquisition is completed before performing tomographic image reconstruction. The third advantage is that high-resolution and high-contrast images can be obtained due to the reduction of motion artifacts. Each X-ray source is also mounted on a substructure that causes the source to vibrate around its origin. When an individual X-ray source is activated, the combination of the vibration speed and the orbital speed results in a relatively stationary position of the X-ray source. The fourth advantage is that the system can perform much wider sweeps to acquire more data projections faster. More data projections mean better image construction, which will result in a reduced misdiagnosis rate. The fifth advantage is that due to a wider angle and faster imaging acquisition, a time component can be added to 3D spatial imaging to form a 4D imaging dataset. The sixth advantage is that the X-ray flexible curved panel detector geometry will result in much less image distortion.

[0012] The invention has been described in terms of preferred embodiments, and it should be recognized that equivalents, alternatives, and modifications other than those explicitly stated are possible and within the scope of the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 An ultrafast 3D digital radiography system with multiple X-ray sources in motion using an X-ray flexible curved panel detector is shown.

[0014] Figure 2 An example is shown where, when the primary and secondary motor worktables move in opposite directions but at the same speed, an individual X-ray source emits an X-ray beam at a temporarily stationary position.

[0015] Figure 3An exemplary configuration is shown where a five X-ray source system uses an X-ray flexible curved panel detector to acquire 25 projection datasets by traveling only one-fifth of the respective total travel distances.

[0016] Figure 4 An exemplary configuration is shown of a combination of three independent system sets that can be used in parallel to cover a much larger X-ray scan angle. DETAILED DESCRIPTION

[0017] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, which show exemplary embodiments. Various embodiments are now described with reference to the drawings, in which like reference numerals refer to such elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more embodiments. However, it is apparent that such embodiments may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing one or more embodiments.

[0018] Thus, for example, those of ordinary skill in the art will recognize that diagrams, schematics, illustrations, etc. represent conceptual views or processes showing systems and methods embodying the present invention. The functions of the various elements shown in the figures can be provided by using dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are merely conceptual. Their functions can be performed by the operation of program logic, by dedicated logic, by the interaction of program control and dedicated logic, or even manually, and the particular technique can be selected by the entity implementing the present invention. Those of ordinary skill in the art also understand that the exemplary hardware, software, processes, methods, and / or operating systems described herein are for illustrative purposes and are thus not intended to be limited to any particular specified manufacturer.

[0019] Figure 1An ultrafast 3D digital radiography system using an X-ray flexible curved panel detector 7 with multiple X-ray sources 5 in motion is shown. A primary motor 1 engages a primary motor table 2 on which there are secondary motors 3, secondary motor tables 4, and multiple X-ray sources 5. All motors, all motor tables, and the X-ray sources 5 are mounted in a support frame structure 6. Each secondary motor 3 engages a secondary motor table 4. All secondary motor tables 4 are mounted on the primary motor table 2. Each X-ray source 5 is mounted on a secondary motor table 4. Each motor is controlled by programmable motion control hardware and can move the motor table back and forth at a predetermined speed. The secondary motor tables 4 are positioned such that the spacing from an adjacent table is equal. Thus, all X-ray sources 5 move together with the primary motor table 2, but each individual X-ray source 5 can move separately with a secondary motor table 4. The X-ray flexible curved panel detector 7 can be mounted on an additional linear table. The X-ray flexible curved panel detector 7 can also move back and forth based on the position of the X-ray sources 5 to have a wider image coverage.

[0020] The primary motor 1 with a travel encoder and a position control system can be mounted on the frame structure 6 to provide movement along an arcuate guide rail that can have any predetermined shape. One or more secondary motors 3 coupled to the primary motor 1 by a coupling and rotatable about its axis are positioned around the primary motor 1 and engage the primary motor table 2 to drive the secondary motor tables 4. Multiple X-ray sources 5 can be mounted on the secondary motor tables 4 and are driven by the secondary motors 3 to move along the arcuate guide rail with the primary motor 1. The X-ray sources 5 can be activated by an external exposure control unit connected to the secondary motors 3. In an embodiment, the X-ray flexible curved panel detector 7 can be used as an X-ray receiver. The primary motor 1 can be mounted on a motorized table with a travel encoder and a position control system and is operated by a primary motor controller to sweep around the arcuate guide rail at a constant speed in one direction.

[0021] The primary motor table 2 provides translational movement for the X-ray sources 5. The secondary motor tables 4 provide a left or right oscillatory movement to each individual X-ray source 5. Based on an iterative method of 3D image reconstruction, each individual X-ray source 5 generates a 3D data set containing all projections along an arcuate section. Because there are multiple X-ray sources 5, projection data can be acquired with a wider sweep than can be achieved with only a single X-ray source. Due to the non-uniformity in X-ray absorption of different parts of body tissue, X-ray data in different fields of view and perspectives is very sensitive to distortion. All images can be acquired under conditions similar to the object being imaged to form good image reconstruction data. The sweep angle between individual images is very small to ensure consistent quality across all imaging data. The entire image acquisition process of the present invention uses motion compensation-based image processing techniques.

[0022] The primary motor workbench 2 is coupled to the primary motor 1 by means of planetary gears which are mounted on a structure moving along an arcuate trajectory defined by guide rails. The X-ray source initially moves at the same speed as the group, and each individual X-ray source 5 can also move a small distance rapidly around its static position. The number of X-ray sources 5 mounted on the structure is for illustrative purposes only. Depending on the specific implementation, there may be more or fewer than five sources. The secondary motor workbench 4 is coupled to the secondary motor 3. Each secondary motor workbench 4 moves along the arcuate trajectory of the guide rails in the direction of the back-and-forth movement of the primary motor workbench 2. The X-ray source 5 moves relative to the object at a predetermined speed. The transmission of X-rays through the object results in a projection data set which can be used to form an image of the object.

[0023] A plurality of X-ray sources 5 are each mounted on the secondary motor workbench 4. The X-ray sources 5 are triggered in a programmed sequence, where each X-ray source is switched on in sequence by an external exposure control unit. When the speed of the secondary motor workbench 4 is substantially equal to the speed of the primary motor workbench 2, the active individual X-ray source can remain relatively stationary during the X-ray pulse triggered exposure duration. On the other hand, the X-ray flexible curved panel detector 7 can be attached to the outer surface of the rigid structure. Each of the plurality of X-ray sources 5 will be activated sequentially for a certain period during which they emit X-rays passing through the object, which are detected by the X-ray flexible curved panel detector 7.

[0024] The plurality of X-ray sources 5 on the array move at a constant speed relative to the object in different moving directions. When an individual X-ray source has a speed equal to the group speed but in the opposite moving direction, each individual X-ray source can also move a small distance rapidly around its static position. The individual X-ray sources are triggered by an external exposure control unit. This arrangement allows the X-ray sources to remain relatively stationary during the X-ray pulse triggered exposure duration. The plurality of X-ray sources result in a greatly reduced source travel distance for the individual X-ray sources. 3D radiography image data can be acquired in a much shorter time with a much wider overall sweep angle, and image analysis can also be performed in real time. When the scan is carried out in the above system, the 3D X-ray receiver is the X-ray flexible curved panel detector 7 such that it can have a curved surface geometry to minimize large truth. The 3D X-ray receiver detects the X-ray images projected from the various X-ray sources 5.

[0025] The support frame structure 6 can be used to support and hold the primary motor table 2, the plurality of secondary motor tables 4, and the X-ray source 5 in relative positions. Each of the secondary motor tables in the secondary motor tables 4 can be driven by a corresponding secondary motor 3, which in turn is driven by a power source. The support frame structure 6 can be a tubular frame or a cuboid frame, which has sufficient space for the primary motor table 2, the secondary motor tables 4, and the X-ray source 5. The primary motor table 2 can be driven by a corresponding primary motor 1, which in turn is driven by a power source. The primary motor 1 can be engaged with the primary motor table 2 such that when it rotates, the primary motor table 2 also rotates. In some embodiments, the primary motor 1 can rotate at a constant speed, while the secondary motors 3 can rotate at different speeds based on various movement instructions provided by the user. The support frame structure 6 can have sufficient mechanical strength and stiffness to provide structural support for the system.

[0026] The X-ray flexible curved panel detector 7 receives X-ray flux from an array of X-ray sources 5 arranged in motion to perform ultrafast, high-efficiency 3D radiography. In this system, there are a plurality of pulsed X-ray sources 5 mounted on a structure in motion to form a source array. The plurality of X-ray sources 5 move simultaneously around an object at a constant speed as a group on a predefined orbit. Each individual X-ray source can also move a small distance rapidly around its static position. When an individual X-ray source has a speed equal to the group speed but in the opposite direction of movement, the individual X-ray source 5 and the X-ray flexible curved panel detector 7 are triggered by an external exposure control unit. This arrangement allows the X-ray source 5 to remain relatively stationary during the X-ray pulse-triggered exposure duration to keep the image sharp. The plurality of X-ray sources 5 results in a greatly reduced source travel distance for an individual X-ray source 5.

[0027] Figure 2Shows the moment when the primary motor stage 2 and the secondary motor stage 4 move in opposite directions but at the same speed, and the individual X-ray source emits an X-ray beam at the temporary stationary position. For one data acquisition cycle, the primary motor stage 2 moves in one direction at a constant speed and then returns to the initial position. When the primary motor stage 2 moves at a constant speed, each secondary motor stage 4 vibrates at a predetermined speed. When the secondary motor stage 4 travels in the direction opposite to the primary motor stage 1 and has the same constant speed, the X-ray source 5 and the X-ray flexible panel detector 7 are triggered. At this trigger moment, the X-ray source 5 behaves as if the X-ray source 5 is stationary while emitting the X-ray beam. Therefore, the dynamic arrangement of the stationary-state X-ray source 5 allows the X-ray imaging system to acquire a large number of images from different spatial angular positions in a very short time. The duration of the constant-speed movement of the secondary motor stage 4 can be programmed by software to match the X-ray exposure time. When one secondary motor stage 4 is at a constant speed, the other secondary motor stage 4 can accelerate, decelerate, or move back to the initial position to prepare for their next constant speed. The X-ray source 5 can also be programmed to perform exposures on demand in a random order based on each individual external trigger pulse. Given the widely available ultra-high-speed computers, image analysis can be performed in real time using image acquisition. The judgment of the captured images will affect the position of the X-ray source 5 for the next shot. There is no need to wait until the entire image acquisition is completed before performing image reconstruction.

[0028] The primary motor stage 2 moves on an arc-shaped guide rail together with one or more secondary motor stages 4, and uses an array of pulsed X-ray sources 5 to perform ultra-fast and efficient two-dimensional 3D radiography. The working principle of this concept is to move the entire structure at a group constant speed on a predetermined arc-shaped track. The group can consist of one or more secondary motor stages 4 attached with an array of pulsed X-ray sources 5. Each individual X-ray source 5 can also move a small distance rapidly around its static position at a speed proportional to the group speed. When the individual X-ray source 5 has a speed equal to the group speed but in the opposite moving direction, the individual X-ray source 5 is triggered by an external exposure control unit. This arrangement allows the X-ray source 5 to remain relatively stationary during the X-ray pulse trigger exposure duration. The multiple X-ray sources 5 result in a greatly reduced source travel distance for the individual X-ray source 5. The array of pulsed X-ray sources 5 will generate a set in the projection data set. The X-ray detector is a flexible panel detector 7, whose curvature can be changed on-site based on application needs. The X-ray receiver is the X-ray flexible panel detector 7. 3D radiography image projection data can be acquired in a much shorter cycle with a much wider overall sweep. Image analysis can also be performed in real time while scanning.

[0029] The secondary motor 3 will then start moving in the direction of movement of the primary motor. The X-ray source 5 will start radiating X-rays, and simultaneously the X-ray receiver will receive X-ray imaging data or charge packets generated by the radiation. At the end of the movement of the primary motor 1, the primary motor starts rotating back towards its starting position. After the X-ray source 5 has finished radiating X-rays, the secondary motor 3 also starts moving back to its original position.

[0030] One or more secondary motor worktables 4 are mounted on the structure for each X-ray source 5 array. Each secondary motor worktable in the secondary motor worktables 4 is designed to move its associated X-ray source 5 in a predetermined order. The predefined order can sweep the associated X-ray source 5 at a constant speed in a group around an arc-shaped track with a predetermined shape. The secondary motor worktable 4 can also move its associated X-ray source 5 a small distance quickly around its static position relative to its initial position. A speed control unit that allows independent control of the speed of the secondary motor worktable 4 is coupled to each secondary motor worktable in the secondary motor worktables 4. This provides the ability to control the speed of the secondary motor worktable 4.

[0031] The X-rays in the group movement will be triggered only when they have a speed equal to the group speed but in the opposite direction of movement. Each individual X-ray source can also move a small distance quickly around its static position when there is no opposite movement by another X-ray source 5. When the individual X-ray source 5 has a speed equal to the group speed but in the opposite direction of movement, the individual X-ray source 5 and the X-ray flexible curved panel detector 7 are activated by an external exposure control unit. This arrangement allows the X-ray source 5 to remain relatively stationary during the exposure duration triggered by the X-ray pulse. The primary motor worktable 2 and one or more secondary motor worktables 4 will be positioned at a predetermined initial position. The primary motor 1 will sweep the primary motor worktable 2 at a predetermined constant speed. The primary motor worktable 2 and the secondary motor worktable 4 will be coupled to each other by gears or belts or other linkage devices (such as chains, cables, ropes, etc.). One or more individual pulsed X-ray sources 5 will be mounted on the moving structure to form a source array. The plurality of X-ray sources 5 move relative to the object simultaneously at a constant speed as a group on a predefined arc-shaped track. Each individual X-ray source 5 can also move a small distance quickly around its static position.

[0032] The X-ray flexible curved panel detector 7 is a new form of X-ray detector, which is much thinner than traditional X-ray templates. It also has very high flexibility and can be easily bent into many different curvatures. For example, in some embodiments, the detector can even be bent into a circle to obtain an image around the human chest. Its geometric distortion is minimal and it is very sensitive. Because multiple sources are used simultaneously, this combination makes it suitable for mammography or 3D X-ray security inspection. The detector can be placed at the central position in the array and detect all sources simultaneously. The large source array allows a random firing scheme to reduce the exposure time of each source while achieving overall high image quality. The X-ray flexible curved panel detector 7 with variable pixel sizes is a new type of X-ray detector, which includes pixel sizes variable by binning. This will enable a single detector to provide sufficient data resolution in various applications.

[0033] Figure 3 The full exposure position is shown. In this case, there are five X-ray sources 5, and the five X-ray sources 5 perform a total of 25 X-ray exposures at different angular positions. However, each secondary motor table 4 only needs to travel one-fifth of the total travel distance. Therefore, in the case where multiple X-ray sources 5 work in parallel, a large amount of projection data can be obtained in a fraction of the time. The X-ray flexible curved panel detector 7 is the X-ray receiver. In this case, the total number of the overall X-ray sources 5 is one set of five. In fact, the total number of X-ray sources 5 can be one set of two to even eight or more. Electronic signals always proceed faster than mechanical movements. The bottleneck of the limiting factor is always the movement of the motor table itself. The next bottleneck is the detector reading limit. Because the detector also needs some time to read out many millions of pixel data and then transfer it to the computer.

[0034] The X-ray sources 5 are mounted on a moving structure to form a source array. When each individual X-ray source 5 has a speed equal to the group speed but in the opposite moving direction, each X-ray source 5 can also move rapidly around its static position by a small distance. The individual X-ray sources 5 and the X-ray flexible curved panel detector 7 are activated by an external exposure control unit. This arrangement allows the X-ray sources 5 to remain relatively stationary during the exposure duration triggered by the X-ray pulse. Multiple X-ray sources result in a greatly reduced source travel distance for each individual X-ray source 5. The X-ray receiver is the X-ray flexible curved panel detector 7. 3D radiography image data can be obtained in a much shorter time with a much wider overall sweep, and image analysis can also be performed in real time while scanning. As an example of an imaging receiver, the X-ray detector has very high flexibility due to the nature of the substrate material, thus allowing stronger robustness against some undesirable effects such as vibration shock, strong magnetic field, etc. The X-ray flexible curved panel detector 7 is generally formed of a single continuous material.

[0035] The X-ray flexible curved panel detector 7 is coupled to the X-ray source 5 via a high voltage cable, and a flexible cable connects the X-ray source 5 to an exposure control unit that provides a trigger signal to the source. Similarly, a flexible cable couples the X-ray detector to an acquisition control unit that generates exposure and timing signals to detect a plurality of X-ray sources 5 and detectors mounted on a structure and moving along an arc-shaped guide rail at a constant group speed. The X-ray source 5 has a typical peak power and produces a pulsed beam with an average power. Each detector typically collects a large amount of data during one pulse width. The detector signal processing unit converts the signals from each detector into digital image data using common 3D X-ray detector system methods known in the art. This fast 3D radiography technology and equipment provide both wide-angle coverage and fast imaging.

[0036] Figure 4 The configuration of three independent sets of X-ray imaging systems that can be used in parallel as a composition to cover more sweep angles is shown. If the sweep angle coverage of each individual set is relatively small, e.g., less than 100 degrees, then the three sets can be in the same plane to cover nearly 360 degrees. However, in the three-set composition configuration, the three sets do not have to be in the same plane. In fact, in addition to one-set and three-set compositions, two-set compositions can also be used. One advantage of the two-set configuration is that they are likely to be in the same plane. The present invention has been described in detail with specific reference to the preferred embodiments of the present invention. However, it should be understood that changes and modifications can be made within the spirit and scope of the present invention. Therefore, the embodiments disclosed in the present invention are considered to be illustrative in all respects and not restrictive. The scope of the present invention is indicated by the appended claims, and all changes falling within the meaning and scope of their equivalents are intended to be included therein.

[0037] The flexible curved panel detector 7 includes a light receiving region having a curved surface to form a curved geometry. A gantry supports the X-ray source 5 at one end of the detector and moves it relative to the sample to be examined along an arc-shaped trajectory. For example, the sample can be a human body part or an object such as an electronic device part. A fixed motor-driven detector stage can also be mounted behind the detector. An array of a plurality of X-ray sources 5 is supported by a structure that can move them simultaneously in a direction opposite to the direction of the motor-driven X-ray source stage. The X-ray sources 5 in motion include five sources indicated by numbers. The sources are each spaced apart semi-circularly at an angle around the arc-shaped guide rail. The sources are spaced apart from each other at an angle. Each of the sources is coupled to a corresponding controller such that when the source has a speed equal to the group speed but has an opposite direction of movement, it will be triggered to emit X-rays.

[0038] The sweep angle and radius can vary. The radius of the arcuate path determines the maximum object size. It can also be measured in terms of the track length or the time for a complete movement. Each X-ray source in the X-ray source 5 has its own motion control system. A plurality of motion systems (one for each X-ray source 5) can be configured to move around the object simultaneously at a constant speed in a group on a predefined track. An individual X-ray source 5 can also move a small distance rapidly around its static position. When an individual X-ray source 5 has a speed equal to the group speed but in the opposite direction of movement, the individual X-ray source 5 is triggered by an external exposure control unit. This arrangement allows the X-ray source 5 to remain relatively stationary during the exposure duration of an X-ray pulse trigger. Each X-ray source in the X-ray source 5 is controlled by its respective independent motion control system. The plate detector structure provides detection for the plurality of pulsed X-ray sources 5 during motion operations. For example, a flexible curved plate detector or other types of X-ray detectors. The X-ray flexible curved plate detector 7 will enable a curved surface geometry to minimize image distortion.

[0039] The present invention relates to ultrafast 3D X-ray imaging and can be used in different fields such as medical diagnosis, industrial process inspection, traffic safety inspection, X-ray security inspection, etc. This patent also provides multiple embodiments. In a first embodiment, a 3D X-ray imaging system using a plurality of pulsed X-ray sources in motion with a primary motor table that moves freely on an arcuate guide rail with a predetermined shape includes: a primary motor that is coupled to the primary motor table 2 and controls the speed of the primary motor table 2; a plurality of secondary motor tables 4 that are coupled to the primary motor table 2 and move in the direction of the arcuate guide rail; a plurality of secondary motors 3, each of which engages a secondary motor table 4 and controls the speed of the secondary motor table 4; a plurality of X-ray sources 5, each of which is moved by a secondary motor table 4; a support frame structure 6 that provides a housing for the primary motor table 1 and the secondary motor tables 4; and an X-ray flexible curved plate detector 7 that is used to receive the X-ray flux to generate imaging data.

[0040] The primary motor 1 engages with the primary motor workbench 2 and controls the speed of the primary motor workbench 2, wherein the structure is movably coupled to the primary motor workbench 2 and coupled to the secondary motor workbench 4. One embodiment of the present invention uses an array of X-ray sources 5 to provide fast 3D radiographic images by moving each X-ray source 5 along a predefined orbit. The main drive structure is used to move one or more X-ray sources 5 simultaneously in two orthogonal directions while scanning an object. The X-ray sources 5 can move around the object in opposite directions, wherein when one X-ray source 5 moves in one direction, the other X-ray source 5 moves in the opposite direction. A plurality of motors control individual motors to control the individual movement of each X-ray source 5. Each X-ray source 5 moves at the same speed as the other X-ray sources 5 but in a different time frame. Each X-ray source 5 can also move a small distance rapidly around its static position, wherein when an individual X-ray source 5 has a speed equal to the group speed but an opposite moving direction, the individual X-ray source 5 is triggered by an external exposure control unit. This arrangement allows the X-ray sources 5 to remain relatively stationary during the X-ray pulse trigger exposure duration. The flexible curved panel detector will enable a curved surface geometry to minimize distortion.

[0041] A first embodiment of the present invention includes a system for providing fast dimensional 3D radiography using a plurality of pulsed X-ray sources in motion, the system comprising: a primary motor workbench that moves freely along an arcuate guide rail with a predetermined shape; a primary motor 1 that is coupled to the primary motor workbench 2 and controls the speed of the primary motor workbench 2; a plurality of secondary motor workbenches 4 that are coupled to the primary motor workbench 2 and move along the direction of the arcuate guide rail; a plurality of secondary motors 3, each secondary motor engaging a secondary motor workbench 4 and controlling the speed of the secondary motor workbench 4; a plurality of X-ray sources 5, each X-ray source being moved by a secondary motor workbench 4; a support frame structure 6 that provides a housing for the primary motor workbench 2 and the secondary motor workbenches 4; and an X-ray flexible curved panel detector 7 that is used to receive X-ray flux to generate imaging data.

[0042] The primary motor 1 moves the primary motor table 2. A plurality of secondary motors 3 engage the secondary motor tables 4, and each secondary motor controls the speed of the secondary motor table 4. The secondary motor table 4 has a set of secondary motors 3 that control the movement of the secondary motor table along the direction of the arc-shaped guide rail. Each secondary motor table 4 may have one or more X-ray sources 5 mounted thereon. The X-ray flexible curved panel detector 7 receives the X-ray flux from the plurality of X-ray sources 5, and the plurality of X-ray sources move simultaneously around the object at a constant speed in a group along a predefined orbit. Each individual X-ray source 5 may also move a small distance rapidly around its static position. When the individual X-ray source 5 has a speed equal to the group speed but in the opposite direction of movement, the individual X-ray source 5 is triggered by an external exposure control unit. This arrangement allows the X-ray source 5 to remain temporarily stationary during the X-ray pulse-triggered exposure duration.

[0043] Next, the support frame structure 6 is described in detail. It consists of two sets of mounting brackets, namely, the primary motor table set, the secondary motor table set, and the detector set. The primary motor table set supports one or more motor secondary tables mounted on one or more X-ray sources 5. The primary motor table has its motor, and it moves along the arc-shaped guide rail by engaging with the guide rail and is controlled by the speed of the primary motor. The motor can be an electric stepper motor or a servo motor, etc.

[0044] One or more secondary motor tables 4 support each X-ray source 5 and move along the direction of the arc-shaped guide rail. For each primary motor table 2, there may be several pairs of secondary motor tables 4 to allow the simultaneous movement of the primary motor table 2 and its associated secondary motor tables 4. At least one flexible curved panel detector 7 (X-ray receiver) is mounted on the detector table and receives the X-ray flux. The first drive unit and the second drive unit drive the first and second motor tables respectively. The first drive unit includes: a first gearbox connected to the primary motor table set, and a first speed control module connected to the first gearbox.

[0045] The present invention is described with respect to an ultrafast, high efficiency dimensional 3D radiography system with a plurality of pulsed X-ray sources 5 moving at a constant velocity. The plurality of pulsed X-ray sources 5 are mounted on a moving structure to form a source array. The array moves along a predetermined arcuate path while sweeping an object with an overall wide view angle. Each individual X-ray source 5 can also move rapidly about its stationary position. When an individual X-ray source 5 has a velocity equal to the group velocity but in the opposite direction of movement, the individual X-ray source 5 is triggered by an external exposure control unit. This arrangement allows the X-ray sources 5 to remain relatively stationary during the X-ray pulse triggered exposure duration. Image data is acquired from the X-ray sources 5 using an X-ray flexible curved panel detector 7. 3D projection data is acquired when a secondary motor table 4 moves in a direction opposite to that of the primary motor table 2 and at a selected velocity of the primary motor table 2. This arrangement allows the X-ray sources 5 to remain relatively stationary during the X-ray pulse triggered exposure duration.

[0046] The description will focus on systems and methods for performing rapid dimensional X-ray imaging, but these techniques and devices can be applied to other applications, such as in mammography or other forms of dimensional imaging using X-rays, such as the X-ray flexible curved panel detector 7. One embodiment relates to a plurality of pulsed X-ray sources 5 mounted on a moving structure to form an array of X-ray sources 5. The plurality of X-ray sources move simultaneously relative to an object at a constant velocity as a group along a predefined arcuate path. Each individual X-ray source 5 can also move rapidly about its stationary position by a small distance. When an individual X-ray source 5 has a velocity equal to the group velocity but in the opposite direction of movement, the individual X-ray source 5 and the X-ray flexible curved panel detector 7 are activated by an external exposure control unit. This arrangement allows the X-ray sources 5 to remain relatively stationary during the activation of the X-ray sources 5 and the exposure of the X-ray detector. Another embodiment of the present invention includes an X-ray flexible curved panel detector 7 for detecting X-ray photons emitted from an X-ray source 5 positioned on a structure moving relative to an object being imaged, wherein the flexible curved panel detector 7 includes a front surface with an X-ray scintillator for receiving the X-ray photons.

[0047] The sweeping of the primary motor table 2 is performed by engaging the primary motor 1 with the primary motor table 2 and then rotating the primary motor 1 to engage a predetermined number of gears and shafts to provide free movement of the primary motor table 2 along an arcuate guide rail with a predetermined shape. The method further includes sweeping the primary motor table 2 at a predetermined constant velocity by the primary motor 1.

[0048] Multiple X-ray sources 5 move simultaneously around an object in a group at a constant speed on a predefined orbit. Three of the present invention have been described in this patent application, namely, a system and method for fast 3D radiography using multiple pulsed X-ray sources 5 in motion, which includes: a primary motor table 2 that moves freely on an arc-shaped guide rail with a predefined shape; a primary motor 1 that engages with the primary motor table 2 and controls the speed of the primary motor table 2; multiple secondary motor tables 4 that are coupled to the primary motor table 2 and move along the direction of the arc-shaped guide rail; multiple secondary motors 3, each of which engages with a secondary motor table 4 and controls the speed of the secondary motor table 4; multiple X-ray sources, each of which is moved by a secondary motor table 4; a support frame structure 6 that provides a housing for the primary motor table 2 and the secondary motor tables 4; and an X-ray flexible curved panel detector 7 that is used to receive X-ray flux to form imaging data.

[0049] Various modifications and changes to the present invention will be apparent to those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. It should be noted that the steps recited in any method claim do not necessarily need to be performed in the order in which they are recited. Those of ordinary skill in the art will recognize variations in the order of performing the steps. Additionally, the lack of mention or discussion of a feature, step, or component provides a basis for a claim that excludes the non-existent feature or component by conditional or similar claim language.

[0050] Although various embodiments of the present invention have been described above, it should be understood that they are presented by way of example only and not limitation. The various figures may depict an exemplary architecture or other configuration for the present invention to assist in understanding the features and functionality that may be included in the present invention. The present invention is not limited to the exemplary architectures or configurations shown, but rather various alternative architectures and configurations may be used to achieve the desired features. In fact, it will be apparent to those skilled in the art how alternative functions, logical, or physical partitioning and configurations may be implemented to achieve the desired features of the present invention. Additionally, many different component names other than those depicted herein may be applied to the various partitions. Further, for flowcharts, operation descriptions, and method claims, the order of steps presented herein should not force the various embodiments to perform the recited functionality in the same order unless the context indicates otherwise.

[0051] Unless otherwise expressly stated, the terms and phrases used in this document and their variations shall be construed as open-ended rather than limiting. By way of example of the foregoing, the term "including" shall be interpreted to mean "including but not limited to" or the like; the term "example" is used to provide exemplary instances of items in a discourse, rather than an exhaustive or limiting list thereof; the term "a" or "an" shall be interpreted to mean "at least one", "one or more" or the like; and adjectives such as "conventional", "traditional", "normal", "standard", "known" and terms of similar import shall not be construed as limiting the items described to a given time or to items available as of a given time, but rather shall be interpreted to cover conventional, traditional, normal or standard techniques that are available or known now or at any time in the future. Thus, in the case where this document refers to techniques that are obvious or known to a person of ordinary skill in the art, such techniques cover those that are obvious or known to a person skilled in the art now or at any time in the future.

Claims

1. A system for providing fast 3D radiography using an X-ray flexible curved panel detector with a motion-compensated multiple pulsed X-ray source, which comprises: A primary motor table that moves freely on an arc-shaped guide rail with a predetermined shape; A primary motor coupled to the primary motor table to control the speed of the primary motor table; A plurality of secondary motor tables coupled to the primary motor table and moving along the direction of the arc-shaped guide rail; A plurality of secondary motors, each of which engages a secondary motor table and controls the speed of the secondary motor table; A plurality of pulsed X-ray sources, each of which is moved by a secondary motor table; A support frame structure that provides a housing for the primary motor table and the secondary motor tables; And An X-ray flexible curved panel detector for receiving X-ray flux, wherein the system further comprises: A predefined orbit; and A source array that includes the plurality of pulsed X-ray sources mounted on a moving structure, wherein each pulsed X-ray source among the plurality of pulsed X-ray sources moves around an object simultaneously at a constant speed of a group on the predefined orbit, and when a single X-ray source among the plurality of pulsed X-ray sources has the same speed as the constant speed of the group but in the opposite moving direction, the single X-ray source and the X-ray flexible curved panel detector are triggered by an exposure control unit.

2. The system according to claim 1, wherein the speed or position of the primary motor table or the secondary motor table is adjustable by software.

3. The system according to claim 1, wherein the current and voltage of the X-ray source are adjustable by software.

4. The system according to claim 1, wherein the exposure time of the X-ray source is adjustable by software.

5. The system according to claim 1, wherein the X-ray source is stationary relative to the X-ray flexible curved panel detector during the X-ray pulse trigger exposure duration.

6. The system according to claim 1, wherein the next X-ray source and exposure conditions are determined based on the result of each and the cumulative analysis of the X-ray imaging data.

7. The system according to claim 1, wherein the X-ray flexible curved panel detector acquires 3D radiography image projection data by using a predetermined sweep over a predetermined period of time, and wherein image analysis is performed in real time during the scan.

8. The system according to claim 1, wherein each individual X-ray source moves rapidly around a static position at a predetermined distance.

9. The system according to claim 1, wherein a 3D X-ray radiography image is reconstructed based on each image with an angled geometry of the X-ray exposure source.

10. A method for fast 3D radiography using an X-ray flexible curved panel detector with a motion-compensated multiple pulsed X-ray source, which is performed using the system according to any one of claims 1 to 9, the method comprises: Position a primary motor worktable and one or more secondary motor worktables to a predetermined initial position; Sweep the primary motor worktable at a predetermined constant speed by the primary motor; Oscillate each of the secondary motor worktables in the secondary motor worktables in a predetermined order by corresponding secondary motors; Electrically activate an X-ray source and an X-ray flexible curved panel detector when the secondary motor worktable moves in a direction opposite to that of the primary motor worktable and at a selected speed of the primary motor worktable; and After receiving X-ray flux from the X-ray source, use the X-ray flexible curved panel detector to acquire image data.

11. The method according to claim 10, wherein comprises: Using a worktable for scanning an object.

12. The method according to claim 10, wherein comprises: Using a random firing scheme to randomly activate the X-ray source from one of any sources in the array.

13. The method according to claim 10, wherein comprises: Reconstruct 3D X-ray radiography based on each image of an angled geometry with an X-ray source.

14. The method according to claim 10, wherein the X-ray flexible curved panel detector acquires 3D radiography image projection data using a predetermined sweep over a predetermined time while performing image analysis in real time during the scan.

15. The method according to claim 10, wherein comprises: Changing the sweep angle based on the region of interest.

16. The method according to claim 10, wherein comprises: Changing the X-ray source voltage input based on the object density during the sweep.

17. The method according to claim 10, wherein the X-ray detector is coupled to a linear worktable to adjust the position based on the position of the X-ray source.

18. The method according to claim 10, wherein 4D imaging is performed by adding a time component to the 3D spatial imaging data.

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