A device and method for auxiliary distance measurement of blade and body ultrasonic detection of gas turbine compressor

Abstract

The present invention discloses an auxiliary distance measurement device and method for ultrasonic detection of gas turbine compressor blades and blade body, including an ultrasonic detection module, a distance measurement module, an encoder, a data processing module and an alarm. The method steps are: (1) installing an encoder and a distance measurement sensor; (2) connecting the ultrasonic detector, the distance measurement module and the encoder to the data processing module; (3) starting detection, observing the waveform, and paying attention to the alarm; (4) judging whether to alarm based on the sound range of the echo signal in the ultrasonic detector and the straight-line distance from the front end of the probe of the distance measurement sensor to the blade root platform; (5) comprehensively judging whether it is a crack defect based on the alarm situation. The present invention can accurately and real-time assist in distinguishing whether the echo signal is a chamfer echo of the blade root platform or a crack defect echo at the chamfer of the blade body and the root when inspecting the compressor blade, avoiding missed detection and misjudgment of crack defects at the chamfer, ensuring the reliability and accuracy of the detection results, and providing technical guarantee for the safe and stable operation of the unit.

Description

Technical Field

[0001] The invention belongs to the technical field of ultrasonic non-destructive testing, and in particular is an auxiliary distance measuring device and method for ultrasonic testing of blades and blade bodies of a gas engine compressor. Background Art

[0002] Compressor blades are one of the core components of gas turbines. They must withstand complex cyclic stresses during service, and are prone to crack defects in typical parts of the blade body (such as near the outlet edge, the rounded part between the blade body and the root, the middle of the back arc surface, the blade top, etc.), which seriously affect the safe and stable operation of the unit. Therefore, the judgment of the quality and health status of compressor blades in service requires careful and effective testing to provide a technical reference. At present, fluorescent penetration or ultrasonic testing methods are generally used to detect compressor blades. Fluorescent penetration has high requirements on the cleanliness of the blade body surface, there are many interference factors in the detection, and it can only detect cracks with a larger surface opening width. Ultrasonic testing has the advantages of strong adaptability on site, high accuracy of test results, and good repeatability. It is the preferred and reliable method for compressor blade and blade body testing. Generally, ultrasonic surface wave probes or large-angle shear wave oblique probes are used for compressor blade body testing. However, when this method is used, the ultrasonic probe is oriented toward the blade root and slides from the air inlet side to the air outlet side to perform blade body testing. The inherent echo of the blade root platform chamfer always exists. The echo sound path is close to the crack defect echo sound path of the blade body and the blade root chamfer, which is generally only about 3mm-10mm. When an echo appears in this area, the only way to determine whether the echo is a platform chamfer echo or a crack echo at the blade body chamfer is to check whether the echo display sound path is greater than the straight-line distance from the front end of the probe to the blade root platform. If it is greater, it is a platform chamfer echo. If it is less than, it may be a crack defect echo. However, since the distance between the probe and the blade root platform changes at any time during manual scanning, on-site inspections are generally carried out by controlling the scanning path to be a straight line and empirically judging the echo to be the platform chamfer echo or the crack echo at the rounded part. It is very easy to confuse the two, resulting in missed detection or misjudgment of crack defects at the rounded part of the blade body and blade root. The rounded part is a high-incidence area for crack defects. How to achieve accurate, effective and rapid detection of crack defects at the rounded part of the blade body and blade root has become the focus of current gas turbine operation and maintenance technology researchers and developers. Summary of the invention

[0003] The purpose of the present invention is to provide a gas turbine compressor blade and blade body ultrasonic detection auxiliary ranging device and method to address the limitation that the platform chamfer echo is easily confused with the crack defect echo at the chamfer of the blade body and the blade root during the current gas turbine compressor blade and blade body ultrasonic detection, resulting in missed detection or misjudgment of crack defects in this area, affecting the reliability and accuracy of the detection results. The device and method are simple and easy to operate, and can perform accurate, efficient and reliable detection of crack defects at the chamfer of the blade body and the blade root of the compressor blade during temporary shutdown or maintenance of the unit, providing technical guarantee for the safe and stable operation of the unit.

[0004] The present invention is achieved by adopting the following technical solutions:

[0005] An auxiliary distance measuring device for ultrasonic detection of blades and blade body of a gas turbine compressor, comprising an ultrasonic detection module, a distance measuring module, an encoder, a data processing module and an alarm;

[0006] The ultrasonic detection module includes an ultrasonic probe, an ultrasonic detector and a bracket; the distance measurement module includes a distance measurement sensor; the encoder includes a magnetic wheel, a support arm, a spring and a nut;

[0007] The ultrasonic probe is connected to the bracket, the ultrasonic probe is connected to the ultrasonic detector, the ranging sensor is connected to the bracket, the magnetic wheel is movably connected to the bottom of the support arm, the spring is sleeved in the support arm, the top of the support arm is passed through the bracket, and the nut is tightened on the top of the support arm; the ultrasonic detector, the ranging sensor, the encoder and the alarm are respectively connected to the data processing module.

[0008] A further improvement of the present invention is that the ultrasonic probe is connected to the ultrasonic detector via a first connecting line, and the ultrasonic detector, ranging sensor, encoder and alarm are connected to the data processing module via a second connecting line, a third connecting line, a fourth connecting line and a fifth connecting line respectively.

[0009] A further improvement of the present invention is that the ultrasonic probe is a surface wave probe or a large-angle oblique probe.

[0010] A further improvement of the present invention is that the encoder is a single magnetic wheel encoder.

[0011] A further improvement of the present invention is that the distance measuring sensor is a laser distance measuring sensor or an infrared distance measuring sensor, and the measurement accuracy is within 1 mm.

[0012] A further improvement of the present invention is that the bracket is an "X"-shaped structure.

[0013] A further improvement of the present invention is that the data processing module has the functions of generating sound wave path, generating ranging distance, comparing, and storing abnormal signals.

[0014] A further improvement of the present invention is that the abnormal signal storage function includes storage of abnormal signal waveform and probe position information.

[0015] A further improvement of the present invention is that the alarm has light flashing alarm and sound alarm functions.

[0016] A method for assisting distance measurement of blades and airframes of a gas turbine compressor by ultrasonic detection, the method is based on the aforementioned device for assisting distance measurement of blades and airframes of a gas turbine compressor by ultrasonic detection, and comprises the following steps:

[0017] Step 1: Install the encoder and the distance sensor on the bracket, and install the bracket on the ultrasonic probe;

[0018] Step 2: Connect the ultrasonic probe to the ultrasonic detector, and connect the ultrasonic detector, ranging sensor, and encoder to the data processing module;

[0019] Step 3: Start the test, add a proper amount of coupling agent, point the front end of the ultrasonic probe toward the blade root, slide along the air inlet side to the air outlet side, observe the ultrasonic detector screen and determine the echo waveform of the blade area, and always pay attention to the flashing light and sound alarm of the alarm;

[0020] Step 4: The data processing module synchronously collects the acoustic path of the echo signal in the ultrasonic detector, the straight-line distance from the front end of the probe of the distance sensor to the blade root platform, and the sliding distance of the probe in the encoder on the blade surface. If the acoustic path of the echo signal in the ultrasonic detector is greater than the straight-line distance of the sensor, no alarm will be given; if the acoustic path of the echo signal in the ultrasonic detector is less than the straight-line distance of the sensor, an alarm will be given and the stroke position information of the probe will be stored;

[0021] Step 5: If an alarm occurs, the probe stops scanning and analyzes the specific location of the echo signal. It then determines whether the echo signal is a crack defect signal from multiple angles, combining the waveform amplitude and blade surface condition.

[0022] The present invention has at least the following beneficial technical effects:

[0023] The present invention provides a gas turbine compressor blade and blade body ultrasonic detection auxiliary ranging device and method. The device and method are simple and easy to operate, and can accurately and real-time assist in distinguishing whether an echo signal is a blade root platform chamfer echo or a crack defect echo at the chamfer of the blade body and the root when the compressor blade is detected during temporary shutdown or overhaul of the unit, thereby avoiding missed detection and misjudgment of crack defects at the chamfer, ensuring the reliability and accuracy of the detection results, and providing technical guarantee for the safe and stable operation of the unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 The present invention is a schematic diagram of an auxiliary distance measurement device and method for ultrasonic detection of blades and blade bodies of a gas turbine compressor.

[0025] Figure 2 It is a front view of a sensor in a device and method for ultrasonic detection of blades and blade bodies of a gas turbine compressor according to the present invention.

[0026] Figure 3 It is a top view of a sensor in a gas engine compressor blade and body ultrasonic detection auxiliary ranging device and method according to the present invention.

[0027] Description of reference numerals:

[0028] 1. Ultrasonic detection module, 2. Distance measurement module, 3. Encoder, 4. Data processing module, 5. Alarm;

[0029] 101, ultrasonic probe, 102, ultrasonic detector, 103 bracket, 104 first connecting line, 105 second connecting line; 201, ranging sensor, 202, fixing stud, 203, fixing bolt, 204, third connecting line, 301, magnetic wheel, 302, support arm, 303, spring, 304, nut, 305, fourth connecting line, 501, fifth connecting line. DETAILED DESCRIPTION

[0030] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings.

[0031] Refer to the attached Figure 1 , Attachment Figure 2 and attached Figure 3 The present invention provides an auxiliary ranging device for ultrasonic detection of blades and blade body of a gas turbine compressor, comprising an ultrasonic detection module 1, a ranging module 2, an encoder 3, a data processing module 4, and an alarm 5.

[0032] The ultrasonic detection module 1 includes an ultrasonic probe 101, an ultrasonic detector 102, a bracket 103, a first connecting line 104 and a second connecting line 105; the ranging module 2 includes a ranging sensor 201, a fixing stud 202, a fixing bolt 203 and a third connecting line 204; the encoder 3 includes a magnetic wheel 301, a support arm 302, a spring 303, a nut 304 and a fourth connecting line 305; the data processing module 4 includes a sound wave path generation function, a ranging distance generation function, a comparison function, and an abnormal signal storage function; the alarm 5 includes a light flashing alarm and a sound alarm.

[0033] Among them, the ultrasonic probe 101 is connected to the bracket 103 through a fixing stud 202, the ultrasonic probe 101 is connected to the ultrasonic detector 102 through a first connecting line 104, the ranging sensor 201 is connected to the bracket 103 through a fixing bolt 203, the magnetic wheel 301 is movably connected to the bottom of the support arm 302, the spring 303 is sleeved in the support arm 302, the top of the support arm 302 is passed through the bracket 103, and the nut 304 is tightened on the top of the support arm 302; the ultrasonic detector 102, the ranging sensor 201, the encoder 3 and the alarm 5 are respectively connected to the data processing module 4 through the second connecting line 105, the third connecting line 204, the fourth connecting line 305 and the fifth connecting line 501.

[0034] The present invention provides a method for assisting distance measurement of a blade body of a gas turbine compressor by ultrasonic detection, comprising the following steps:

[0035] Step 1: Install the encoder 3 and the distance sensor 201 on the bracket 103, and install the bracket 103 on the ultrasonic probe 101;

[0036] Step 2: Connect the ultrasonic probe 101 to the ultrasonic detector 102, and connect the ultrasonic detector 102, the distance measuring sensor 201, and the encoder 3 to the data processing module 4;

[0037] Step 3: Start the detection, add a proper amount of coupling agent and place the ultrasonic probe 101 on the surface of the blade body, with the front end of the ultrasonic probe 101 facing the blade root, slide along the air inlet side to the air outlet side, observe the screen of the ultrasonic detector 102 and determine the echo waveform of the blade body area, and always pay attention to the flashing light and sound alarm of the alarm 5.

[0038] Step 4: The data processing module 4 synchronously collects the acoustic range of the echo signal in the ultrasonic detector 102, the straight-line distance from the front end of the probe of the distance measuring sensor 201 to the blade root platform, and the sliding distance of the probe in the encoder 3 on the blade surface. The gate in the ultrasonic detector 102 is set to cover all the detected acoustic range, and the acoustic range of the echo signal in the gate is automatically transmitted to the data processing module 4. If the acoustic range of the echo signal in the ultrasonic detector 102 is greater than the straight-line distance of the sensor 201, no alarm will be given. If the acoustic range of the echo signal in the ultrasonic detector 102 is less than the straight-line distance of the sensor 201, an alarm will be given, and the stroke position information of the probe 101 will be stored;

[0039] Step 5: If an alarm occurs, the probe 101 stops scanning and analyzes the specific position of the echo signal, combining the waveform amplitude, blade surface state, etc., and can use penetration testing, magnetic particle testing and other multi-angle methods to determine whether the echo signal is a crack defect signal.

[0040] The ultrasonic probe 101 is a surface wave probe or a large-angle oblique probe, and the encoder 3 is a single magnetic wheel encoder. The magnetic wheel design can ensure that the encoder fits tightly with the blade body to prevent position deviation caused by wheel slippage or non-rotation.

[0041] The distance measuring sensor 201 is a laser distance measuring sensor or an infrared distance measuring sensor, and the measurement accuracy is within 1 mm, which can meet the requirements for accurately distinguishing the chamfer echo of the blade root platform and the crack defects at the rounded part.

[0042] The bracket 103 is an "X"-shaped structure, the fixing stud 202 is a hexagonal stud, and the fixing bolt 203 is a hexagonal flat round head bolt. The hexagonal design can facilitate the rapid disassembly and assembly of the ultrasonic probe 101 and the ranging sensor 201 during on-site detection.

[0043] The abnormal signal storage function includes storing information such as abnormal signal waveform and probe position.

[0044] The alarm device 5 has both light flashing and sound alarm functions, and the dual alarm function can ensure that on-site inspection personnel can detect abnormal signal conditions in time.

[0045] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for assisting distance measurement of blade body of gas turbine compressor using ultrasonic detection. It is characterized in that The method is based on an auxiliary distance measurement device for ultrasonic detection of blades and blade bodies of a gas turbine compressor. The device comprises an ultrasonic detection module (1), a distance measurement module (2), an encoder (3), a data processing module (4) and an alarm (5); wherein the ultrasonic detection module (1) comprises an ultrasonic probe (101), an ultrasonic detector (102) and a bracket (103); the distance measurement module (2) comprises a distance measurement sensor (201); the encoder (3) comprises a magnetic wheel (301), a support arm (302), a spring (303) and a nut (304); the ultrasonic probe (101) and the bracket (103) are connected to each other. The ultrasonic probe (101) is connected to the ultrasonic detector (102), the distance sensor (201) is connected to the bracket (103), the magnetic wheel (301) is movably connected to the bottom of the support arm (302), the spring (303) is sleeved in the support arm (302), the top of the support arm (302) is inserted into the bracket (103), and the nut (304) is screwed on the top of the support arm (302); the ultrasonic detector (102), the distance sensor (201), the encoder (3) and the alarm (5) are respectively connected to the data processing module (4); The method comprises the following steps: The first step is to install the encoder (3) and the distance measuring sensor (201) on the bracket (103), and install the bracket (103) on the ultrasonic probe (101); Step 2: Connecting the ultrasonic probe (101) to the ultrasonic detector (102), and connecting the ultrasonic detector (102), the distance measuring sensor (201), and the encoder (3) to the data processing module (4); Step 3: Start the test, add an appropriate amount of coupling agent, point the front end of the ultrasonic probe (101) toward the blade root, slide along the air inlet side to the air outlet side, observe the screen of the ultrasonic detector (102) and determine the echo waveform of the blade body area, and always pay attention to the flashing light and sound alarm of the alarm (5); Step 4: The data processing module (4) synchronously collects the acoustic path of the echo signal in the ultrasonic detector (102), the linear distance from the front end of the probe of the distance measuring sensor (201) to the blade root platform, and the sliding distance of the probe in the encoder (3) on the blade surface. If the acoustic path of the echo signal in the ultrasonic detector (102) is greater than the linear distance of the sensor (201), no alarm is issued; if the acoustic path of the echo signal in the ultrasonic detector (102) is less than the linear distance of the sensor (201), an alarm is issued, and the stroke position information of the probe (101) is stored; Step 5: If an alarm occurs, the probe (101) stops scanning, analyzes the specific position of the echo signal, and determines from multiple angles whether the echo signal is a crack defect signal in combination with the waveform amplitude and the blade surface state.

2. According to claim 1, a method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades, It is characterized in that The ultrasonic probe (101) is connected to the ultrasonic detector (102) via a first connection line (104); the ultrasonic detector (102), the distance measuring sensor (201), the encoder (3) and the alarm (5) are connected to the data processing module (4) via a second connection line (105), a third connection line (204), a fourth connection line (305) and a fifth connection line (501), respectively.

3. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 1, It is characterized in that The ultrasonic probe (101) is a surface wave probe or a large-angle oblique probe.

4. The method for assisting distance measurement of blade body ultrasonic detection of a gas turbine compressor blade according to claim 1, It is characterized in that The encoder (3) is a single magnetic wheel encoder.

5. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 1, It is characterized in that The distance measuring sensor (201) is a laser distance measuring sensor or an infrared distance measuring sensor, and has a measurement accuracy within 1 mm.

6. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 1, It is characterized in that The support (103) is an "X"-shaped structure.

7. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 1, It is characterized in that The data processing module (4) has the functions of generating sound wave path, generating ranging distance, comparing, and storing abnormal signals.

8. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 7, It is characterized in that The abnormal signal storage function includes abnormal signal waveform and probe position information storage.

9. The method for assisting distance measurement of blade body ultrasonic detection of gas turbine compressor blades according to claim 1, It is characterized in that The alarm (5) has light flashing alarm and sound alarm functions.

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