Aero-engine support plate blade in-situ eddy current detection device

Abstract

The invention relates to the technical field of aero-engine nondestructive testing, and discloses an aero-engine support plate blade in-situ eddy current testing device and a testing method thereof, and the aero-engine support plate blade in-situ eddy current testing device comprises a handle, a telescopic probe rod and a testing end. The detection end is rotationally connected with the telescopic probe rod and comprises an adjusting swing block, a supporting end base, a clamping and positioning assembly and a transmission detection mechanism. The clamping and positioning assembly adopts a V-shaped fork block design, and can adapt to the shape and thickness of the blade for clamping, so that the detection end and the blade are kept stable. The transmission detection mechanism is composed of a miniature lead screw, a linear guide rail, an anti-backlash gear set and a servo motor and drives the detection probe assembly to accurately move along the surface of the blade. The detection probe adopts a leaf spring to support a flexible array eddy current sensor, and self-adaptive adjustment can be realized to ensure that the detection surface is tightly attached to the curved surface of the blade. The invention provides a device and a method capable of realizing rapid, full-area and high-sensitivity in-situ eddy current detection on a support plate blade under the condition that an engine is not disassembled and adaptive to air inlet space constraint.

Description

Technical Field

[0001] This invention relates to the field of non-destructive testing technology for aero-engines, and in particular to an in-situ eddy current testing device for aero-engine support blades. Background Technology

[0002] The guide vanes (also known as inlet guide vanes) behind the air intake and in front of the fan / low-pressure compressor of an aero-engine are critical components for both structural support and airflow rectification. Their structural integrity directly affects the aerodynamic performance and operational safety of the engine. These blades operate under extreme environments of high pressure, high-frequency vibration, and aerodynamic loads for extended periods, making them highly susceptible to defects such as fatigue cracks and corrosion damage. If these defects are not detected in time, they may lead to blade breakage or even serious malfunctions such as engine failure.

[0003] In practical engineering applications, eddy current testing is currently the most effective non-destructive testing method for defects such as fatigue cracks in aero-engine support blades. While detachable testing can obtain more comprehensive test data, it requires disassembling part of the engine structure, which is not only time-consuming and labor-intensive but may also affect the overall performance and condition of the engine. Therefore, in-situ testing (without disassembly) is usually required in practical applications. However, in-situ eddy current testing of aero-engine support blades faces two major challenges: one is that the narrow and long air intake (up to 2 meters) prevents traditional manual eddy current testing probes from effectively reaching the blade location due to insufficient length and rigidity; the other is that traditional eddy current testing probes need to move and scan in multiple directions on the blade surface to cover the test area. This process is highly dependent on the operator's skills and experience, and there is a risk of missed detections due to operator fatigue. Moreover, manual testing is extremely inefficient. Therefore, how to overcome the spatial limitations of the narrow (2-meter-level) air intake without disassembling the engine and achieve rapid and highly sensitive in-situ eddy current testing of aero-engine support blades is a key technical challenge that urgently needs to be overcome in the field of in-service aero-engine testing. Summary of the Invention

[0004] To address the above problems, this invention provides an in-situ eddy current detection device for aero-engine support blades, which is implemented as follows:

[0005] An in-situ eddy current detection device for aero-engine support blades includes:

[0006] Handle 1;

[0007] Telescopic probe 2, one end of which is connected to the handle 1;

[0008] Turntable bearing assembly 3, connected to the other end of the telescopic probe 2, includes:

[0009] The upper connecting plate 31 and the lower connecting plate 32 are connected by a rotating shaft, and the edge of the lower connecting plate 32 is provided with an annular groove.

[0010] An axial bearing 33 is disposed between the upper connecting plate 31 and the lower connecting plate 32, and is fixedly connected to the telescopic probe 2;

[0011] A spring pin is located at the end of the telescopic probe 2 and cooperates with the annular groove to achieve angular positioning.

[0012] The detection end 4, through the turntable bearing assembly 3, achieves a 180° horizontal rotation relative to the telescopic probe 2, including:

[0013] Adjust the swing block 41, which is fixedly connected to the lower connecting plate 32;

[0014] The support end seat 42 is integrally formed with the adjusting swing block 41;

[0015] A pair of symmetrical positioning plates 43 extend from both ends of the support end seat 42;

[0016] V-shaped positioning fork block 44 is provided at the end of the positioning plate 43. The opening and closing angle of the V-shaped positioning fork block 44 can be adjusted according to the support plate blades of different thicknesses.

[0017] The transmission assembly 45 is disposed between the two side walls of the positioning plate 43 and includes: a miniature lead screw 451, a linear guide rail 452, a backlash-free gear set 453, a miniature servo motor 454 with an encoder, and a slider 455. The miniature lead screw 451 is connected to the miniature servo motor 454 through the backlash-free gear set 453.

[0018] The detection probe assembly 46 includes: a housing 461, a limiting block 462, a spring sheet 463, and a flexible array eddy current detection sensor 464;

[0019] The housing 461 is detachably mounted on the slider of the transmission assembly 45. The limiting block 462 is integrally formed with the front end of the housing 461. The spring sheet 463 is fixedly disposed at the bottom of the limiting block 462. The flexible array eddy current detection sensor is attached to the detection surface of the spring sheet 463.

[0020] The spring sheet 463 is configured to provide constant contact pressure during the detection process, and the flexible array eddy current detection sensor 464 maintains adaptive contact with the surface to be tested through the spring sheet 463.

[0021] Furthermore, the annular slot has 24 positioning recesses evenly distributed along its circumference to achieve multi-position positioning with 15° increments; the spring pin is electromagnetically driven and includes a position feedback sensor.

[0022] Furthermore, the V-shaped positioning fork block 44 is detachably mounted at the end of the positioning plate 43. The V-shaped positioning fork block 44 and the positioning plate 43 are respectively provided with matching conical positioning holes and conical positioning pins, and the V-shaped positioning fork block is assembled through the pin hole cooperation.

[0023] Furthermore, the mating surfaces of the V-shaped positioning fork block 44 and the positioning plate 43 are respectively provided with mutually cooperating magnetic plates and electromagnets for electromagnetic locking.

[0024] Furthermore, the V-shaped positioning fork block 44 adopts a spring-loaded opening structure, which can adapt to the clamping and positioning of blades of different thicknesses.

[0025] Furthermore, the detection probe assembly 46 also includes: selectively integrating any of the following positioning units: laser positioning or video positioning, to identify and determine the area to be tested.

[0026] Furthermore, it also includes a heat protection and anti-static brush. The heat protection cover is a silicone layer with a temperature resistance of 300°C, which covers the detection surface of the flexible array eddy current detection sensor 464.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] This invention proposes a device and method for rapid, full-area, high-precision in-situ eddy current detection of support blades without disassembling the engine, adapting to the spatial constraints of the air intake. Specifically:

[0029] I. This invention, through innovative mechanical structure design, effectively solves the spatial limitation problem of in-situ inspection of aero-engine support blades. The device can flexibly adjust its angle and extension distance within narrow air intake channels, achieving a depth and adaptability unattainable by traditional rigid structures. Employing a highly integrated and compact design, the components work collaboratively through precise mechanical connections, minimizing the overall volume while ensuring structural strength, perfectly adapting to the complex internal space environment of aero-engines.

[0030] Second, this invention enables precise positioning and stable contact during the detection process, and the detection probe can perform accurate scanning along a preset path. The sensor can adaptively conform to complex curved surfaces, solving the detection error problem caused by poor contact between traditional rigid sensors and the blade surface.

[0031] Third, in-situ testing capabilities eliminate the cumbersome process of engine disassembly required by traditional methods, increasing testing efficiency several times over. The modular design facilitates the replacement and maintenance of critical components, reduces operating costs, and meets the dual requirements of testing quality and efficiency in the aviation maintenance field, demonstrating significant engineering application value. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the present invention or the prior art, or to provide a simple description of the drawings used in the prior art, it is obvious that those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0033] Figure 1 This is a schematic diagram of the detection process in this embodiment.

[0034] Figure 2 This is a schematic diagram of the detection device in this embodiment (the detection end is perpendicular to the telescopic probe at 90°).

[0035] Figure 3 This is a schematic diagram of the detection device in another state in this embodiment (the detection end is parallel to the telescopic probe).

[0036] Figure 4 for Figure 3 A magnified schematic diagram of the structure of region A in the middle.

[0037] Figure 5 This is a schematic diagram of the detection end.

[0038] Handle -1;

[0039] Telescopic probe-2

[0040] Turntable bearing assembly-3, upper connecting plate-31, lower connecting plate-32, axial bearing-33;

[0041] Detection end-4, Adjustment block-41, Support end seat-42, Positioning plate-43, V-shaped positioning fork block-44, Transmission assembly-45, Miniature lead screw-451, Linear guide rod-452, Backlash-free gear set-453, Servo motor-454, Slider-455;

[0042] Detection probe assembly-46, housing-461, limiting block-462, spring sheet-463, flexible array eddy current detection sensor-464;

[0043] Support plate blade -5. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0045] The in-situ detection device for aero-engine support plate blades of the present invention mainly consists of three parts: a hand handle, a multi-angle adjustment structure, and a precision detection structure. Specifically, it includes: a handle 1, a telescopic probe 2, a turntable bearing assembly 3, and a detection end 4 connected in sequence.

[0046] The telescopic probe 2 adopts a multi-sleeve structure, and each telescopic segment is positioned by a spring locking mechanism. The maximum extension can be set according to the detection conditions. In other embodiments, the telescopic probe 2 may also adopt other automatic telescopic structures.

[0047] Turntable bearing assembly 3 includes:

[0048] The upper connecting plate 31 and the lower connecting plate 32 are connected by a rotating shaft, and the edge of the lower connecting plate 32 is provided with an annular groove.

[0049] An axial bearing 33 is disposed between the upper connecting plate 31 and the lower connecting plate 32, and is fixedly connected to the telescopic probe 2;

[0050] A spring pin is located at the end of the telescopic probe 2 and cooperates with the annular groove to achieve angular positioning.

[0051] The turntable bearing assembly features a flattened design, with the overall thickness adjusted according to the specific workpiece. This reduces the structural volume while maintaining radial load capacity. The main load is borne by axial bearings and upper and lower connecting discs, while spring pins and slots enable flexible angular deflection and stable positioning. The compact design and dual positioning mechanism ensure load-bearing performance while achieving an ultra-thin modular design at the inspection end, improving operational stability and positioning accuracy in confined, long-distance inspection conditions.

[0052] The detection end 4, through the turntable bearing assembly 3, achieves a 180° horizontal rotation relative to the telescopic probe 2, including:

[0053] The adjusting block 41 is fixedly connected to the lower connecting plate 32. This connection can be mechanical, such as using high-strength bolts or conical locating pins; or it can employ special connection processes, such as laser micro-welding or electron beam bonding. Bolt connection is preferred to ensure rigidity while facilitating maintenance.

[0054] The support end base 42 is integrally formed with the adjusting swing block 41 by 3D printing.

[0055] A pair of symmetrical positioning plates 43 extend from both ends of the support end seat 42 and are used to mount the transmission assembly 45.

[0056] A V-shaped positioning fork block 44 is disposed at the end of the positioning plate 43. The opening angle of the V-shaped positioning fork block 44 can be adjusted to accommodate support plate blades 5 of different thicknesses, ensuring that the relative position between the detection end and the support plate blade remains fixed, facilitating the temperature operation of subsequent transmission components and detection probe components. In this embodiment, the V-shaped inclined surface of the V-shaped positioning fork block is made of protective material to prevent wear on the blades.

[0057] The transmission assembly 45 is disposed between the two side walls of the positioning plate 43 and includes: a miniature lead screw 451, a linear guide rail 452, a backlash-free gear set 453, a miniature servo motor 454 with an encoder, and a slider 455. The miniature lead screw 451 is connected to the miniature servo motor 454 through the backlash-free gear set 453.

[0058] The transmission system can be intelligently linked with the scanning detection of the detection probe assembly. In conjunction with the positioning fork block, it enables the feasibility of mobile scanning detection under long-distance working conditions, improving detection efficiency and accuracy. Through the mobile detection of precision instruments, it can fully cover the area to be tested and prevent missed detections.

[0059] The detection probe assembly 46 includes: a housing 461, a limiting block 462, a spring sheet 463, and a flexible array eddy current detection sensor 464;

[0060] The housing 461 is detachably mounted on the slider of the transmission assembly 45. The limiting block 462 is integrally formed with the front end of the housing 461. The spring plate 463 is fixedly disposed at the bottom of the limiting block 462. The flexible array eddy current detection sensor is attached to the detection surface of the spring plate 463. The multi-module detachable design improves the maintenance efficiency of the device. The flexible array eddy current detection sensor is supported by the spring plate, enabling it to adaptively conform to complex curved surfaces and overcome lift-off.

[0061] The spring sheet 463 is configured to provide constant contact pressure during the detection process, and the flexible array eddy current detection sensor 464 maintains adaptive contact with the surface to be tested through the spring sheet 463.

[0062] Furthermore, the annular slot has 24 positioning recesses evenly distributed along its circumference to achieve multi-position positioning with 15° increments; the spring pin is electromagnetically driven and includes a position feedback sensor.

[0063] In this embodiment, the V-shaped positioning fork block 44 is detachably mounted at the end of the positioning plate 43. The V-shaped positioning fork block 44 and the positioning plate 43 are respectively provided with matching tapered positioning holes and tapered positioning pins, which are used to assemble the V-shaped positioning fork block. Modular snap-fit ​​fasteners allow for quick replacement of the fork block.

[0064] Furthermore, the mating surfaces of the V-shaped positioning fork block 44 and the positioning plate 43 are respectively provided with mutually cooperating magnetic plates and electromagnets for electromagnetic locking.

[0065] Alternatively, the V-shaped positioning fork block 44 adopts a spring-loaded opening structure. In this embodiment, two opposing inclined blocks can be set and connected by a torsion spring. An initial clamping force can be set, which can adapt to clamping and positioning blades of different thicknesses. The two inclined surfaces can be designed with self-locking angles to ensure that the blades can be automatically centered after clamping.

[0066] Furthermore, the detection probe assembly 46 also includes: selectively integrating any of the following positioning units: laser positioning or video positioning, to identify and determine the area to be tested, guide the detection device to extend in, and perform visual verification at the same time.

[0067] Furthermore, it also includes a heat protection and anti-static brush. The heat protection cover is a silicone layer with a temperature resistance of 300°C, which covers the detection surface of the flexible array eddy current detection sensor 464.

[0068] The present invention also discloses a detection method using the detection device described above, the specific detection method comprising the following steps:

[0069] S1. Manual or electric operation, adjust the turntable bearing assembly 3 to make the detection end parallel to the telescopic probe, so as to pass through the complex stealth structure;

[0070] S2. Adjust the detection end and the telescopic probe to a 90° perpendicular position;

[0071] S3. The telescopic probe is advanced in a segmented manner, and the detection device is extended into the engine air intake to the blade of the support plate to be tested by using a laser locator or video positioning guidance.

[0072] S4. Move the detection end forward so that the V-shaped positioning block can hold the support plate blade, and start the micro servo motor 454 to drive the detection probe assembly 46 to move along the pre-linear guide rail to scan the blade surface.

[0073] S5. The detection signal collected by the detection probe assembly 46 is transmitted via wired or wireless means to the mobile terminal for processing and analysis.

[0074] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. An in-situ eddy current detection device for aero-engine support blades, characterized in that, include: Handle (1); Telescopic probe (2), one end of which is connected to the handle (1); A turntable bearing assembly (3), connected to the other end of the telescopic probe (2), includes: The upper connecting plate (31) and the lower connecting plate (32) are connected by a rotating shaft, and the edge of the lower connecting plate (32) is provided with an annular groove. An axial bearing (33) is disposed between the upper connecting plate (31) and the lower connecting plate (32) and is fixedly connected to the telescopic probe (2); A spring pin is provided at the end of the telescopic probe (2) and cooperates with the annular groove to achieve angular positioning; The detection end (4) achieves a 180° horizontal rotation relative to the telescopic probe (2) through the turntable bearing assembly (3), including: Adjust the swing block (41) and fix it to the lower connecting plate (32); The support end seat (42) and the adjusting swing block (41) are integrally formed; A pair of symmetrical positioning plates (43) extend from both ends of the support end seat (42); V-shaped positioning fork block (44) is provided at the end of the positioning plate (43). The opening and closing angle of the V-shaped positioning fork block (44) can be adjusted according to the support plate blades of different thicknesses. The transmission assembly (45) is disposed between the two side walls of the positioning plate (43) and includes: a miniature lead screw (451), a linear guide rail (452), a backlash-free gear set (453), a miniature servo motor (454) with an encoder, and a slider (455). The miniature lead screw (451) is connected to the miniature servo motor (454) through the backlash-free gear set (453). The detection probe assembly (46) includes: a housing (461), a limiting block (462), a spring sheet (463), and a flexible array eddy current detection sensor (464); The housing (461) is detachably mounted on the slider of the transmission assembly (45), the limiting block (462) is integrally formed with the front end of the housing (461), the spring sheet (463) is fixedly disposed at the bottom of the limiting block (462), and the flexible array eddy current detection sensor is attached to the detection surface of the spring sheet (463). The spring sheet (463) is configured to provide constant contact pressure during the detection process, and the flexible array eddy current detection sensor (464) maintains adaptive contact with the surface to be tested through the spring sheet (463).

2. The in-situ eddy current detection device for aero-engine support blades according to claim 1, characterized in that, The annular slot has 24 positioning recesses evenly distributed along its circumference, enabling multi-position positioning with 15° increments; the spring pin is electromagnetically driven and includes a position feedback sensor.

3. The in-situ testing device for aero-engine support blades according to claim 1, characterized in that, The V-shaped positioning fork block (44) is detachably mounted at the end of the positioning plate (43). The V-shaped positioning fork block (44) and the positioning plate (43) are respectively provided with matching conical positioning holes and conical positioning pins, and the V-shaped positioning fork block is assembled by the pin hole cooperation.

4. The in-situ eddy current detection device for aero-engine support blades according to claim 3, characterized in that, The V-shaped positioning fork block (44) and the positioning plate (43) are respectively provided with a magnetic guide plate and an electromagnet that cooperate with each other for electromagnetic locking.

5. The in-situ eddy current detection device for aero-engine support blades according to claim 1, characterized in that, The V-shaped positioning fork block (44) adopts a spring-loaded opening structure, which can adapt to the blades of different thicknesses for clamping and positioning.

6. The in-situ eddy current detection device for aero-engine support blades according to claim 1, characterized in that, The detection probe assembly (46) further includes: selectively integrating any of the following positioning units: laser positioning or video positioning, to identify and determine the area to be tested.

7. The in-situ eddy current detection device for aero-engine support blades according to claim 1, characterized in that, It also includes a heat shield and an anti-static brush. The heat shield is a silicone layer that is resistant to temperatures up to 300°C and covers the detection surface of the flexible array eddy current detection sensor (464).

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