Automatic calibration systems

Abstract: A voltage control (22) controls the voltage applied between an anode (12) and a cathode filament (14) of an x-ray tube (10). A filament control (16) controls the amount of current fed through the filament. A voltage controlled oscillator (42) and counter (44) monitor the magnitude of a tube current (24) flowing between the cathode and the anode to generate x-rays (26). A microprocessor (50) calibrates the filament current such that the filament current value stored in a filament current look-up table (122) for each selectable tube voltage and tube current combination actually produces the selected tube current. The filament current is set (60) to a small current value and progressively incremented (66) until a tube current (24) is monitored (64). To calibrate each selectable tube voltage, tube current combination, the filament current is incremented from this initial current flow or emission point (52) and the resultant tube current is compared (98) with the selected tube current. A substantial portion of the filament current values stored in the filament current look-up table are determined in this way and the rest are determined by interpolation (140).

Description: This invention relates to a method of calibrating x-ray tube filament currents. This invention also relates to an x-ray tube system. Each model and type of x-ray tube conventionally has a published set of filament emission curves or tables. These curve sets or tables commonly take the form of a graph of filament current against tube current or mA for each of plurality of fixed tube voltages or kV. For example, the curve set might include curves for each of three or four tube voltages between 50 kV and 150 kV. In an x-ray device, the x-ray tube is commonly operated for a selected duration at a selected tube current and voltage combination. This generates a corresponding amount of x-rays of the appropriate energy to penetrate the patient or subject and properly expose photographic film or provide appropriate x-ray flux for other x-ray detection equipment. Generally, the tube voltage across the anode and cathode is readily set. The tube current is controlled by adjusting the current flowing through the cathode filament. Increasing the filament current increases electron emission from the cathode which increases the tube current or electron flow between the cathode and anode. By referring to the filament emission curve set, the filament current required to produce a selected tube current at a selected tube voltage is readily determined. Heretofore, x-ray equipment has been calibrated with data taken from the filament emission curves. Most commonly, the filament emission curves were used to set the filament current that would be supplied for each combination of x-ray tube currents and voltages that could be selected. To be sure that these were accurate, an initial calibration process was frequently conducted. Either manually or automatically, exposures were taken with each of a plurality of the selected x-ray tube current and voltage parameters. The actual tube current produced was compared with the selected tube current. When the actual and selected tube currents differed, the filament current was adjusted down or up from the value read from the curves as necessary to bring the actual and selected tube currents together. One of the problems with this prior art calibration technique is that it could damage the x-ray tube filament. The filament has a low impedance and operates at a high current. Filament temperature varies generally with power across it, i.e. I²R where I is the filament current and R is the filament resistance and filament current varies generally as V/R, where V is the voltage applied across the filament. Even normal manufacturing tolerances of this filament can cause a major change in its resistance, hence its generating temperature and the resultant tube current. For example, typical tolerances for the filament current on the curve table are of the order of ± 0.15 amps, A variation of 0.15 amps can make a difference of plus or minus 300 to 400 mA in the tube current Particularly when testing the high tube current values, the filament might produce up to 400 mA more than expected. This extra tube current increases the heating of the anode. A tube current increase of the 300 to 400 milliamp range can increase the anode temperature to the melting point or cause other thermal damage. US-A-4930145 discloses a filament current regulator for an X-ray generator which includes a calibration circuit which compares the actual x-ray tube filament current to a predefined filament current reference value. Another circuit is included which compares the actual x-ray tube voltage, applied across the anode and to cathode of the tube, to a predefined reference voltage value. The regulator adjusts the filament current during a first time interval of an exposure based on only the filament current comparison, and during the remainder of the exposure based substantially on the excitation voltage comparison. The regulator apparatus also integrates the difference between the actual filament current and the reference current value over a given interval during the exposure. The integrated result is employed by the regulator to redefine the filament current reference value. It is an object of this invention to provide a new and improved calibration procedure which avoids damage to the x-ray tube anode. According to the invention there is provided a method of calibrating x-ray tube filament currents of an x-ray tube having an anode and a cathode filament, wherein said method comprises determining the filament current at the emission point by : a) applying a selected voltage across the cathode filament and the anode of the x-ray tube; b) applying a small current to the cathode filament of the x-ray tube at which no tube current flows; c) while the selected voltage is being applied, monitoring for tube current between the cathode filament and the anode; and d) increasing the cathode filament current and repeating steps a) - c) until tube current is monitored, the filament current at this point being designated as the filament current at the emission point. Further, according to the invention there is provided an x-ray tube system comprising: an x-ray tube having an anode , a cathode filament, and a power supply means for selectively applying a voltage across the anode and cathode filament; x-ray tube voltage control means for selectively controlling the voltage applied across the anode and cathode filament; cathode filament current control means for controlling a current applied through the cathode filament; and tube current monitoring means for monitoring a tube current flow between the cathode filament and the anode; characterized in that calibration means are provided including: means arranged to cause the cathode filament current control means to apply a small current to the cathode filament of the x-ray tube at which no tube current flows; means arranged to cause the x-ray tube voltage control means to apply a selected voltage across the cathode filament and the anode; means arranged to cause the tube current monitoring means to determine whether the x-ray tube current flows between the cathode filament and the anode while the preselected voltage is being applied; and means arranged to cause the cathode filament current control means to increase the cathode filament current until a tube current flows between the cathode filament and the anode. One advantage of the present invention is that it avoids thermally damaging the x-ray tube. Another advantage of the present invention resides in approaching each calibration current from below which reduces tube current overshoot. Another advantage of the present invention is that it may quickly, in less than two minutes, automatically calibrate a full range of x-ray tube operating parameters. One system and method in accordance with the invention will now be described, by way of example, with reference to the accompanying drawings in which:- Figure 1 is a diagrammatic illustration of an x-ray tube in combination with an automatic calibration and control circuit; Figure 2 is illustrative of an exemplary tube current (mA), tube voltage (KV), and filament current (I fil ) relationship; Figure 3 is a flow chart illustrating the steps or means for identifying the emission point, and, Figure 4 illustrates appropriate steps or means for determining the filament current calibration at each of a plurality of tube current and voltage settings. With reference to Figure 1, an x-ray tube 10 has an anode 12 and a cathode filament 14. A filament current control means 16 provides a selectably adjustable current through the cathode filament 14 causing the filament to boil off an electron cloud. A power supply 20 under the control of kV or tube voltage control means 22 applies a selected voltage between the cathode filament 14 and the anode 12. The potential difference causes a tube current 24 as the boiled off electrons are attracted from the cathode filament 14 to the surface of the anode 12. The collision of this high energy electron beam 24 with the anode causes a beam of x-rays 26 to be generated. However,the energy of the collision is so high that the anode 12 heats to near its melting point. The x-rays 26 traverse a patient receiving region and impinge on an x-ray sensitive medium 28, such as photographic film, solid state x-ray detectors, or the like. Optionally, the anode 12 may rotate such that the electron beam 24 dwells a shorter duration at a given point on the anode surface to reduce heating and avoid thermal degradation. The power supply 20 includes a high tension transformer 30 whose primary voltage is controlled by the tube voltage control 22. A pair of secondary windings are each connected across analogous rectifier bridges 32, 34 such that the selected tube voltage is created across output terminals 36⁺ and 36⁻. Because the current flow through the x-ray tube is essentially a closed loop, the same current that flows between the cathode and the anode flows through a resistor 40 connecting the rectifier bridges 32, 34. Accordingly, the x-ray current 24 can be sensed by sensing the voltage across the resistor 40. A voltage controlled oscillator 42 is connected across the resistor 40 such that it produces an output signal whose frequency or pulse rate varies in proportion to the voltage across resistor 40, hence the tube current 24. A counter means 44 counts the output pulses of the voltage controlled oscillator 42 for a unit time to provide a numeric output indicative of the actual tube current 24. With continuing reference to FIGURE 1 and further reference to FIGURE 2, a microprocessor control circuit 50 instructs the filament current control 16 and the tube voltage control 22 in accordance with the actual tube current 24 as determined by the counter 44. At a selected tube voltage, generally the highest voltage rating, e.g. 120 kV, no tube current 24 flows when the filament current I fil is low , e.g. below 3.0 amps. As the filament current increases, no tube current will flow until an emission point 52 is reached, e.g. around 3.4 amps. Thereafter, each small increase in the filament amperage causes the tube current to change generally along a fixed voltage, mA v I fil curve 54. As the tube voltage is decreased towards the minimum tube voltages 56, e.g. 40 kV, a progressively higher filament current becomes necessary to reach the emission point, as described by curve 58. In this manner, the tube voltage, tube current, and filament current relationship is defined by a generally warped surface. With continuing reference to Figure 2 and further reference to Figure 3, the microprocessor 50 has a means or performs a step 60 causing the filament current control means 16 to set the filament current to some initial low value, e.g. 3.0 amps. A step or means 62 causes the x-ray tube voltage control means 22 to apply the maximum selectable tube voltage across the cathode 14 and anode 12 to start an exposure. A tube current determining means or step 64 monitors the output of counter 44 to determine whether a tube current 24 is flowing. If there is no tube current flowing, a step or means 66 causes the filament current control means 16 to increase the filament current by a preselected increment. The tube voltage is applied again at 62 and a check is again made at 64 to determine whether the tube current 24 has started to flow. This increment, expose, and check routine is continued cyclically until a tube current 24 is sensed. Once the tube current 24 has started to flow, a step or means 70 divides the filament current increment by two to reduce the increment size. A step or means 72 causes the filament current control means 16 to decrease the filament current by the half size increment. A step or means 74 causes the voltage control means 22 to start another exposure so that a tube current monitoring step or means 76 can check whether the tube current 24 still flows at this lower filament current. If the tube current 24 is still flowing at this lower current, a filament current decreasing means or step 78 causes the filament current to be decreased by the currently set increment. If the tube current is no longer flowing at this filament current, a filament current increasing means or step 80 causes the filament current to be increased by the currently set half increment. An increment reducing means or step 82 divides the filament current increment in half again. Optionally, step or means 82 may be disposed between steps or means 74 and 76. This process of adjusting the filament current, starting an exposure to see if a tube current flows, and dividing the filament current increment by two continues until a step or means 84 determines that a preselected minimum filament current increment size has been reached. The filament current at this point is then designated as the filament current at the emission point 52. With reference to Figure 4 and continuing reference to Figure 2, once the emission point 52 is determined, the filament current which causes a first selected tube current 90 to flow at maximum tube voltage is determined. A step or means 92 sets the filament current at the emission current level, i.e. at the filament current level which produces the smallest measurable tube current which is lower than the selected tube current 90. A tube current incrementing means or step 94 sets a desired tube current value successively to each of a plurality of preselected values and resets the tube voltage to the maximum voltage. An x-ray exposure starting step or means 96 causes the tube voltage control means 22 to apply the tube voltage across the anode 12 and cathode 14 and a tube current detecting means or step 98 determines whether the tube current measured by the counter means 44 exceeds the tube current selected with a tube current selecting step or means 94. If the actual tube current is below the selected tube current, a filament current incrementing step or means 100 increments the filament current by a preselected filament current increment and the exposure and comparing steps are repeated. This expose, compare and increment procedure is repeated until the actually measured tube current exceeds the selected tube current. Once the tube current exceeds the selected tube current, a step or means 102 divides the filament current increment by two to reduce the step or increment size. A step or means 104 causes the filament current control means 16 to decrease or decrement the filament current by the half size increment. A step or means 106 causes the voltage control means 22 to start another exposure so that a tube current monitoring step or means 108 can check whether the tube current still exceeds the selected tube current at this lower filament current. If the tube current still exceeds the selected tube current at this lower filament current, a filament current decreasing means or step 110 causes the filament current to be decreased by the currently set increment, and if the tube current is less than selected at this filament current, a filament current increasing means or step 112 causes the filament current to be increased by the currently set increment. An increment reducing step 114 divides the filament current step in half again. This process of adjusting the filament current, starting an exposure to see if the tube current exceeds the selected current, and dividing the filament increment by two continues until a step or means 116 determines that a preselected minimum filament current increment size has been reached. The filament current at this point is then designated as the calibrated filament current at the selected kV and mA. When the minimum increment value determining step or means 116 determines that the best possible calibration has been attained, a recording means 118 records the filament current for the selected tube voltage and tube current combination in an appropriate memory cell 120 a filament current memory means 122 (Figure 1). A tube voltage decrementing means or step 124 decrements the tube voltage to a lower one of the selected tube voltages. The filament current is again incremented and zeroed in on the appropriate tube filament current value to attain the first selected tube current at this lower selected tube voltage. The filament current value is recorded in an appropriate memory cell 128 of the filament current memory means 122. This process is repeated until a tube voltage minimum determining step or means 130 determines that the minimum selectable tube voltage has been reached. When the minimum tube voltage is reached, a step or means 132 resets the filament current to the previously calibrated filament current at the maximum kV, i.e. point 90. The tube current incrementing step or means 94 increments the tube current and resets the tube voltage value to the maximum value. Thus, the first exposure at this new mA-kV combination is guaranteed not to exceed the anode loading limit. The tube current calibration process is repeated until the appropriate filament current is determined to achieve the next selected calibration point 134 and each of a selected plurality of successive tube voltage, tube current combinations are obtained. Although every selectable tube current, tube voltage combination might be selected and calibrated individually, it is preferred that only a fraction of the tube current, tube voltage combinations are actually calibrated and that the rest are determined by interpolation. To this end, an interpolating means or step 140 interpolates the actually calibrated tube currents (denoted by a solid circle in Figure 2 and an x in memory 122 of Figure 1) to determine appropriate tube currents for each selectable tube current, tube voltage combination. It is to be appreciated that once the emission current level is determined, the selected tube current, tube voltage combinations can be calibrated in various orders. Preferably, the calibration is conducted from the minimum tube current towards the maximum tube current. Once the current filament memory 122 has been filled, the x-ray tube is calibrated and ready to be operated. An operator keyboard 142 has appropriate input buttons or dials for the operator to select any one of the selectable x-ray tube voltage and current combinations. The microprocessor means 50 addresses the current filament memory 122 with the selected tube voltage and current and retrieves the corresponding filament current. The microprocessor then controls the current filament control means 16 to provide the retrieved filament current and controls the tube voltage control means 22 to provide the selected tube voltage for a selected exposure duration.

Claims: A method of calibrating x-ray tube filament currents of an x-ray tube (10) having an anode (12) and a cathode filament (14), wherein said method comprises, as a first step, determining the filament current at the emission point (52) by : a) applying a selected voltage across the cathoder filament (14) and the anode (12) of the x-ray tube (10); b) applying a small current to the cathode filament (14) of the x-ray tube (10) at which no tube current flows; c) while the selected voltage is being applied, monitoring for tube current between the cathode filament (14) and the anode (12); and d) increasing the cathode filament current and repeating steps a) - c) until tube current is monitored, the filament current at this point being designated as the filament current at the emission point (52). A method of calibrating x-ray tube filament currents according to Claim 1, characterised in that it further comprises the steps of: e) applying a first selected tube voltage which is lower than or equals the selected voltage applied in step b); f) increasing the filament current (I fil ) from the filament current value at which the filament emission point (52) was monitored; g) monitoring the resultant tube current; h₁) comparing the monitored tube current with a preselected tube current; and, h₂) repeating steps f) - h) until the selected tube current is reached. A method as claimed in Claim 2 further including the step of: i) storing the filament current at which the preselected tube current is reached in a filament current memory means (122) in a memory cell (120) that is addressable by the selected tube voltage and tube current pair which defines a tube current/tube voltage calibration for the x-ray tube. A method as claimed in Claim 3 further including the step of: j) decrementing the first selected tube voltage to a lower selected tube voltage and repeating steps f) - i), wherein, in step f), the filament current (I fil ) is increased from the previously calibrated filament current instead of from the filament current value at which the filament emission point (52) was monitored. A method as claimed in Claim 4 further including the step of: k) incrementing the preselected tube current and repeating steps e) - j), whereby anode overloading is avoided by basing each of a plurality of tube current/tube voltage calibrations on the previously calibrated tube current/tube voltage values. A method as claimed in Claim 3 further including incrementing the preselected tube current and repeating steps f) to i). A method as claimed in any preceding claim wherein the step of increasing the filament current includes changing the filament current in increments of a first magnitude. A method as claimed in Claim 7 further including the step of decrementing the filament current by an increment of half said first magnitude, after the filament emission point is first monitored and repeating step c); if the tube current is still detected, decrementing the filament current by an increment of a quarter of said first magnitude and if the tube current is no longer detected, incrementing the tube current by the increment of a quarter of said first magnitude, and repeating step c). A method as claimed in Claim 7 when dependent on any of Claims 2 to 6 further including: after the tube current exceeds the preselected tube current, decrementing the filament current by an increment of half said first magnitude and repeating steps g) and h); if the tube current still exceeds the preselected tube current, decrementing the filament current by an increment of a quarter of said first magnitude and if the tube current is below the preselected tube current, incrementing the tube current by an increment of a quarter of said first magnitude and repeating steps g) and h). A method of calibrating pairs of x-ray tube filament current and tube voltage values, which comprises the steps of applying a filament current and tube voltage at a first previously calibrated pair of values to an x-ray tube (10), said calibrated pair being determined by the method according to Claim 2; setting the tube voltage to a second selected value; progressively increasing the filament current until a tube current reaches a second selected value; recording the filament current at which the tube current reaches the second selected value and recording the tube voltage/tube current values; repeating the progressively increasing steps for each of a plurality of filament current and voltage pairs, whereby anode overloading is prevented by basing each calibration on previously calibrated values. An x-ray tube system comprising: an x-ray tube (10) having an anode (12), a cathode filament (14), and a power supply means (20) for selectively applying a voltage across the anode (12) and cathode filament (14); x-ray tube voltage control means (22) for selectively controlling the voltage applied across the anode (12) and cathode filament (14); cathode filament current control means (16) for controlling a current applied through the cathode filament; and tube current monitoring means (64) for monitoring a tube current flow (24) between the cathode filament and the anode, characterized in that calibration means are provided including: means (50) arranged to cause the cathode filament current control means to apply a small current to the cathode filament of the x-ray tube at which no tube current flows; means (50) arranged to cause the x-ray tube voltage control means to apply a selected voltage across the cathode filament and the anode; means arranged to cause the tube current monitoring means (64) to determine whether the x-ray tube current (24) flows between the cathode filament and the anode while the preselected voltage is being applied; and means (66) arranged to cause the cathode filament current control means to increase the cathode filament current until a tube current flows between the cathode filament and the anode. An x-ray tube system as claimed in Claim 11 wherein the calibration means further includes: means (98) for comparing the monitored tube current with a preselected tube current. An x-ray tube system as claimed in Claim 11 or 12 further including: filament current memory means (122) for storing each filament current at which a selected tube current is monitored, the filament current memory means being addressable by each of a plurality of preselected tube voltage and tube current values. An x-ray tube system as claimed in Claims 11, 12 or 13 wherein the means (66) arranged to cause the cathode filament current control means (16) to increase the filament current increases the filament current in preselected current increments and wherein the calibration means further includes: means (78) for decreasing the filament current in the preselected current increments, and means (70, 82) for reducing the preselected current increments.

Inventors: SAMMON ROBERT J, SAMMON, ROBERT J.
Applicants: PICKER INT INC, PICKER INTERNATIONAL, INC.
Application year: 1991
Main classification: H05G1
IPC codes: H01J35, H05G1