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Design optimization of MR-compatible rotating anode x-ray tubes for stable operation.

ABSTRACT: Hybrid x-ray/MR systems can enhance the diagnosis and treatment of endovascular, cardiac, and neurologic disorders by using the complementary advantages of both modalities for image guidance during interventional procedures. Conventional rotating anode x-ray tubes fail near an MR imaging system, since MR fringe fields create eddy currents in the metal rotor which cause a reduction in the rotation speed of the x-ray tube motor. A new x-ray tube motor prototype has been designed and built to be operated close to a magnet. To ensure the stability and safety of the motor operation, dynamic characteristics must be analyzed to identify possible modes of mechanical failure. In this study a 3D finite element method (FEM) model was developed in order to explore possible modifications, and to optimize the motor design. The FEM provides a valuable tool that permits testing and evaluation using numerical simulation instead of building multiple prototypes.Two experimental approaches were used to measure resonance characteristics: the first obtained the angular speed curves of the x-ray tube motor employing an angle encoder; the second measured the power spectrum using a spectrum analyzer, in which the large amplitude of peaks indicates large vibrations. An estimate of the bearing stiffness is required to generate an accurate FEM model of motor operation. This stiffness depends on both the bearing geometry and adjacent structures (e.g., the number of balls, clearances, preload, etc.) in an assembly, and is therefore unknown. This parameter was set by matching the FEM results to measurements carried out with the anode attached to the motor, and verified by comparing FEM predictions and measurements with the anode removed. The validated FEM model was then used to sweep through design parameters [bearing stiffness (1 × 10(5)-5 × 10(7) N/m), shaft diameter (0.372-0.625 in.), rotor diameter (2.4-2.9 in.), and total length of motor (5.66-7.36 in.)] to increase the fundamental frequency past the operating range at 50 Hz.The first large vibration during the prototype motor operation was obtained at 21.64 ± 0.68 Hz in the power spectrum. An abrupt decrease in acceleration occurred at 21.5 Hz due to struggling against the resonance vibrations. A bearing stiffness of 1.2 × 10(5) N/m in the FEM simulation was used to obtain a critical speed of 21.4 Hz providing 1.1% error. This bearing stiffness value and the 3D model were then confirmed by the experiments with the anode removed, demonstrating an agreement within 6.4% between simulation results and measurements. A calculated first critical frequency (fundamental frequency) of 68.5 Hz was obtained by increasing the bearing stiffness to 1 × 10(7) N/m and increasing the shaft diameter by 68.0%. Reducing the number of bearings in the design permits decreasing the total length of the motor by 1.7 in., and results in a fundamental frequency of 68.3 Hz in concert with additional changes (shaft diameter of 0.625 in., rotor diameter of 2.4 in., and bearing stiffness of 1 × 10(6) N/m).An FEM model of the x-ray tube motor has been implemented and experimentally validated. A fundamental frequency above the operational rotation speed can be achieved through modification of multiple design parameters, which allows the motor to operate stably and safely in the MR environment during the repeated acceleration/deceleration cycles required for an interventional procedure. The validated 3D FEM model can now be used to investigate trade-offs between generated torque, maximum speed, and motor inertia to further optimize motor design.

SUBMITTER: Shin M

PROVIDER: S-EPMC3808452 | biostudies-other | 2013 Nov

REPOSITORIES: biostudies-other

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Project description:Using hybrid x-ray∕MR (XMR) systems for image guidance during interventional procedures could enhance the diagnosis and treatment of neurologic, oncologic, cardiovascular, and other disorders. The authors propose a close proximity hybrid system design in which a C-arm fluoroscopy unit is placed immediately adjacent to the solenoid magnet of a MR system with a minimum distance of 1.2 m between the x-ray and MR imaging fields of view. Existing rotating anode x-ray tube designs fail within MR fringe field environments because the magnetic fields alter the electron trajectories in the x-ray tube and act as a brake on the induction motor, reducing the rotation speed of the anode. In this study the authors propose a novel motor design that avoids the anode rotation speed reduction.The proposed design replaces the permanent magnet stator found in brushed dc motors with the radial component of the MR fringe field. The x-ray tube is oriented such that the radial component of the MR fringe field is orthogonal to the cathode-anode axis. Using a feedback position sensor and the support bearings as electrical slip rings, the authors use electrical commutation to eliminate the need for mechanical brushes and commutators. A vacuum compatible prototype of the proposed motor design was assembled, and its performance was evaluated at various operating conditions. The prototype consisted of a 3.1 in. diameter anode rated at 300 kHU with a ceramic rotor that was 5.6 in. in length and had a 2.9 in. diameter. The material chosen for all ceramic components was MACOR, a machineable glass ceramic developed by Corning Inc. The approximate weight of the entire assembly was 1750 g. The maximum rotation speed, angular acceleration, and acceleration time of the motor design were investigated, as well as the dependence of these parameters on rotor angular offset, magnetic field strength, and field orientation. The resonance properties of the authors' assembly were also evaluated to determine its stability during acceleration, and a pulse width modulation algorithm was implemented to control the rotation speed of the motor.At a magnetic flux density of 41 mT orthogonal to the axis of rotation (on the lower end of the expected flux density in the MR suite) the maximum speed of the motor was found to be 5150 revolutions per minute (rpm). The acceleration time necessary to reach 3000 rpm was found to be approximately 10 s at 59 mT. The resonance frequency of the assembly with the anode attached was 1310 rpm (21.8 Hz) which is far below the desired operating speeds. Pulse width modulation provides an effective method to control the speed of the motor with a resolution of 100 rpm.The proposed design can serve as a direct replacement to the conventional induction motor used in rotating anode x-ray tubes. It does not suffer from a reduced rotation speed when operating in a MR environment. The presence of chromic steel bearings in the prototype prevented testing at the higher field strengths, and future iterations of the design could eliminate this shortcoming. The prototype assembly demonstrates proof of concept of the authors' design and overcomes one of the major obstacles for a MR compatible rotating anode x-ray tube.

Project description:Combining x-ray fluoroscopy and MR imaging systems for guidance of interventional procedures has become more commonplace. By designing an x-ray tube that is immune to the magnetic fields outside of the MR bore, the two systems can be placed in close proximity to each other. A major obstacle to robust x-ray tube design is correcting for the effects of the magnetic fields on the x-ray tube focal spot. A potential solution is to design active shielding that locally cancels the magnetic fields near the focal spot.An iterative optimization algorithm is implemented to design resistive active shielding coils that will be placed outside the x-ray tube insert. The optimization procedure attempts to minimize the power consumption of the shielding coils while satisfying magnetic field homogeneity constraints. The algorithm is composed of a linear programming step and a nonlinear programming step that are interleaved with each other. The coil results are verified using a finite element space charge simulation of the electron beam inside the x-ray tube. To alleviate heating concerns an optimized coil solution is derived that includes a neodymium permanent magnet. Any demagnetization of the permanent magnet is calculated prior to solving for the optimized coils. The temperature dynamics of the coil solutions are calculated using a lumped parameter model, which is used to estimate operation times of the coils before temperature failure.For a magnetic field strength of 88 mT, the algorithm solves for coils that consume 588 A∕cm(2). This specific coil geometry can operate for 15 min continuously before reaching temperature failure. By including a neodymium magnet in the design the current density drops to 337 A∕cm(2), which increases the operation time to 59 min. Space charge simulations verify that the coil designs are effective, but for oblique x-ray tube geometries there is still distortion of the focal spot shape along with deflections of approximately 3 mm in the radial and circumferential directions on the anode.Active shielding is an attractive solution for correcting the effects of magnetic fields on the x-ray focal spot. If extremely long fluoroscopic exposure times are required, longer operation times can be achieved by including a permanent magnet with the active shielding design.

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Design optimization of MR-compatible rotating anode x-ray tubes for stable operation.

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