Computed Tomography Inspection of Large Dense Components
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Solution Overview
Problem
Conventional CT systems face challenges in inspecting large and dense components with complex geometries, as they require higher X-ray energy levels, making it difficult to achieve sensitivity and accuracy, especially when X-rays fail to penetrate effectively.
Innovation Solution
A method that involves orienting the component to minimize X-ray path lengths, using lower energy CT scans for segments where penetration is possible, and combining data from multiple orientations to create a high-resolution image, leveraging 3D reference data and CAD files for registration and merging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If higher X-ray energy levels are used to inspect large and dense components, then X-ray penetration capability is improved, but sensitivity and measurement accuracy deteriorate
Solution Approach 1:
The component is divided into multiple segments or regions, each scanned from optimally oriented angles. This allows different portions of the component to be inspected using lower energy X-rays at appropriate angles, avoiding the need for uniformly high energy across the entire component.
Solution Approach 2:
The inspection approach moves from a single fixed orientation to multiple orientations and angles. By scanning the component from different angular positions, the system finds optimal paths where X-rays traverse shorter distances through dense material, enabling use of lower energy X-rays while maintaining penetration capability.
2Reliability
If conventional CT scanning is used for large and dense components, then inspection coverage is improved, but X-ray energy requirements increase
Solution Approach 1:
The system dynamically adjusts scanning parameters including orientation, angle, and energy levels based on the specific geometry and density distribution of the component. This dynamic adaptation allows the system to maintain adequate penetration where needed while using lower energy where possible, reducing overall energy requirements.
Solution Approach 2:
The inspection method changes multiple parameters simultaneously: X-ray energy level, source-to-object distance, object orientation, and detector positioning. By optimizing this combination of parameters, the system achieves adequate penetration for large dense components without requiring maximum energy levels throughout the entire inspection process.
3Measurement precision
If multiple component orientations are scanned to optimize X-ray penetration, then inspection sensitivity is improved, but scanning time and complexity increase
Solution Approach 1:
A preliminary scan or 3D model analysis is performed to identify optimal scanning orientations and critical regions before the main inspection. This preliminary characterization allows the system to plan the most efficient multi-orientation scanning sequence, focusing detailed high-sensitivity scans only on regions that require them.
Solution Approach 2:
The system applies full multi-orientation scanning complexity only to regions where it is necessary for detecting specific defect types or inspecting particularly dense areas. Other regions are inspected using simpler, faster single-orientation scans, reducing overall scanning time while maintaining sensitivity where critical.
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 approach enables more sensitive and accurate inspections of large or dense components by optimizing X-ray penetration, resulting in improved dimensional metrology and defect detection with higher resolution images.
Implementation Method 1
Computed Tomography (CT) is a computer-aided tomographic process that uses irradiation (such as X-rays) to produce three-dimensional internal and external representations of a scanned object
Implementation Method 2
The amount and density of the material of the object impacts the ability of X-rays to penetrate the part and reach the X-ray detector
Data Source
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AI summary
A method of inspecting a component using computed tomography is described, the method comprising the steps of: (a) providing a computed tomography (CT) scanner; (b) providing a target component; (c) reviewing the geometry of the component; (d) estimating the best component orientation; (e) orienting the component; (f) scanning the component with the CT scanner; (g) loading CT scan data into 3D image software; (h) registering the best CT scan data; (i) determining acceptable and unacceptable regions of CT scan data; (j) determining additional component orientations; (k) repeating steps (e) through (i) until all regions of CT scan data for the component are acceptable; and (1) creating a merged volume of acceptable CT scan data.