Method and apparatus for inspecting an engine

Abstract

A computer-implemented method comprising: receiving data comprising two-dimensional data and three-dimensional data of a component of an engine; identifying a feature of the component using the two-dimensional data; determining coordinates of the feature in the two-dimensional data; determining coordinates of the feature in the three-dimensional data using: the determined coordinates of the feature in the two-dimensional data; and a predetermined transformation between coordinates in the two-dimensional data and coordinates in the three-dimensional data; and measuring a parameter of the feature of the component using the determined coordinates of the feature in the three-dimensional data.

Description

Technical Field

[0001] This disclosure relates to methods and apparatus for inspecting engines. Background Technology

[0002] Aircraft typically include one or more engines that provide propulsion thrust and / or electrical power. During operation, one or more engines may become damaged (e.g., due to relatively high operating temperatures or damage from foreign objects). Aircraft engines are usually inspected at regular intervals by human inspectors to determine the condition of internal components. If components are found to be in unacceptable condition, the engine is typically removed from the aircraft for repair. During such inspections, the aircraft is grounded and cannot be used for operation by the airline. Furthermore, the quality and duration of the inspection depend on the skill and experience of the inspector. Summary of the Invention

[0003] According to a first aspect, a computer-implemented method is provided, comprising: receiving data including two-dimensional data and three-dimensional data of engine components; using the two-dimensional data to identify features of the components; determining coordinates of the features in the two-dimensional data; determining the coordinates of the features in the three-dimensional data using: the determined coordinates of the features in the two-dimensional data; a predetermined transformation between the coordinates in the two-dimensional data and the coordinates in the three-dimensional data; and using the determined coordinates of the features in the three-dimensional data to measure parameters of the features of the components.

[0004] Before identifying the features of the component, the method may further include: using three-dimensional data to identify the features of the component; determining the coordinates in three-dimensional data of a first volume that defines the coordinates of the features; determining the coordinates of a first region in two-dimensional data corresponding to the first volume using the determined coordinates of the first volume in the three-dimensional data; and a predetermined transformation.

[0005] Using two-dimensional data to identify the features of a component may include using a subset of two-dimensional data corresponding to the first region.

[0006] Determining the coordinates in the three-dimensional data of the first volume may include using the following to identify the first volume in the three-dimensional data: features of the identified component; and a three-dimensional model of the component.

[0007] Before using three-dimensional data to identify the features of the component, the method may further include: using two-dimensional data of the component to identify a second region, which excludes predetermined components and / or predetermined sub-components of the engine within the two-dimensional data; using the following to determine the coordinates of a second volume in the three-dimensional data corresponding to the second region: the coordinates of the determined second region in the two-dimensional data; and a predetermined transformation.

[0008] Using three-dimensional data to identify the features of a component can include using a subset of three-dimensional data corresponding to a second volume to identify the features of the component.

[0009] The computer-implemented method may further include: controlling the storage of the measured parameters.

[0010] The engine can be associated with the aircraft, and the data can be generated during the first period in which the aircraft is not deployed for operation.

[0011] The computer-implemented method can be executed during a second time period in which the aircraft is released for operation.

[0012] Computer-implemented methods can be executed automatically in response to received data.

[0013] Computer-implemented methods can be executed without human intervention.

[0014] According to the second aspect, a computer program is provided that, when executed by a computer, causes the computer to perform the computer-implemented methods as described in any of the preceding paragraphs.

[0015] According to a third aspect, a non-transitory computer-readable storage medium is provided that includes computer-readable instructions, which, when executed by a computer, cause the computer to perform a computer-implemented method as described in any of the preceding paragraphs.

[0016] According to a fourth aspect, an apparatus is provided comprising: a controller configured to perform a computer-implemented method as described in any of the preceding paragraphs.

[0017] According to a fifth aspect, a method is provided comprising: inspecting an engine during a first time period to identify damage, the engine being associated with an aircraft; receiving three-dimensional data of one or more components of the engine, the three-dimensional data being generated during the first time period; determining during the first time period whether the identified damage exceeds a threshold; if the identified damage does not exceed the threshold, providing instructions to release the aircraft for operation during a second time period following the first time period; and inspecting the received three-dimensional data during the second time period to measure the damage.

[0018] The inspection of the received 3D data includes: using the 3D data to identify features of the component; determining the coordinates of the features in the 3D data; and using the determined coordinates of the features in the 3D data to measure the parameters of the features of the component.

[0019] The method may further include: receiving two-dimensional data of components including an engine, the two-dimensional data being generated during a first time period; and wherein examining the received three-dimensional data includes: using the two-dimensional data to identify features of the component; determining the coordinates of the features in the two-dimensional data; determining the coordinates of the features in the three-dimensional data using: the determined coordinates of the features in the two-dimensional data; a predetermined transformation between the coordinates in the two-dimensional data and the coordinates in the three-dimensional data; and using the determined coordinates of the features in the three-dimensional data to measure parameters of the features of the component.

[0020] Before using two-dimensional data to identify the features of a component, the method may further include: using three-dimensional data to identify the features of the component; determining the coordinates in three-dimensional data of a first volume that defines the coordinates of the features; determining the coordinates of a first region in two-dimensional data corresponding to the first volume using the determined coordinates of the first volume in the three-dimensional data; and a predetermined transformation.

[0021] Using two-dimensional data to identify the features of a component may include using a subset of two-dimensional data corresponding to the first region.

[0022] Determining the coordinates in the three-dimensional data of the first volume may include using the following to identify the first volume in the three-dimensional data: features of the identified component; and a three-dimensional model of the component.

[0023] Before using three-dimensional data to identify the features of the component, the method may further include: using two-dimensional data of the component to identify a second region, which excludes predetermined components and / or predetermined sub-components of the engine within the two-dimensional data; using the following to determine the coordinates of a second volume in the three-dimensional data corresponding to the second region: the coordinates of the determined second region in the two-dimensional data; and a predetermined transformation.

[0024] Using three-dimensional data to identify the features of a component can include using a subset of three-dimensional data corresponding to a second volume to identify the features of the component.

[0025] The method may further include: controlling the storage of the measured parameters.

[0026] The inspection of the received 3D data during the second time period can be performed by a computer.

[0027] The inspection of the received 3D data during the second time period can be performed automatically by the computer in response to the receipt of the 3D data.

[0028] The inspection of the received 3D data can be performed during a predetermined period of time from the time the aircraft is released for operation.

[0029] According to the sixth aspect, a computer program is provided that, when executed by a computer, causes the computer to perform the methods described in any of the preceding paragraphs.

[0030] According to a seventh aspect, a non-transitory computer-readable storage medium is provided that includes computer-readable instructions, which, when executed by a computer, cause the computer to perform the methods described in any of the preceding paragraphs.

[0031] According to the eighth aspect, an apparatus is provided, comprising: a controller configured to perform the methods described in any of the preceding paragraphs.

[0032] According to a ninth aspect, a method is provided comprising: inspecting an industrial system during a first time period to identify damage; receiving three-dimensional data of one or more components of the industrial system, the three-dimensional data being generated during the first time period; determining during the first time period whether the identified damage exceeds a threshold; if the identified damage does not exceed the threshold, providing instructions to enable the industrial system to operate during a second time period following the first time period; and inspecting the received three-dimensional data during the second time period to measure the damage.

[0033] According to a tenth aspect, a method is provided comprising: inspecting an engine during a first time period to identify damage, the engine being associated with an aircraft; receiving two-dimensional data of one or more components of the engine, the two-dimensional data being generated during the first time period; determining during the first time period whether the identified damage exceeds a threshold; if the identified damage does not exceed the threshold, providing instructions to release the aircraft for operation during a second time period following the first time period; and inspecting the received two-dimensional data during the second time period to measure the damage.

[0034] According to the eleventh aspect, a method is provided comprising: inspecting an industrial system (e.g., an engine) during a first time period to identify damage (the engine may or may not be associated with an aircraft); receiving data from one or more components of the industrial system, the data being generated during the first time period; determining during the first time period whether the identified damage exceeds a threshold; if the identified damage does not exceed the threshold, providing instructions to enable the industrial system to operate during a second time period following the first time period; and inspecting the received data during the second time period to measure the damage.

[0035] Those skilled in the art will understand that, except where mutually exclusive, features described in any of the foregoing aspects can be applied to any other aspect with necessary modifications. Furthermore, except where mutually exclusive, any feature described herein can be applied to any aspect and / or combined with any other feature described herein. Attached Figure Description

[0036] The embodiments will now be described by way of example only with reference to the accompanying drawings, in which:

[0037] Figure 1 The illustration shows schematic diagrams of equipment used for engine inspection according to various examples;

[0038] Figure 2 The illustration shows a cross-sectional side view of a gas turbine engine according to various examples;

[0039] Figure 3 The diagram shows... Figure 2 The diagram shows a close-up cross-sectional side view of the upstream section of a gas turbine engine.

[0040] Figure 4 The diagram shows... Figure 2 and Figure 3 The diagram shows a partial cross-sectional view of the gearbox of a gas turbine engine.

[0041] Figure 5 The diagram illustrates a flowchart of the first method for inspecting an engine;

[0042] Figure 6 The diagram illustrates the timeline of the first method for inspecting the engine;

[0043] Figure 7 The diagram illustrates the timeline of the second method for inspecting the engine;

[0044] Figure 8 The flowchart illustrates the third method for inspecting the engine;

[0045] Figure 9 The illustration shows a side view of a turbine blade according to the first example;

[0046] Figure 10 The illustration shows a side view of a turbine blade according to the second example;

[0047] Figure 11 The illustration shows a side view of a turbine blade according to the third example;

[0048] Figure 12 The flowchart illustrates the fourth method for inspecting the engine;

[0049] Figure 13 The flowchart illustrates the fifth method for inspecting the engine; and

[0050] Figure 14 The diagram illustrates the flowchart of the sixth method for inspecting the engine. Detailed Implementation

[0051] In the following description, the terms "connection" and "linkage" refer to operatively connecting and joining. It should be understood that any number of intermediate parts may exist between the mentioned features, including no intermediate parts.

[0052] Figure 1 The illustration shows a schematic diagram of an apparatus 10 for inspecting an engine 12 according to various examples. The apparatus 10 includes: a controller 14; a user input device 16; a display 18; and an inspection device 20 including a sensor 22.

[0053] In some examples, device 10 may be a module. As used herein, the term "module" refers to a device or apparatus in which one or more features are added at a later time, and may be added by another manufacturer or by an end user. For example, in the case where device 10 is a module, device 10 may include only controller 14, while the remaining features (such as user input device 16, display 18, inspection device 20, and sensor 22) may be added by another manufacturer or by an end user.

[0054] The controller 14, user input device 16, display 18, inspection device 20, and sensor 22 may be wirelessly connected to each other and may therefore include transceiver circuitry and one or more antennas. Alternatively or additionally, the controller 14, user input device 16, display 18, inspection device 20, and sensor 22 may be wiredly connected to each other and may therefore include interface circuitry (such as a Universal Serial Bus (USB) plug and socket).

[0055] Controller 14 may include any suitable circuitry to cause the events described herein and as follows Figure 5 , 8 The methods illustrated in 12, 13, and 14 are executed. Controller 14 may include: control circuitry; and / or processor circuitry; and / or at least one application-specific integrated circuit (ASIC); and / or at least one field-programmable gate array (FPGA); and / or a single-processor or multi-processor architecture; and / or a sequential / parallel architecture; and / or at least one programmable logic controller (PLC); and / or at least one microprocessor; and / or at least one microcontroller; and / or a central processing unit (CPU); and / or a graphics processing unit (GPU) to execute the methods.

[0056] In various examples, controller 14 may include at least one processor 24 and at least one memory 26. Memory 26 stores a computer program 28 comprising computer-readable instructions that, when read by processor 24, cause events described herein and as such. Figure 5 , 8The methods illustrated in 12, 13, and 14 are executed. Computer program 28 can be software or firmware, or a combination of software and firmware.

[0057] Controller 14 may be part of inspection device 20, an "edge" computer, or a remote computer (such as a high-performance computing cluster in the "cloud"). Alternatively, controller 14 may be distributed among multiple devices and locations. For example, controller 14 may be distributed between inspection device 20 and an "edge" computer, or it may be distributed between inspection device 20 and a high-performance computing cluster in the "cloud".

[0058] Processor 24 may include at least one microprocessor and may include a single-core processor, may include multiple processor cores (such as a dual-core processor or a quad-core processor), or may include multiple processors (at least one of which may include multiple processor cores).

[0059] Memory 26 can be any suitable non-transitory computer-readable storage medium, one or more data storage devices, and may include hard disks and / or solid-state storage (such as flash memory). Memory can be permanent, non-removable memory, or it can be removable memory (such as a Universal Serial Bus (USB) flash drive or a Secure Digital Card). Memory may include: local memory used during the actual execution of a computer program; mass storage; and cache memory, which provides temporary storage for at least some computer-readable or computer-usable program code to reduce the number of times code can be retrieved from mass storage during code execution.

[0060] Computer program 28 may be stored on non-transitory computer-readable storage medium 30. Computer program 28 may be transferred from non-transitory computer-readable storage medium 30 to memory 26. Non-transitory computer-readable storage medium 30 may be, for example, a USB flash drive, external hard disk drive, external solid-state drive, secure digital (SD) card, or optical disc (such as CD, DVD, or Blu-ray disc). In some examples, computer program 28 may be transferred to memory 26 via signal 32 (which may be a wireless or wired signal).

[0061] Input / output devices can be connected to controller 14 directly or via an intermediate input / output controller. Various communication adapters can also be connected to controller 14 to enable device 10 to connect to other devices or remote printers or storage devices via an intermediate private or public network. Non-limiting examples include modems and network adapters that provide such communication adapters.

[0062] User input device 16 may include any one or more suitable means for enabling a user to at least partially control device 10. For example, user input device 16 may include one or more keyboards, keypads, touchpads, touchscreen displays, and computer mice. User input device 16 may be part of or a peripheral of inspection device 20, an "edge" computer, or a remote computer (e.g., a computer in the "cloud" located in another city or country). Controller 14 is configured to receive signals from user input device 16.

[0063] Display 18 can be any suitable display used to convey information to an operator. For example, display 18 can be a liquid crystal display, a light-emitting diode display, an active-matrix organic light-emitting diode display, a thin-film transistor display, or a cathode ray tube display. Display 18 can be part or a peripheral of inspection device 20, an "edge" computer, or a remote computer (e.g., a computer in the "cloud" located in another city or country). Controller 14 is arranged to provide signals to display 18 to cause display 18 to convey information to a user.

[0064] The inspection device 20 can be separate from the engine 12 and can be inserted into the engine 12 to inspect it. For example, the inspection device 20 can be a duct mirror comprising a flexible tube (such as a snake arm), with a sensor 22 mounted at one end of the flexible tube and a display 18 mounted at the opposite end. Alternatively, the inspection device 20 can be embedded within the engine 12 and positioned to inspect the engine 12 at one or more locations. The controller 14 can be configured to control the operation of the inspection device 20. For example, in the case where the inspection device 20 is a robot, the controller 14 can be configured to control the position and orientation of the inspection device 20 within the engine 12.

[0065] Sensor 22 is configured to generate three-dimensional data and may include a structured light 3D scanner, a stereo camera, or any other suitable device. Sensor 22 may also be configured to generate two-dimensional data and may include a camera (e.g., a charge-connected device (CCD) or complementary metal-oxide-semiconductor (CMOS)). Thus, in some examples, sensor 22 may include a structured light 3D scanner for generating three-dimensional data and a camera for generating two-dimensional data.

[0066] In the case where sensor 22 includes a 3D scanner (such as a structured light sensor) and a camera, memory 26 also stores a conversion algorithm 29 that enables the transformation between coordinates in 2D data generated by the camera and coordinates in 3D data generated by the 3D scanner. For example, conversion algorithm 29 can be generated by controller 14 for each image and point cloud received by controller 14 (using triangulation and calibration parameters), and it enables the transformation between pixel positions in image files (e.g., such as .jpg, .bmp, or .raw files) and point positions in point cloud data (e.g., such as .csv files).

[0067] Engine 12 is associated with and configured to generate propulsive thrust and / or electrical energy for said aircraft 34. For example, engine 12 may be a gas turbine engine, such as a geared turbofan engine (e.g., Figure 2 , 3 (As illustrated in Figure 4) or a "direct-drive" turbofan engine (where the turbine is directly connected to the fan). Alternatively, engine 12 can be a reciprocating engine or an electric motor. In some examples, engine 12 can be a system comprising a gas turbine engine or a reciprocating engine and a generator. In such a system, the output of the gas turbine engine or the reciprocating engine is connected to the generator.

[0068] Engine 12 can be "associated" with aircraft 34 by being mounted on it (often referred to as "on the wing"). For example, engine 12 can be mounted in or under the wing of aircraft 34, or it can be mounted inside or on the fuselage of aircraft 34. Alternatively, engine 12 may not be coupled to aircraft 34, but may be located at the same airport or maintenance facility as aircraft 34 (often referred to as "near the wing").

[0069] Figure 2 An example of a gas turbine engine 12 is illustrated, which has a main rotational axis 35 and includes an air inlet 36 and a propulsion fan 38 that generates two airflows: a core airflow A and a bypass airflow B. The gas turbine engine 12 includes a core 40 that receives the core airflow A. The engine core 40 includes a series of components flowing axially: a low-pressure compressor 42, a high-pressure compressor 44, a combustion chamber 46, a high-pressure turbine 48, a low-pressure turbine 50, and a core exhaust nozzle 52. A nacelle 54 surrounds the gas turbine engine 12 and defines a bypass passage 56 and a bypass exhaust nozzle 58. The bypass airflow B flows through the bypass passage 56. The fan 38 is attached to and driven by the low-pressure turbine 50 via a shaft 60 and a planetary gearbox 62.

[0070] In operation, the core airflow A is accelerated and compressed by the low-pressure compressor 42 and directed to the high-pressure compressor 44, where further compression occurs. The compressed air discharged from the high-pressure compressor 44 is directed to the combustion chamber 46, where it is mixed with fuel and the mixture is combusted. The resulting hot combustion products then expand through the high-pressure turbine 48 and the low-pressure turbine 50 before being discharged through the nozzle 52, thereby driving the high-pressure turbine 48 and the low-pressure turbine 50 to provide some propulsive thrust. The high-pressure turbine 48 drives the high-pressure compressor 44 via a suitable interconnecting shaft 64. The fan 38 typically provides most of the propulsive thrust. The planetary gearbox 62 is a reduction gearbox.

[0071] Figure 3 An exemplary arrangement for a geared fan gas turbine engine 12 is shown. The low-pressure turbine 50 (see [link to image]) Figure 1 A drive shaft 60 is connected to the sun gear or sun gear 66 of the planetary gear arrangement 62. Radially outer of and meshing with the sun gear 66 are multiple planet gears 68, which are connected together by a planet carrier 70. The planet carrier 70 constrains the planet gears 68 to precess synchronously around the sun gear 66, while allowing each planet gear 68 to rotate about its own axis. The planet carrier 70 is connected to the fan 38 via a linkage 72 to drive it to rotate about the engine axis 35. Radially outer of and meshing with the planet gears 68 are ring gears or toroidal gears 74, which are connected to a fixed support structure 78 via a linkage 76.

[0072] Note that, as used herein, the terms "low-pressure turbine" and "low-pressure compressor" can refer to the lowest-pressure turbine stage and the lowest-pressure compressor stage (i.e., excluding fan 38) and / or the turbine stage and compressor stage connected together via an interconnecting shaft 60 having the lowest rotational speed in engine 12 (i.e., excluding the gearbox output shaft driving fan 38), respectively. In some literature, the terms "low-pressure turbine" and "low-pressure compressor" used herein can alternatively be referred to as "intermediate-pressure turbine" and "intermediate-pressure compressor." When using such alternative nomenclature, fan 38 can be referred to as the first or lowest-pressure compression stage.

[0073] exist Figure 4 The planetary gearbox 62 is shown in more detail as an example. Each of the sun gear 66, planet gears 68, and ring gear 74 includes teeth around their outer circumference for meshing with other gears. However, for clarity, in Figure 4Only exemplary portions of the teeth are illustrated. Although four planetary gears 68 are illustrated, it will be apparent to the reader in the art that more or fewer planetary gears 68 may be provided. Practical applications of planetary gearboxes 62 typically include at least three planetary gears 68.

[0074] exist Figure 3 and 4 The planetary gearbox 62 illustrated as an example is of the planetary type, wherein the planet carrier 70 is coupled to the output shaft via a linkage 72, while the ring gear 74 is fixed. However, any other suitable type of planetary gearbox 62 can be used. As a further example, the planetary gearbox 62 can be a star arrangement, wherein the planet carrier 70 is held fixed, and the ring (or annular) gear 74 is allowed to rotate. In such an arrangement, the fan 38 is driven by the ring gear 74. As a further alternative example, the gearbox 62 can be a differential gearbox, wherein both the ring gear 74 and the planet carrier 70 are allowed to rotate.

[0075] It should be understood that Figure 3 and Figure 4 The arrangement shown is merely an example, and various alternatives are within the scope of this disclosure. As an example only, any suitable arrangement may be used to position the gearbox 62 in the engine 12 and / or to connect the gearbox 62 to the engine 12. As a further example, the connection between the gearbox 62 and other components of the engine 12 (such as the input shaft 60, output shaft, and mounting structure 78) may also be an example. Figure 3 The linkages 72 and 76 in the example can have any desired stiffness or flexibility. As a further example, any suitable bearing arrangement can be used between the rotating and stationary parts of the engine (e.g., between the input and output shafts from the gearbox and the stationary structure, such as the gearbox housing), and this disclosure is not limited to... Figure 3 Exemplary arrangements. For example, in the case where gearbox 62 has a star arrangement (as described above), those skilled in the art will readily understand that the arrangement of the output and support linkages and the bearing positions will typically be similar to those in... Figure 3 It is different from what is shown as an example in the text.

[0076] Figure 5 The illustration shows a first method for inspecting engine 12 according to various examples.

[0077] At box 80, the method includes inspecting engine 12 during a first time period to identify damage. In some examples, a human inspector may be located in the same position as engine 12 and may use a pipe mirror (which may be inspection device 20 or a separate pipe mirror) to inspect components of engine 12. For example, a human inspector may use a pipe mirror to inspect... Figure 2The turbine blades of the high-pressure turbine 48 and / or low-pressure turbine 50 of the gas turbine engine 12 illustrated in the figure are used to identify damage.

[0078] As used herein, “damage” includes any alteration to one or more components of engine 12 that degrades one or more components from their initial state and may adversely affect the current or future performance of one or more components. Therefore, “damage” includes, but is not limited to: loss of material from a component; alteration of the shape of a component; and alteration of the size of a component.

[0079] It should be understood that the "first time period" is the period during which engine 12 can be inspected "on the wing" or "near the wing". During the first time period, aircraft 34 is not operational and is not cleared for flight by the airport's control or maintenance facilities.

[0080] At box 82, the method includes receiving three-dimensional data of one or more components of the engine 12. In some examples, the inspection device 20 may be inserted into the engine 12, and the controller 14 may receive data from the sensor 22. Figure 2 The diagram shows three-dimensional data of one or more components of the engine 12. For example, the inspection device 20 can be inserted into the high-pressure turbine 48 of the gas turbine engine 12, and the controller 14 can receive three-dimensional data of the turbine blades of the high-pressure turbine 48.

[0081] When sensor 22 includes a structured light sensor, controller 14 can store 3D data in row and column pixel order (XY order). Specifically, controller 14 can use triangulation and calibration parameters to calculate the 3D coordinates of pixels with projected light, and then store the 3D coordinates in a .csv file using the XY order.

[0082] In the case where sensor 22 includes a stereo camera and generates two images, block 82 may further include converting the received two-dimensional data into three-dimensional data. Specifically, controller 14 can find corresponding pixels between the stereo images and then use triangulation and calibration parameters to calculate the three-dimensional coordinates. Controller 14 can then store the three-dimensional coordinates in a .csv file using row and column pixel order (XY order).

[0083] If sensor 22 further includes a two-dimensional sensor, block 82 may additionally include a module for receiving two-dimensional data from one or more components of engine 12. See later. Figure 12 , 13 Section 14 describes the use of this two-dimensional data in detail.

[0084] At box 84, the method includes determining whether the identified damage exceeds a threshold during a first time period. In some examples, a human inspector may use their experience and knowledge to determine whether the identified damage is acceptable or unrelated to operation on aircraft 34. For example, at box 80, in the case where a human inspector identifies damage to the turbine blades of high-pressure turbine 48, at box 84, he or she may use his or her experience and knowledge to determine whether the identified damage is acceptable or unrelated to operation.

[0085] At box 86, the method includes providing instructions to release the aircraft for operation during a second time period following the first time period, if the identified damage does not exceed a threshold. In some examples, a human inspector may provide instructions to enable the control console to release aircraft 34 for operation during the second time period. For example, at box 84, if a human inspector determines that the identified damage to the turbine blades of the high-pressure turbine 48 is acceptable for operation, he may provide instructions to enable aircraft 34 to be released for operation.

[0086] It should be understood that a “second time period” is a period in which engine 12 and aircraft 34 are operational and released by the airport’s control console for flight. Therefore, a second time period may include one or more time periods in which aircraft 34 is in the air and in which aircraft 34 can carry people and / or cargo.

[0087] At block 88, the method includes examining the received 3D data during a second time period to measure damage received by one or more components. Block 88 can be executed by controller 14. In some examples, block 88 is executed automatically by controller 14 in response to receiving 3D data. In other examples, a human operator can initiate the examination of the received 3D data by operating user input device 16, and block 88 can be executed by controller 14 in response to receiving a signal from user input device 16.

[0088] According to Figure 8 , 12 Box 88 may be executed by any of the methods illustrated in Figures 13 and 14, and these are described in detail later in the detailed description. Additionally, in some examples, boxes 80, 84, and 86 may be executed by controller 14.

[0089] Figure 6The diagram illustrates a timeline of the first method for inspecting the engine. The timeline includes a horizontal axis 90 for time and boxes 80, 82, 84, 86, and 88 positioned along the horizontal axis 90. A first time period is defined between time t0 and time t1. A second time period is defined between time t1 and t3. A third time period is defined from time t3, and this third time period is the period during which the engine 12 can be inspected again “on the wing” or “near the wing.” Similar to the first time period, the aircraft 34 is not operational during the third time period and is not released for flight by the airport's control or maintenance facilities.

[0090] The inspection of the received 3D data can be performed during a predetermined time period after the aircraft 34 is released for operation. For example, the controller 14 can be configured to complete box 88 within a time period defined between time t1 and time t2 (where time t2 is after time t1 but before time t3).

[0091] The first time period and the second time period are in Figure 6 The diagram shows segments with similar durations to aid in clarity. It should be understood that, in most cases, the second time segment is longer than the first.

[0092] The first method may be advantageous because aircraft 34 can be released for operation earlier than in the current method. Specifically, box 80 can be executed relatively quickly because human inspectors can avoid performing detailed measurements of engine 12 components (e.g., turbine blade creep), and at box 84, if they determine the damage is not above a threshold, they can instruct aircraft 34 to be released for operation. Detailed measurements of engine 12 components can be performed by controller 14 during a second period when aircraft 34 is operational, and even during flight. Therefore, the first method can reduce the time spent on Aircraft Off-Ground (AOG) due to inspection.

[0093] Figure 7 The illustration shows a timeline of the second method for inspecting engine 12. Figure 7 Timeline charts are similar to Figure 6 The timeline charts use the same reference numbers when the features are similar.

[0094] Figure 7 The method illustrated in the figure is the same as Figure 6The difference in the method illustrated is that block 88 is executed and completed during the first time period and before block 86. For example, controller 14 may check the received three-dimensional data in response to receiving three-dimensional data at block 82 to measure damage received by one or more components of engine 12, or it may check the received three-dimensional data in response to receiving a signal from user input device 16 to measure damage received by one or more components of engine 12.

[0095] Figure 7 The method illustrated in the figure is also similar to Figure 6 The difference in the method illustrated is that box 86 is executed only if the damage is determined to be below the acceptable damage threshold at boxes 84 and 88.

[0096] Similar to Figure 6 The first time period and the second time period are in Figure 7 The figures are illustrated as having similar durations to aid in clarity. It should be understood that, in most cases, the second time period is longer than the first time period.

[0097] The second method can be executed when controller 14 has sufficient computing resources and availability to enable execution of box 88 within an acceptable time period from the receipt of 3D data at box 82. For example, controller 14 can select between the first and second methods by evaluating which computing resources are available upon receiving 3D data at box 82, and determine whether box 88 can be executed within a predetermined time period. If controller 14 determines that box 88 can be executed within the predetermined time period, controller 14 can execute the second method. If controller 14 determines that box 88 may not be able to be executed within the predetermined time period, controller 14 can execute the first method.

[0098] Figure 7 The method illustrated in the diagram is advantageous because box 88 can be executed relatively quickly by controller 14 during the first time period, and thus provides a quick and accurate check before releasing aircraft 34 for operation.

[0099] Figure 8 The diagram illustrates a flowchart of a third method for inspecting engine 12. This third method can... Figure 5 , 6 Execute in box 88 shown in Figure 7.

[0100] At box 92, the method includes using the received 3D data to identify features of the component. As used herein, the term “feature” includes any alteration to the component that degrades the component from its initial state (i.e., “feature” is some form of damage and may also be referred to as “damage feature”). Figure 9 , 10Figure 11 illustrates three examples of this "feature" of turbine blades, and it is described in more detail in the following paragraphs. It should be understood that these examples are not exclusive, and turbine blades can have different features. Similarly, it should be understood that other types of components can have similar features. Figure 9 , 10 Features that are different from those shown in Figure 11.

[0101] Figure 9 The illustration shows a side view of a turbine blade 94 according to a first example. The turbine blade 94 includes a platform 96, an airfoil 98, and a shroud 100. The airfoil 98 defines a plurality of cooling holes 102 and has a leading edge 104 and a trailing edge 106. The turbine blade 94 includes a feature 108, in this example, a crack extending between adjacent cooling holes 102 near the leading edge 104 of the airfoil 98. Measurable dimensions of the crack 108 include length, width, and depth.

[0102] Figure 10 The illustration shows a side view of turbine blade 110 according to the second example. Turbine blade 110 is similar to turbine blade 94, and the same reference numerals are used where features are similar.

[0103] The turbine blade 110 includes a feature 112, which in this example is an erosion extending along the leading edge 104 and toward the trailing edge 106. The erosion 112 is defined by the removal of surface material from the turbine blade 94 and may include a plurality of cavities 114 extending into the airfoil 98. Measurable dimensions of the erosion 112 include the length, width, surface area, and depth of the eroded area relative to the uneroded area.

[0104] Figure 11 The illustration shows a side view of turbine blade 116 according to the third example. Turbine blade 116 is similar to turbine blades 94 and 110, and the same reference numerals are used where features are similar.

[0105] Turbine blade 116 includes feature 118, which in this example is the creep of turbine blade 116. Creep 118 may be defined by an extension of airfoil 98 and can be measured by measuring the distance L1 between platform 96 and shroud 100 at trailing edge 106 and subtracting the distance L2 of airfoil 98. L2 may be the distance between platform 96 and shroud 100 after the manufacture of turbine blade 116 but before its use in engine 12 (i.e., the initial state of turbine blade 116). Alternatively, L2 may be the design distance between platform 96 and shroud 100 (i.e., the distance in the computer-aided design (CAD) model of turbine blade 116).

[0106] Creep 118 may additionally or alternatively be defined by the angle through which the airfoil 98 twists about the longitudinal axis of the turbine blade 116 (which extends between the platform 96 and the shield 100 and is perpendicular to the platform 96 and the shield 100).

[0107] return Figure 8 In some examples, the features to be identified can be predetermined by the controller 14. In other words, the controller 14 can be pre-configured to identify features of the component, and the controller 14 does not require further input to determine the features to be identified. In other examples, the controller 14 can control the display 18 to display multiple features, and the user can operate the user input device 16 to select one or more of the displayed features to be identified.

[0108] Controller 14 may use any one or more suitable methods to identify features. For example, controller 14 may use any one or more of the following to identify features: CAD alignment / registration, Procrustes analysis, Iterative Nearest Point (IPC) registration, Random Sample Consensus (RANSAC), plane matching, point cloud segmentation, and machine learning.

[0109] At box 120, the method includes determining the coordinates of a feature identified in the 3D data. In some examples, the controller 14 may determine the coordinates of the identified feature by determining the coordinates of the periphery of the identified feature in the received 3D data.

[0110] At box 122, the method includes measuring parameters of the feature of the part using coordinates of the feature determined in the three-dimensional data. As used herein, "parameters" include the physical dimensions of the feature (e.g., length, width, etc.), the number of features, the density of features, and the spacing between features. In some examples, box 122 may include measuring multiple parameters of the feature using coordinates of the feature in the determined three-dimensional data.

[0111] The controller 14 may use the determined coordinates to measure at least one of the following: one or more angles, one or more lengths, area, volume of identified features, number of identified features, density of identified features, and spacing between features. In order to perform one or more measurements, the controller 14 may perform point cloud processing (such as RANSAC, 3D object matching), CAD alignment with the model of the part, and / or point cloud stitching.

[0112] take Figure 9 As an example, controller 14 can use the determined coordinates of crack 108 to measure the length, width, and depth of crack 108 in airfoil 98. Considering Figure 10The controller 14 can use the determined coordinates of the eroded portion 112 to measure the surface area and depth of the eroded portion 112 of the airfoil 98. The controller 14 can also use the determined coordinates to determine the depth and diameter of the cavity 114. (Go to...) Figure 11 The controller 14 can use the determined coordinates to measure the length L1, and then determine the creep of the turbine blade 116 by subtracting L2 from L1.

[0113] At box 122, the method may additionally include controlling the storage of one or more measured parameters in dataset 123 in memory 26.

[0114] Figure 12 The diagram illustrates a flowchart of a fourth method for inspecting engine 12. When sensor 22 includes both two-dimensional and three-dimensional sensors, controller 14 can execute the fourth method. Figure 12 The fourth method illustrated in the figure is the same as Figure 5 The first method illustrated in the figure and the method with Figure 8 The third method illustrated in the figure is similar, and the same reference numerals are used where the boxes are similar.

[0115] At box 82, the method includes receiving data including two-dimensional and three-dimensional data of one or more components of engine 12. For example, controller 14 may receive .jpg files (two-dimensional data) of one or more components of engine 12 from a camera of sensor 22 and .csv files (three-dimensional data) of the same one or more components of engine 12 from a structured light sensor of sensor 22.

[0116] At box 124, the method includes using two-dimensional data to identify features of one or more parts. For example, controller 14 can use any suitable technique to identify features in the .jpg file received at box 82. Suitable techniques include correlation, matching, texture analysis, and artificial intelligence (e.g., deep learning neural networks).

[0117] At box 126, the method includes determining the coordinates of features identified in the two-dimensional data. For example, controller 14 can determine the coordinates of each pixel of the features identified in box 124 of a .jpg file.

[0118] At block 128, the method includes determining the coordinates of the identified feature in the received 3D data using the coordinates of the identified feature in the determined 2D data and a predetermined transformation algorithm 29. For example, controller 14 can calculate the coordinates of the identified feature in the received 3D data by applying transformation algorithm 29 to the 2D coordinates of the feature determined at block 126.

[0119] The fourth method then moves to box 122 and includes measuring one or more parameters of the identified feature of the part using the coordinates of the identified feature in the 3D data. The fourth method may also include controlling the storage of the measured one or more parameters at box 122.

[0120] The fourth method may be advantageous when the controller 14 has a higher probability of recognizing features in two-dimensional data than in three-dimensional data. For example, some features (such as erosion) may be relatively challenging for the controller 14 to recognize in three-dimensional data because the change in coordinates (relative to the original state of the part) may be small. However, such features can be easily recognized by the controller 14 in two-dimensional data due to changes in color or pattern.

[0121] Figure 13 The diagram illustrates a flowchart of the fifth method for inspecting engine 12. This fifth method is similar to... Figure 5 The first method illustrated in the figure, Figure 8 The third method illustrated in the figure and Figure 12 The fourth method is illustrated in the figure, and the same reference numerals are used in cases where the boxes are similar.

[0122] At box 82, the fifth method includes receiving data including two-dimensional and three-dimensional data of components of engine 12. The fifth method then moves to box 92 and includes using the received three-dimensional data to identify features of the components of engine 12.

[0123] At box 130, the fifth method includes determining the coordinates in three-dimensional data of a first volume that defines the coordinates of the feature. In some examples, the first volume may be defined by the three-dimensional periphery of the identified feature. In other examples, the first volume may be defined by a three-dimensional region of interest containing the three-dimensional coordinates of the identified feature. The region of interest may be identified using a three-dimensional (CAD) model of the component stored in memory 26 to aid in the identification of sub-components including the identified feature.

[0124] The fifth method then moves to box 132 and includes determining the coordinates of a first region in the two-dimensional data corresponding to the first volume using the coordinates of the first volume in the determined three-dimensional data and a predetermined transformation algorithm 29. For example, the controller 14 can calculate the coordinates of the first region by applying the transformation algorithm 29 to the coordinates of the determined first volume.

[0125] At box 134, the fifth method includes using a subset of two-dimensional data corresponding to the first region to identify features of the component. For example, if the two-dimensional data received at box 82 comprises a 1920-pixel by 1080-pixel image and the feature is erosion, the subset of data corresponding to the first region has coordinates from 200 to 500 on the horizontal (X) axis and from 600 to 800 on the vertical (Y) axis. Controller 14 may perform feature analysis and identification on this subset of the two-dimensional data as described above with reference to box 124.

[0126] It should be understood that box 134 may identify the same features as those identified at box 92, but additional features may be identified because the analysis is performed on two-dimensional data, while box 134 is performed on three-dimensional data. For example, controller 14 may identify the eroded portion 112 of airfoil 98 at box 92, and may identify the eroded portion 112 and cracks at box 134.

[0127] The fifth method then moves to box 126 and includes determining the coordinates of the feature identified in box 134 in the two-dimensional data.

[0128] At box 128, the fifth method includes using the following to determine the coordinates of the feature identified in box 134 in the three-dimensional data: the coordinates of the feature in the two-dimensional data determined at box 126 and a predetermined transformation algorithm 29.

[0129] The fifth method then moves to box 122 and includes measuring one or more parameters of the feature identified at box 134 using the three-dimensional coordinates of the feature determined at box 128. The fifth method may also include storing control over the one or more parameters measured at box 122.

[0130] The fifth method can advantageously increase the likelihood of identifying the features of the engine 12's components because feature analysis and identification are performed on both the two-dimensional and three-dimensional data received at frame 82.

[0131] Figure 14 The illustration shows the sixth method for inspecting engine 12. The sixth method is related to... Figure 5 The first method illustrated in the figure, Figure 8 The third method illustrated in the figure Figure 12 The fourth method illustrated in the figure and Figure 13 The fifth method illustrated in the figure is similar, and the same reference numerals are used where the boxes are similar.

[0132] At box 82, the method includes receiving data including two-dimensional data and three-dimensional data of engine 12.

[0133] The sixth method then moves to box 136 and includes identifying a second region using two-dimensional data of the components of engine 12. The second region excludes predetermined components and / or predetermined sub-components of engine 12 within the two-dimensional data. For this example, controller 14 can be configured to identify crack 108 in airfoil 98 (as described above, either pre-configured or user-configured) and can exclude platform 96 and shield 100 (which are sub-components of turbine blades 94, 110, 116). Where the two-dimensional data includes data about other components (e.g., stator blades), controller 14 can exclude such components from the second region at box 136.

[0134] At box 138, the sixth method includes using the following to determine the coordinates of the second volume in the three-dimensional data corresponding to the second region: the coordinates of the second region in the determined two-dimensional data and a predetermined transformation algorithm 29. For example, the controller 14 may apply the transformation algorithm 29 to the two-dimensional coordinates of the second region determined at box 136 to calculate the coordinates of the second volume in the three-dimensional data.

[0135] The sixth method then moves to box 140 and includes identifying features of the part using a subset of the 3D data corresponding to the second volume calculated at box 138. It should be understood that box 140 is similar to... Figure 8 The third method illustrated in the figure and Figure 13 Box 92 in the fifth method illustrated in the figure, but the difference is that feature analysis and recognition are performed only on a subset of the three-dimensional data (i.e., the three-dimensional data corresponding to the second volume).

[0136] The sixth method then moves through boxes 130, 132, 134, 126, 128, and 122 to provide measurements of one or more parameters of the identified component features. The sixth method may also include controlling the storage of the measured one or more parameters at box 122.

[0137] The sixth method can be advantageous because the analysis of the two-dimensional data to remove irrelevant data (at boxes 136 and 138) can improve the efficiency of the analysis of the three-dimensional data (at box 140). This can reduce the time spent by controller 14 executing box 140, and / or enable a reduction in the use of the computing resources of controller 14.

[0138] Figure 8 , 12 The methods illustrated in 1, 13 and 14 may be advantageous because one or more stored measurement parameters 123 can be used to determine the condition of a component and schedule the next inspection of that component (as well as potential repairs or replacements).

[0139] It will be understood that the present invention is not limited to the embodiments described above, and various modifications and improvements can be made without departing from the concepts described herein. For example, different embodiments may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment that includes both hardware and software elements.

[0140] Figure 8 , 12 The methods illustrated in Figures 13 and 14 are described based on identifying and measuring a single feature of a single component. It should be understood that these methods can also be used to identify and measure multiple features on a single component. Furthermore, these methods can be used to identify multiple features across multiple components (where a single component may have one or more features).

[0141] In some examples, block 82 may include receiving only two-dimensional data from one or more components of engine 12, and block 88 includes examining the received two-dimensional data during a second time period to measure damage. In these examples, controller 14 may use the techniques mentioned in reference block 124 above to identify one or more features in the two-dimensional data, and may use the two-dimensional data to measure one or more parameters of those features.

[0142] In some examples, this can be performed on engines unrelated to the aircraft, such as industrial gas turbines. Figure 5 The methods described are illustrated in the figures and described above. In these examples, the first time period is a check phase for the engine (where the engine is not running), and the second time period is a phase for engine operation. Furthermore, this method can be performed on any industrial system (e.g., an oil and gas facility) where the first time period is a check phase for the industrial system (where the industrial system is not running) and the second time period is a phase for the industrial system operation. Figure 5 The method is illustrated in the figure.

[0143] Unless mutually exclusive, any feature may be used alone or in combination with any other feature, and this disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.

Claims

1. A computer-implemented method for inspecting an engine, comprising: Receive data, the data including two-dimensional data and three-dimensional data of engine components, wherein the two-dimensional data is acquired by a two-dimensional sensor and the three-dimensional data is acquired by a three-dimensional sensor; The two-dimensional data is used to identify the features of the component; Determine the coordinates of the features in the two-dimensional data; The coordinates of the feature in the three-dimensional data are determined using: the determined coordinates of the feature in the two-dimensional data; and a predetermined transformation between the coordinates in the two-dimensional data and the coordinates in the three-dimensional data; and The parameters of the feature of the component are measured using the coordinates of the feature in the determined three-dimensional data; Prior to identifying the features of the component, the method further includes: The three-dimensional data is used to identify the features of the component; Determine the coordinates in the three-dimensional data of a first volume that defines the coordinates of the feature; The coordinates of the first region in the two-dimensional data corresponding to the first volume are determined using the following: the coordinates of the first volume in the three-dimensional data; and the predetermined transformation.

2. The computer-implemented method of claim 1, wherein using the two-dimensional data to identify features of the component includes using a subset of the two-dimensional data corresponding to the first region.

3. The computer-implemented method according to claim 1, wherein determining the coordinates in the three-dimensional data of the first volume comprises: The first volume in the three-dimensional data is identified using the following features of the identified component; And a three-dimensional model of the component.

4. The computer-implemented method of claim 1, wherein before using the three-dimensional data to identify features of the component, the method further comprises: The two-dimensional data of the component is used to identify a second region, the second region excluding predetermined components and / or predetermined sub-components of the engine within the two-dimensional data; The coordinates of the second volume in the three-dimensional data corresponding to the second region are determined using the following: the coordinates of the second region in the two-dimensional data; and the predetermined transformation.

5. The computer-implemented method of claim 4, wherein using the three-dimensional data to identify features of the component comprises: Features of the component are identified using a subset of the three-dimensional data corresponding to the second volume.

6. The computer-implemented method according to claim 1, further comprising: Control the storage of measured parameters.

7. The computer-implemented method of claim 1, wherein the engine is associated with an aircraft, and the data is generated during a first time period during which the aircraft is not released for operation.

8. The computer-implemented method of claim 7, wherein the computer-implemented method is performed during a second time period during which the aircraft is released for operation.

9. The computer-implemented method of claim 1, wherein the computer-implemented method is executed automatically in response to receiving the data.

10. The computer-implemented method of claim 9, wherein the computer-implemented method is performed without human intervention.

11. A non-transitory computer-readable storage medium comprising computer-readable instructions, which, when executed by a computer, cause the computer to perform a computer-implemented method according to any one of claims 1 to 10.

12. An apparatus comprising: A controller configured to perform a computer-implemented method according to any one of claims 1 to 10.

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