Inspection device for automatically determining the condition of a machine component and method for automatically inspecting a machine component.

Abstract

Apparatus and method for automatically inspecting machine components. This is an inspection apparatus (100) that allows automatically determining the state of a machine component in service (900) through a plurality of inspection phases; the apparatus (100) includes: a computer unit (120), a 3D scanner (130), a plurality of inspection sensors (141, 142, 143) to perform a plurality of inspection phases on the component (900); the computer unit (120) interacts with the scanner (130) and the sensors (141, 142, 143) to generate an annotated 3D model of the component (900); the computer unit (120) is configured to perform simulation on the machine component (900) to determine the state of one or more regions of the machine component (900);In addition, the computer unit (120) may be fitted with a verification mechanism to apply one or more criteria (122, 124) to the simulation results, and automatically determine whether the component (900) is operational and / or repairable and generate a status report accordingly.

Description

1 / 23 Inspection device for automatically determining the condition of a machine component and method for automatically inspecting a machine component. DESCRIPTION TECHNICAL FIELD

[0001] The subject matter disclosed here relates to apparatus and methods for automatically inspecting components, particularly after a period of machine operation, i.e., so-called maintenance parts. BACKGROUND OF THE TECHNIQUE

[0002] The components of a machine, for example, machines for the oil and gas industry (in particular, turbomachinery), may need to be checked after the machine has operated for some time in order to prevent failures and machine downtime – typically, these checks are repeated periodically. This applies especially to components that are subject to wear and / or breakage, which may be due, for example, to high temperature, high pressure, high mechanical stress, corrosion, erosion.

[0003] To perform some types of verification, it may be necessary to completely or partially disassemble a machine so that the component (or components) can be removed and subjected to inspection.

[0004] The result of such an operation may be: the component is in good condition, that is, operational and can be mounted on the machine again as is; the component is not operational and needs to be repaired (in some way) before being mounted on the machine again; the component is neither operational nor repairable and a new component needs to be mounted on the machine.

[0005] Systems are known for performing specific inspection phases. For example, US patent document 2017 / 0176342 A1 discloses a system for inspecting turbine blades; a computer can Petition 870260036283, dated 04 / 17 / 2026, page 14 / 75 2 / 23 Compare the differences between inputs from a scanner and a predetermined ideal blade surface with predetermined limits; the computer can create a report describing the predicted changes in efficiency or performance that may occur after searching for a recommended blade surface repair (corresponding to the difference between actual efficiency or performance and ideal efficiency or performance). Additionally, software systems are known, for example, from US documents 2007 / 217672 A1 and US 2014 / 207419 A1, to assist a human inspector in visually inspecting a machine component by constructing an annotated 3D model of the component and presenting this model to the inspector on a computer screen; as usual, the point-by-point assessment of the component's condition is manual and is based on the inspector's training and experience.

[0006] However, the overall inspection and evaluation procedure is still essentially manual, even though some specific inspection phases can be automated. SUMMARY

[0007] Therefore, it would be desirable to improve the inspection procedure, in particular, to offer an inspection procedure for machine components that is carried out automatically. It should be understood that in the present invention the term component should be interpreted broadly as including any part of a machine that may be subject to inspection after machine operation; the solutions described herein are most advantageously used for mechanical objects.

[0008] According to a first aspect, the subject matter disclosed here relates to an inspection apparatus that allows the automatic determination of the state of a machine component in service through a plurality of inspection phases; the apparatus includes: a unit of Petition 870260036283, dated 04 / 17 / 2026, p. 15 / 75 3 / 23 A computer, a 3D scanner, and multiple inspection sensors are used to perform multiple inspection phases on the component; the computer unit interacts with the scanner and sensors to generate an annotated 3D model of the component. The computer unit is configured to perform a simulation on the machine component to determine the state of one or more regions of the machine component. Additionally, the computer unit may be equipped with a verification mechanism that applies one or more criteria to the simulation results and automatically determines whether the component is operational and / or repairable. Based on this determination, the computer unit can issue a status report to a user of the inspection device; for example, the status report can be provided through a user interface of the computer unit and / or stored in the computer unit's memory for future use.

[0009] According to a second aspect, the subject matter disclosed in the present invention relates to a method for inspecting an operational machine component; the method includes an initial phase and then one or more different inspection phases; during the initial phase, a scan of the component is performed and a 3D model of the component is created; the inspection phases allow the creation of an annotated 3D model of the component. Furthermore, the method may include a final phase during which a simulation is performed in order to determine the state of one or more regions of the machine component and then one or more criteria are applied to the simulation results to determine whether the component is usable and / or repairable. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A fuller understanding of the disclosed embodiments of the invention and many of the advantages associated therewith will be readily obtained as a better understanding is gained by reference to the following detailed description, when considered in connection with Petition 870260036283, dated 04 / 17 / 2026, page 16 / 75 4 / 23 the attached drawings.

[0011] Figure 1 shows a very general schematic diagram of an inspection apparatus.

[0012] Figure 2 shows a schematic diagram of a first embodiment of an inspection apparatus.

[0013] Figure 3 shows a schematic diagram of a second type of inspection device.

[0014] Figure 4 shows a flowchart of one version of an inspection method. DETAILED DESCRIPTION OF THE MODALITIES

[0015] An innovative inspection device allows for the automatic determination of the condition of a machine component in service, for example, whether the component is worn or broken, through a plurality of inspection phases performed one after the other. The device includes a scanner and a plurality of sensors that are controlled by a computer in order to automatically create a computerized representation of the component (obtained from the scanner) with associated information (obtained from the sensors) regarding the condition of the various parts of the component; in this way, an annotated 3D model of the component can be generated. This annotated 3D model is easy to process automatically by computers.This annotated 3D model of the component can be used, for example, to determine if the component is operational and / or repairable by performing, for example, a mechanical or thermal simulation on the component and then automatically applying one or more criteria to the simulation results; in this way, a general assessment of the mechanical or thermal state of the component (as is) is possible even under machine operating conditions, but while the component is disassembled from the machine.

[0016] Reference will now be made in detail to the modalities of Petition 870260036283, dated 04 / 17 / 2026, page 17 / 75 5 / 23 revelations that are illustrated in the drawings. The modalities are provided by way of explanation of the revelation, not as a limitation thereof. Indeed, it will be evident to those skilled in the art that various modifications and variations may be made to the present revelation without departing from the scope or spirit of the revelation.

[0017] The innovative inspection apparatus is useful for determining the condition of a machine component (which may be called a machine part) that has already been used in a machine for some time during the machine's operation, i.e., a so-called service part. This condition may refer, for example, to any deformation of the component (e.g., change in overall shape and / or change in overall size) and / or any change in a surface geometry (e.g., local loss of material, e.g., due to erosion or corrosion, or local deposition of material, e.g., total or partial obstruction of a hole), and / or any change in a surface layer or a subsurface layer (e.g., reduction in the thickness of a protective layer or a surface or deep crack), and / or a change in a component core and corresponding effect(s) on the mechanical condition (e.g., shear stress, tensile stress,The torsion, and / or thermal state (e.g., temperature), and / or chemical state (e.g., oxidation) of one or more regions of the component, particularly when the component is under machine operating conditions; it should be noted that other states may be considered, for example, electrical state, magnetic state, optical state, electromagnetic state. The first component inspected and then evaluated was previously disassembled from a machine.

[0018] In Figure 1, Figure 2 and Figure 3, the mechanical component 900 to be inspected is schematically shown and is, for example, and without limitation, a turbine blade including a base portion. Petition 870260036283, dated 04 / 17 / 2026, page 18 / 75 6 / 23 and a portion of the airfoil. It should be understood that innovative apparatus and methods, according to the present disclosure, may be used to inspect other parts of the machine, for example, the so-called gas turbine hot gas path parts (HGPP) and the so-called combustion parts (CC).

[0019] According to these embodiments, a component 900 is, at one time, introduced into an inspection chamber 111 of a container 110 before being inspected; the container 110 has walls and an opening, which typically has a door 112, to access the inspection chamber 111 and introduce the component 900. The container 110 may be the same as or similar to a cargo container and may be transportable in order to allow inspection of machine components directly where the machine is installed, for example, in an oil and gas processing plant. It should be noted that, according to some embodiments, it is possible to avoid the container.

[0020] Figure 1 schematically shows an inspection apparatus 100 which includes at least one computer unit 120, a 3D scanner 130, a plurality of inspection sensors 141, 142, 143, and an industrial robot 160 with an articulated arm. The computer unit 120 may include, among other things, a processor or a controller or a microprocessor or similar (not shown), a data memory (not shown), a program memory (not shown), a user interface 126 for users, which are schematically shown as 90 in Figure 1. As shown in the figure, all these elements may be housed in the container 110. As shown in the figure, the computer unit 120 may be electrically coupled to an external computer system 190 via a wired and / or wireless connection including, for example, the Internet or another computer network.The large arrows emanating from unit 120 in the figure indicate the possibility that computer unit 120... Petition 870260036283, dated 04 / 17 / 2026, page 19 / 75 7 / 23 control, for example, scanner 130, inspection sensors 141, 142, 143, and industrial robot 160, but includes the possibility that the computer unit 120 receives data and / or information from them, in particular, from the scanner and the inspection sensors. It should be noted that even if the scanner is shown in the figures as a separate device distinct from the inspection sensors, according to some embodiments the scanner may correspond to an optical inspection sensor configured to move relative to the machine component; there are three possibilities: 1) only the sensor makes absolute movements, 2) only the component makes absolute movements, 3) both the sensor and the component make absolute movements.Next, when referring to the functions performed by the inspection device essentially through a program or programs, which may be software or firmware, stored in the program memory of the computer unit, the expression provided for will be used.

[0021] Figure 1 shows three inspection sensors 141, 142, 143, which are different from each other (i.e., represented by the different shapes of their symbols); however, it is possible to consider a different number, the minimum number being one, but the typical number being greater than one. Any of these sensors could be, for example: - an optical sensor, in particular, a white light interferometry sensor or laser sensor, - a borescope sensor, - an electromagnetic wave sensor, in particular, a microwave probe sensor, - an inductive sensor, in particular, an eddy current sensor, - an induction or infrared thermographic sensor, - an ultrasonic sensor, - a fluorescence sensor, in particular, a sensor of Petition 870260036283, dated 04 / 17 / 2026, page 20 / 75 8 / 23 X-ray fluorescence; For example, sensor 141 could be a borescope sensor for assessing, for example, the integrity of cavities (e.g., holes), sensor 142 could be a thermographic sensor for assessing, for example, the integrity of thermal barriers, sensor 143 could be an eddy current sensor for assessing, for example, the integrity of a surface and / or a subsurface layer from a mechanical point of view (e.g., the presence of cracks or voids).

[0022] In general, an innovative inspection device (such as, for example, device 100 in Figure 1) comprises: - a computer unit (such as unit 120 in Figure 1), - a scanner (such as, for example, the 3D scanner 130 in Figure 1, which can be laser or white light) configured to scan a machine component (such as, for example, component 900 in Figure 1) the computer unit is coupled to the scanner and is arranged to create a 3D model of the component based on the component scan, and - a plurality of inspection sensors (such as, for example, sensors 141, 142, 143 in Figure 1) configured to perform a corresponding plurality of inspection phases on the component - the computer unit is configured to be coupled to each of the inspection sensors, typically one after the other, and is arranged to create an annotated 3D model of the component based on the 3D model of the component and data received from the inspection sensors.

[0023] For example, considering Figure 1, the operation could be as follows: - Computer unit 120 can connect to and control scanner 130, receive scan data, and create a 3D model of the component. Petition 870260036283, dated 04 / 17 / 2026, page 21 / 75 9 / 23 based on scan data - typically, scan data is received during relative movements between parts of the scanner and the component, then - Computer unit 120 can connect to and control the first sensor 141, receive initial detection data, generate initial inspection information from the initial detection data, and associate the initial inspection information with the current 3D model of the component, so as to create a 3D model of the component with initial annotations added (e.g., diameters and depth at each hole of the component) - typically, the initial detection data is received while relative movements occur between parts of the first sensor and the component, then - Computer unit 120 can connect to and control the second sensor 142, receive second detection data, generate second inspection information from the second detection data, and associate the second inspection information with the current 3D model of the component, so as to create a 3D model of the component with added second annotations (e.g., thermal barrier quality at each point where there is a thermal barrier on the component surface) - typically, the second detection data is received without substantial movement between parts of the second sensor and the component, so - Computer unit 120 can connect to and control the third sensor 143, receive third-party detection data, generate third-party inspection information from the third-party detection data, and associate the third-party inspection information with the current 3D model of the component, in order to create a 3D model of the component with added third-party annotations (e.g., missing subsurface material at each point on the component's surface) - typically, the third-party detection data is received Petition 870260036283, dated 04 / 17 / 2026, page 22 / 75 10 / 23 while relative movements occur between the parts of the third sensor and the component.

[0024] Therefore, considering Figure 1, the resulting annotated 3D model of the component can contain the precise external shape of the component under inspection, as well as three types of annotations associated with the various positions of the component; then, this annotated 3D model is easy to be processed automatically by computers.

[0025] The computer unit (such as unit 120 in Figure 1) of the innovative inspection apparatus is configured to receive and / or retrieve a design model of the machine component to be evaluated (such as component 900 in Figure 1). The design model is retrieved if it is stored on a memory device, such as a hard disk, from the computer unit, and is received if it is stored on a memory device, such as a hard disk, from a different and remote computer system. The design model is used to obtain detailed information regarding the machine component (e.g., ideal surface geometry and / or internal structure and / or materials and manufacturing steps and / or treatments and / or operating conditions and / or relationships with other machine components).Retrieval and reception may require that the machine component be previously identified based, for example, on input received from a user.

[0026] The computer unit (such as, for example, unit 120 in Figure 1) of the innovative inspection apparatus is configured to perform, for example, a mechanical, thermal or chemical simulation on the machine component (such as, for example, component 900 in Figure 1) in order to determine, for example, a mechanical state (e.g., shear stress, tensile stress, torsion), or a thermal state (e.g., temperature), or a chemical state (e.g., oxidation) of one or more Petition 870260036283, dated 04 / 17 / 2026, page 23 / 75 11 / 23 regions of the machine component. This simulation takes into account the created 3D model of the machine component (e.g., the actual surface geometry of the entire component), inspection data generated from at least one inspection phase (e.g., actual non-visible features of the component), and the received and / or retrieved design model of the machine component (e.g., ideal surface geometry and / or internal structure and / or materials and manufacturing steps and / or treatments and / or operating conditions and / or relationships with other machine components). Preferably, this simulation is performed under the machine's operating conditions if the simulation results are influenced by these conditions.

[0027] The computer unit (such as, for example, unit 120 in Figure 1) of the innovative inspection apparatus comprises a verification mechanism, which is typically one or more pieces of firmware and / or software to which configuration data can be supplied and / or which can be stored, for example, in the program memory of the computer unit; the configuration data may include one or more operability criteria (see, for example, box 122 in Figure 1), and / or one or more repairability criteria (see, for example, box 124 in Figure 1), and / or may be stored, for example, in the data memory of the computer unit.

[0028] The verification mechanism can be arranged to apply one or more criteria to the simulation results and, based on the application of these criteria, determine whether the machine component is operational. It is expected that such operationality criteria will be determined by the designer / manufacturer of the machine and its components; however, the machine user (e.g., the manufacturer's customer) can contribute at least to some of the operationality criteria. The operationality criteria (shown, for example, as 122 in Figure 1) can be Petition 870260036283, dated 04 / 17 / 2026, page 24 / 75 12 / 23 stored in the computer unit at the time of machine manufacture and / or at the time of machine installation; according to some embodiments, they may be changed after installation. The verification mechanism may be arranged to generate a machine component status report for a user (example shown as 90 in Figure 1) based, for example, on the determination of operability. A status report that includes operability data may be issued via a user interface (shown, for example, as 126 in Figure 1) of the computer unit, for example, its screen, and / or be stored in a memory of the computer unit for future use.

[0029] Alternatively or additionally, the verification mechanism may be arranged to apply one or more criteria to the simulation results and, based on the application of these criteria, determine whether the machine component can be repaired. It is expected that such repairability criteria will be determined by the designer / manufacturer of the machine and its components; however, the machine user (e.g., the manufacturer's customer) may contribute at least to some of the repairability criteria. The repairability criteria (shown, for example, as 124 in Figure 1) may be stored in the computer unit at the time of machine manufacture, and / or at the time of machine installation; according to some embodiments, they may be changed after installation.The verification mechanism can be arranged to generate a machine component status report for a user (example shown as 90 in Figure 1) based, for example, on repairability determination. A status report that includes repairability data can be issued through a user interface (shown, for example, as 126 in Figure 1) of the computer unit, for example, its screen, and / or be stored in a memory of the unit. Petition 870260036283, dated 04 / 17 / 2026, page 25 / 75 13 / 23 computer unit for future use.

[0030] It should be noted that, according to the prior art, inspection information is evaluated (manually) point by point and compared with reference information. For example, if a lack of thermal insulation coating is detected at a first point on a component surface, its size is compared with two limit values, and the component is considered operational, repairable, or disposable depending on such comparisons; then, if a lack of thermal insulation coating is detected at a second point on the component surface, the same procedure is repeated. However, according to the prior art, the overall effect of the various thermal insulation losses is not considered.Conversely, as revealed here, by means of (automatic) simulation of the temperature distribution of the machine component (i.e., the actual component as scanned and inspected with all its losses), preferably under machine operating conditions, it is possible (automatically) to consider, for example, the effects of all thermal insulation coating losses, and the simulated temperature at one or more points of the components can be (automatically) compared with, for example, two limit values ​​(which may be different from point to point).

[0031] As is evident from Figure 1, the functions of the verification mechanism can be divided in various ways between the internal computer unit (e.g., unit 120) and the external computer system (e.g., system 190), depending on the embodiment. Therefore, according to some embodiments, the internal computer unit is arranged to create an annotated 3D model of the component and transmit it to the external computer system, and the external computer system is arranged to receive an annotated 3D model, to perform simulations and to apply one or more criteria – alternatively, the 3D model Petition 870260036283, dated 04 / 17 / 2026, page 26 / 75 14 / 23 noted can be shared between the internal computer unit and the external computer system; in this way, the operational and / or repairability result data can derive from cooperation between the internal computer unit and the external computer system. The external computer system can be considered part of an innovative inspection apparatus.

[0032] Typically, the computer unit (such as, for example, unit 120 in Figure 1) may be arranged to identify the specific component to be inspected (e.g., turbine blade part no., for example, SMH48303) or a category of component to be inspected (e.g., blade for high-power turbines); in fact, the inspection phases to be performed and / or the sequence of phases and / or the criteria to be applied should be expected to depend on either or both. This identification may be based on input received by the device from a user (see, for example, 90 in Figure 1); for example, before introducing a component into the inspection compartment of the device, an operator may enter a corresponding code via a keyboard (see, for example, 126 in Figure 1) of the computer unit.This identification can be based on input received by a code reader designed to read a code marked on the component to be inspected. This identification can also be based on scanning and automatically recognizing the component to be inspected.

[0033] The computer unit (such as unit 120 in Figure 1) can be arranged to receive and / or retrieve a design model of the component to be inspected. For example, with reference to Figure 1, unit 120 can communicate with system 190 and obtain the design model from a design database that stores models of components from various different machines, as they were originally designed. Petition 870260036283, dated 04 / 17 / 2026, page 27 / 75 15 / 23 designed by design engineers. It should be noted that the term design model should not be interpreted as limited to the shape of the component, but may include other characteristics such as tolerances and / or materials and / or manufacturing treatments and / or testing procedures and / or inspection procedures; for example, model-based engineering (MBE) is an engineering approach that uses models as an integral part of the technical baseline that includes the requirements, analysis, design, implementation and verification of a feature, system and / or product throughout the acquisition lifecycle.

[0034] The computer unit (such as unit 120 in Figure 1) can be arranged to correlate the 3D model of the component derived from its scan in the inspection apparatus with its design model. For example, by comparing (which is a form of correlation) the 3D model with the design model, it is possible to determine any deformation in the component that has occurred due to its use in the machine. It is possible that the inspection phases to be performed and / or the sequence of phases and / or the criteria to be applied depend on the design model of the component to be inspected.

[0035] The computer unit (such as unit 120 in Figure 1) can be arranged to apply criteria based on a simulation performed on the specific component to be inspected. The simulation can be performed by the internal computer unit or by an external computer system that provides the simulation results to the internal computer unit. The simulation may consist of evaluating the durability of the specific component to be inspected in terms of oxidation, or creep, or LCF, or HCF, or crack propagation life, or FMEA, based on analytical and / or statistical models.

[0036] It should be noted that one or more of the criteria may be Petition 870260036283, dated 04 / 17 / 2026, page 28 / 75 16 / 23 based on the duration and / or operating condition of the machine component to be accessed. For example, if a component has been used for several years, it should be expected that the thickness of any of its coatings will be reduced from its design value or that the sealing of any of its gaskets will be reduced from its design value. These changes may depend not only on the operating time but also on the operating conditions.

[0037] It should be noted that one or more of the criteria may be a multiple criterion; for example, such a criterion may correspond to the combination (e.g., a logical combination) of a first check on inspection information from a first inspection phase, and a second check on inspection information from a second inspection phase.

[0038] Advantageously, some or all of the inspection sensors among the plurality of inspection sensors are of the non-contact type, that is, the sensor does not need to touch the surface of the component to be inspected; in any case, touching the surface can be accepted (even if it is not necessary) so that the positioning of the sensor requires less precision. It should not be excluded that one or more of the inspection sensors may be of the contact type; however, in this case, not only may some precision in positioning be necessary, but also some control over the pressure applied to the surface of the component.

[0039] Typically, the plurality of inspection sensors comprises at least one inspection sensor for inspecting a surface geometry, and at least one inspection sensor for inspecting a surface layer or a subsurface layer. It should not be excluded that the plurality of inspection sensors may comprise at least one inspection sensor for inspecting a component core, i.e., portions of the internal volume. Petition 870260036283, dated 04 / 17 / 2026, page 29 / 75 17 / 23

[0040] Figure 2 and Figure 3 refer, respectively, to a first embodiment 200 of an innovative inspection apparatus, and to a second embodiment 300 of an innovative inspection apparatus. However, before going into such details, an inspection method will be described with the aid of the flowchart 400 in Figure 4 and the block diagram in Figure 1.

[0041] The method is useful for inspecting components after a period of machine operation, such as component 900 in Figure 1, (although one could also use it to inspect new components), and comprises an initial phase 401 (which may be called the modeling phase), then one or more different inspection phases 402 (considering Figure 1, three inspection phases should be performed, typically one after the other) and then a final phase 403 (which may be called the verification phase). It should be noted that the method can be performed near or far from the machine where the component has been used. Furthermore, it should be noted that the final phase 403 can be performed well after the inspection phase and in a different location from where the inspected component is.Finally, it should be noted that the final phase 403 may be performed by an apparatus different from the inspection apparatus that performed the initial phase 401 and the inspection phases 402; such inspection apparatus may be identical or similar to the inspection apparatuses disclosed herein and may comprise a computer unit.

[0042] According to the modality in Figure 4, the initial phase 401 comprises the following steps: A) Scanning (block 410) of the machine component disassembled from the machine, B) Create (block 420) a 3D model of the machine component based on the scan of the machine component. C) Identify (block 430) the machine component or a Petition 870260036283, dated 04 / 17 / 2026, page 30 / 75 18 / 23 machine component category based on input received from a user, and D) receive and / or retrieve (block 440) a machine component design model.

[0043] Considering Figure 1, the initial phase 401 is essentially executed through unit 120 and scanner 130; robot 160 can also contribute.

[0044] According to the modality in Figure 4, the initial phase 402 comprises the following steps: E) Inspect (block 450) the machine component using at least one inspection sensor, F) generate (block 460) inspection information based on at least one inspection step, and G) Associate (block 470) the inspection information with the 3D model of the machine component in order to create an annotated 3D model of the machine component - as explained earlier, typically, the 3D model is annotated incrementally based on inspection information from various inspection phases.

[0045] Considering Figure 1, an inspection phase 402 is essentially performed through unit 120, robot 160, and any of the sensors 141, 142, and 143.

[0046] According to the modality in Figure 4, the final phase 403 comprises the following steps: I) To perform (block 475), for example, a mechanical or thermal simulation or thermal simulation on the machine component in order to determine, for example, a mechanical, thermal or chemical state of one or more Petition 870260036283, dated 04 / 17 / 2026, page 31 / 75 19 / 23 regions of the machine component, taking into account the created 3D model of the machine component, inspection data generated from at least one inspection step, and the design model received and / or retrieved from the machine component; H) Apply (block 480) one or more criteria to the results, for example, of mechanical, thermal or chemical simulation, performed in order to determine whether the machine component is useful, and / or L) Apply (block 490) one or more criteria to the results of, for example, mechanical, thermal or chemical simulation performed, in order to determine whether the machine component is repairable.

[0047] Considering Figure 1, the final phase 403 is essentially executed through unit 120 and / or system 190 based on inspection criteria 122 and / or 124; according to the embodiment of Figure 1, all criteria are stored in unit 120. The determination of whether it is operational and / or the determination of whether it is repairable can be used to issue a status report with operationality data and / or repairability data, for example, in the form of a list of various inspection results; the status report can be issued to a user, for example, by the computer unit, in particular its display, and / or stored, for example, in a memory of the computer unit and then possibly all or part of the status report can be transferred to an external computer system.It should be noted that, according to some modalities, the status report may contain only a selection of operational data and / or repairability data, for example, only positive inspection results or only negative inspection results.

[0048] Preferably and advantageously, the simulation performed in stage I is carried out under machine operating conditions. Furthermore, Petition 870260036283, dated 04 / 17 / 2026, page 32 / 75 20 / 23 advantageously, at least one of the criteria in step H and / or L may be based on a duration and / or condition of the machine's operating period; finally, at least one of the criteria in step H and / or L may be a multiple criterion, where a multiple criterion is based on at least two inspection steps.

[0049] A first embodiment 200 of an innovative inspection apparatus will be described below with the aid of Figure 2. It should be noted that elements 210, 211, 212, 220, 230, 241, 242, 243, 260 and 290 in Figure 2 may be identical or similar, respectively, to elements 110 (container), 111 (inspection room), 112 (door), 120 (internal computer unit), 130 (scanner), 141 (first inspection sensor), 142 (second inspection sensor), 143 (third inspection sensor), 160 (robot), 162 (articulated arm) and 190 (external computer system) in Figure 1, and perform the same or similar functions.

[0050] Apparatus 200 of Figure 2 comprises a support element 250, in particular, a table, for supporting the component 900 to be inspected. The support element 250 may comprise an accessory 252 dedicated to the component to be inspected; for example, in Figure 2, the base portion of the turbine blade fits perfectly between, for example, four fixed members 252 of the support element 250. The support element 250 may be rotatable and / or tiltable.

[0051] The support element 250 may be rotatable and / or tiltable. If the support element 250 is movable, the computer unit 220 may be arranged to control the movement of the support element 250. If the support element 250 is movable, it may contribute to the scanning of component 900; for example, scanning may occur during the rotation and / or tilting of the support element 250, and the corresponding rotation and / or tilting of the supported component 900. Petition 870260036283, dated 04 / 17 / 2026, page 33 / 75 21 / 23

[0052] The apparatus 200 of Figure 2 comprises at least one industrial robot 260 with an articulated arm 262, preferably a five-axis or six-axis articulated arm; the articulated arm 262 is configured to carry an inspection sensor, and the computer unit 220 is arranged to control the movement of the articulated arm 262. The robot 260 may also contribute to scanning the component 900; for example, the arm 262 may carry an optical sensor and may move around the component 900 in order to scan it; in this case, the scanner 230 may correspond to an optical sensor to be carried by the robot's articulated arm. According to preferred embodiments, the apparatus has only one robot to inspect the component. According to preferred embodiments, the apparatus has only one robot to repair the component.

[0053] Typically, the articulated arm 262 is configured to alternately carry two or more inspection sensors, and the computer unit 220 is arranged to control the change of sensor carried by the arm; in Figure 2, the dashed lines connecting the sensors and the end of the arm member schematically show actions to select a sensor from its rest position, perform an inspection on the component, and return the sensor to its rest position.

[0054] Computer unit 220 is arranged to move an inspection sensor along an inspection path (which may depend on the component and the sensor).

[0055] A second embodiment 300 of an innovative inspection apparatus will be described below, with the aid of Figure 3. It should be noted that elements 310, 311, 312, 320, 330, 341, 342, 343, 360 and 390 in Figure 3 may be identical or similar, respectively, to elements 110 (container), 111 (inspection room), 112 (door), 120 (internal computer unit), 130 (scanner), 141 (first inspection sensor), 142 (second sensor). Petition 870260036283, dated 04 / 17 / 2026, page 34 / 75 22 / 23 (inspection), 143 (third inspection sensor), 160 (robot), 162 (articulated arm) and 190 (external computer system) in Figure 1, and perform equal or similar functions.

[0056] The apparatus 300 of Figure 3 comprises at least one industrial robot 360 with an articulated arm 362, preferably a five-axis or six-axis articulated arm; the articulated arm 362 is configured to transport the component 900 to be inspected, and the computer unit 320 is arranged to control the movement of the articulated arm 362. The articulated arm 362 may comprise an attachment 350 dedicated to the component to be inspected; for example, in Figure 3, the base portion of the turbine blade fits perfectly between, for example, four fixed members 352 of the attachment 350. In this way, the industrial robot, in particular the articulated arm, can be configured to hold, move and / or manipulate the machine component.

[0057] The articulated arm 362 can be arranged to transport (in a fixed or mobile manner) the machine component 900 to be inspected when the scanner 330 scans the component.

[0058] According to the embodiment in Figure 3, some or all of the inspection sensors 341, 342, 343 are fixedly mounted on a frame or structure of the apparatus 300 in different positions (in Figure 3, the representation is, for example, near a wall of the container 310).

[0059] According to the embodiment in Figure 3, the computer unit 320 is arranged to move the machine component 900 to be inspected along an inspection path. It should be noted that a first portion of the inspection path may be the movement of the component close to an inspection sensor, a second portion of the inspection path (which may depend on the component and the sensor) may be the movement of the component within a zone of the inspection sensor. Petition 870260036283, dated 04 / 17 / 2026, page 35 / 75 23 / 23 while the sensor is active, in order to perform the desired inspection, a third portion of the inspection path may be the movement of the component away from the inspection sensor. In Figure 3, the dashed lines connecting the sensors and the accessory schematically show the various first and third portions of the inspection paths for inspection sensors 341, 342, 343.

[0060] The essential difference between the first mode in Figure 2 and the second mode in Figure 3 is that, during the inspection phases, according to the first mode, the component is fixed (separated from possible rotation and / or inclination of the support element) and the sensors move, while according to the second mode, the sensors are fixed and the component moves. It is evident that other modes may correspond to a combination of these two alternatives.

[0061] In light of the above, it is evident that the innovative device and method disclosed herein provide inspection possibilities far beyond those provided by devices and methods according to the prior art, especially those intended to assist human inspectors. According to the prior art, the results of the inspections were compared directly with the reference data. Petition 870260036283, dated 04 / 17 / 2026, p. 36 / 75

Claims

1 / 6 CLAIMS 1. INSPECTION APPARATUS (100) FOR AUTOMATICALLY DETERMINING THE STATE OF A MACHINE COMPONENT (900) after a period of machine operation based on a plurality of inspection phases, the machine component (900) having already been used in a machine, the apparatus (100) comprising: - a computer unit (120), - a scanner (130) configured to analyze the machine component (900) disassembled from the machine, the computer unit (120) being coupled to the scanner (130) and arranged to create a 3D model of the machine component (900) based on the scanning of the machine component (900), - a plurality of inspection sensors (141, 142, 143) configured to perform a corresponding plurality of inspection phases on the machine component (900), the computer unit (120) is configured to be coupled to each of the inspection sensors (141, 142,143) and is arranged to generate inspection information from each of the inspection phases and correspondingly associate the inspection information with the 3D model of the machine component (900) in order to create an annotated 3D model of the machine component (900); characterized by the computer unit (120) being configured to receive and / or retrieve a design model of the machine component (900); wherein the computer unit (120) is configured to execute a simulation on the machine component (900) in order to determine the state of one or more regions of the machine component (900), taking into account the created 3D model of the machine component (900), inspection data generated from at least one inspection phase, and the design model received and / or retrieved of the machine component (900),wherein the computer unit (120) comprises a verification mechanism that includes one or more operational criteria (122) based on the design model received and / or retrieved from the machine component (900) and the simulation performed, wherein the verification mechanism is arranged to: - apply the one or more operational criteria to the simulation results, - determine whether the machine component (900) is operational based on the application of operability criteria, and - generate a status report of the machine component (900) for a user (90) based on the determination that it is operational.

2. INSPECTION APPARATUS (900), according to claim 1, characterized in that the verification mechanism includes one or more repairable criteria (124), and is further arranged to: - apply the one or more repairable criteria to the simulation results, - determine whether the machine component (900) is repairable based on the application of repairable criteria; wherein the status report of the machine component (900) is also based on the repairable determination.

3. INSPECTION APPARATUS (100), according to claim 1, characterized in that the computer unit (120) is configured to perform a mechanical, thermal or chemical simulation on the machine component (900) in order to determine a mechanical, thermal or chemical state of one or more regions of the machine component (900).

4. INSPECTION APPARATUS (100), according to claim 1, characterized in that at least one of the criteria (122, 124) is predetermined and associated with the machine component (900) or a category of the machine component (900).

5. INSPECTION APPARATUS (100), according to claim 1, characterized in that at least one of the criteria (122, 124) is based on a design model of the machine component (900); or in that at least one of the criteria (122, 124) is based on a duration and / or a condition of the machine's operating period; or in that at least one of the criteria (122, 124) is a multiple criterion, wherein a multiple criterion is based on at least two inspection phases.

6. INSPECTION APPARATUS (100), according to claim 1, characterized in that the computer unit (120) is arranged to determine a sequence of inspection phases based on the machine component (900) or on a category of machine component (900).

7. INSPECTION APPARATUS (100), according to claim 1, characterized in that the computer unit (120) is arranged to identify the machine component (900) and / or a category of machine component (900) based on input received from a user (90) of the inspection apparatus (100).

8. INSPECTION APPARATUS (100), according to claim 1, characterized in that the simulation is carried out under machine operating conditions.

9. INSPECTION APPARATUS (100), according to claim 1, characterized in that the computer unit (120) is arranged to correlate the 3D model of the machine component (900) with the design model of the machine component (900).

10. INSPECTION APPARATUS (100), according to claim 1, characterized in that some or all of the inspection sensors Petition 870260036283, dated 04 / 17 / 2026, page 39 / 75 4 / 6 among the plurality of inspection sensors (141, 142, 143) are of the non-contact type and / or of the contact type.

11. INSPECTION APPARATUS (100), according to claim 1, characterized in that the plurality of inspection sensors (141, 142, 143) comprise: - at least one inspection sensor for inspecting a surface geometry of the machine component (900), and - at least one inspection sensor configured to inspect a surface layer or a subsurface layer or a core of the machine component (900).

12. INSPECTION APPARATUS (200), according to claim 1, characterized by further comprising: - a support element (250) configured to support the machine component (900) to be inspected, and - at least one industrial robot (260) with an articulated arm (262), preferably a five-axis or six-axis articulated arm, wherein the support element (250) is preferably rotatable and / or tiltable; wherein the articulated arm (262) is configured to carry inspection sensors; wherein the computer unit (220) is arranged to control the support element (250) and / or the articulated arm (262).

13. INSPECTION APPARATUS (300), according to claim 1, characterized by further comprising: - at least one industrial robot (360) with an articulated arm (362), preferably a five-axis or six-axis articulated arm, configured to hold, move and / or manipulate the machine component Petition 870260036283, dated 17 / 04 / 2026, page 40 / 75 5 / 6 (900) to be inspected; wherein the computer unit (320) is arranged to control the articulated arm (362); wherein some or all of the inspection sensors, among the plurality of inspection sensors (341, 342, 343), are fixed to a frame or structure of the inspection apparatus (300) in different positions.

14. INSPECTION APPARATUS (100), according to claim 1, characterized by further comprising: - a container (110); wherein the container (110) houses at least the computer unit (120), the scanner (130), the plurality of inspection sensors (141, 142, 143) and, preferably, at least one industrial robot (160) with an articulated arm; wherein the container (110) has an opening (112) through which the machine component (900) to be inspected is introduced into an inspection room (111); wherein the container (110) is preferably configured to be transportable.

15. METHOD FOR AUTOMATICALLY INSPECTING A MACHINE COMPONENT after a period of machine operation by means of an inspection apparatus (100), comprising a computer unit (120), a computer unit (120) including inspection criteria (122, 124), the method being characterized by comprising an initial phase (401), then one or more different inspection phases (402), and after that, a final phase (403); the initial phase (401) comprising the steps of: A) performing a scan (410) of the machine component Petition 870260036283, dated 17 / 04 / 2026, page 41 / 75 6 / 6 disassembled from the machine, B) creating (420) a 3D model of the machine component based on the scan of the machine component, D) receiving and / or retrieving (block 440) a design model of the machine component;wherein an inspection phase (402) comprises the steps of: E) inspecting (450) the machine component using at least one inspection sensor, F) generating (460) inspection information based on at least one inspection step, G) associating (470) the inspection information with the 3D model of the machine component, in order to create an annotated 3D model of the machine component; wherein the final phase (403) comprises the steps of: I) performing (475) a simulation on the machine component in order to determine the state of one or more regions of the machine component (900), taking into account the created 3D model of the machine component, inspection data generated from at least one inspection step, and the design model received and / or retrieved from the machine component;H) apply (480) one or more operational criteria (122) based on the design model received and / or recovered from the machine component (900) and the simulation performed to the simulation results performed in order to determine whether the machine component is operational. Petition 870260036283, dated 17 / 04 / 2026, page 42 / 75;

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