Modular power distribution unit for x-ray generation

Abstract

A PDU (56) includes a motherboard (72) supporting an AC busbar (74), a DC busbar (76), and an AC busbar (78), wherein the AC busbar (74) is configured to receive power. The PDU (56) includes one or more AC-to-DC boards (80) electrically coupling the AC busbar (74) to the DC busbar (76), wherein the one or more AC-to-DC boards (80) are configured to draw power from the AC busbar (74), convert the power to DC power, and supply DC power to the DC busbar (76). The PDU (56) includes one or more peak power reduction boards (90) electrically coupling an energy storage system (92) to the DC busbar (76), wherein the one or more peak power reduction boards (90) are configured to access stored DC energy from the energy storage system (92) and supply the stored DC energy to the DC busbar (76) when power demand exceeds a threshold.

Description

Background Technology

[0001] The subject matter disclosed in this article relates to imaging systems, and more specifically to modular power distribution units for X-ray generation.

[0002] Non-invasive imaging techniques allow images of a patient's internal structures or features to be obtained without performing invasive procedures on the patient. Specifically, such non-invasive imaging techniques rely on various physical principles (such as differential transmission of X-rays through a target volume or reflection of sound waves) to acquire data and construct images or otherwise represent the patient's observed internal features.

[0003] For example, in computed tomography (CT) and other X-ray-based imaging techniques, X-ray radiation crosses the subject of interest (such as a human patient), and a portion of the radiation affects the detector that collects image data. In digital X-ray systems, photodetectors generate signals representing the amount or intensity of radiation impacting discrete pixel areas on the detector surface. These signals can then be processed to generate images that can be displayed for viewing. In CT imaging systems, as the gantry moves around the patient, a detector array comprising a series of detector elements generates similar signals at various locations.

[0004] Certain X-ray imaging systems (e.g., CT imaging systems, X-ray imaging systems, mammography systems, interventional imaging systems, fluoroscopy systems) utilize power distribution units (PDUs) when generating X-rays. Specifically, the PDU needs to meet the (continuous and peak) power requirements of the corresponding X-ray imaging system. Several types of PDUs may be required based on customer orders. Each PDU is designed and manufactured based on a specific order. Furthermore, each type of X-ray imaging system (and different layers of the same X-ray imaging modality) has its own dedicated PDU. The same X-ray imaging system shipped to different countries may require PDU modifications. Moreover, all existing PDUs worldwide used for X-ray imaging system types exhibit voltage drop issues. Each PDU line exhibits its own unique failure modes. Additionally, any modification to the X-ray imaging system requires PDU modifications. New X-ray imaging systems may require increased power grid capacity. Summary of the Invention

[0005] The following outlines some embodiments commensurate with the scope of the originally claimed subject matter. These embodiments are not intended to limit the scope of the claimed subject matter, but rather to provide only a brief overview of the possible forms of the subject matter. In reality, the subject matter may include many forms that are similar to or different from the embodiments described below.

[0006] In one embodiment, a power distribution unit for an X-ray imaging apparatus is provided. The power distribution unit includes a motherboard that mechanically supports a plurality of mains busbars, a plurality of direct current (DC) busbars, and a plurality of alternating current (AC) busbars, wherein the plurality of mains busbars are configured to receive power from the power grid. The power distribution unit also includes one or more mains-to-DC boards that electrically couple the plurality of mains busbars to the plurality of DC busbars, wherein the one or more mains-to-DC boards are configured to absorb power from the plurality of mains busbars, convert the power to DC power, and supply DC power to the plurality of DC busbars. The power distribution unit further includes one or more peak power reduction boards that electrically couple an energy storage system to the plurality of DC busbars, wherein the one or more peak power reduction boards are configured to access stored DC energy from the energy storage system and supply the stored DC energy to the plurality of DC busbars when power demand exceeds a programmed threshold. The power distribution unit includes a modular architecture.

[0007] In another embodiment, a medical imaging system is provided. The medical imaging system includes an X-ray source configured to emit X-rays. The medical imaging system also includes a high-voltage generator configured to supply power to the X-ray source. The medical imaging system further includes a power distribution unit having a modular architecture and configured to receive and store power from the power grid, wherein the power distribution unit is configured to regulate a high-voltage (500V to 800V) direct current (DC) output to components of the medical imaging system including the high-voltage generator. The power distribution unit includes a motherboard that mechanically supports a plurality of mains busbars, a plurality of DC busbars, and a plurality of alternating current (AC) busbars, wherein the plurality of mains busbars are configured to receive power from the power grid. The power distribution unit also includes one or more mains-to-DC boards that electrically couple the plurality of mains busbars to the plurality of DC busbars, wherein the one or more mains-to-DC boards are configured to absorb power from the plurality of mains busbars, convert the power to DC power, and supply DC power to the plurality of DC busbars. The power distribution unit further includes one or more peak power reduction plates that electrically couple the energy storage system to a plurality of DC busbars, wherein the one or more peak power reduction plates are configured to access stored DC energy from the energy storage system and to supply the stored DC energy to the plurality of DC busbars when power demand exceeds a programmed threshold.

[0008] In another embodiment, a method for manufacturing a modular power distribution unit for an X-ray imaging apparatus is provided. The method includes providing a motherboard that mechanically supports a plurality of mains busbars, a plurality of direct current (DC) busbars, and a plurality of alternating current (AC) busbars, wherein the plurality of mains busbars are configured to receive power from the power grid. The method further includes coupling one or more mains-to-DC boards to the motherboard to electrically couple the plurality of mains busbars to the plurality of DC busbars, wherein the one or more mains-to-DC boards are configured to absorb power from the plurality of mains busbars, convert the power to DC power, and provide DC power to the plurality of DC busbars. The method further includes coupling one or more peak power reduction boards to the motherboard to electrically couple an energy storage system to the plurality of DC busbars, wherein the one or more peak power reduction boards are configured to access stored DC energy from the energy storage system and, when power demand exceeds a programmed threshold, provide the stored DC energy to the plurality of DC busbars, or receive power to recharge the energy storage system. Attached Figure Description

[0009] These and other features, aspects, and advantages of the subject matter disclosed herein will be better understood when reading the following detailed description with reference to the accompanying drawings, in which like reference numerals denote like parts throughout the drawings, wherein:

[0010] Figure 1 This is a combined drawing view and block diagram of a computed tomography (CT) imaging system as discussed in this article;

[0011] Figure 2 It is a block diagram of the medical imaging load according to various aspects of this disclosure;

[0012] Figure 3 This is a schematic diagram of a modular power distribution unit according to various aspects of this disclosure (e.g., having a common energy storage element);

[0013] Figure 4 This is a schematic diagram of a modular power distribution unit according to various aspects of this disclosure (e.g., having multiple individual energy storage elements);

[0014] Figure 5 It is a schematic diagram of a modular power distribution unit according to various aspects of this disclosure (e.g., having a mains-to-AC board);

[0015] Figure 6 It is a schematic diagram of a modular power distribution unit according to various aspects of this disclosure (e.g., having multiple separate energy storage elements for both AC power and DC power);

[0016] Figure 7This is a schematic diagram of a modular power distribution unit (e.g., with an energy storage system) for a CT imaging system requiring 200 kVA, according to various aspects of this disclosure.

[0017] Figure 8 This is a schematic diagram of a modular power distribution unit (e.g., lacking an energy storage system) for a CT imaging system requiring 200 (kVA) according to various aspects of this disclosure;

[0018] Figure 9 It is coupled to various aspects of this disclosure Figure 7 A schematic diagram of the DC uninterruptible power supply for the modular power distribution unit in the diagram;

[0019] Figure 10 It is coupled to various aspects of this disclosure Figure 7 A schematic diagram of the AC uninterruptible power supply of the modular power distribution unit in the diagram;

[0020] Figure 11 This is a schematic diagram of a modular power distribution unit (e.g., with an energy storage system) for a CT imaging system requiring 210kVA and 3kVA for reconstruction, according to various aspects of this disclosure.

[0021] Figure 12 This is a schematic diagram of a modular power distribution unit (e.g., without an energy storage system) for a CT imaging system requiring 210kVA and 13kVA for reconstruction, according to various aspects of this disclosure; and

[0022] Figure 13 This is a flowchart of a method for manufacturing a modular power distribution unit for an X-ray imaging apparatus according to various aspects of this disclosure. Detailed Implementation

[0023] One or more specific implementations will be described below. To provide a concise description of these implementations, not all features of an actual implementation will be described in this specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, many implementation-specific decisions must be made to achieve the developer's specific objectives, such as complying with system-related and business-related constraints that may differ from implementation to implementation. Furthermore, it should be understood that such development efforts may be complex and time-consuming, but will in any case remain routine tasks of design, fabrication, and manufacturing for those skilled in the art who benefit from this disclosure.

[0024] When describing elements of various embodiments of the subject matter of this invention, the articles “a,” “an,” “the,” and “the” are intended to indicate the presence of one or more elements among the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that additional elements may be present in addition to the listed elements. Furthermore, any numerical examples in the following discussion are intended to be non-limiting, and therefore the additional numerical values, ranges, and percentages are within the scope of the disclosed embodiments.

[0025] While the various aspects discussed below are presented in the context of medical imaging, it should be understood that the disclosed techniques are not limited to such medical settings. In fact, the examples and explanations provided in such medical settings are merely for illustrative purposes by offering real-world examples of implementation and application. However, the disclosed techniques can also be used in other settings, such as image reconstruction for non-destructive inspection of manufactured parts or goods (i.e., quality control or quality inspection applications) and / or non-invasive inspection of packages, boxes, luggage, etc. (i.e., security screening or screening applications). In general, the disclosed techniques can be used in any imaging or screening background, image processing, or photography field utilizing X-ray sources.

[0026] This disclosure provides embodiments of a modular power distribution unit for a medical imaging system. The medical imaging system can be an X-ray source configured to emit X-rays. For example, the medical imaging system can be a computed tomography imaging system, a fluoroscopy imaging system, an interventional imaging system, and a radiographic imaging system (i.e., a conventional imaging system including a mammography system). In some embodiments, the medical imaging system can be used in conjunction with a magnetic resonance imaging system. Although discussed in the context of medical imaging, the modular power distribution unit can also be used with electric vehicles, energy storage, battery chargers, and other applications.

[0027] Modular power distribution units provide plug-and-play power distribution units (e.g., common power distribution units) for powering all types of X-ray systems. Modular power distribution units are configured for all loads. They feature a modular architecture built from four different types of boards. These different types of boards provide building blocks for each product. In some implementations, the four types of boards include a motherboard, a mains-to-DC board, a DC-to-AC board, and a peak power reduction board. The different types of boards (particularly the mains-to-DC board and the DC-to-AC board) are programmable to regulate voltage and frequency. Programmability allows the same hardware to be adapted to any hardware requirements and most power grid parameters (i.e., nominal voltage and frequency). Modular power distribution units are configured to couple to a DC uninterruptible power supply (UPS) or an AC uninterruptible power supply to support basic operation during extended power outages.

[0028] Modular switchgear units can be easily and inexpensively scaled to meet product needs. They provide redundancy for maintenance and repair without downtime. Specifically, a single fault will not cause all switchgear units to shut down. Modular switchgear units can integrate peak power reduction and energy storage. With the availability (integration) of peak power reduction, grid upgrades may not be necessary. Modular switchgear units include a regulated (self-regulating) DC bus. This self-regulation avoids voltage drop issues when units are loaded. Modular switchgear units may also include built-in hot-landing features.

[0029] The limited number of boards designed and manufactured for modular switchgear units allows for scalability through different products, modes, and options. Modular switchgear units include fully programmable output voltages (both AC and DC), thus providing the same hardware for different applications and / or power grid connections. Modular switchgear units reduce costs due to the limited number of different boards produced in batches. Modular switchgear units offer options for adding redundancy. Modular switchgear units can be customized and / or provide power availability solutions to meet customer needs. Modular switchgear units offer a more compact design than typical switchgear units. Modular switchgear units may also include intelligent power monitoring and control options. Modular switchgear units enable future system upgrades by simply upgrading existing modular switchgear units.

[0030] The disclosed embodiments include a power distribution unit for an X-ray imaging apparatus. The power distribution unit includes a motherboard that mechanically supports multiple mains busbars, multiple direct current (DC) busbars, and multiple alternating current (AC) busbars, wherein the multiple mains busbars are configured to receive power from the power grid. The power distribution unit also includes one or more mains-to-DC boards that electrically couple the multiple mains busbars to the multiple DC busbars, wherein the one or more mains-to-DC boards are configured to absorb power from the multiple mains busbars, convert the power to DC power, and supply DC power to the multiple DC busbars. The power distribution unit further includes one or more peak power reduction boards that electrically couple an energy storage system to the multiple DC busbars, wherein the one or more peak power reduction boards are configured to access stored DC energy from the energy storage system and supply the stored DC energy to the multiple DC busbars when power demand exceeds a programmed threshold. The energy storage system is also configured to receive power to recharge the energy storage system. The power distribution unit includes a modular architecture.

[0031] In some implementations, the modular architecture of the power distribution unit is configured for use with the same X-ray imaging modal of different types as well as with different types of X-ray imaging modalities. In some implementations, the one or more mains-to-DC boards are configured to regulate the DC voltage supplied to the multiple DC busbars to a set DC voltage value.

[0032] In some embodiments, the power distribution unit includes one or more DC-to-AC boards that electrically couple multiple DC busbars to multiple AC busbars. The one or more DC-to-AC boards are configured to draw DC power from the multiple DC busbars, convert the DC power to AC power, and provide AC power to the multiple AC busbars. In some embodiments, the one or more DC-to-AC boards are configured to regulate the AC voltage of the AC power supplied to the multiple AC busbars to both a set amplitude and a set frequency. In some embodiments, the one or more DC-to-AC boards are configured to provide single-phase AC power to the multiple AC busbars. In some embodiments, the one or more DC-to-AC boards are configured to provide three-phase AC power to the multiple AC busbars. Configuration can be achieved by selecting appropriate firmware and / or by hardware modifications.

[0033] In some embodiments, the one or more peak power cutters are configured to supply a portion of the DC power to an energy storage system for storage. In some embodiments, the one or more peak power cutters include a plurality of peak power cutters, and the energy storage system includes a common energy storage element coupled to each of the plurality of peak power cutters. In some embodiments, the one or more peak power cutters include a plurality of peak power cutters, and the energy storage system includes a plurality of energy storage elements, and each of the plurality of energy storage elements is individually coupled to a corresponding peak power cutter among the plurality of peak power cutters.

[0034] In some embodiments, the distribution unit further includes one or more mains-to-AC boards that electrically couple multiple mains busbars to multiple AC busbars, wherein the one or more mains-to-DC boards are configured to draw power from the multiple mains busbars and supply AC power to the multiple AC busbars. In some embodiments, the distribution unit includes one or more additional peak power reduction boards that electrically couple an additional energy storage system to the multiple AC busbars, wherein the one or more additional peak power reduction boards are configured to access stored DC energy from the additional energy storage system and supply the stored DC energy to the multiple AC busbars when power demand exceeds a programmed threshold. The additional energy storage system is also configured to receive power to recharge itself. In some embodiments, the one or more additional peak power reduction boards include multiple additional peak power reduction boards, and the additional energy storage system includes a common energy storage element coupled to each of the multiple additional peak power reduction boards. In some embodiments, the one or more additional peak power reduction plates include a plurality of additional peak power reduction plates, and the additional energy storage system includes a plurality of energy storage elements, and each of the plurality of energy storage elements is individually coupled to a corresponding additional peak power reduction plate in the plurality of additional peak power reduction plates.

[0035] In some implementations, multiple DC busbars are configured to be coupled to a DC uninterruptible power supply. In some implementations, multiple AC busbars are configured to be coupled to an AC uninterruptible power supply.

[0036] The disclosed embodiments include a method for manufacturing a modular power distribution unit for an X-ray imaging apparatus. The method includes providing a motherboard that mechanically supports a plurality of mains busbars, a plurality of direct current (DC) busbars, and a plurality of alternating current (AC) busbars, wherein the plurality of mains busbars are configured to receive power from the power grid. The method also includes coupling one or more mains-to-DC boards to the motherboard to electrically couple the plurality of mains busbars to the plurality of DC busbars, wherein the one or more mains-to-DC boards are configured to absorb power from the plurality of mains busbars, convert the power to DC power, and provide DC power to the plurality of DC busbars. The method further includes coupling one or more peak power reduction boards to the motherboard to electrically couple an energy storage system to the plurality of DC busbars, wherein the one or more peak power reduction boards are configured to access stored DC energy from the energy storage system and, when power demand exceeds a programmed threshold, provide the stored DC energy to the plurality of DC busbars, or receive power to recharge the energy storage system. In some embodiments, the modular power distribution unit does not include peak power reduction. In some implementations, the method includes coupling one or more DC-to-AC boards to a motherboard to electrically couple a plurality of DC busbars to a plurality of AC busbars, wherein the one or more DC-to-AC boards are configured to draw DC power from the plurality of DC busbars, convert the DC power to AC power, and provide AC power to the plurality of AC busbars.

[0037] Taking into account the foregoing and referring to Figure 1 A computed tomography (CT) imaging system 10 is illustrated by way of example. The CT imaging system 10 includes a gantry 12. The gantry 12 has an X-ray source 14 that projects a beam of X-rays 16 toward a detector assembly 15 on an opposite side of the gantry 12. The X-ray source 14 projects the X-ray beam 16 through a patient-front collimator assembly 13, which determines the size and shape of the X-ray beam 16. The detector assembly 15 includes a collimator assembly 18 (patient-back collimator assembly), a plurality of detector modules 20 (e.g., detector elements or sensors), and a data acquisition system (DAS) 32. The plurality of detector modules 20 detect the projected X-rays passing through the imaged subject or object 22, and the DAS 32 converts this data into a digital signal for subsequent processing. Each detector module 20 in a conventional system generates an analog electrical signal representing the intensity of the incident X-ray beam and therefore the intensity of the attenuated beam as it passes through the subject or object 22. During the scan to acquire X-ray projection data, the gantry 12 and the components mounted thereon rotate about a rotation center 25 (e.g., an isocenter) to collect attenuation data from multiple viewpoints relative to the imaging volume.

[0038] The rotation of gantry 12 and the operation of X-ray source 14 are controlled by control system 26 of CT imaging system 10. Control system 26 includes X-ray controller 28, which provides power and timing signals to X-ray source 14; collimator controller 29, which controls the aperture length and width of patient precollimator 13 (and therefore, the size and shape of the X-ray beam 16); and gantry motor controller 30, which controls the rotational speed and position of gantry 12. Image reconstructor 34 receives sampled and digitized X-ray data from DAS 32 and performs high-speed image reconstruction. The reconstructed image is applied as input to computer 36, which stores the image in storage device 38. Computer 36 also receives commands and scan parameters from operator via console 40. Associated display 42 allows operator to view reconstructed images and other data from computer 36. Computer 36 uses commands and parameters provided by operator to provide control signals and information to DAS 32, X-ray controller 28, collimator controller 29, and gantry motor controller 30. Additionally, computer 36 operates examination table motor controller 44, which controls electric examination table 46 (e.g., patient examination table) to position the patient 22 and rack 12. Specifically, examination table 46 causes various parts of the patient 22 to move through rack openings or apertures 48.

[0039] Figure 2 This discussion takes place within the context of computed tomography (CT) imaging systems. As described above, the disclosed embodiments can be used with other medical imaging systems (e.g., fluorescence fluoroscopy imaging systems and radiographic imaging systems) that have an X-ray source. Figure 2 It is directed to one or more medical imaging payloads 52 (e.g., Figure 1 A power supply system 50 provides power to the computed tomography imaging system 10 and / or other electronic devices 54 (e.g., the computer 36, console 40, and / or display 42 of the computed tomography imaging system 10). A mains alternating current (AC) power source (e.g., from the mains grid) can supply power (e.g., single-phase or multi-phase AC power, such as three-phase AC power) via AC power line 51 to a power distribution unit (PDU) 56 through AC input 57 (e.g., a single-phase or three-phase power plug). The PDU 56 can convert AC power to DC power and supply the DC power to the medical imaging load 52 and / or other electronic devices 54. In some embodiments, the PDU 56 also supplies AC power to the medical imaging load 52 and / or other electronic devices 54. In some embodiments, the PDU 56 also supplies power to a rotating electronic load 59. As described in more detail below, the PDU 56 includes a mains-to-DC board 80 and a DC-to-AC board 84.

[0040] In some embodiments, power distribution unit 56 includes an active rectifier. Power distribution unit 56 is located outside the fixed portion of the CT scanner of system 10. Power can be transferred from the fixed portion of the CT scanner of system 10 to the rotating portion via slip rings or wirelessly. In some embodiments, power distribution unit 56 includes a digital control board (DCB) 55 for online power monitoring. The DCB 55 is also configured to perform diagnostics offline or remotely if any problems exist on power distribution unit 56 or the active rectifier. The DCB 55 controls the operation of the active rectifier. In some embodiments, the active rectifier is communicatively coupled to a controller on system 10 (e.g., a controller for a rack) to enable the controller to monitor and diagnose any problems with power distribution unit 56. In some embodiments, the active rectifier is communicatively coupled to the controller via an Ethernet connection (or other type of communication interface, such as serial or controller area network). System 10 can monitor and / or report various parameters of power system 50 (e.g., power distribution unit 56 including the active rectifier). These parameters may include input voltage, input current, battery voltage and charging current, inverter AC voltage, inverter AC current, heatsink temperature, all rail voltages, and other parameters. These parameters can be transmitted from the controller (e.g., wired or wirelessly) to the host computer 36 and / or console 40. In addition to monitoring, the controller can perform diagnostics on the power distribution unit 56 (via a communication interface).

[0041] The power distribution unit 56 includes an energy storage system 58 configured to store electricity supplied by the AC power line 51. In some embodiments, the energy storage system 58 includes one or more energy storage components. For example, in some embodiments, the energy storage system 58 may include a battery system having one or more battery packs. In some embodiments, the energy storage components may include multiple batteries, supercapacitors, or other storage elements stacked in series. In some embodiments, the energy storage system 58 serves as an uninterruptible power supply (UPS). For example, a UPS may be used to provide power (e.g., backup power) during operation of the CT system 10 (e.g., peak power operation). In some embodiments, the power distribution unit 56 does not include an energy storage system.

[0042] The power distribution unit 56 also includes an energy storage management system 60 configured to manage or control power storage on and from the energy storage system 58. In some embodiments, the energy storage management system 60 may include a battery charger and control circuitry. In some embodiments, the energy storage management system 60 is configured to enable the storage of power on the energy storage system 58 (e.g., a battery) without pre-conditioning the power. In some embodiments, the energy storage management system 60 is configured to utilize the energy storage system 58 (e.g., during imaging scans) by shutting off power to the battery charger during acceleration of the rack 12 and subsequently turning on power to the battery charger during X-ray emission from the X-ray source 14 (e.g., an X-ray tube). In some embodiments, the energy storage management system 60 is configured to monitor the battery life of the energy storage system 58 and provide an indication via a user interface that the battery is nearing the end of its life. For example, the energy storage management system 60 may monitor the equivalent series resistance (ESR) of the battery and compare that ESR to a threshold (e.g., a maximum permissible ESR value). In some implementations, the energy storage management system 60 can determine the state of charge of the battery and / or determine whether an imaging scan can be performed. For example, when the battery has sufficient charge, the energy storage management system 60 can utilize the battery for peak power operation, or if there is insufficient charge, it can wait to utilize the battery for peak power operation when there is sufficient charge.

[0043] While one or more medical imaging loads 52 are described below for use with a computed tomography (CT) system, it should be understood that the implementation is suitable for use with other imaging configurations. One or more medical imaging loads 52 may include a high-voltage generator 62 coupled to a power distribution unit 56 and / or a rotating electronic load 59 coupled to the power distribution unit 52. The high-voltage generator 62 may supply power to the X-ray tube 14 of the computed tomography (CT) imaging system 10. The X-ray tube 14 may emit an X-ray beam toward a subject or object (e.g., a patient). The beam strikes a radiation detector array after being attenuated by the subject. The intensity of the attenuated beam radiation received at the detector array may depend on the attenuation of the X-ray beam by the subject. Each detector element of the detector array generates a separate electrical signal indicating the attenuated beam received by each detector element. The electrical signals are transmitted to a data processing system for analysis, thereby producing an image. Furthermore, the X-ray source and detector array may rotate in the imaging plane around a gantry 12 and around the subject or object via an axial drive and motor 64. When the frame 12 rotates, it converts the electrical power from the power distribution unit 56 into rotational kinetic energy via the motor 64.

[0044] There are two types of controls: internal (internal control 61) and external (e.g., in the form of a control system 66). Internal control 61 controls various switches to generate commanded voltage / current / power when needed. External control informs the distribution unit 56 which voltage / current / power is needed and when. Internal control 61 can be centralized, distributed, or hybrid. When internal control 61 is centralized, it consists of control hardware (DSP / FPGA / CPU or a combination thereof) located directly on the motherboard, which sends commands to all switches. When internal control 61 is distributed, it is control hardware located on each board (more but simpler). When internal control 61 is hybrid, it is located on each board, including the motherboard. External control can be located outside the distribution unit 56 and can be positioned with a rack control system. Distribution unit 56 can be controlled by a control system 66 (via control signals) having an FPGA or processor 68 or more FPGAs or more processors and memory 70. In some embodiments, control system 66 is part of distribution unit 56 (e.g., energy storage management system 60). In some embodiments, the control system 66 is a stand-alone unit. The processor 68 may be operatively coupled to the memory 70 to execute instructions for implementing the techniques currently disclosed. These instructions may be encoded in a program or code stored in a tangible, non-transitory computer-readable medium, such as the memory 70 and / or other storage devices. The processor 68 may be a general-purpose processor (e.g., a processor for a desktop / laptop computer), a system-on-a-chip (SoC) device, an application-specific integrated circuit (ASIC), or some other processor configuration. In this embodiment, the memory 70 includes computer-readable media, such as, but not limited to, hard disk drives, solid-state drives, magnetic disks, flash drives, optical disks, digital video disks, random access memory (RAM), and / or any suitable storage device that enables the processor 68 to store, retrieve, and / or execute instructions and / or data. The memory 70 may include one or more local and / or remote storage devices. The processor 68 may control components of the power distribution unit 56 (e.g., a charger, battery, etc.) to power one or more medical imaging loads 52.

[0045] Figure 3 This is a schematic diagram of the modular power distribution unit 56. Figure 3 The left side is a schematic diagram of the physical structure of the modular power distribution unit 56. Figure 3The right side is a schematic diagram of the hybrid function / physical structure of the modular power distribution unit 56. The modular power distribution unit 56 is configured to regulate power and provide peak power reduction to an X-ray imaging system (e.g., a CT imaging system). Each component of the modular power distribution unit 56 is not shown. The modular power distribution unit 56 is a plug-and-play power distribution unit with a modular architecture. This modular architecture is configured for use with the same X-ray imaging modal of different types, as well as with different types of X-ray imaging modalities.

[0046] Modular power distribution unit 56 comprises different types of boards. Modular power distribution unit 56 includes a motherboard 72 (e.g., a main printed circuit board). Motherboard 72 includes contactors and connections to mains power (e.g., power from the grid) and one or more racks for one or more X-ray imaging systems. In some embodiments, modular power distribution unit 56 includes intelligent power monitoring options (e.g., [missing information]) as part of motherboard 72. Figure 2 The DCB 55 in the diagram can utilize this intelligent power monitoring option from an active rectifier. In some embodiments, the modular power distribution unit 56 includes a control board as part of a motherboard 72. The mains-to-DC board 80, peak power reduction board 90, and DC-to-AC board 84 are oriented intersecting the plane of the motherboard 72 (i.e., extending from the page). In some embodiments, the orientation and / or mounting strategy of the components may differ from that described.

[0047] Motherboard 72 mechanically supports various buses (e.g., copper strips) and different types of boards coupled to it. Main AC power (e.g., from the grid) can supply power (e.g., single-phase or multi-phase AC power, such as three-phase AC power) to modular power distribution unit 56 via AC power lines and AC inputs (e.g., single-phase or three-phase power plugs). As shown, motherboard 72 mechanically supports multiple AC busbars 74 configured to receive power from the grid. Motherboard 72 also mechanically supports multiple DC busbars 76 (e.g., + and - (as shown), and neutral (not shown) if needed). Motherboard 72 further mechanically supports multiple AC busbars 78. The number of AC busbars 74 and AC busbars 78 can vary depending on the type of AC power received and output. As shown, the number of AC busbars 74 and AC busbars 78 is for three-phase AC power.

[0048] Modular power distribution unit 56 includes one or more AC-to-DC boards 80 coupled to a motherboard 72. The number of AC-to-DC boards 80 may vary depending on requirements (e.g., 1, 2, 3, 4, or more boards 80). As shown, modular power distribution unit 56 includes four AC-to-DC boards 80. One or more AC-to-DC boards 80 electrically couple multiple AC busbars 74 to multiple DC busbars 76. Specifically, one or more AC-to-DC boards 80 are configured to draw power (AC power) from the multiple AC busbars 74, convert the power to DC power, and supply DC power to the multiple DC busbars 76 as indicated by arrow 82. One or more AC-to-DC boards 80 are configured to regulate (e.g., via self-regulation) the DC voltage of the DC power supplied to the multiple DC busbars 76 to a set DC voltage value (which may vary depending on the application). Each AC-to-DC board 80 may include a control switch, a controller, and an AC-to-DC converter (e.g., Figure 2 (Internal control 61). Multiple DC busbars 76 can provide DC power to the DC load of the X-ray medical imaging system, as indicated by arrow 83.

[0049] In some implementations, such as Figure 3 As depicted, the modular power distribution unit 56 also includes one or more DC-to-AC boards 84. The number of DC-to-AC boards 84 may vary depending on the requirements (e.g., one, two, three, four, or more boards 84). As shown, the modular power distribution unit 56 includes three DC-to-AC boards 84. One or more DC-to-AC boards 84 electrically couple multiple DC busbars 76 to multiple AC busbars 78. The one or more DC-to-AC boards 84 are configured to draw DC power from the multiple DC busbars 76, convert the DC power to AC power, and supply AC power to the multiple AC busbars 78 as indicated by arrow 86. The one or more DC-to-AC boards 84 are configured to regulate the AC voltage of the AC power supplied to the multiple AC busbars 78 to both a set amplitude and a set frequency (which may vary depending on the application). Each DC-to-AC board 84 may include a control switch, a controller, and an AC-to-DC inverter. The multiple AC busbars 78 can supply power to the AC load of an X-ray medical imaging system, as indicated by arrow 88.

[0050] Modular power distribution unit 56 includes one or more peak power reduction panels 90. The number of peak power reduction panels 90 can vary (e.g., one, two, three, four, or more panels 90). Some implementations may not require any peak power reduction panels. As shown, modular power distribution unit 56 includes four peak power reduction panels 90. One or more peak power reduction panels 90 will connect the energy storage system 92 (e.g., Figure 2The energy storage system 92 (58) is electrically coupled to multiple DC busbars 76. The energy storage system 92 may include batteries (lithium-ion or lead-acid batteries) or supercapacitors (e.g., electrochemical capacitors) or other storage elements. One or more peak power reduction plates 90 are configured to access stored DC energy from the energy storage system 92 and to supply the stored DC energy to the multiple DC busbars 76 when power demand exceeds a programmed threshold (e.g., during peak power reduction), as indicated by arrow 93. One or more peak power reduction plates 90 are also configured to supply some of the DC power to the energy storage system 92 for storage, as indicated by arrow 93. As shown, the energy storage system 92 (e.g., energy storage plates) includes a common energy storage element 94 (e.g., a single energy storage element) coupled to each peak power reduction plate 90.

[0051] In some embodiments, multiple DC busbars 76 are configured to couple to a DC uninterruptible power supply 96 (e.g., having a battery, supercapacitor, etc.). In some embodiments, multiple AC busbars 78 are configured to couple to an AC uninterruptible power supply 98 (e.g., having a battery, supercapacitor, etc.).

[0052] Figure 4 This is a schematic diagram of the modular power distribution unit 56. Figure 4 The modular power distribution unit 56 in the middle is similar to Figure 3 The modular power distribution unit 56, in addition to the energy storage system 92, is a modular power distribution unit. Figure 4 The energy storage system 92 includes a plurality of energy storage elements 100. Each of the plurality of energy storage elements 100 is individually coupled to a corresponding peak power reduction plate 90 among the plurality of peak power reduction plates 90. Thus, each peak power reduction plate 90 has its own energy storage element 100. Therefore, the energy storage is distributed.

[0053] Figure 5 This is a schematic diagram of the modular power distribution unit 56. Figure 5 The left side is a schematic diagram of the physical structure of the modular power distribution unit 56. Figure 3 The right side is a schematic diagram of the hybrid function / physical structure of the modular power distribution unit 56. Motherboard 72, as shown... Figure 3 However, the modular power distribution unit 56 has AC output power independent of the DC side.

[0054] Modular power distribution unit 56 includes one or more AC-to-DC boards 80 coupled to a motherboard 72. The number of AC-to-DC boards 80 may vary depending on requirements (e.g., 1, 2, 3, 4, or more boards 80). As shown, modular power distribution unit 56 includes four AC-to-DC boards 80. One or more AC-to-DC boards 80 electrically couple multiple AC busbars 74 to multiple DC busbars 76. Specifically, one or more AC-to-DC boards 80 are configured to draw power (AC power) from the multiple AC busbars 74, convert the power to DC power, and supply DC power to the multiple DC busbars 76 as indicated by arrow 82. One or more AC-to-DC boards 80 are configured to regulate (e.g., via self-regulation) the DC voltage of the DC power supplied to the multiple DC busbars 76 to a set DC voltage value (which may vary depending on the application). Each AC-to-DC board 80 may include a control switch, controller (e.g., Figure 2 The system includes local or hybrid internal controls 61 and AC-to-DC converters. Multiple DC busbars 76 can supply DC power to the DC load of the X-ray medical imaging system, as indicated by arrow 83.

[0055] Modular power distribution unit 56 includes one or more peak power reduction panels 90. The number of peak power reduction panels 90 can vary (e.g., one, two, three, four, or more panels 90). In some embodiments, the modular power distribution unit may not include peak power reduction panels. As shown, modular power distribution unit 56 includes four peak power reduction panels 90. One or more peak power reduction panels 90 connect the energy storage system 92 (e.g., Figure 2 The energy storage system 92 (58) is electrically coupled to multiple DC busbars 76. The energy storage system 92 may include batteries (lithium-ion or lead-acid batteries), supercapacitors (e.g., electrochemical capacitors), or other storage elements. One or more peak power reduction plates 90 are configured to access stored DC energy from the energy storage system 92 and to supply the stored DC energy to the multiple DC busbars 76 when power demand exceeds a programmed threshold (e.g., during peak power reduction), as indicated by arrow 93. One or more peak power reduction plates 90 are also configured to supply some of the DC power to the energy storage system 92 for storage, as indicated by arrow 93. As shown, the energy storage system 92 (e.g., energy storage plates) includes a common energy storage element 94 (e.g., a single energy storage element) coupled to each peak power reduction plate 90. In some embodiments, the energy storage system 92 may include multiple energy storage elements.

[0056] The modular power distribution unit 56 also includes one or more AC-to-mains (APM) boards 104. The number of APM boards 104 can vary depending on requirements (e.g., one, two, three, four, or more boards 104). As shown, the modular power distribution unit 56 includes three APM boards 104. The APM boards 104 electrically couple multiple AC busbars 74 to multiple AC busbars 78. One or more APM boards 104 are configured to draw power from the multiple AC busbars 74 and supply AC power to the multiple AC busbars 78, as indicated by arrow 106. The number of AC busbars 74 and AC busbars 78 can vary depending on the type of AC power received and output. As shown, the number of AC busbars 74 and AC busbars 78 is used for three-phase AC power. The multiple AC busbars 78 can supply power to the AC load of an X-ray medical imaging system, as indicated by arrow 88.

[0057] Modular power distribution unit 56 includes one or more additional peak power reduction panels 108. The number of additional peak power reduction panels 108 can vary (e.g., one, two, three, four, or more panels 108). As shown, modular power distribution unit 56 includes two additional peak power reduction panels 108. One or more additional peak power reduction panels 108 will add an energy storage system 110 (e.g., Figure 2 The additional energy storage system 110 (58) is electrically coupled to multiple AC busbars 78. The additional energy storage system 110 may include batteries (lithium-ion or lead-acid batteries) or supercapacitors (e.g., electrochemical capacitors) or other storage elements. One or more additional peak power reduction plates 108 are configured to access stored DC energy from the additional energy storage system 110 and, when power demand exceeds a programmed threshold (e.g., during peak power reduction), supply the stored DC energy to the multiple AC busbars 78, as indicated by arrow 111. One or more additional peak power reduction plates 108 are also configured to supply a portion of the AC power to the additional energy storage system 110 for storage, as indicated by arrow 111. As shown, the additional energy storage system 110 (e.g., additional energy storage plates) includes an additional common energy storage element 112 (e.g., a single energy storage element) coupled to each additional peak power reduction plate 108. In some embodiments, the additional energy storage system 110 may be used as an AC uninterruptible power supply.

[0058] Figure 6 This is a schematic diagram of the modular power distribution unit 56. Figure 6 The modular power distribution unit 56 in the middle is similar to Figure 5 The modular power distribution unit 56 includes, in addition to the energy storage system 92 and the auxiliary energy storage system 110. Figure 6The energy storage system 92 includes a plurality of energy storage elements 100. Each of the plurality of energy storage elements 100 is individually coupled to a corresponding peak power reduction plate 90 among the plurality of peak power reduction plates 90. Thus, each peak power reduction plate 90 has its own energy storage element 100. Therefore, the energy storage is distributed. Figure 6 The supplemental energy storage system 110 includes a plurality of supplemental energy storage elements 114. Each of the plurality of supplemental energy storage elements 114 is individually coupled to a corresponding supplemental peak power reduction board 108 among the plurality of supplemental peak power reduction boards 108. Thus, each supplemental peak power reduction board 108 has its own supplemental energy storage element 114. Therefore, energy storage is distributed. In some embodiments, the supplemental energy storage system 110 can be used as an AC uninterruptible power supply.

[0059] As described above, the modular architecture of the power distribution unit 56 is configured for use with the same X-ray imaging modal of different types as well as with different types of X-ray imaging modal. Figure 7 and Figure 8 This is a schematic diagram of different modular power distribution units 56 used in the same CT imaging system requiring 200kVA. Figure 7 and Figure 8 In the middle, the AC power to DC board 80 is rated at 50kVA each, and the peak power reduction board 90 is rated at 50kVA each. Figure 7 The modular power distribution unit 56 in the middle is similar to Figure 3 The power distribution unit 56 in the example. Figure 7 As shown, the modular power distribution unit 56 has three mains-to-DC boards 80 with a total rated capacity of 150 kVA, and an additional peak power reduction board 90 with a rated capacity of 50 kVA. Conversely, Figure 8 The modular power distribution unit 56 lacks an energy storage system, but instead has four AC-DC boards 80 with a total rated capacity of 200kVA. Figure 9 A DC uninterruptible power supply 96 coupled to a DC busbar 76 is depicted. Figure 10 An AC uninterruptible power supply 98 coupled to the mains busbar 74 is depicted.

[0060] Figure 11 and Figure 12 These are schematic diagrams of different modular power distribution units 56 used in the same CT imaging system but with different power requirements. For Figure 11 CT imaging systems require 210kVA and 3kVA for reconstruction. For Figure 12 The same CT imaging system requires 210kVA and 13kVA for reconstruction. Figure 11 and Figure 12In this circuit, the AC power supply to the DC board 80 is rated at 50kVA each, the peak power reduction board 90 is rated at 50kVA each, and the AC power supply to the AC board 84 is rated at 4kVA. Figure 11 The modular power distribution unit 56 in the middle is similar to Figure 3 The power distribution unit 56 in the example. Figure 11 As shown, the modular power distribution unit 56 has three mains-to-DC boards 80 with a total rating of 210 kVA (from the power grid to the machine), two peak power reduction boards 90 with an additional rating of 100 kVA, and one DC-to-AC board 84 with an additional rating of 4 kVA. Conversely, Figure 12 The modular power distribution unit 56 in the middle has more AC power. Figure 12 The modular power distribution unit lacks an energy storage system and instead has five mains-to-DC boards 80 with a total rating of 250 kVA (from the power grid to the machine) and four DC-to-AC boards 84 with a total rating of 16 kVA.

[0061] Figure 13 This is a flowchart of method 116 for manufacturing a modular power distribution unit for X-ray imaging equipment. It can be performed simultaneously and / or according to... Figure 13 One or more steps of the different sequential execution methods 116 are described.

[0062] Method 116 includes providing a motherboard that mechanically supports a plurality of mains busbars, a plurality of DC busbars, and a plurality of AC busbars (block 118). The plurality of mains busbars are configured to receive power from the power grid. Method 116 also includes coupling one or more mains-to-DC boards to the motherboard to electrically couple the plurality of mains busbars to the plurality of DC busbars (block 120). The one or more mains-to-DC boards are configured to absorb power from the plurality of mains busbars, convert the power to DC power, and provide DC power to the plurality of DC busbars. In some embodiments, method 116 further includes coupling one or more peak power reduction boards to the motherboard to electrically couple an energy storage system to the plurality of DC busbars (block 122). The one or more peak power reduction boards are configured to access stored DC energy from the energy storage system and, when power demand exceeds a programmed threshold, provide the stored DC energy to the plurality of DC busbars or receive power to recharge the energy storage system. In some implementations, method 116 includes coupling one or more DC-to-AC boards to electrically couple a plurality of DC busbars to a plurality of AC busbars (block 124). The one or more DC-to-AC boards are configured to draw DC power from the plurality of DC busbars, convert the DC power to AC power, and supply AC power to the plurality of AC busbars.

[0063] The technical advantages of the disclosed embodiments include providing a modular power distribution unit that offers plug-and-play functionality (e.g., a common power distribution unit) for powering all types of X-ray systems. The modular power distribution unit is configured for all loads. It features a modular architecture constructed from four different types of boards. The technical advantages of the disclosed embodiments include providing different types of boards (particularly, AC-to-DC and AC-to-AC boards) that are programmable to regulate voltage and frequency. This programmability allows the same electrical hardware to be adapted to any product hardware requirements.

[0064] The technical effects of the disclosed embodiments include providing a modular power distribution unit that can be easily and inexpensively scaled according to product needs. The modular power distribution unit provides redundancy for maintenance and repair without downtime. In particular, a single fault will not cause all power distribution units to shut down. The technical effects of the disclosed embodiments include providing a modular power distribution unit that integrates peak power reduction and energy storage. With the availability of peak power reduction, power grid upgrades may not be necessary. The technical effects of the disclosed embodiments include providing a modular power distribution unit that includes a regulated (self-regulating) DC bus. This self-regulation avoids voltage drop problems. The modular power distribution unit also includes a built-in hot landing feature.

[0065] The technical effects of the disclosed embodiments include enabling the design and manufacture of a limited number of boards for the modular power distribution unit, allowing scalability through different products and different modes and options. The technical effects of the disclosed embodiments include providing fully programmable output voltages (both AC and DC), thus providing the same hardware for different applications and / or power grid connections. The technical effects of the disclosed embodiments include reduced costs due to the mass production of a limited number of different boards. The technical effects of the disclosed embodiments include providing a modular power distribution unit that can be customized to customer needs and / or provide solutions for power availability. The technical effects of the disclosed embodiments include providing a more compact design.

[0066] Referring to the technology presented herein and protected by the claims, and applying it to physical objects and concrete examples of practical nature, which explicitly improves the present art, and is therefore not abstract, intangible, or purely theoretical. Furthermore, if any claim appended to the end of this specification contains one or more elements designated as “component for [performing]…the function” or “step for [performing]…the function,” such elements are intended to be interpreted according to 35 USC 112(f). However, for any claim containing elements designated in any other manner, such elements are not intended to be interpreted according to 35 USC 112(f).

[0067] This written description uses examples to disclose the subject matter of the invention, including best practices, and also enables those skilled in the art to practice the subject matter, including making and using any device or system and performing any included methods. The patent scope of this subject matter is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that have minor differences from the literal language of the claims.

Claims

1. A power distribution unit (56) for an X-ray imaging device, the power distribution unit comprising: A motherboard (72) mechanically supports a plurality of mains busbars (74), a plurality of direct current (DC) busbars (76) and a plurality of alternating current (AC) busbars (78), wherein the plurality of mains busbars (74) are configured to receive power from the grid; One or more mains-to-DC boards (80) electrically couple the plurality of mains busbars (74) to the plurality of DC busbars (74), wherein the one or more mains-to-DC boards (80) are configured to absorb power from the plurality of mains busbars (74), convert the power into DC power, and provide the DC power to the plurality of DC busbars (76); and One or more peak power reduction plates (90) electrically couple an energy storage system (92) to the plurality of DC busbars (74), wherein the one or more peak power reduction plates (90) are configured to access stored DC energy from the energy storage system (92) and supply the stored DC energy to the plurality of DC busbars (74) when power demand exceeds a programmed threshold; and The power distribution unit (56) described therein includes a modular architecture.

2. The power distribution unit (56) according to claim 1, wherein the modular architecture of the power distribution unit (56) is configured for use with the same X-ray imaging modal of different types and for use with different types of X-ray imaging modal.

3. The power distribution unit (56) according to claim 1, wherein the one or more mains-to-DC boards (80) are configured to adjust the DC voltage of the DC power supplied to the plurality of DC busbars (76) to a set DC voltage value.

4. The power distribution unit (56) according to claim 1, the power distribution unit further comprising one or more DC-to-AC boards (84) electrically coupling the plurality of DC busbars (76) to the plurality of AC busbars (78), wherein the one or more DC-to-AC boards (84) are configured to absorb DC power from the plurality of DC busbars (76), convert the DC power into AC power, and provide the AC power to the plurality of AC busbars (78).

5. The power distribution unit (56) according to claim 4, wherein the one or more DC to AC boards (84) are configured to adjust the AC voltage of the AC power supplied to the plurality of AC busbars (78) to both a set amplitude and a set frequency.

6. The power distribution unit (56) according to claim 4, wherein the one or more DC to AC boards (84) are configured to provide single-phase AC power to the plurality of AC busbars (78).

7. The power distribution unit (56) according to claim 4, wherein the one or more DC to AC boards (84) are configured to provide three-phase AC power to the plurality of AC busbars (78).

8. The power distribution unit (56) according to claim 1, wherein the one or more peak power reduction plates (90) are configured to provide some of the DC power to the energy storage system (92) for storage.

9. The power distribution unit (56) according to claim 1, wherein the one or more peak power reduction plates (90) comprise a plurality of peak power reduction plates (90), and the energy storage system (92) comprises a common energy storage element (94) coupled to each of the plurality of peak power reduction plates (90).

10. The power distribution unit (56) according to claim 1, wherein the one or more peak power reduction plates (90) comprise a plurality of the peak power reduction plates (90), and the energy storage system (92) comprises a plurality of energy storage elements (100), and each of the plurality of energy storage elements (100) is individually coupled to a corresponding peak power reduction plate (90) among the plurality of peak power reduction plates (90).

11. The power distribution unit (56) according to claim 1, the power distribution unit further comprising one or more AC-to-mains boards (104) that electrically couple the plurality of AC busbars (74) to the plurality of AC busbars (78), wherein the one or more AC-to-DC boards (80) are configured to absorb power from the plurality of AC busbars (74) and supply AC power to the plurality of AC busbars (78).

12. The power distribution unit (56) of claim 11, the power distribution unit further comprising one or more additional peak power reduction boards (108) electrically coupling an additional energy storage system (110) to the plurality of AC busbars (78), wherein the one or more additional peak power reduction boards (108) are configured to access stored DC energy from the additional energy storage system (110) and to supply the stored DC energy to the plurality of AC busbars (78) when power demand exceeds a programmed threshold.

13. The power distribution unit (56) of claim 12, wherein the one or more additional peak power reduction plates (108) comprise a plurality of additional peak power reduction plates (108), and the additional energy storage system (110) comprises a common energy storage element (112) coupled to each of the plurality of additional peak power reduction plates (108).

14. The power distribution unit (56) according to claim 12, wherein the one or more additional peak power reduction plates (108) comprise a plurality of additional peak power reduction plates (108), and the additional energy storage system (110) comprises a plurality of energy storage elements (112), and each of the plurality of energy storage elements (112) is individually coupled to a corresponding additional peak power reduction plate (108) among the plurality of additional peak power reduction plates (108).

15. The power distribution unit (56) according to claim 1, wherein the plurality of DC busbars (76) are configured to be coupled to a DC uninterruptible power supply (96).

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