Self-aligning CT detector sensors with keyed mounting
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Solution Overview
Problem
Computed tomography (CT) imaging systems face challenges in precise alignment and replacement of detector modules, requiring specialized fixtures and skilled technicians, which complicates manufacturing, installation, and field maintenance, especially as detector coverage increases.
Innovation Solution
The integration of self-aligning features, such as alignment pins and threaded bosses, into detector modules allows for precise alignment and secure attachment without specialized fixtures, enabling tileable and scalable detector configurations that facilitate easy installation, maintenance, and single-sensor swapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional detector modules are used without self-aligning features, then detector coverage can be increased, but alignment precision deteriorates and requires specialized fixtures and skilled technicians
Solution Approach 1:
The detector sensor incorporates self-aligning features including alignment pins that automatically mate with corresponding features on the module frame, enabling the sensor to self-align during installation without requiring external alignment fixtures or specialized technician skills
Solution Approach 2:
The detector module is divided into tileable detector sensors that can be independently installed and aligned, with each sensor containing its own alignment features, allowing modular assembly without complex global alignment requirements
2Ease of repair
If traditional detector modules are used without tileable construction, then detector coverage can be increased, but ease of repair deteriorates and requires full module replacement
Solution Approach 1:
The detector module is segmented into multiple independent tileable detector sensors, each with its own mounting structure and alignment features, allowing individual sensors to be removed and replaced without affecting other sensors in the module
Solution Approach 2:
The alignment pins and keyed features are pre-configured on each detector sensor and module frame, enabling quick plug-and-play replacement of individual sensors without requiring time-consuming alignment procedures or specialized tools
3Ease of manufacture
If traditional detector modules are used without self-aligning features, then detector coverage can be increased, but ease of manufacture deteriorates and requires extensive testing and reworking
Solution Approach 1:
The alignment pins on detector sensors automatically mate with corresponding keyed features on the module frame during assembly, enabling workers to install sensors without requiring precision alignment skills or complex fixtures, thereby easing manufacturing while maintaining precision
Solution Approach 2:
The alignment features are pre-configured on each detector sensor before assembly, allowing sensors to be pre-tested and pre-aligned individually, then quickly integrated into the module without requiring extensive post-assembly alignment testing or reworking
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
This solution simplifies the alignment and replacement of detector modules, reducing manufacturing and maintenance costs, enabling plug-and-play functionality without the need for skilled technicians and specialized tools, while ensuring precise alignment and efficient data collection.
Implementation Method 1
The alignment plate includes alignment pins forming a datum structure to align the detector sensor on the module frame
Implementation Method 2
one or more threaded bosses configured to receive a fastener therein that secures the detector sensor to the module frame
Implementation Method 3
The module frame includes keyed features formed therein that receive the alignment pins of each respective detector sensor therein when the detector sensors are mounted on the module frame
Data Source
AI summary
CT detector modules are disclosed that include a module frame and a plurality of tileable detector sensors positioned on the module frame. Each of the tileable detector sensors includes an array of detector elements and a mounting structure directly or indirectly coupled to the detector elements to provide for a mounting and alignment of the detector sensor to the module frame. The mounting structure includes an alignment plate positioned generally opposite the array of detector elements, with the alignment plate having alignment pins forming a datum structure to align the detector sensor on the module frame and one or more threaded bosses configured to receive a fastener therein that secures the detector sensor to the module frame. The module frame includes keyed features that receive the alignment pins when the detector sensors are mounted on the module frame, so as to align the detector sensors on the module frame.