CT Machine Failure Investigations

CT Machine Failure Investigations: Root
Causes & Repair Solutions

CT scanners have been widely used in the medical industry in almost all hospitals at or above the
county level in China and oversea countries. CT scanners are machines commonly encountered
in medical services. Now let me briefly introduce the basic structure of a CT scanner and the
main causes of CT scanner failures.
A. Basic structure of CT scanner
After years of development, CT scanners have undergone significant improvements, including an

increase in the number of detector layers and faster scanning speed. However, their hardware
components remain largely the same and can be divided into three main parts:
1）X-ray detector gantry

2）Computerized console
3）Patient table for positioning
4）Structurally and functionally, CT scanners consist of the following components:
The part responsible for controlling computer scanning and image reconstruction
The mechanical part for patient positioning and scanning, which includes the scanning gantry
and the bed
High-voltage X-ray generator and X-ray tube for producing X-rays
Data acquisition and detection component for extracting information and data
Based on these fundamental structural characteristics of CT scanners, one can determine the
basic direction for troubleshooting in case of malfunctions.
Two classifications, sources, and characteristics of CT machine faults
CT machine failures can be classified into three types: failures caused by environmental factors,
faults resulting from improper operation, and failures due to aging and component deterioration
within the CT system, leading to parameter drift and mechanical wear.
1）Failures caused by environmental factors

Environmental factors such as temperature, humidity, air purification, and power supply stability
can contribute to CT machine failures. Insufficient ventilation and high room temperatures can
cause appliances such as power supplies or transformers to overheat, potentially leading to
circuit board damage. Machine interruptions and excessive temperature drift resulting from
inadequate cooling can generate image artifacts. Surges in CT supply voltage can disrupt proper
computer functioning, causing instability in machine operations, abnormal pressure, X-ray
instability, and ultimately affecting image quality. Poor air purification can result in dust
accumulation, leading to malfunctions in optical signal transmission control. Excessive humidity
can cause short-circuits and electronic device failures. Environmental factors can pose significant
harm to CT machines, sometimes even causing permanent damage. Therefore, maintaining an
optimal operating environment is crucial for minimizing CT machine faults and extending their
service life.
2）Faults caused by human error and improper operation

Common factors contributing to human error include lack of time for warm-up routines or
calibration, resulting in abnormal image uniformity or quality issues, and incorrect patient
positioning leading to undesirable images. Metal artifacts can be produced when patients are
wearing metallic objects during scans. Operating multiple CT machines simultaneously can lead
to crashes, and improper selection of scanning parameters can introduce image artifacts.
Typically, human errors do not cause severe consequences, as long as the underlying reasons are
identified, proper procedures are followed, and the system is restarted or re-operated, thereby
successfully troubleshooting the issues.
3) Hardware failures and damage within the CT system

CT hardware components may experience their own production failures. In most mature CT
systems, failures occur according to a saddle-shaped trend over time, following statistical
probability. The installation period is characterized by a higher failure rate in the first six
months, followed by a relatively stable low failure rate during a long period of five to eight
years. After this period, the failure rate gradually increases.
a. Mechanical part failures
The following major faults are mainly discussed:
As equipment ages, mechanical failures increase every year. In the early days of CT, a reverse
rotation mode was used in the scan cycle, with a very short rotation speed that switched from
uniform to slow and stopped repeatedly. This led to a higher rate of mechanical failure. Issues
such as unstable speed, uncontrollable spinning, braking problems, and belt tension issues were
common. Additionally, cable wear and fractures occurred. Nowadays, the majority of CT
machines use slip ring technology for smooth one-way rotation, and some high-end machines
even incorporate magnetic drive technology, significantly reducing breakdowns in rotating
machinery. However, slip rings introduce their own set of faults, as prolonged friction can result
in poor contact and trigger mechanical and electrical failures such as uncontrolled spinning,
high-pressure control, ignition (in the case of high slip rings), and loss of control signals (in the
case of slip ring transmission). Regular maintenance and replacement of slip rings is essential.
Other components, like X-ray collimators, are also prone to mechanical failures such as getting
stuck or going out of control, while fans may fail after long-term operation. The pulse generator
responsible for motor rotation control signals may experience wear or damage, leading to pulse
loss phenomena.
b. X-ray component-generated faults
X-ray CT machine production control relies on several components including high-frequency

inverters, high-voltage transformers, X-ray tubes, control circuits, and high-voltage cables.
Common faults include:
X-ray tube failures: These include rotating anode failure, manifested by loud rotating noise, and
serious cases where switching becomes impossible or the anode gets stuck, resulting in
overcurrent when exposed. Filament failures can cause no radiation. Glass core leakage leads to
rupture or leakage, preventing exposure and causing vacuum drop and high-voltage ignition.
High-voltage generation failures: Faults in the inverter circuit, breakdowns, short-circuits in the
high-voltage transformer, and ignition or breakdown of high-voltage capacitors often cause the
corresponding fuse to blow. Exposure becomes impossible or is automatically interrupted due to
protection.
High-voltage cable faults: Common issues include loose connectors causing ignition,
overvoltage, or high voltage. In early CT machines, prolonged use can lead to wear and tear on
high-voltage ignition cables, resulting in internal short-circuits. These failures usually correspond
to a blown fuse.
c. Computer-related faults
Failures in the computer part of CT machines are relatively rare and usually easy to repair. They
mainly involve minor issues with components such as keyboards, mice, trackballs, etc. However,
failures in hard disks, tape drives, and magneto-optical devices can occur as a result of prolonged
use, with an increase in bad zones leading to total damage.
For more information about CT machines and the use of high-voltage ceramic capacitors in X-
ray equipment, please visit www.hv-caps.com.
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CT Machine Failure Investigations: Root

Causes & Repair Solutions

A. Basic structure of CT scanner

After years of development, CT scanners have undergone significant improvements, including an

1）X-ray detector gantry

Two classifications, sources, and characteristics of CT machine faults

1）Failures caused by environmental factors

2）Faults caused by human error and improper operation

3) Hardware failures and damage within the CT system

a. Mechanical part failures

The following major faults are mainly discussed:

b. X-ray component-generated faults

X-ray CT machine production control relies on several components including high-frequency

Phone: +86 13689553728

Add: 9B2, TianXiang Building, Tianan Cyber Park , Futian, Shenzhen, P. R. C

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