Flexible digital detector array

Abstract

A flexible digital detector array apparatus is provided that includes a control system including a block control module, a gate control module, and at least one data module. The block control module and the gate control module can be arranged to perform multiplexing operations. The apparatus can also include a flexible substrate coupled to the control system at edges of the flexible substrate via a plurality of connectors. The flexible substrate can include a switch region including a plurality of switch pixels arranged within a plurality of blocks. Each switch pixel can be communicatively coupled to the block control module and the gate control module. The apparatus can also include a sensing region including an array of sensing pixels. The array of sensing pixels can generate image data in response to X-rays incident thereon and provide the image data to the plurality of data modules. Each switch pixel of the plurality of switch pixels can be arranged to control a read state of a portion of the sensing pixels.

Description

[0001] Related Applications

[0002] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63 / 315,122, filed March 1, 2022, the entire contents of which are hereby expressly incorporated by reference herein. TECHNICAL FIELD

[0003] The subject matter described herein relates to flexible x-ray sensors. BACKGROUND

[0004] Sensors, such as x-ray sensors, can be used to detect defects in a pipe configured in a pipeline. Defects can exist in the pipe material or in welds that connect pipe sections. Sensors can also be used to measure properties or qualities of a fluid flowing through the pipe. An x-ray sensor can include an array of digital detector elements configured to sense defects, pipe properties, or fluid properties within the pipe. It can be advantageous to form an x-ray sensor having a flexible mating surface that can substantially match the profile of an object being sensed. In this way, the maximum surface area of the sensor is in contact with the object being sensed and the x-ray sensor can increase precision and sensitivity compared to sensors having a non-conformal mating surface. SUMMARY

[0005] In one aspect, a flexible digital detector array apparatus is provided. In some embodiments, the apparatus can include a control system including a block control module including block control circuitry, a gate control module including gate control circuitry, and at least one data module including data circuitry. The block control module and the gate control module can be configured to perform multiplexing operations. The apparatus can also include a flexible substrate that can be coupled to the control system at edges of the flexible substrate via a plurality of connectors. The flexible substrate can also include a switching region including a plurality of switching pixels arranged within a plurality of blocks. Each switching pixel can be communicatively coupled to the block control module via the block control circuitry and to the gate control module via the gate control circuitry. The apparatus can also include a sensing region including an array of sensing pixels that can be configured to generate image data in response to x-rays incident thereon. The array of sensing pixels can also be configured to provide the image data to the plurality of data modules via the data circuitry. Each switching pixel of the plurality of switching pixels can be configured to control a read state of a portion of the sensing pixels.

[0006] In another implementation, the block control module can be configured to provide a first block control signal to a first block comprising a first plurality of switch pixels to power on the first block and to provide a second block control signal to blocks other than the first block to power off the blocks other than the first block.

[0007] In another implementation, the gate control module can be configured to provide a first gate control signal to a second plurality of switch pixels and to provide a second gate control signal to all switch pixels other than the second plurality of switch pixels. Each switch pixel of the second plurality of switch pixels can be in a different block and the first gate control signal can cause a first switch pixel of the first block and the second plurality of switch pixels to activate. The activation can cause a first portion of pixels of the sensing region to transition from a non-read state to a read state.

[0008] The apparatus of claim 3, wherein in response to the transition to the read state, image data generated by the first portion of pixels associated with the first switch pixel is provided to the at least one data module via the data circuit.

[0009] In another implementation, the first block control signal and the first gate control signal can comprise a first predetermined voltage and the second block control signal and the second gate control signal comprise a second predetermined voltage.

[0010] In another implementation, the flexible substrate can comprise a coating that encapsulates the data modules, the gate modules, and the block control module.

[0011] In another implementation, each pixel of the at least one sensing pixel array can comprise at least one photodiode and at least one sensing thin film transistor (TFT). Additionally, each switch pixel of the plurality of flexible switch pixels can comprise at least one gate TFT and at least one gate capacitor. Further, the block controller can comprise a first gate integrated circuit (GIC) and the gate controller can comprise a second gate integrated circuit (GIC). Moreover, the at least one data module can comprise at least one readout integrated circuit (ROIC).

[0012] In another implementation, each sensing pixel of the at least one sensing pixel array can further comprise at least one sensing pixel capacitor. Additionally, the apparatus can further comprise a film laminated to the flexible substrate, the film forming a scintillator.

[0013] In another implementation, the film can comprise a gadolinium oxysulfide film or a cesium iodide film.

[0014] In another implementation, the block control module and the gate control module can each comprise 32, 64, 128, 256, 512, or 1024 ports to connect to the plurality of blocks or the plurality of switch pixels, respectively.

[0015] In another embodiment, the sensing pixels of the sensing region can have a first dimension between 25 mm to 250 mm and a second dimension between 100 mm to 600 mm.

[0016] In another aspect, a method of using a flexible x-ray digital detector array is provided. In some embodiments, the method can include configuring a flexible x-ray digital detector array (DDA) relative to an object to be detected. In some embodiments, the flexible DDA can include a bus and a control system including: a block control module including block control circuitry; a gate control module including gate control circuitry; and at least one data module including data circuitry. The block control module and the gate control module are configured to perform multiplexing operations. The flexible DDA can further include a flexible substrate coupled to the control system at one edge of the flexible substrate via a plurality of connectors. The flexible substrate can include a switching region including a plurality of switching pixels arranged within a plurality of blocks, each switching pixel communicatively coupled to the block control module via the block control circuitry and communicatively coupled to the gate control module via the gate control circuitry. The flexible DDA can further include a sensing region including a pixel array that can be configured to generate image data in response to x-rays incident thereon and provide the image data to the plurality of data modules via the data circuitry. Each switching pixel of the plurality of switching pixels controls a read state of a portion of the sensing pixels. In this embodiment, the method can further include scanning the object using an x-ray emitting device. The method can further include acquiring, by a computing system including at least one processor, the image data characterizing the scanned object.

[0017] In another embodiment, acquiring can further include providing, via the block circuitry, a first block control signal to a first block including a first plurality of switching pixels and a second block control signal to blocks other than the first block. In this embodiment, the method can further include providing a first gate control signal to a second plurality of switching pixels and a second gate control signal to all switching pixels other than the second plurality of switching pixels. Each switching pixel of the second plurality of switching pixels can be in a different block and the first gate control signal can cause a first switching pixel of the first block and the second plurality of switching pixels to activate, thereby causing a first portion of the pixels of the sensing region to transition from the non-read state to the read state. In this embodiment, the method can further include receiving, by the at least one processor, the image data from the first portion of the pixels characterizing the scanned object from the at least one data module via a communication module coupled to the bus. In this embodiment, the method can further include providing, via the block circuitry, a second block control signal to the first block. This can cause the first switching pixel to deactivate, thereby causing the first portion of the pixels of the sensing region to transition from the read state to the non-read state.

[0018] In another embodiment, the acquiring can further include the step of providing a second gate control signal to a second plurality of switch pixels. The method can further include the step of providing, via the block circuit, a first block control signal to the first block and a second block control signal to the blocks other than the first block. The method can further include providing a first gate control signal to a third plurality of switch pixels and a second gate control signal to all switch pixels other than the third plurality of switch pixels. Each switch pixel of the third plurality of switch pixels can be in a different block, and the first gate control signal can cause the second block and a second switch pixel of the third plurality of switch pixels to activate, causing the second portion of the pixels of the sensing region to transition from the non-reading state to the reading state. The method can further include receiving, by the at least one processor, via the communication module coupled to the bus, image data from the second portion of the pixels characterizing the scanned object from the at least one data module. The method can further include providing, via the block circuit, a second block control signal to the first block. This can cause the second switch pixel to deactivate, causing the second portion of the pixels of the sensing region to transition from the reading state to the non-reading state. The method can further include repeating the acquiring step for all switch pixels in the first block. In some embodiments, the method can further include repeating the acquiring step for all blocks in the plurality of blocks.

[0019] In another embodiment, the acquiring can further include the step of providing a second gate control signal to a second plurality of switch pixels. The acquiring can further include providing, via the block circuit, a first block control signal to a second block including a fourth plurality of switch pixels and a second block control signal to the blocks other than the second block. In this embodiment, the method can further include providing a first gate control signal to a third plurality of switch pixels and a second gate control signal to all switch pixels other than the third plurality of switch pixels. Each switch pixel of the third plurality of switch pixels can be in a different block, and the first gate control signal can cause the second block and a second switch pixel of the third plurality of switch pixels to activate, causing the second portion of the pixels of the sensing region to transition from the non-reading state to the reading state. The method can further include receiving, by the at least one processor, via the communication module coupled to the bus, image data from the second portion of the pixels characterizing the scanned object from the at least one data module; providing, via the block circuit, a second block control signal to the second block. In this embodiment, this can cause the second switch pixel to deactivate, causing the second portion of the pixels of the sensing region to transition from the reading state to the non-reading state. The method can further include repeating the acquiring step by starting with providing a first block control signal to the first block and a first gate control signal to a fifth plurality of switch pixels. Alternatively, the method can further include repeating the acquiring step by starting with providing a first block control signal to the third block and a first gate control signal to a fifth plurality of switch pixels.

[0020] In another embodiment, the first block control signal and the first gate control signal can comprise a first predetermined voltage, and the second block control signal and the second gate control signal comprise a second predetermined voltage.

[0021] In another aspect, a flexible x-ray digital detector array system is provided. In some embodiments, the system can include a bus. The system can also include a control system comprising: a block control module comprising block control circuitry; a gate control module comprising gate control circuitry; and at least one data module comprising data circuitry. The block control module and the gate control module are configured to perform multiplexing operations. The system can also include a flexible substrate coupled to the control system at one edge of the flexible substrate via a plurality of connectors. The flexible substrate can include a switching region comprising a plurality of switching pixels arranged within respective blocks. Each switching pixel can be communicatively coupled to the block control module via the block control circuitry and to the gate control module via the gate control circuitry. The system can also include a sensing region comprising a sensing pixel array configured to generate image data in response to x-rays incident thereon and provide the image data to the plurality of data modules via the data circuitry. Each switching pixel of the plurality of switching pixels can be configured to control a read state of a portion of the sensing pixels. The system can also include a plurality of connectors disposed on the edge of the flexible substrate, the plurality of connectors configured to communicatively connect the block control module, the gate control module, and the at least one data module to the bus. The system can also include a communication module coupled to the bus and configured to perform a communication protocol within the system. The system can also include a battery module coupled to the bus and configured to provide power to the system. The system can also include a computing system comprising at least one processor configured to acquire image data characterizing a scanned object.

[0022] In another embodiment, the flexible substrate can be detachably coupled to the bus at the plurality of connectors for replacement.

[0023] In another embodiment, the communication module can be any one of: a 5G or 6G communication module, a Wi-Fi module, and a wired Ethernet module.

[0024] In another embodiment, the system can also include a global positioning system (GPS) module configured to provide positioning data corresponding to a location of the system to an external system. BRIEF DESCRIPTION OF DRAWINGS

[0025] These and other features will be more readily understood from the following detailed description, taken in conjunction with the accompanying drawings, in which:

[0026] Figure 1 is a diagram illustrating an embodiment of a flexible DDA according to the subject matter provided herein;

[0027] Figure 2 is a diagram illustrating an embodiment of a control module and portions of a flexible DDA according to the subject matter provided herein; Figure 1

[0028] Figure 3 is a diagram illustrating an embodiment of an architecture of a flexible DDA according to the subject matter provided herein; Figure 1

[0029] Figure 4 is a diagram illustrating an embodiment of an initial state of a flexible DDA according to the subject matter provided herein; Figure 1

[0030] Figure 5 is a diagram illustrating an embodiment of a read start state of a first line of a first block of a flexible DDA according to the subject matter provided herein; Figure 1

[0031] Figure 6 is a diagram illustrating an embodiment of a read end state of a first line of a first block of a flexible DDA according to the subject matter described herein; Figure 1

[0032] Figure 7 is a diagram illustrating an embodiment of a transition of a read start state of a second line of a first block of a flexible DDA according to the subject matter provided herein; Figure 1

[0033] Figure 8 is a diagram illustrating an embodiment of another architecture of a flexible DDA; and Figure 1

[0034] Figure 9 is a flow diagram illustrating an embodiment of a method for performing detection using a flexible DDA according to the subject matter provided herein. Figure 1

[0035] It should be noted that the drawings are not necessarily drawn to scale. The drawings are intended to depict only typical aspects of the subject matter disclosed herein, and therefore should not be considered as limiting the scope of the disclosure. DETAILED DESCRIPTION

[0036] ​​​​​​​​Existing digital X-ray sensors for in-pipe inspection of defects or monitoring of fluids configured in industrial pipelines can include rigid mating or sensing surfaces that do not conform completely to curved objects such as pipes. As a result, the application of existing digital X-ray sensors on objects of multiple shapes is limited. Additionally, conventional X-ray sensors include a non-modular arrangement of electronic components as designed by the manufacturer, which can limit customer configurability and application use of the X-ray sensor. For example, conventional X-ray sensors require electronic components, such as data modules or gate modules including rigid printed circuit boards (PCBs), arranged around the periphery of the sensor pixel array such that electrical connections are provided on all sides of the sensor pixel array.

[0037] A further limitation of existing X-ray sensors is their limited configurability and modularity. Typically, X-ray sensors are manufactured with a predetermined number and / or configuration of processing or data modules that can be communicatively coupled to an X-ray control module. The user intended use can be limited to the available modules or configuration without the ability to dynamically modify or configure the X-ray sensor with additional processing modules to meet their desired application or data processing needs.

[0038] The systems and devices described herein include a flexible X-ray sensor formed as a digital detector array (DDA). The DDA can include a master board configured with a control module and a plurality of configurable and interchangeable processing modules coupled to a flexible sensing array. The master board can include image processing capabilities combined with the control module. The DDA can include a gate module and a data module that can be incorporated into a flexible substrate. The arrangement of the gate module and data module on the flexible substrate can be connected to the control module via a connector. The connector allows the components of the DDA to be easily replaced. The control module can be coupled to a variety of additional configurable and extensible processing modules that can be arranged depending on the detection requirements or user intended application. The control module can control the operation of the flexible sensing array and the DDA to process acquired image data. The processing modules can include a Wi-Fi module, a battery module, an optional wired module that can be coupled to a computing device, a global positioning system (GPS) module for providing location data, a wireless communication module (e.g., for 5G / 6G communication protocols), and an external wired interface module that can, for example, couple the DDA to an Ethernet cable. The flexible sensing array of the DDA includes an array of light sensitive pixels on a plastic substrate and includes a scintillator for detecting X-rays and can also include a protective enclosure for a ruggedized solution.

[0039] A DDA can include a control system that includes a plurality of interchangeable data modules, gate modules, and block control modules coupled to a motherboard via connectors. A data module can include at least one readout integrated circuit (ROIC). A gate module can include at least one gate chip or gate integrated circuit (GIC). A block control module can include a block control chip or module. The block control module and the gate module can be the same. The data modules, gate modules, and block control modules can be configured at one side of a flexible sensing array such that the DDA can be fully flexible in one direction relative to an object to be detected. The flexible sensing array can include a sensing region that includes sensing pixels and a non-sensing region that includes switching pixels. The non-sensing region can be configured such that each switching pixel can include one transistor and one capacitor implemented in a thin film. In this way, all scan lines or TFTs of the sensing pixels in the sensing region can be controlled with a single gate module in the non-sensing region. Conventionally, one GIC can control up to 256 scan lines. In the DDAs described herein, multiple blocks of 256 scan lines can be controlled using a block control chip in combination with a gate module.

[0040] Advantages of the DDAs described herein include a flexible sensing array that can be easily replaced, for example, if damaged during detection, and thus can reduce the overall operational cost of the X-ray sensor. The DDAs described herein can also enable control electronics and processing modules to be shielded from damaging radiation by decoupling them from the flexible sensing array and not positioning them behind the sensing array as in conventional rigid X-ray sensors. Shielding can be provided locally in the electronics module parts, while the imaging area can be free from shielding, such as heavy metal shielding. Thus, there is less backscatter and first order signal quality by orienting the control and processing modules away from the backside of the flexible sensing array. In this way, the lifetime operation of the DDA can be improved compared to conventional X-ray sensors. Additionally, because heavy metal shielding is not needed for large sensing areas, the overall system weight can be reduced. Thus, the system is easier to maneuver in the field.

[0041] Another advantage is that the flexible sensing array of the DDA can allow the sensor to be used for a greater variety of applications and to detect object shapes than a planar rigid X-ray sensor. For example, curved or bent objects can be detected without any geometric magnification or post-processing calculations to correct for magnification due to the distance to the detected object. Thus, the flexible sensing array of the DDA described herein can provide greater data throughput and detection flexibility with respect to different geometric shapes of the detected object. The use and configurability of the different interchangeable processing modules available to the DDA described herein can also improve detection quality and increase detection efficiency compared to conventional X-ray sensors that do not include such modular, additional processing modules. As technology advances, additional modules can be readily added to the detection system without the need to acquire and integrate a completely separate system. User budgets can be reduced while increasing detection functionality by utilizing only those processing modules needed or specific to a particular detection method or requirement.

[0042] Embodiments of the sensor and method of operation are discussed herein with respect to use in an oil and gas production environment. However, embodiments of the present disclosure can be used to sense properties of curved or non-curved objects and fluids within curved or non-curved objects in any application or environment without limitation.

[0043] Figure 1This is a diagram illustrating an embodiment of a flexible DDA 100 according to the subject matter provided herein. The DDA 100 can be coupled to an object 150 for object detection. As shown, the DDA 100 may include a flexible array 105 coupled to a control system 110. The control system 110 may include a motherboard (MB) 155 and one or more control and processing modules. For example, the control system 110 may include a control module 115, a Wi-Fi module 120, a battery module 125, an optional wired module 130, a GPS module 140, and a cellular data module such as a 5G module 145. The control system 110 may be arranged with one or more modules coupled to the control module 115 in a modular and easily configurable manner, such that any module can be extendedly coupled to the control module 115 and the motherboard 155. The control module 115 can control the operation of the flexible sensing array 105 and the data exchange between the flexible sensing array 105 and one or more modules of the control system 110. The control module 115 can control the switching operation of the flexible array 105, which will be further described herein. Wi-Fi module 120 can wirelessly receive and transmit data with another computing device. Battery module 125 can provide power to DDA 100. Optional wired module 130 can provide a wired interface for coupling computing devices (such as computing device 135). GPS module 140 can provide positioning data, such as GPS coordinate data, about the location of the object 150 being detected. Cellular data module 145 may include a 5G cellular data module.

[0044] Figure 2 This illustrates the subject matter provided in this article. Figure 1 The diagram illustrates an embodiment of a DDA 100, which includes a control module 115 and a flexible sensing array 105. The DDA 100 may include a data module 205, a gate module 210, and a block control module 115. The data module 205, gate module 210, and block control module 115 may be coupled to a motherboard 155 on one side via multiple connectors 215. The data module 205, gate module 210, and block control module 115 may be coupled to the flexible sensing array 105 at a bonding interface 220. The block control module 115 may include a block control chip 225. The gate module 210 may include a GIC 230. Each data module in the data module 205 may include a ROIC 235.

[0045] The flexible array 105 can be formed on a flexible plastic substrate and can include an outer coating. The outer coating can act as an outer cladding of the flexible array 105 and can provide ingress protection to protect the flexible array 105 from water or dust in harsh environments. The outer coating can encapsulate the data, gate, and block control modules. In some embodiments, the outer coating can provide electrostatic discharge protection. The flexible array 105 can have a first aspect ratio and can include pixel arrays of different sizes, such as 25-250 x 100-600 mm. In some embodiments, the pixel array can be 110 mm x 480 mm, which corresponds to 1450 pixels x 6400 pixels. A variety of pixel array sizes, dimensions, and pixel counts or geometries can be contemplated without limitation. As shown, the flexible array 105 can include a switch region 240 and a sensing region 245. The switch region 240 can be coupled to the block control module 115 and the gate module 210 configured to control scanning of the sensing region 245. The sensing region 245 can be coupled to a data module including a plurality of ROICs 235 configured to receive readout data from the sensing region 245. The scintillator can be formed by laminating a film on the flexible array 105. The film can be a gadolinium oxysulfide film or a cesium iodide film, depending on the application.

[0046] Figure 3 is a diagram illustrating an embodiment of an architecture 300 of a flexible DDA 100 in accordance with the subject matter provided herein. Figure 1 and Figure 2 Figure 3 ​As shown, the switch region 240 can be arranged in multiple blocks 305, such as blocks 305A-305D. The block control module 115 can control individual blocks 305 associated with portions of the sensing region 245, and the gate module 210 can control individual gate lines. The combination of the two modules can control the scan lines (i.e., individual portions of the sensing pixels) within the sensing region 245 one by one. The flexible array 105 can include arrays of millions of sensing pixels. Each pixel in the sensing region 245 can include a photodiode, a thin film transistor (TFT), and a capacitor on a flexible substrate. A scintillator 310 can be provided on top of the array 105 to convert X-rays into visible light. The scintillator can be laminated using a pressure sensitive adhesive. The switch region 240 has an array of switch pixels that includes TFTs and capacitors, but not photodiodes. In some embodiments, the array of switch pixels can include multiple TFTs and multiple capacitors. These pixels are configured as scan line switches. There are 256 horizontal gate lines parallel to the data lines from the gate module 210, and each line has multiple connections to the switch pixels from each block, more specifically to the gate electrodes of the TFTs. In some embodiments, there can be 32, 64, 128, or 512 gate lines depending on the capabilities and configuration of the gate module 210. There are an additional number N of block control lines from the block control module that connect to the switch pixels, where N corresponds to the number of blocks. One block control line has multiple connections to all the switch pixels from a single block, more specifically to the source electrodes of the TFTs. The block control module can turn on and off each block 305 in a desired or programmatically determined scan order. The total number of scan lines of the flexible array 105 in the sensing region 245, represented in vertical lines, can be determined as N*256. The scan lines have connections to the switch pixels via the drain electrodes of the TFTs at one end. And on the other side, they are connected to the sensing pixels via the gate electrodes of the TFTs to turn on and off the sensing pixel TFTs. In one scan line, M sensing pixels are connected, where M is the number of data lines.

[0047] Each switch pixel in block 305 can include a TFT and a capacitor. The source electrode of the TFT can be connected to the block control module 115 through a block control line and a metal line perpendicular to the gate lines in the switch region 240. The drain electrode of the TFT can be connected to the sensing pixel via a vertical metal line in the switch region 240 and a scan line in the sensing region 245. A capacitor can be configured at the drain electrode for each switch pixel. The gate electrode of the TFT can be connected to the gate module 210. There are 256 scan lines in the sensing region 245 within a single block. The Lth scan line from each block is connected to the Lth gate line via a switch pixel. To read the charge from the sensing pixel, the scan line associated with the pixel is set to an on voltage by turning on a block control line and a gate line together. When the block control module 115 is on, it can supply +9V (on voltage) to the source electrode of the switch pixel. And because the TFT of the pixel is turned on through the gate line, the scan line is set to the on voltage. In some embodiments, the block control module 215 can supply a voltage between +5V and +15V when on. The supplied voltage can be large enough to turn on the TFT of the sensing pixel. When the block control module 115 is off, it can supply -9V (negative voltage). In some embodiments, the block control module 115 can supply a voltage between -5V and -15V when off. The supplied voltage can be large enough to turn off the TFT of the sensing pixel. To reset the pixel, the block control line is off while the gate line is on, thus the scan line associated with the switch pixel is set to an off voltage. In this way, the block control module 115 and the gate module 210 can individually control all 256xN scan lines. To read the charge from all pixels, the block control module 115 and the gate module 210 can repeat turning on and off 256xN times.

[0048] Figure 4 is a diagram illustrating an initial state 400 of a flexible DDA 105 according to the subject matter provided herein. Figure 1 As shown, in the initial state, the block control module 115 can be configured such that all block control lines 405 are off, and the gate module 210 can be configured such that all gate lines 410 are on. In this state, because all scan lines 415 are set to an off voltage, all TFTs of the sensing pixels will be off. This state can also be associated with an accumulation state in which the photodiode accumulates photoelectron charges in the pixel capacitor before collecting the photoelectron charges to the ROIC 235. Data can be received at each ROIC 235 via data lines 420.

[0049] Figure 5 is a diagram illustrating an initial state 400 of a flexible DDA 105 according to the subject matter provided herein. Figure 1This diagram illustrates an embodiment of the read start state 500 of the first scan line of the first block of a flexible DDA. When the read start state 500 is initiated, the block control module 115 is configured to turn on only the first block control line, and the gate module 210 is configured to turn on only one of the four gate lines. The remaining three gate lines are turned off. In this state, the first scan line is set to the turn-on voltage, and therefore, all TFTs of the sensing pixels associated with the first scan line are turned on. Pixels can then transfer charge to the ROIC, while other pixels accumulate photoelectron charge using their closed TFTs.

[0050] Figure 6 This illustrates the subject matter described in this article. Figure 1 A diagram illustrating the implementation of the first line read end state 600 of the first block of the flexible DDA. When Figure 5 When the read start status 500 is complete, DDA 100 executes. Figure 6 The image shows readout end state 600. In this state, DDA 100 is configured to turn off block control module 115, while gate module 210 is configured to turn on only one of the four gate lines, which was turned on in the readout start state. In this state 600, the first scan line is set to the off voltage, and all TFTs of the sensing pixel associated with the first scan line are turned off. All other scan lines remain at the off voltage, and all other TFTs of the sensing pixels remain off. The pixel associated with the first scan line begins charge buildup for the next frame.

[0051] Figure 7 This illustrates the subject matter provided in this article. Figure 1 A diagram illustrating the implementation of the transition from the second line of the first block of the flexible DDA to the read start state of 700. (See diagram for example.) Figure 7 As shown, transition 700 includes configuring the block control module to turn on the first block control line and configuring the gate module 210 to turn off the first gate line and turn on the next or subsequent gate line. In this state, all TFTs of the sensing pixels associated with the second scan line are turned on. Therefore, the pixels associated with the second scan line can transfer charge to the ROIC, while other pixels accumulate photoelectron charge using the closed TFTs.

[0052] about Figures 4 to 7The switching operations described for the first and second scan lines can be performed iteratively for all scan lines in a continuous manner by configuring block control module 115 and gate module 210. This is an exemplary method of multiplexing all scan lines within a block 305A. The switching operations can also be performed iteratively for all blocks 305 in the switching region 240 using a combination of block control module 115 and gate module 210. The time taken to transfer charge from a pixel associated with a single scan line can be called the line time, which includes the readout start state and the readout end state. Therefore, the total readout time will be the line time multiplied by the total number of scan lines. To achieve a specific X-ray accumulation time, each scan line begins readout after a specific delay, which corresponds to the accumulation time minus the line time. During this delay, all sensing pixels accumulate photoelectron charge in the pixel capacitor using the closed pixel TFT.

[0053] Figure 8 This illustrates the subject matter provided in this article. Figure 1 A diagram illustrating another implementation of the flexible DDA architecture, where two block control lines control one block 800. Figure 7 similar, Figure 8 This corresponds to the transition to the read start state of the second line of the first block. In this configuration, there are more than twice as many block control lines. The first block control line can be connected only to the odd-numbered switch pixels of the first block, while the second control line can be connected only to the even-numbered switch pixels of the first block. Similarly, the third and fourth block control lines can be used for the switch pixels of the second block. In this way, during the state change from the end of read to the start of read from the next scan line, the TFT of the previously closed switch pixel has a voltage change only from the gate electrode. In the previous example 700, the TFT has voltage changes on both the gate electrode and the source electrode simultaneously, which makes the TFT state unclear. In some embodiments, three or more block control lines can be used to control a block. In this way, the switch pixels can be controlled in a more precise and stable manner.

[0054] Figure 9 This illustrates the use of topic 800 provided in this article. Figure 1a flowchart of an embodiment of a method of flexible DDA performing inspection. At 910, a flexible DDA 100 described herein can be configured for inspecting an object. Configuring the DDA 100 can include selecting one or more modules of the control system 110 and coupling the selected modules to the control module 115. In some embodiments, the object can be a piece of industrial equipment or a portion of a pipeline included in a pipeline. The object can be any object on which X-ray inspection is to be performed. In some embodiments, configuring the DDA can include initiating an inspection process, calibrating aspects of the DDA 100, or coupling and configuring one or more computing devices 135.

[0055] At 920, the DDA 100 can be applied to the object to be inspected. For example, the DDA 100 can be applied or positioned relative to a curved outer wall of a pipeline to be inspected. In some embodiments, applying the DDA 100 to the object to be inspected can include receiving GPS data to identify a location at which the object should be inspected. Applying the DDA 100 to the object can also include mating the flexible array 105 with the object such that a contact interface is formed between the surface of the object and the flexible array 105.

[0056] At 930, the DDA 100 can acquire sensing data characterizing the object 150. For example, the DDA 100 can operate according to the switching operation described with respect to FIG. 8 to collect data associated with the object 150. In some embodiments, the sensing data can include X-ray image data in a pixel-by-pixel format or a time-series format. Figures 3 to 8

[0057] At 940, the DDA 100 can provide the sensing data. For example, the DDA 100 can provide the sensing data via a GUI of the computing device 135. In some embodiments, the DDA 100 can store the sensing data in a memory configured in the computing device 135 or the control module 115. In some embodiments, the DDA 100 can provide the sensing data to a computing device or data storage device (e.g., a memory or a server) coupled via the optional wired module 130. In some embodiments, providing the sensing data can be accomplished by transmitting the data via the Wi-Fi module 120 or the cellular data module 145.

[0058] ​The improved manufacturing methods described herein address the technical problem of performing X-ray inspection of objects having curved surfaces in a physical environment of limited space. The unique design of the DDAs provided herein can enable the inspection of non-planar object surfaces in a reduced volume environment. The DDAs described herein can also enable dynamic reconfiguration prior to or during inspection, enabling quick and efficient resolution of user or inspection requirements. The DDAs herein require less processing geometry adjustments or calculations related to correction magnification compared to planar sensors. The placement of control systems on a single side of the DDAs rather than around the periphery or backside of the DDAs can also reduce issues of backscattered radiation, signal loss, and reduced component performance due to radiation exposure.

[0059] The subject matter described herein can be implemented in analog electronic circuits, digital electronic circuits, and / or computer software, firmware, or hardware, including the structural means disclosed in this specification and structural equivalents thereof, or in combinations of them. The subject matter described herein can be implemented as one or more computer program products, such as one or more computer programs tangibly embodied in information carrier (e.g., in a machine -readable storage device), or embodied in propagated signals, for execution by, or to control the operation of, data processing apparatus (e.g., a programmable processor, a computer, or multiple computers). A computer program (also known as a program, software, software application, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file. A program can be stored in a portion of a file that holds other programs or data, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and are interconnected by a communication network.

[0060] The processes and logic flows described in this specification, including the method steps of the subject matter described herein, can be performed by one or more programmable processors executing one or more computer programs to perform functions of the subject matter described herein by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit), and the subject matter described herein can be implemented as a special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit).

[0061] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0062] To provide for interaction with a user, the subject matter described herein can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback, and input from the user can be received in any form, including acoustic, speech, or tactile input.

[0063] The technology described herein can be implemented using one or more modules. As used herein, the term “module” refers to computing software, firmware, hardware, and / or various combinations thereof. At a minimum, however, a module is not software, alone, that is implemented in hardware, firmware, or is recorded on a non-transitory processor-readable storage medium (i.e., modules are not software alone that is an instruction to be executed by a processor). Rather, a “module” is a hardware- based component that is self-contained and can be removed and added to another component. Two different modules can share the same physical hardware, such as the same processor and network interface. Modules described herein can be combined, integrated, separated, and / or duplicated to support various applications. Also, a function described herein as being performed at a particular module can be performed at one or more other modules and / or by one or more other devices. Furthermore, a module can be implemented in relation to any other module to support execution thereof. Additionally, a module can be moved from one device to another and / or included in both devices.

[0064] The subject matter described herein can be implemented in a computing system that includes a back end component (e.g., a data server), a middleware component (e.g., an application server), or a front end component (e.g., a client computer having a graphical user interface or a web browser through which a user can interact with an implementation of the subject matter described herein), or any combination of such back end, middleware, and front end components. The components of the system can be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet.

[0065] Certain example embodiments are described in order to provide a thorough understanding of the structure, function, manufacture, and use of the systems, apparatuses, and methods disclosed herein. One or more examples of these embodiments have been solely illustrated in the drawings. Those skilled in the art will understand that the systems, apparatuses, and methods described herein are non-limiting example embodiments, and the scope of the present invention is defined solely by the claims. Features illustrated or described as part of one example embodiment can be combined with features illustrated or described as part of another embodiment. Such modifications and variations are intended to be included within the scope of the present invention. Further, in the present disclosure, like-named components of the embodiments generally have similar features, and thus not every instance of a like-named component will be described in detail.

[0066] As used herein throughout the specification and claims, the approximation language may be used to modify any quantitative representation that can vary a little from the stated quantitative representation but not to cause a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" should not be limited to the exact value so designated. In at least some instances, the approximation language may correspond to the precision of an instrument used to measure the value. Ranges can be combined and / or interchanged, such ranges being identified and included within all claims, unless context or language indicates otherwise.

[0067] Other features and advantages of the present application will be apparent from the foregoing other embodiments. Accordingly, the application is not to be limited, except as by the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.

Claims

1. An apparatus, the apparatus comprising: a control system including a block control module comprising block control circuitry, a gate control module comprising gate control circuitry, and at least one data module comprising data circuitry; and a flexible substrate coupled to the control system at edges of the flexible substrate via a plurality of connectors, the flexible substrate comprising: a switching region comprising a plurality of switching pixels arranged within a plurality of blocks along a length of the flexible substrate, each switching pixel communicatively coupled to the block control module via the block control circuitry and communicatively coupled to the gate control module via the gate control circuitry, wherein the block control module and the gate control module are configured to perform a multiplexing operation by iteratively performing a switching operation for all scan lines in each block in a sequential manner; and a sensing region comprising an array of sensing pixels configured to generate image data in response to X-rays incident thereon and provide the image data to at least one data module via the data circuitry, wherein each switching pixel of the plurality of switching pixels comprises one transistor and one capacitor implemented in a thin film and controls activation of a readout state of a portion of the array of sensing pixels.

2. The apparatus of claim 1, wherein the block control module is configured to provide a first block control signal to a first block comprising a first plurality of switching pixels to power on the first block and to provide a second block control signal to blocks other than the first block to power off the blocks other than the first block.

3. The apparatus of claim 2, wherein, the gate control module is configured to provide a first gate control signal to a second plurality of switching pixels and to provide a second gate control signal to all switching pixels other than the second plurality of switching pixels, wherein each switching pixel of the second plurality of switching pixels is in a different block of the switching region and the first gate control signal causes a first switching pixel of the second plurality of switching pixels in the first block to activate, thereby causing a first portion of sensing pixels of the sensing region to transition from a non-readout state to a readout state.

4. The apparatus of claim 3, wherein in response to transitioning to the readout state, image data generated by the first portion of sensing pixels associated with the first switching pixel is provided to the at least one data module via the data circuitry.

5. The apparatus of claim 3, wherein the first block control signal and the first gate control signal comprise a first predetermined voltage and the second block control signal and the second gate control signal comprise a second predetermined voltage.

6. The apparatus of claim 1, wherein the flexible substrate comprises a coating encapsulating the data module, the gate control module, and the block control module.

7. The apparatus of claim 1, wherein each sensing pixel of the array of sensing pixels comprises at least one photodiode and at least one sensing thin film transistor (TFT); each of the plurality of switch pixels includes at least one gate TFT and at least one gate capacitor; the block control module includes a first gate integrated circuit (GIC); the gate control module includes a second gate integrated circuit (GIC); and the at least one data module includes at least one readout integrated circuit (ROIC).

8. The device of claim 7, wherein each of the sensing pixels in the array of sensing pixels further includes at least one sensing pixel capacitor, and the device further comprises: a film laminated to the flexible substrate, the film forming a scintillator.

9. The device of claim 8, wherein the film comprises a gadolinium oxysulfide film or a cesium iodide film.

10. The device of claim 1, wherein the block control module and the gate control module each include 32, 64, 128, 256, 512, or 1024 ports that connect the block control module and the gate control module to the plurality of blocks or the plurality of switch pixels, respectively.

11. The device of claim 1, wherein the sensing pixels of the sensing region have a first dimension associated with a width between 25 mm to 250 mm and a second dimension associated with a length between 100 mm to 600 mm.

12. A method comprising: configuring a flexible X-ray digital detector array (DDA) relative to an object to be detected, the flexible DDA including a bus, a control system including a block control module including block control circuitry, a gate control module including gate control circuitry, and at least one data module including data circuitry, and a flexible substrate coupled to the control system at one edge of the flexible substrate via a plurality of connectors, the flexible substrate including a switch region and a sensing region, the switch region including a plurality of switch pixels arranged within a plurality of blocks along a length of the flexible substrate, each switch pixel communicatively coupled to the block control module via the block control circuitry and to the gate control module via the gate control circuitry, wherein the block control module and the gate control module are configured to perform a multiplexing operation by iteratively performing a switch operation for all scan lines in each block in a continuous manner, the sensing region including an array of sensing pixels configured to generate image data in response to X-rays incident thereon and provide the image data to the at least one data module via the data circuitry, wherein each of the plurality of switch pixels controls activation of a read state of a portion of sensing pixels; scanning the object using an X-ray emitting device; acquiring, by a computing system including at least one processor communicatively coupled to the flexible DDA, image data characterizing the scanned object.

13. The method of claim 12, wherein the acquiring further comprises: providing, via the block control circuit, a first block control signal to a first block comprising a first plurality of switch pixels to energize the first block, and a second block control signal to the blocks other than the first block; providing a first gate control signal to a second plurality of switch pixels, and a second gate control signal to all switch pixels other than the second plurality of switch pixels, wherein each switch pixel of the second plurality of switch pixels is in a different block, and the first gate control signal causes a first switch pixel in the first block and in the second plurality of switch pixels to activate, thereby causing a first portion of the sensing pixels of the sensing area to transition from a non-read state to a read state; receiving, by the at least one processor, image data from the first portion of the sensing pixels from the scanned object characterizing the scanned object via a communication module coupled to the bus from the at least one data module; providing, via the block control circuit, a second block control signal to the first block causing the first switch pixel to deactivate, thereby causing the first portion of the sensing pixels of the sensing area to transition from the read state to the non-read state.

14. The method of claim 13, wherein the obtaining further comprises: providing the second gate control signal to the second plurality of switch pixels; providing, via the block control circuit, the first block control signal to the first block and the second block control signal to the blocks other than the first block; providing the first gate control signal to a third plurality of switch pixels, and the second gate control signal to all switch pixels other than the third plurality of switch pixels, wherein each switch pixel of the third plurality of switch pixels is in a different block, and the first gate control signal causes a second switch pixel in the first block and in the third plurality of switch pixels to activate, thereby causing a second portion of the sensing pixels of the sensing area to transition from a non-read state to a read state; receiving, by the at least one processor, image data from the second portion of the sensing pixels from the scanned object characterizing the scanned object via a communication module coupled to the bus from the at least one data module; providing, via the block control circuit, the second block control signal to the first block causing the second switch pixel to deactivate, thereby causing the second portion of the sensing pixels of the sensing area to transition from the read state to the non-read state; repeating the obtaining of all the switch pixels in the first block; and repeating the obtaining of all the blocks in the plurality of blocks.

15. The method of claim 14, wherein the obtaining further comprises: providing the second gate control signal to the second plurality of switch pixels; providing, via the block control circuit, the first block control signal to a second block comprising a fourth plurality of switch pixels, and the second block control signal to the blocks other than the second block. providing the first block control signal to the first block and the first gate control signal to a fifth plurality of switch pixels, or by providing the first block control signal to a third block and the first gate control signal to the fifth plurality of switch pixels. receiving, by the at least one processor, image data from the second portion of the sensing pixels from the scanned object via a communication module coupled to the bus from the at least one data module; providing the second block control signal to the second block via the block control circuit causing the second switch pixel to deactivate, thereby causing the second portion of the sensing pixels of the sensing area to transition from the read state to the non-read state; and repeating the acquiring steps by providing the first block control signal to the first block and the first gate control signal to a fifth plurality of switch pixels, or by providing the first block control signal to a third block and the first gate control signal to the fifth plurality of switch pixels.

16. The method of claim 13, wherein the first block control signal and the first gate control signal comprise a first predetermined voltage, and the second block control signal and the second gate control signal comprise a second predetermined voltage.

17. A system, the system comprising: a bus; the device of claim 1; a plurality of connectors disposed on the edge of the flexible substrate, the plurality of connectors configured to communicatively connect the block control module, the gate control module, and the at least one data module to the bus; a communication module coupled to the bus and configured to execute a communication protocol within the system; a battery module coupled to the bus and configured to provide power to the system; and a computing system comprising at least one data processor configured to acquire the image data.

18. The system of claim 17, wherein the flexible substrate is configured to be detachably coupled to the bus at the plurality of connectors for replacement.

19. The system of claim 17, wherein the communication module is any one of: a 5G or 6G communication module, a Wi-Fi module, and a wired Ethernet module.

20. The system of claim 17, further comprising: a global positioning system (GPS) module configured to provide positioning data corresponding to the system location to an external system.

21. The system of claim 17, wherein the at least one data processor is configured to acquire the image data by providing the first block control signal to the first block and the first gate control signal to a fifth plurality of switch pixels, or by providing the first block control signal to a third block and the first gate control signal to the fifth plurality of switch pixels.

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