Embodiments of the invention relate generally to x-ray tubes and, more particularly, to an anti-fretting coating for an attachment joint and a method of making same.
Computed tomography X-ray imaging systems typically include an x-ray tube, a detector, and a gantry assembly to support the x-ray tube and the detector. In operation, an imaging table, on which an object is positioned, is located between the x-ray tube and the detector. The x-ray tube typically emits radiation, such as x-rays, toward the object. The radiation typically passes through the object on the imaging table and impinges on the detector. As radiation passes through the object, internal structures of the object cause spatial variances in the radiation received at the detector. The detector converts the received radiation to electrical signals and then transmits data received, and the system translates the radiation variances into an image, which may be used to evaluate the internal structure of the object. One skilled in the art will recognize that the object may include, but is not limited to, a patient in a medical imaging procedure and an inanimate object as in, for instance, a package in an x-ray scanner or computed tomography (CT) package scanner.
A typical x-ray tube includes a cathode that provides a focused high energy electron beam that is accelerated across a cathode-to-anode vacuum gap and produces x-rays upon impact with an active material or target provided. Because of the high temperatures generated when the electron beam strikes the target, typically the target assembly is rotated at high rotational speed for purposes of spreading the heat flux over a larger extended area.
As such, the x-ray tube also includes a rotating system that rotates the target for the purpose of distributing the heat generated at a focal spot on the target. The rotating subsystem is typically rotated by an induction motor having a cylindrical rotor built into an axle that supports a disc-shaped target and an iron stator structure with copper windings that surrounds an elongated neck of the x-ray tube. The rotor of the rotating subsystem assembly is driven by the stator.
The target is attached to a support shaft, which is in turn supported by roller bearings that are typically hard mounted to a base plate. Thus, the target provides a thermal path to the roller bearings that can cause the roller bearings to operate at elevated temperature, compromising the life thereof. In order to minimize or reduce the operating temperature of the bearings, often a thermally resistive material is placed between the target and the bearings. The thermally resistive material, referred to sometimes as a thermal barrier, can be designed having a high thermal resistance to include using a material having a relatively low thermal conductivity, a very thin wall and additional length—all resulting in an increased thermal resistance between the target and the bearing. Thermal resistance can be further increased by introducing a bolted joint between the shaft and the roller bearings, as it is well known that contact resistance in, for instance, a bolted joint can cause a large thermal resistance and temperature drop thereacross in conduction heat transfer. As known in the art, bolted joint strength may be enhanced by designing components such that they have an interference fit, and in some instances bolts may be foregone entirely, leaving joint strength entirely to the interference fit at an interface therebetween. Not only may such designs be intended to increase thermal conductivity, bolted and/or interference joints may be introduced into a design to facilitate assembly of components (such as an anode or target assembly) during fabrication of an x-ray tube.
However, because the target is typically rotated about its axis at a high rate of speed, typically 100 Hz or more, and because the x-ray tube itself is rotated at a high rate of speed on a gantry, typically 2 Hz or more, enormous periodic loads can be generated at interfaces that join the target and other rotating components. So, high-frequency periodic loads are applied to the joint due to the target rotation and some unavoidable residual unbalance of the rotating components and low-frequency periodic loads due to the tube rotation on the CT gantry. Such loads in a bolted joint can cause bending of the joints components causing small relative motion to occur, which can cause fretting, leading to particulate generation within the x-ray tube. Fretting and particulate generation can occur in bolted joints and at interfaces that include, for instance, interference joints. In fact, particles can be generated at any interface where materials are such as in a bolted joint or an interference fit pressed together (but not fused or otherwise bonded together, such as in a welded or brazed joint, as examples). And, the effect can increase significantly with increased gantry and/or increased target rotating speed, leading to increased fretting and particulate generation as x-ray tubes are rotated faster on gantries and as targets are rotated faster within x-ray tubes.
As known in the art, particulate in an x-ray tube can degrade performance and life in a number of ways that include, for instance, accelerated bearing wear if the wear particles fall into the bearing and electrical discharge activity in the high voltage environment of the x-ray tube. Both of these issues reduce the useful life of the x-ray tube.
Accordingly, it would be advantageous to have an x-ray tube that could be rotated at a high speed on a gantry and at a high target rotational speed without a reduction in life due to particulate generation at connection joints in the x-ray tube.
Embodiments of the invention provide an apparatus and method of attaching a target to a bearing having a reduced amount of particulate generation at interfaces of attachment locations thereof.
According to one aspect of the invention, an x-ray tube includes a cathode adapted to emit electrons, a bearing assembly comprising a bearing hub, a target assembly positioned to receive the emitted electrons, the assembly having a target hub coupled to the bearing hub at an attachment face, wherein the attachment face comprises a first material compressed against a second material, and a first anti-wear coating attached to one of the first material and the second material and positioned between the first material and the second material.
In accordance with another aspect of the invention, a method of fabricating an anode assembly for an x-ray tube includes applying a first anti-wear coating to one of a first material and a second material, and coupling an x-ray target to a bearing at an interface that is comprised of the first material and the second material.
Yet another aspect of the invention includes an x-ray imaging system that includes a gantry, a detector attached to the gantry, and an x-ray tube attached to the gantry. The x-ray tube includes a bearing having a bearing hub, a target having a target hub coupled to the bearing hub at a contact location, and a first anti-fretting coating. The contact location includes a first material attached to a second material, and the first anti-fretting coating is attached to one of the first material and the second material at the contact location and is positioned between the first material and the second material.
Various other features and advantages of the invention will be made apparent from the following detailed description and the drawings.
The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.
In the drawings:
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A processor 20 receives the signals from the detector 18 and generates an image corresponding to the object 16 being scanned. A computer 22 communicates with processor 20 to enable an operator, using operator console 24, to control the scanning parameters and to view the generated image. That is, operator console 24 includes some form of operator interface, such as a keyboard, mouse, voice activated controller, or any other suitable input apparatus that allows an operator to control the x-ray system 10 and view the reconstructed image or other data from computer 22 on a display unit 26. Additionally, console 24 allows an operator to store the generated image in a storage device 28 which may include hard drives, flash memory, compact discs, etc. The operator may also use console 24 to provide commands and instructions to computer 22 for controlling a source controller 30 that provides power and timing signals to x-ray source 12.
Bearing assembly 58 includes a center shaft 68 attached to rotor 62 at a first end 70 and attached to anode assembly 56 at a second end 72. A front inner race 74 and a rear inner race 76 rollingly engage a plurality of front balls 78 and a plurality of rear balls 80, respectively. Bearing assembly 58 also includes a front outer race 82 and a rear outer race 84 configured to rollingly engage and position, respectively, the plurality of front balls 78 and the plurality of rear balls 80. Bearing assembly 58 includes a stem 86 which is supported by a backplate 88 of x-ray tube 50. A stator (not shown) is positioned radially external to and drives rotor 62, which rotationally drives anode assembly 56.
Anode assembly 56 includes a target 90 having a heat sink material 92 such as graphite attached thereto. Target 90 is attached to a bearing hub 94 at an attachment location or contact region 96 via a number of means that are illustrated in subsequent embodiments of
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As stated, due to enormous loads during operation from high frequency-induced relative motion that is compounded by low frequency input from rotation about the gantry, fretting and relative motion of components may cause particulate to generate at a first interference location 110 such as where outer diameter of bearing hub 94 contacts target 90, and/or at a second location 112 such as along an axial surface where bearing hub 94 contacts target 90. Thus, according to the invention an anti-wear or anti-fretting coating may be applied to bearing hub 94 at a first hub location as a first hub coating 114, or a second hub location as a second hub coating 116. Similarly, an anti-wear or anti-fretting coating may be applied to target 90 at a first target location as a first target anti-wear or anti-fretting coating 118 or a second target location as a second anti-wear or anti-fretting target coating 120. According to the invention, coatings 114-120 may be chromium nitride, titanium nitride, diamond-like carbon, tungsten carbide, tungsten carbon-carbon (WC/C), TiCN, TiAlN, AlTiN, and ZrN, as examples. Further, although a number of examples are provided, it is contemplated that the invention is not to be so limited. According to the invention, coatings 114-120 may include any material for a coating that reduces fretting, wear of components, and ultimately particulate generation for rotating components in a vacuum, such as in an x-ray tube, that have counterfaces pressed or otherwise maintained against each other. In one example coatings 114-120 include materials having a hardness of 1750 measured on the Vickers HV scale.
Coatings 114-120 reduce wear and fretting via one or more processes. Firstly, the coating is harder than the base material to which it is adhered, so its wear rate (adhesive and abrasive wear rate) is lower than the base material. Secondly, in a vacuum its coefficient of friction can be lower than the base material system thereby lower friction wear action. Also, the metallurgical affinity between the counterface materials is much less by using dissimilar materials. These factors all combine to reduce the rate of particulate production in high temperature and high vacuum environments, such as experienced in an x-ray tube, of up to approximately 600° C. in a vacuum of 1E-6 torr. Thus, particulate generation can be reduced by using preferably different coatings on each mating surface (e.g., CrN-WC). In another example coatings 114-120 are applied having a thickness of approximately 2-5 microns (although coatings such as coatings 114-120 for this and other embodiments are shown having thicknesses greater than 2-5 microns for illustrative purposes). Further, it is contemplated that any coating thickness may be applied for coatings 114-120 and other coatings described herein, and that the invention is not limited to coating thicknesses of 2-5 microns, but may have greater or lesser thicknesses than 2-5 microns.
According to the invention, coatings 114-120 may be applied using physical vapor deposition (PVD) (such as but not limited to sputtering and ion plating, as examples) and other known techniques for applying a smooth and uniform application of material. Further, embodiments of the invention include having coatings applied to each part such that a first coating is pressed against a second coating. For instance, in one embodiment coating 114 may be applied to bearing hub 94 and coating 118 may be applied to target 90 at attachment location 96 such that coating 114 is pressed against coating 118 when the interference fit is formed. In this embodiment, coatings 114 and 118 are preferably of different materials. That is, as one example coating 114 may be chromium nitride and coating 118 may be titanium nitride. In another example, coating 118 is diamond-like carbon and bearing hub 94 is uncoated (i.e., coating 114 is not present). As such, embodiments of the invention include a first material pressed against a second material, and the opposing materials are preferably of different materials. Thus, because of the different materials, friction therebetween the two is minimized and there is a reduced amount of adhesive wear because an amount of diffusion bonding between the materials is reduced, as compared to an interface of two of the same materials pressed against each other.
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Thus, according to the embodiments illustrated, a target may be attached to a bearing hub by using interference fits, bolted joints, or combinations thereof. Further, such attachment may also be accomplished using a thermal barrier and bolted joints, interference fits, or combinations thereof. In locations where contact points or surfaces are formed, anti-wear or anti-fretting coatings may be applied to one contact surface, the other contact surface, or both. As such, embodiments of the invention include a first material pressed against a second material, and the opposing materials are preferably of different materials. Thus, because of the different materials, friction therebetween the two is minimized and there is a reduced amount of adhesive wear because an amount of diffusion bonding between the materials is reduced, as compared to two of the same materials pressed against each other.
Further, although the embodiments described are for an x-ray tube application and for a joint attaching an x-ray tube target to a bearing hub, it is to be understood that the invention is not to be so limited, and it is contemplated that the invention may be applicable to any rotating components where fretting may occur, causing particulate generation.
According to an embodiment of the invention, an x-ray tube includes a cathode adapted to emit electrons, a bearing assembly comprising a bearing hub, a target assembly positioned to receive the emitted electrons, the assembly having a target hub coupled to the bearing hub at an attachment face, wherein the attachment face comprises a first material compressed against a second material, and a first anti-wear coating attached to one of the first material and the second material and positioned between the first material and the second material.
According to another embodiment of the invention, a method of fabricating an anode assembly for an x-ray tube includes applying a first anti-wear coating to one of a first material and a second material, and coupling an x-ray target to a bearing at an interface that is comprised of the first material and the second material.
Yet another embodiment of the invention includes an x-ray imaging system that includes a gantry, a detector attached to the gantry, and an x-ray tube attached to the gantry. The x-ray tube includes a bearing having a bearing hub, a target having a target hub coupled to the bearing hub at a contact location, and a first anti-fretting coating. The contact location includes a first material attached to a second material, and the first anti-fretting coating is attached to one of the first material and the second material at the contact location and is positioned between the first material and the second material.
The invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
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