JP2009025120A - Detector assembly and inspection system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a detector system and a detector assembly for use in a nondestructive test (NDT) having reduced weight and size, having a capacity for supplying a static X-ray image during actual time, and having a constitution that is settable, in matching with wide-range NDT use. <P>SOLUTION: This detector assembly 14 includes an X-ray detector 20, having a settable constitution having an area smaller than 10.2 (cm)×10.2 (cm); and an embedded-type control device 22 connected to the X-ray detector 20 having the settable constitution, and constituted so as to control the X-ray detector 20 having a settable constitution, and to perform format-setting of image data from the X-ray detector 20, having the settable constitution for radio transmission. The detector assembly 14 also includes a radio transmitting device 24, constituted so as to transmit by radio the image data to an interface device 18 of user; and a power storage device 26, constituted so as to supply the power to the X-ray detector 20 having the settable constitution, the radio transmitting device 24 and the embedded-type control device 22. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates generally to detector systems, and more specifically configured to generate, process and transmit digital x-ray images for non-destructive testing (NDT) applications. The present invention relates to a small area and lightweight wireless detector system.

  Various types of detector systems are known and used in different applications. For example, X-ray inspection systems are used in NDT applications to detect structural flaws and the inclusion of foreign materials without causing any damage to the product. Unfortunately, in many NDT applications, such systems require a large detector size, weight, and additional components such as heavy power supplies and fragile cables. So it can not be used. In addition, certain industries, such as the aerospace industry and the oil and gas industry, require portable lightweight detector systems that can be operated into difficult-to-access locations.

  Certain systems use large area detectors that store acquired image data on the device itself or on a memory card that can be retrieved later. However, such devices have limited acquisition modes in which they can operate and cannot be connected to other data networks or control other devices such as x-ray sources. . In certain other systems, detectors are used that are powered from the accumulator but transmit data only over wires. However, such a device has a basic software application that controls only the detector and cannot be linked to an NDT workflow. Further, such detectors cannot control the x-ray source or create images in a standard NDT image format.

  Accordingly, it would be desirable to develop a detector system for non-destructive testing (NDT) applications with reduced weight and dimensions. It would also be desirable to develop a wireless detector system that has the ability to provide real-time static X-ray images and is configurable for a wide range of NDT applications.

  In summary, in one embodiment, a detector assembly is provided. The detector assembly is coupled to a configurable x-ray detector having an area of 10.2 centimeters (cm) x 10.2 centimeters (cm) or less, and a configurable x-ray detector. And an embedded controller configured to control the configurable X-ray detector and format image data from the configurable X-ray detector for non-transmission. The detector assembly also provides power to a wireless transmitter configured to wirelessly transmit image data to a user interface device, and a configurable X-ray detector, wireless transmitter, and implantable controller. And a power storage device configured as described above.

  In another embodiment, a detector assembly is provided. The detector assembly includes a configurable x-ray detector and a configurable x-ray detector coupled to the configurable x-ray detector for controlling and configuring the configurable x-ray detector. And an embedded controller that is configured to format the image data from The detector assembly also provides power to a wireless transmitter configured to wirelessly transmit image data to a user interface device, and a configurable X-ray detector, wireless transmitter, and implantable controller. And a power storage device configured to. The detector assembly weighs no more than 2.27 kg.

  In another embodiment, an inspection system is provided. The inspection system includes a detector assembly configured to obtain image data corresponding to the object. The detector assembly is coupled to a configurable x-ray detector having an area of 10.2 centimeters (cm) x 10.2 centimeters (cm) or less, and a configurable x-ray detector. An embedded controller configured to control the configurable X-ray detector and to format the image data from the configurable X-ray detector for non-transmission, and to transmit the image data wirelessly A wireless transmission device configured to transmit; and a power storage device configured to supply power to a configurable X-ray detector, wireless transmission device, and implantable control device. The inspection system also receives image data from a configurable X-ray detector via a wireless transmitter and saves the image data in a predetermined format for use in non-destructive testing (NDT) applications. Including a user interface device.

  These and other features, aspects and advantages of the present invention will be better understood when the following detailed description is read with reference to the accompanying drawings. Like parts are designated by like reference numerals throughout the drawings.

  As will be described in detail below, various embodiments of the present technique can be used to detect NDT used in industrial applications such as the aerospace and oil and gas industries to detect structural flaws and foreign material inclusions in products. It functions to provide a small area wireless detector assembly that is configured to generate, process and transmit digital x-ray images for use. Referring now to the drawings, FIG. 1 illustrates an NDT x-ray detector system 10 for inspecting an object 12 with a detector assembly 14. The inspection object 12 is disposed between the X-ray source 16 and the detector assembly 14. The operation will be described. The X-ray source 16 transmits X-rays directed to the inspection object 12. Further, the detector assembly 14 generates image data corresponding to the inspection object 12 based on the radiation incident from the X-ray source 16. In the illustrated embodiment, a user interface device 18 is provided that is configured to receive image data from the detector assembly 14 for use in NDT applications. In one embodiment, the user interface device 18 includes a laptop computer.

  The detector assembly 14 includes a configurable X-ray detector 20 for generating an image corresponding to the inspection object 12. In this exemplary embodiment, configurable x-ray detector 20 includes a small area detector having an area of 10.2 centimeters (cm) x 10.2 centimeters (cm) or less. Further, the image resolution of the configurable X-ray detector 20 is about 1k × 1k pixels with pixel dimensions of about 50 microns to about 100 microns. In certain embodiments, the weight of detector assembly 14 is not greater than about 2.27 kg. In one embodiment, configurable x-ray detector 20 includes a complementary metal oxide semiconductor (CMOS) detector.

  According to certain embodiments, the configurable x-ray detector 20 includes a scintillator material selected to minimize the dose required by the image. For example, a high resolution scintillator material such as Min-R-Med can be used for higher doses. Examples of scintillator materials include, but are not limited to, gadolinium oxysulfide (GOS), cesium iodide (CsI), and optical fiber scintillators. According to a more specific embodiment, the configurable X-ray detector 20 is characterized by scintillator pixel dimensions and pitch, which can be selected based on the desired application, thereby providing a wide variety of NDTs. It can be used for any purpose. According to certain embodiments, user interface device 18 includes software that facilitates real-time interactive control of configurable x-ray detector 20 and x-ray source 16.

  In the illustrated embodiment, the detector assembly 14 is coupled to a configurable x-ray detector 20 and includes an implantable controller 22 that is configured to control the configurable x-ray detector 20. Including. In this exemplary embodiment, the embedded controller 22 is based on a PC / 104 platform. The configurable X-ray detector 20 is in communication with the embedded controller 22 via a universal serial bus (USB), Ethernet ™, or a frame grabber. However, it is conceivable to use other types of communication protocols. In this embodiment, the embedded controller 22 is configured to format the image data from the configurable X-ray detector 20 for wireless transmission. The formatted image data from the embedded control device 22 is wirelessly transmitted to the user interface device 18 via the wireless transmission device 24. In this exemplary embodiment, the wireless transmitter 24 is an 802.11 pre-N radio configured to wirelessly transmit image data to the user interface device 18 within a range of approximately 30.48 meters (m). Includes protocol. However, other commercially available wireless protocols can be used for the wireless transmitter 24.

  Still further, the detector assembly 14 includes a power storage device 26 for supplying power to the configurable x-ray detector 20 and the implantable controller 22. In one example, power storage device 26 includes a rechargeable storage battery having dimensions less than about 2.54 cm × 8.89 cm × 8.89 cm and having an operating time of at least 30 minutes. In this example, the rechargeable battery has a maximum discharge capacity of about 2 amps (A) and can generate a voltage of about 14.4 volts (V). The detector assembly 14 and user interface device 18 include software architecture that facilitates the generation and processing of image data, as will be described below with reference to FIGS.

  FIG. 2 is a schematic diagram of an exemplary software architecture 30 of the NDT X-ray detector system 10 of FIG. The architectural components of the detector assembly 14 include a detector hardware interface 32 and a detector software and application program interface (API) 34. In the illustrated embodiment, detector hardware interface 32 is coupled to configurable x-ray detector 20 via hardware cable 36. The detector software and API 34 facilitates control of the configurable X-ray detector 20 and formats image data from the configurable X-ray detector 20 for wireless transmission to the user interface device 18. Configured to set.

  In the illustrated embodiment, image data from the detector assembly 14 is transmitted to the user interface device 18 via the wireless Ethernet socket 38. Specifically, the image data from the detector software and API 34 is transmitted to the core command and control software layer 40 and the application API 42 for processing the image data received from the detector assembly 14. Core instruction and control software layer 40 includes a plurality of software modules to facilitate processing of image data and control of detector assembly 14. Details of such a module will be described later in detail with reference to FIG.

  Still further, the components of the user interface device architecture also include an acquisition application 44. The acquisition application 44 is in communication with the core command and control software layer 40 and the application API 42 via a software TCP / IP socket 46. In this embodiment, the acquisition application 44 includes a graphical user interface (GUI) that is configured to receive operator input to set and initiate various tasks associated with the workflow. In addition, the GUI 44 includes displaying a plurality of screens to the system operator to collect the required input. Further, such inputs can be utilized by the core instruction and control software layer 40 to control the parameters of the detector assembly 14 and the x-ray source 16 (see FIG. 1).

  In the illustrated embodiment, the core instruction and control software layer 40 is configured to save image data from the detector assembly 14 in a predetermined format. Examples of the predetermined format include TIFF and JPEG. According to certain embodiments, the core instruction and control software layer 40 is configured to save image data from the detector assembly 14 in a DICONDE format. Beneficially, by storing such images in DICONDE format, the images are available from GE Inspection Technologies, Inc., located in Lewistown, PA, USA. It can be analyzed by NDT applications such as the (GE Rhythm Review) application. Specifically, such image data is transmitted to the image viewing system 48 via any physical layer network connection (eg, Ethernet) 50 for real-time monitoring of the image data. Such image data can then be stored in storage system 52 for future use. In this exemplary embodiment, image viewing system 48 includes a commercially available GE rhythm review application. However, it is conceivable to use other types of image observation systems.

  FIG. 3 is a schematic diagram illustrating components 60 of the software architecture 30 of the NDT X-ray detector system of FIG. As previously mentioned, the X-ray detector system for NDT includes a detector assembly 14. A user interface device 18 is also provided. Image data acquired by the detector assembly 14 is wirelessly transmitted to the user interface device 18 via the wireless Ethernet 38. In the illustrated embodiment, the architecture for the user interface device 18 includes a capture application (GUI) 44 for receiving operator input to facilitate setting and starting various tasks in the workflow. In addition, a workflow agent layer 62 having inspection workflow scenarios and analysis agents is coupled to the GUI 44. Specifically, the workflow agent layer 62 includes task-oriented options for initialization, calibration, and inspection that organize image acquisition and image analysis through the system.

  The user interface device architecture further includes a core instruction and control software layer 40 configured to receive input from the workflow agent layer 62. In this exemplary embodiment, core instruction and control software layer 40 includes an instruction line interface 64 and a test scan plan 66. In operation, the command line interface 64 allows the workflow agent to send commands to the control and synchronization executive 68. In addition, the inspection scan plan 66 includes a script that encapsulates in a predetermined workflow order instructions that can be selected by the workflow agent as input to the instruction line interface 64.

  Control and synchronization executive 68 receives instructions from instruction line interface 64 and then processes the instructions. In addition, the control and synchronization executive 68 sends detector commands to the host detector controller 70 and creates status and error messages for display to the operator. Such status and error messages are displayed to the operator by the status display device 72. In operation, the host detector controller 70 retrieves the image, processes the image for any required image correction, and processes the image data in a predetermined format such as the DICONDE or DICOM format. Act as a server to create. The image data after such processing is then transmitted to the image observation system 48 via the DICONDE interface 74. In one embodiment, image data from the DICONDE interface 74 is transmitted to the image viewing system 48 via the Ethernet 50.

  In the illustrated embodiment, the image viewing system 48 includes a rhythm review application 48. In one embodiment, the rhythm review application 48 can be installed on an on-board user interface device 18 such as an on-board laptop computer. In an alternative embodiment, the image data can be transmitted to a remote image viewing system for remote review of the image data.

  In the illustrated embodiment, detector assembly 14 includes detector hardware 76 and hardware detector controller 78 coupled to detector hardware 76. The hardware detector controller 78 is configured to maintain the wireless interface as a client to the host detector controller 70. In addition, the hardware detector controller 78 operates an interface to the detector hardware 76 to set and retrieve images from the detector hardware 76. The retrieved image from the detector hardware 76 is then transferred to the host detector controller 70 via the wireless interface 38.

  The detector assembly 14 described above employs a configurable x-ray detector 20 that can be configured for use in a wide variety of applications depending on the desired range of resolution. In the illustrated embodiment, configurable x-ray detector 20 includes a scintillator material selected to minimize the dose required by the image. Further, the configurable X-ray detector 20 is characterized by a scintillator pixel size and pitch, and at least one of the scintillator pixel size and pitch can be selected based on the desired NDT application. FIGS. 4-6 illustrate the performance of an exemplary CMOS detector using two exemplary scintillators.

  FIG. 4 is a graph 100 representing counts obtained by an exemplary complementary metal oxide semiconductor (CMOS) detector using two exemplary scintillators. The horizontal axis 102 represents the input supply current in milliamperes (mA), and the vertical axis 104 represents the sensitivity of the detector in measurement counts. In the illustrated embodiment, the count obtained by a CMOS detector using a Lanex-Fast-Front scintillator material with approximately 30 kV-48 mm pixels is represented by curve 106. In addition, the count obtained by a CMOS detector using Min-R-Medium scintillator material with approximately 30 kV-48 mm pixels is represented by curve 108. For each scintillator, mean and standard deviation estimations were performed for the central region of interest (ROI) of 200 × 200 pixels, and the source-detector distance was 70 cm, and a 1 mm Al filter was used. . Furthermore, the dose rate is about 2.5 R / min at a current of about 5 mA. As can be seen, the count 106 obtained with the CMOS detector with Lanex-Fast-Front scintillator material is relatively higher than the count 108 obtained with the CMOS detector with Min-R-Medium scintillator material. . The signal to noise ratio (SNR) for a CMOS detector with these two scintillators is shown in FIG.

  FIG. 5 is a graph 120 that represents the signal-to-noise ratio (SNR) for a CMOS detector with the two exemplary scintillators described above. The horizontal axis 122 represents the input supply current in milliamperes (mA), and the vertical axis 124 represents the SNR. In the illustrated embodiment, the SNR distribution for a CMOS detector using Lanex-Fast-Front scintillator material is represented by curve 126. Furthermore, the SNR distribution for a CMOS detector using Min-R-Medium scintillator material is represented by curve 126. As can be seen, the CMOS detector with the Lanex-Fast-Front scintillator material has a higher (about 1.5 times) SNR than the CMOS detector with the Min-R-Medium scintillator material. Furthermore, the maximum SNR achieved with Lanex-Fast-Front scintillator materials is achieved with lower input doses of about 50% to about 60% compared to Min-R-Medium scintillator materials.

  FIG. 6 is a graph 130 representing the modulation transfer function (MTF) achieved using a CMOS detector with the two exemplary scintillators described above. The horizontal axis 132 represents the resolution in units of line pairs / millimeter (lp / mm), and the vertical axis 134 represents the MTF. In the illustrated embodiment, the distribution of MTF for a CMOS detector using Lanex-Fast-Front scintillator material is represented by curve 136. Furthermore, the MTF distribution for a CMOS detector using Min-R-Medium scintillator material is represented by curve 138. In this exemplary embodiment, MTF is a measurement performed using an edge method by placing an edge in front of the detector. As can be seen, the detector with Min-R-Medium scintillator material has an MTF of about 50% with a resolution of 2.8 (lp / mm) and the detector with Lanex-Fast-Front scintillator material is It has an MTF of about 50% at 1.7 (lp / mm). Furthermore, the critical MTF of about 10% for a detector with Min-R-Medium scintillator material and Lanex-Fast-Front scintillator is a resolution of 7.5 (lp / mm) and 8.5 (lp / mm), respectively. It occurs in. Accordingly, Min-R-Medium scintillator materials have substantially higher MTF compared to Lanex-Fast-Front scintillators.

  As will be appreciated by those skilled in the art, the scintillator material can be selected such that the configurable x-ray detector 20 achieves the desired performance for use in a particular NDT application. Further, the detector array pixel size and pitch can be selected based on the desired application. Thus, the configurable x-ray detector 20 can use different scintillator materials with different scintillator and pixel pitch combinations to cover a variety of NDT applications, including low dose or high resolution imaging.

  Various aspects of the method described above are useful for different NDT applications, such as in the aerospace and oil and gas industries. The approach described above allows in situ inspection of composites or other aerospace structures. Furthermore, the above-described approach provides a small area wireless that can be manipulated into a hard-to-access location or manipulated by a robotic system and can transmit image data wirelessly to a remote user interface device. A detector system is provided. Advantageously, the detector system described above has the ability to provide real-time static X-ray images that are fully controlled by a remote user interface device such as a laptop computer. The detector system can be used to allow near real-time x-ray imaging to examine previously identified abnormal visual or UT displays for the object of interest. In addition, the system includes hardware and software for generating, processing, and transmitting image data to a remote user interface device for review via the image viewing system. In addition, the detector system can be customized for different types of detectors to facilitate the use of such a system in numerous NDT applications.

  The detector system described above allows X-ray inspection to be used in a larger number of “in-situ” inspection scenarios because of its reduced weight and dimensions. Advantageously, this approach makes it possible to identify significant flaws, part damage or wear at the point of use for a part or mechanical system. More specifically, the light weight allows the detector to be used by a robot operating system with a low weight limit. In addition, the detector system uses a digital X-ray detector, which requires less X-ray exposure than film, thereby reducing X-ray shielding requirements. Lower shielding requirements allow for further field X-ray applications.

  While only certain features of the invention have been illustrated and described, various modifications and changes will occur to those skilled in the art. Accordingly, it is to be understood that the claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.

1 is a schematic diagram of an X-ray detector system for NDT according to an exemplary embodiment of the present technique. 2 is a schematic diagram of an exemplary software architecture of the X-ray detector system for NDT of FIG. 3 is a schematic diagram of the components of the software architecture of the NDT X-ray detector system of FIG. FIG. 5 is a graph representing counts obtained with a complementary metal oxide semiconductor (CMOS) detector using two exemplary scintillators. FIG. 6 is a graph representing the signal to noise ratio (SNR) for a CMOS detector with two exemplary scintillators. FIG. 6 is a graph representing the modulation transfer function (MTF) achieved using a CMOS detector with two scintillators.

Explanation of symbols

10 X-ray detector system for NDT 12 Object 14 Detector assembly 18 User interface device 22 Implantable controller 24 Wireless transmitter 30 Software architecture 36 Hardware cable 38 Wireless Ethernet socket 46 Software TCP / IP socket 50 Network connection 60 Components of software architecture 30 100 Graph representing count 120 Graph representing signal-to-noise ratio (SNR) 130 Graph representing modulation transfer function (MTF)

Claims (10)

A configurable X-ray detector (20) having an area of 10.2 centimeters (cm) x 10.2 centimeters (cm) or less;
Image data from the configurable X-ray detector (20) coupled to the configurable X-ray detector (20) for controlling the configurable X-ray detector (20) Embedded controller (22) configured to format the for transmission
A wireless transmission device (24) configured to wirelessly transmit image data to a user interface device (18);
A power storage device (26) configured to supply power to the configurable X-ray detector (20), the wireless transmitter (24) and the implantable controller (22);
A detector assembly (14) having: The configurable X-ray detector (20) comprises a scintillator material selected from the group consisting of cesium iodide (CsI), gadolinium oxysulfide (GOS), fiber optic scintillators, and combinations thereof. The detector assembly (14) of claim 1. The detector assembly (14) of claim 1, wherein the image resolution of the configurable X-ray detector (20) is about 1k x 1k pixels having a pixel size of about 50 microns to about 100 microns. The wireless transmission device (24) includes an 802.11 wireless protocol and is configured to wirelessly transmit image data to a user interface device (18) within a range of about 30.48 meters (m). The detector assembly (14) of claim 1. The power storage device (26) comprises a rechargeable storage battery having dimensions less than about 2.54 cm x 8.89 cm x 8.89 cm and having an operating time of at least 60 minutes. Detector assembly (14). The user interface device (18) is configured to save image data from the configurable X-ray detector (20) in a DICONDE format for use in non-destructive testing (NDT) applications. The detector assembly (14) of any preceding claim. A configurable X-ray detector (20);
Image data from the configurable X-ray detector (20) coupled to the configurable X-ray detector (20) for controlling the configurable X-ray detector (20) Embedded controller (22) configured to format the for transmission
A wireless transmission device (24) configured to wirelessly transmit image data to a user interface device (18);
A power storage device (26) configured to supply power to the configurable X-ray detector (20), the wireless transmitter (24) and the implantable controller (22). A detector assembly (14) comprising:
The detector assembly (14), wherein the detector assembly (14) has a weight of 2.27 kg or less. A detector assembly (14) configured to obtain image data corresponding to an object (12), comprising:
a) a configurable X-ray detector (20) having an area of 10.2 centimeters (cm) x 10.2 centimeters (cm) or less;
b) coupled to the configurable X-ray detector (20) to control the configurable X-ray detector (20) and from the configurable X-ray detector (20) An embedded controller (22) configured to format image data for non-transmission transmission;
c) a wireless transmission device (24) configured to wirelessly transmit image data; and d) the configurable X-ray detector (20), the wireless transmission device (24) and the embedded control device. A power storage device (26) configured to supply power to (22),
A detector assembly (14) having:
Receive image data from the configurable X-ray detector (20) via the wireless transmitter (24) and save the image data in a predetermined format for use in non-destructive testing (NDT) applications A user interface device (18) configured to:
An inspection system (10) comprising: The inspection system (10) according to claim 8, wherein the predetermined format comprises a TIFF format, or a JPEG format, or an image file format including raw binary data. The inspection system (10) of claim 8, further comprising an image viewing system (48) coupled to the user interface device (18) for real-time monitoring of image data.

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