Circular X-ray Scanner with Dynamic Tube Current Control
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Solution Overview
Problem
Current tomographic inspection systems face challenges in reducing the time required for data collection and improving imaging quality due to the time-consuming movement of the gantry and object, which results in high levels of artefacts in reconstructed images.
Innovation Solution
An X-ray scanner system with a circular arrangement of X-ray tubes and detectors, where the X-ray source points are activated in a predetermined sequence, and the scan cycle frequency is controlled to maintain constant resolution across varying object speeds, with the tube current adjusted proportionally to the conveyor speed, allowing for high-resolution imaging with reduced artefacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gantry and object are moved to conduct tomographic inspection, then the inspection can be performed, but the time required for data collection increases and image artefacts are generated
Solution Approach 1:
The X-ray source is divided into multiple source points arranged in a circular array, allowing simultaneous acquisition of projections from multiple angles without mechanical movement. Each source point contributes to a complete tomographic data set, eliminating the need for sequential gantry rotation and reducing inspection time while maintaining imaging quality.
Solution Approach 2:
The mechanical gantry rotation system is replaced with a stationary circular array of X-ray source points and detectors. This substitution eliminates mechanical movement during data acquisition, preventing motion-induced image artefacts and reducing data collection time while maintaining complete tomographic coverage.
2Productivity
If the object speed is increased to improve throughput, then productivity increases, but image resolution deteriorates
Solution Approach 1:
The system dynamically adjusts the tube current of each X-ray source point based on the object's conveyor speed. When the object moves faster, the tube current is increased proportionally to maintain adequate photon statistics and image resolution. This dynamic parameter adjustment allows high throughput while preserving measurement precision.
Solution Approach 2:
The tube current parameter is changed in direct proportion to the object speed to maintain constant image quality. By increasing the X-ray flux when the object moves faster through the scanner, the system compensates for reduced exposure time, ensuring that productivity increases do not compromise image resolution.
3Adaptability or versatility
If multiple slices are inspected to improve coverage, then the inspection completeness increases, but the time required increases
Solution Approach 1:
The inspection volume is segmented into multiple slices along the conveyor direction, with each slice inspected simultaneously by a dedicated subset of source points and detectors. This parallel processing approach allows complete multi-slice coverage without sequential inspection, increasing inspection completeness while maintaining fast throughput.
Solution Approach 2:
The circular array of source points and detectors serves multiple functions simultaneously, inspecting multiple slices at different depths along the conveyor direction. Each source-detector pair contributes to multiple slice reconstructions, allowing comprehensive coverage of the entire inspection volume in a single pass through the scanner.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high-resolution, artefact-free three-dimensional X-ray images at conveyor speeds of 0.25 to 1.0 m/s, enabling a throughput of 800 to 3000 items per hour with equal spatial resolution in all dimensions and a signal-to-noise ratio of 50 or better, using no more than eight rings of detectors.
Implementation Method 1
X-ray source means arranged to emit X-rays through an imaging volume from a plurality of X-ray tubes
Implementation Method 2
an array of X-ray detectors arranged around the imaging volume and arranged to output detector signals in response to the detection of X-rays
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present application discloses an X-ray scanner having an X-ray source arranged to emit X-rays from source points (12) through an imaging volume. The scanner may further include an array of X-ray detectors (26) which may be arranged around the imagine volume and may be arranged to output detector signals in response to the detection of X-rays. The scanner may further include a conveyor (22) arranged to convey an object through the imaging volume in a scan direction, and may also include at least one processor (30) arranged to process the detector signals to produce an image data set defining an image of the object. The image may have a resolution in the scan direction that is at least 90 % as high as in one direction, and in some cases two directions, orthogonal to the scan direction.