Method and apparatus for inspecting an engine

Abstract

A method 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 whether the identified damage exceeds a threshold during the first time period; providing an instruction to release the aircraft for operation for a second time period after the first time period if the identified damage does not exceed the threshold; and inspecting the received three-dimensional data to measure damage during the second time period.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a method and apparatus for inspecting an engine. BACKGROUND

[0002] Aircraft typically include one or more engines for providing propulsion thrust and / or electrical power to the aircraft. During operation, one or more of the engines can become damaged (e.g., due to relatively high operating temperatures or due to foreign object damage). Aircraft engines are typically inspected by a human inspector at periodic intervals to determine the condition of the engine internals. Where a component is found to be in an unacceptable condition, the engine is typically removed from the aircraft for repair. During such inspections, the aircraft is grounded and unavailable for operation by the airline. In addition, the quality and duration of the inspection depends on the skill and experience of the inspector. SUMMARY

[0003] According to a first aspect, there is provided a method comprising: inspecting an engine to identify damage during a first time period, 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 whether the identified damage exceeds a threshold during the first time period; providing an instruction to release the aircraft for operation for a second time period after the first time period if the identified damage does not exceed the threshold; and inspecting the received three-dimensional data to measure the damage during the second time period.

[0004] Inspecting the received three-dimensional data can comprise: using the three-dimensional data to identify a feature of the component; determining coordinates of the feature in the three-dimensional data; and using the determined coordinates of the feature in the three-dimensional data to measure a parameter of the feature of the component.

[0005] The method can further comprise: receiving data comprising two-dimensional data of the component of the engine, the two-dimensional data being generated during the first time period; and wherein inspecting the received three-dimensional data comprises: using the two-dimensional data to identify a feature of the component; 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 conversion between coordinates in the two-dimensional data and coordinates in the three-dimensional data; and using the determined coordinates of the feature in the three-dimensional data to measure a parameter of the feature of the component.

[0006] Prior to using the two-dimensional data to identify a feature of the component, the method can further comprise: using the three-dimensional data to identify a feature of the component; determining coordinates of a first volume of the three-dimensional data bounding coordinates of the feature; determining coordinates of a first region of the two-dimensional data corresponding to the first volume using the determined coordinates of the first volume of the three-dimensional data and a predetermined conversion.

[0007] Using the two-dimensional data to identify the feature of the component can comprise using a subset of the two-dimensional data corresponding to the first region.

[0008] Determining the coordinates in the three-dimensional data of the first volume can comprise identifying the first volume in the three-dimensional data using: the identified feature of the component and the three-dimensional model of the component.

[0009] The method can further comprise, prior to using the three-dimensional data to identify the feature of the component: using the two-dimensional data of the component to identify a second region, the second region excluding predetermined components and / or predetermined sub-components of the engine within the two-dimensional data; determining coordinates of a second volume in the three-dimensional data corresponding to the second region using: the determined coordinates of the second region in the two-dimensional data and the predetermined conversion.

[0010] Using the three-dimensional data to identify the feature of the component can comprise using a subset of the three-dimensional data corresponding to the second volume to identify the feature of the component.

[0011] The method can further comprise controlling storage of the measured parameter.

[0012] Inspecting the received three-dimensional data during the second time period can be performed by the computer.

[0013] Inspecting the received three-dimensional data during the second time period can be performed by the computer automatically in response to receiving the three-dimensional data.

[0014] Inspecting the received three-dimensional data can be performed during a predetermined time period from the aircraft being released for operation.

[0015] According to a second aspect, there is provided a computer program which, when executed by a computer, causes the computer to perform the method as described in any of the preceding paragraphs.

[0016] According to a third aspect, there is provided a non-transitory computer readable storage medium comprising computer readable instructions which, when executed by a computer, cause the computer to perform the method as described in any of the preceding paragraphs.

[0017] According to a fourth aspect, there is provided an apparatus comprising: a controller configured to perform the method as described in any of the preceding paragraphs.

[0018] According to a fifth aspect, there is provided 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.

[0019] Before identifying the feature of the component, the method can further comprise: identifying the feature of the component using the three-dimensional data; determining coordinates in the three-dimensional data of a first volume bounding the coordinates of the feature; determining coordinates of a first area in the two-dimensional data corresponding to the first volume using: the determined coordinates of the first volume in the three-dimensional data and the predetermined transformation.

[0020] Identifying the feature of the component using the two-dimensional data can comprise using a subset of the two-dimensional data corresponding to the first area.

[0021] Determining coordinates in the three-dimensional data of the first volume can comprise: identifying the first volume in the three-dimensional data using: the identified feature of the component and a three-dimensional model of the component.

[0022] Before identifying the feature of the component using the three-dimensional data, the method can further comprise: identifying a second area using the two-dimensional data of the component, the second area excluding predetermined components and / or predetermined sub-components of the engine within the two-dimensional data; determining coordinates of a second volume in the three-dimensional data corresponding to the second area using: the determined coordinates of the second area in the two-dimensional data and the predetermined transformation.

[0023] Identifying the feature of the component using the three-dimensional data comprises: identifying the feature of the component using a subset of the three-dimensional data corresponding to the second volume.

[0024] The method can further comprise: controlling storage of the measured parameter.

[0025] The engine can be associated with an aircraft, and the data can be generated during a first time period in which the aircraft is not released for running.

[0026] The computer-implemented method can be performed during a second time period in which the aircraft is released for running.

[0027] The computer-implemented method can be performed automatically in response to receiving the data.

[0028] The computer-implemented method can be performed without human intervention.

[0029] According to a sixth aspect, there is provided a computer program which, when executed by a computer, causes the computer to perform the computer-implemented method as described in any of the preceding paragraphs.

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

[0031] According to an eighth aspect, there is provided an apparatus comprising: a controller configured to perform the computer-implemented method as described in any of the preceding paragraphs.

[0032] According to a ninth aspect, there is provided a method 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 operation of the industrial system for a second time period after the first time period; and inspecting the received three-dimensional data during the second time period to measure damage.

[0033] According to a tenth aspect, there is provided a method 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 for a second time period after the first time period; and inspecting the received two-dimensional data during the second time period to measure damage.

[0034] According to an eleventh aspect, there is provided a method comprising: inspecting an industrial system (e.g. an engine, which can or can not be associated with an aircraft) during a first time period to identify damage; receiving data of 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 operation of the industrial system for a second time period after the first time period; and inspecting the received data during the second time period to measure damage.

[0035] The skilled person will appreciate that features described in relation to any one of the above aspects can be applied to any other aspect, mutatis mutandis, except where such application is either not sensible or mutually exclusive. Furthermore, any feature described herein can be applied to any aspect and / or in combination with any other feature described herein, except where such application is either not sensible or mutually exclusive. BRIEF DESCRIPTION OF DRAWINGS

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

[0037] Figure 1 schematics of an apparatus for inspection of an engine according to various examples;

[0038] Figure 2 schematics of a gas turbine engine according to various examples;

[0039] Figure 3 schematics of Figure 2 a close-up cross-sectional side view of an upstream portion of the gas turbine engine illustrated in

[0040] Figure 4 schematics of Figure 2 and Figure 3 a partial cutaway view of a gearbox of the gas turbine engine illustrated in

[0041] Figure 5 a flowchart of a first method of inspecting an engine;

[0042] Figure 6 a timeline diagram of the first method of inspecting an engine;

[0043] Figure 7 a timeline diagram of a second method of inspecting an engine;

[0044] Figure 8 a flowchart of a third method of inspecting an engine;

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

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

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

[0048] Figure 12 a flowchart of a fourth method of inspecting an engine;

[0049] Figure 13 a flowchart of a fifth method of inspecting an engine; and

[0050] Figure 14 a flowchart illustrating a sixth method of inspecting an engine. DETAILED DESCRIPTION

[0051] In the following description, the terms "connected" and "coupled" are used to refer to operatively connected and coupled. It will be understood that there can be any number of intervening components between the referenced features, including none.

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

[0053] In some examples, the apparatus 10 can 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 possibly by another manufacturer or by an end user. For example, in the case that the apparatus 10 is a module, the apparatus 10 can comprise only the controller 14, while the remaining features (such as the user input device 16, the display 18, the inspection device 20, and the sensor 22) can be added by another manufacturer or by an end user.

[0054] The controller 14, the user input device 16, the display 18, the inspection device 20, and the sensor 22 can be coupled to each other via wireless lines, and can therefore comprise transceiver circuitry and one or more antennas. Additionally or alternatively, the controller 14, the user input device 16, the display 18, the inspection device 20, and the sensor 22 can be coupled to each other via wired lines, and can therefore comprise interface circuitry (such as a Universal Serial Bus (USB) plug and socket).

[0055] The controller 14 can comprise any suitable circuitry to cause the performance of the methods illustrated in FIGS. 1 1, 12, 13, and 14 described herein and as Figure 5 , 8 The controller 14 can comprise: 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- 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 perform the methods.

[0056] In various examples, the controller 14 can comprise at least one processor 24 and at least one memory 26. The memory 26 stores a computer program 28 comprising computer readable instructions which, when read by the processor 24, cause the performance of the methods illustrated in Figures 12, 13 and 14 as described herein and as Figure 5 , 8 The computer program 28 can be software or firmware, or can be a combination of software and firmware.

[0057] The controller 14 can be part of the inspection apparatus 20, an “edge” computer or a remote computer such as a high performance computing cluster in the “cloud”. Alternatively, the controller 14 can be distributed between multiple apparatuses and locations. For example, the controller 14 can be distributed between the inspection apparatus 20 and an “edge” computer, or can be distributed between the inspection apparatus 20 and a high performance computing cluster in the “cloud”.

[0058] The processor 24 can comprise at least one microprocessor and can comprise a single core processor, can comprise multiple processor cores such as a dual core processor or a quad core processor, or can comprise multiple processors (at least one of which can comprise multiple processor cores).

[0059] The memory 26 can be any suitable non-transitory computer readable storage medium, one or more data storage devices, and can comprise a hard disk and / or solid state memory such as flash memory. The memory can be a permanent non-removable memory, or can be a removable memory such as a Universal Serial Bus (USB) flash drive or a Secure Digital card. The memory can comprise local memory employed during actual execution of the computer program, mass storage, and cache memory providing temporary storage of at least some computer readable or computer usable program code to reduce the number of times that code can be fetched from mass storage during execution of the code.

[0060] The computer program 28 can be stored on a non-transitory computer readable storage medium 30. The computer program 28 can be transferred from the non-transitory computer readable storage medium 30 to the memory 26. The non-transitory computer readable storage medium 30 can be, for example, a USB flash drive, an external hard drive, an external solid state drive, a Secure Digital (SD) card, an optical disk such as a Compact Disk (CD), a Digital Versatile Disk (DVD) or a Blu-ray disk. In some examples, the computer program 28 can be transferred to the memory 26 via a signal 32 which can be a wireless signal or a wired signal.

[0061] Input / output devices can be coupled directly to controller 14 or through intervening input / output controllers. Various communication adapters can also be coupled to controller 14 to enable device 10 to become coupled to other devices or remote printers or storage devices through intervening private networks or public networks. Non-limiting examples include modems and network adapters for such communication adapters.

[0062] User input devices 16 can include any suitable device or devices for enabling a user to at least partially control device 10. For example, user input devices 16 can include one or more keyboards, keypads, touchpads, touch screen displays, and computer mice. User input devices 16 can be part of or peripheral to an 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 devices 16.

[0063] Display 18 can be any suitable display for communicating 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, or a thin film transistor display or a cathode ray tube display. Display 18 can be part of or peripheral to an 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 communicate information to a user.

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

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

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

[0067] The engine 12 is associated with the aircraft 34 and is configured to generate propulsive thrust and / or electrical energy for the aircraft 34. For example, the engine 12 can be a gas turbine engine, such as a geared turbofan engine (as illustrated in FIGS. 1-4) or a “direct drive” turbofan engine (in which the turbine is directly connected to the fan). Alternatively, the engine 12 can be a reciprocating engine or an electric motor. In some examples, the engine 12 can be a system that includes a gas turbine engine or a reciprocating engine and an electrical generator. In such a system, the output of the gas turbine engine or reciprocating engine is connected to the electrical generator. Figure 2 , 3 In some examples, the engine 12 can be a system that includes a gas turbine engine or a reciprocating engine and an electrical generator. In such a system, the output of the gas turbine engine or reciprocating engine is connected to the electrical generator.

[0068] The engine 12 can be “associated” with the aircraft 34 by being mounted on the aircraft 34 (often referred to as “on-wing”). For example, the engine 12 can be mounted in or under a wing of the aircraft 34, or can be mounted within or on a fuselage of the aircraft 34. Alternatively, the engine 12 can not be coupled to the aircraft 34, but can be located at the same airport or repair facility as the aircraft 34 (often referred to as “off-wing”).

[0069] Figure 2 An example of a gas turbine engine 12 is illustrated, having a main rotational axis 35 and including an air intake 36, and a propulsive fan 38 that generates two air flows: 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 comprises, in axial flow series, a low pressure compressor 42, a high pressure compressor 44, combustion equipment 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 airflow passage 56 and a bypass exhaust nozzle 58. The bypass airflow B passes through the bypass airflow 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 use, core airflow A is accelerated and compressed by low pressure compressor 42 and is directed into high pressure compressor 44 where further compression occurs. Compressed air exiting high pressure compressor 44 is directed into combustion equipment 46 where it is mixed with fuel and the mixture is combusted. The resulting hot combustion products then expand through high pressure turbine 48 and low pressure turbine 50 and drive them thereby to provide some of the propulsive thrust before being exhausted through nozzle 52. High pressure turbine 48 drives high pressure compressor 44 through a suitable interconnecting shaft 64. Fan 38 typically provides the majority of the propulsive thrust. Planetary gearbox 62 is a reduction gearbox.

[0071] Figure 3 An exemplary arrangement for a geared fan gas turbine engine 12 is shown in FIG. 1. Low pressure turbine 50 (see FIG. 1) drives shaft 60, which is coupled to sun gear or sun 66 of planetary gear arrangement 62. Radially outward of and intermeshing with sun 66 are a plurality of planet gears 68, which are coupled together by carrier 70. Carrier 70 constrains planet gears 68 to revolve synchronously about sun 66, while allowing each planet gear 68 to rotate about its own axis. Carrier 70 is coupled via linkage 72 to fan 38 so as to drive its rotation about engine axis 35. Radially outward of and intermeshing with planet gears 68 is annulus or ring gear 74, which is coupled via linkage 76 to fixed support structure 78. Figure 1

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

[0073] In Figure 4 Planetary gearbox 62 is shown in greater detail as an example in FIG. 2. Each of sun 66, planet gears 68, and ring gear 74 includes teeth around their outer periphery to intermesh with the other gears. However, for clarity, only a few teeth are shown in FIG. 2. Sun 66 is coupled to low pressure turbine 50 via linkage 72. Sun 66 is coupled to carrier 70 via a plurality of planet gears 68. Carrier 70 is coupled to fan 38 via linkage 72. Carrier 70 is coupled to ring gear 74 via a plurality of planet gears 68. Ring gear 74 is coupled to fixed support structure 78 via linkage 76. Figure 4 ​Only 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 2turbine blades of the high pressure turbine 48 and / or the low pressure turbine 50 of the gas turbine engine 12 illustrated in FIG. 1 to identify damage.

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

[0079] It should be appreciated that the "first time period" is a time period in which the engine 12 can be inspected "on wing" or "near wing." The aircraft 34 is not operational during the first time period and is not cleared by a control tower or repair facility of an airport for flight.

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

[0081] In the case where the sensor 22 includes a structured light sensor, the controller 14 can store the three-dimensional data in a row and column pixel order (XY order). In particular, the controller 14 can calculate three-dimensional coordinates of pixels with projected light using triangulation and calibration parameters and then store the three-dimensional coordinates in a.csv file using the XY order.

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

[0083] In the case where the sensor 22 additionally includes a two-dimensional sensor, block 82 can additionally include receiving two-dimensional data of one or more components of the engine 12. The use of this two-dimensional data is described in detail later with reference to the controller 14. Figure 12 、 13 and 14.

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

[0085] At block 86, the method includes providing instructions to release the aircraft for operation for a second time period after the first time period if the identified damage does not exceed the threshold. In some examples, the human inspector can provide instructions to enable the console to release the aircraft 34 for operation for the second time period. For example, in the case where the human inspector determines that the identified damage to the turbine blade of the high pressure turbine 48 is acceptable for operation at block 84, he can provide instructions to enable the aircraft 34 to be released for operation.

[0086] It will be appreciated that the“second time period” is a time period in which the engine 12 and the aircraft 34 are operational and released by the console of the airport for flight. Thus, the second time period can include one or more time periods in which the aircraft 34 is in the air and in which the aircraft 34 can carry people and / or cargo.

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

[0088] Block 88 can be performed in accordance with any of the methods illustrated in Figure 8 , 12 , 13, and 14, and these are described in detail later in the detailed description. Furthermore, in some examples, blocks 80, 84, and 86 can be performed by the controller 14.

[0089] Figure 6A timeline diagram illustrating a first method of inspecting the engine is shown. The timeline diagram includes a horizontal axis 90 for time and blocks 80, 82, 84, 86, and 88 positioned along the horizontal axis 90. A first time period is defined between time to and time ti. A second time period is defined between time ti and t3. A third time period is defined from time t3 and is a time period in which the engine 12 can be inspected “on wing” or “near wing” again. Similar to the first time period, the aircraft 34 is not operational during the third time period and is not released for flight by a control tower or repair facility of the airport.

[0090] The inspection of the received three-dimensional data can be performed during a predetermined time period from the release of the aircraft 34 for operation. For example, the controller 14 can be configured to complete block 88 within a time period defined between time ti and time t2, where time t2 is after time ti but before time t3.

[0091] The first time period and the second time period are illustrated in Figure 6 as having similar durations to aid in the clarity of the drawing. It should be appreciated that in most cases, the second time period is longer than the first time period.

[0092] The first method can be advantageous because the aircraft 34 can be released for operation earlier than in the current method. In particular, block 80 can be performed relatively quickly because the human inspector can not perform detailed measurements of components of the engine 12 (e.g., creep of turbine blades) and, in the event that they determine that the damage is not above the threshold, they can instruct the aircraft 34 to be released for operation at block 84. Detailed measurements of components of the engine 12 can be performed by the controller 14 during the second time period in which the aircraft 34 is operational and can even be performed in flight. Thus, the first method can reduce the time of aircraft on ground (AOG) due to inspection.

[0093] Figure 7 A timeline diagram illustrating a second method of inspecting the engine 12 is shown. Figure 7 The timeline diagram of Figure 6 is similar to the timeline diagram of and, where features are similar, the same reference numbers are used.

[0094] Figure 7 The method illustrated in Figure 6The method illustrated in FIG. 1 differs in that block 88 is performed and completed during the first time period and before block 86. For example, the controller 14 can inspect the received three-dimensional data to measure damage received by one or more components of the engine 12 in response to receiving the three-dimensional data at block 82, or can inspect the received three-dimensional data to measure damage received by one or more components of the engine 12 in response to receiving a signal from the user input device 16.

[0095] Figure 7 The method illustrated in FIG. 1 also differs from the method illustrated in FIG. 2 in that block 88 is performed only when it is determined at blocks 84 and 88 that the damage is below the threshold of acceptable damage. Figure 6 The method illustrated in FIG. 1 differs from the method illustrated in FIG. 2 in that block 86 is performed only when it is determined at blocks 84 and 88 that the damage is below the threshold of acceptable damage.

[0096] Similar to the method illustrated in FIG. 2, Figure 6 the first time period and the second time period are illustrated in FIG. 1 as having similar durations to aid in the clarity of the figure. It will be appreciated that in most cases, the second time period is longer than the first time period. Figure 7

[0097] The second method can be performed when the controller 14 has sufficient computing resources and availability to enable block 88 to be performed within an acceptable time period from the receipt of the three-dimensional data at block 82. For example, the controller 14 can select between the first method and the second method at block 82 upon receiving the three-dimensional data by assessing which computing resources are available, and determine whether block 88 can be performed within a predetermined time period. In the event that the controller 14 determines that block 88 can be performed within the predetermined time period, the controller 14 can perform the second method. In the event that the controller 14 determines that block 88 can not be performed within the predetermined time period, the controller 14 can perform the first method.

[0098] Figure 7 The method illustrated in FIG. 1 is advantageous in that block 88 can be performed relatively quickly by the controller 14 during the first time period, and thus provides a quick and accurate inspection prior to releasing the aircraft 34 for operation.

[0099] Figure 8 A flowchart illustrating a third method of inspecting the engine 12 is illustrated. This third method can be performed in block 88 illustrated in FIGS. 1, Figure 5 , 6 and 7.

[0100] At block 92, the method includes identifying a feature of the component using the received three-dimensional data. As used herein, the word "feature" includes any alteration of the component that degrades the component from its initial state (i.e., a "feature" is some form of damage and can also be referred to as a "damage feature"). Figure 9 , 10 ​Figs. 10-11 illustrate three examples of such "features" of turbine blades, and are described in more detail in the following paragraphs. It should be understood that these examples are not exclusive, and that turbine blades can have different features. Likewise, it should be understood that other types of components can have features different from those illustrated in Figs. 10-11. Figure 9 , 10 and 11.

[0101] Figure 9 A side view of a turbine blade 94 according to a first example is illustrated. 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, which in this example is 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 A side view of a turbine blade 110 according to a second example is illustrated. The turbine blade 110 is similar to the turbine blade 94, and like features are numbered the same.

[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 of the turbine blade 94, and can include a plurality of cavities 114 extending into the airfoil 98. Measurable dimensions of the erosion 112 include the length, width, surface area of the erosion, and the depth of the eroded region relative to the uneroded region.

[0104] Figure 11 A side view of a turbine blade 116 according to a third example is illustrated. The turbine blade 116 is similar to the turbine blades 94 and 110, and like features are numbered the same.

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

[0106] Creep 118 can additionally or alternatively be defined by an angle of twist by airfoil 98 about a longitudinal axis of turbine blade 116 (where the longitudinal axis extends between platform 96 and shroud 100 and is perpendicular to platform 96 and shroud 100).

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

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

[0109] At block 120, the method includes determining coordinates of the identified features in the three-dimensional data. In some examples, controller 14 can determine the coordinates of the identified features by determining coordinates of a perimeter of the identified features in the received three-dimensional data.

[0110] At block 122, the method includes measuring parameters of the features of the component using the determined coordinates of the features in the three-dimensional data. As used herein, “parameters” include physical dimensions of the features (e.g., length, width, etc.), a number of features, a density of features, and a spacing between features. In some examples, block 122 can include measuring a plurality of parameters of the features using the determined coordinates of the features in the three-dimensional data.

[0111] Controller 14 can measure at least one of the following using the determined coordinates: one or more angles, one or more lengths, an area, a volume of the identified features, a number of the identified features, a density of the identified features, and a spacing between features. To perform the measurement(s), controller 14 can perform point cloud processing (such as RANSAC, three-dimensional object matching), CAD alignment with a model of the component, and / or point cloud stitching.

[0112] Taking Figure 9 As an example, controller 14 can use the determined coordinates of crack 108 to measure a length, a width, and a 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. Turning to Figure 11 The controller 14 can use the determined coordinates to measure the length LI and then determine the creep of the turbine blade 116 by subtracting L2 from LI.

[0113] At block 122, the method can additionally include controlling storage of the measured one or more parameters in a data set 123 in the memory 26.

[0114] Figure 12 A flowchart illustrating a fourth method of inspecting the engine 12 is shown. The controller 14 can perform the fourth method in the case where the sensors 22 include two-dimensional sensors and three-dimensional sensors. Figure 12 The fourth method illustrated in Figure 5 is similar to the first method illustrated in Figure 8 and the third method illustrated in and uses the same reference numbers where the blocks are similar.

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

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

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

[0118] At block 128, the method includes determining coordinates of the identified features in the received three-dimensional data using the determined coordinates of the identified features in the two-dimensional data and the predetermined conversion algorithm 29. For example, the controller 14 can calculate the coordinates of the identified features in the received three-dimensional data by applying the conversion algorithm 29 to the two-dimensional coordinates of the features determined at block 126.

[0119] The fourth method then moves to block 122 and includes measuring one or more parameters of the identified feature of the component using the coordinates of the identified feature in the three-dimensional data. The fourth method can also include controlling storage of the measured one or more parameters at block 122.

[0120] The fourth method can be advantageous in situations where the controller 14 identifies features in the two-dimensional data with a higher likelihood than identifying features in the three-dimensional data. For example, some features (e.g. erosion) can be relatively challenging for the controller 14 to identify in the three-dimensional data as the change in coordinates (relative to the original state of the component) can be small. However, such features can be easily identified in the two-dimensional data by the controller 14 due to a change in colour or pattern.

[0121] Figure 13 A flowchart illustrating a fifth method of inspecting the engine 12 is shown in Figure 5. The fifth method is similar to the first method illustrated in Figure 1, Figure 5 the third method illustrated in Figure 3 and Figure 8 the fourth method illustrated in Figure 4, and where blocks are similar, the same reference numerals are used. Figure 12

[0122] At block 82, the fifth method includes receiving data comprising two-dimensional data and three-dimensional data of a component of the engine 12. The fifth method then moves to block 92 and includes identifying a feature of the component of the engine 12 using the received three-dimensional data.

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

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

[0125] ​At block 134, the fifth method comprises identifying a feature of the component using a subset of the two-dimensional data corresponding to the first region. For example, in the case where the two-dimensional data received at block 82 comprises an image of 1920 pixels by 1080 pixels and the feature is an erosion, the subset of data corresponding to the first region has coordinates of 200 to 500 on the horizontal (X) axis and coordinates of 600 to 800 on the vertical axis (Y). The controller 14 can perform the feature analysis and identification on this subset of two-dimensional data as described above with reference to block 124.

[0126] It will be appreciated that block 134 can identify the same feature as identified at block 92, but can identify additional features, since the analysis is performed on two-dimensional data, whereas block 134 is performed on three-dimensional data. For example, the controller 14 can identify the eroded portion 112 of the airfoil 98 at block 92, and can identify the eroded portion 112 and a crack at block 134.

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

[0128] At block 128, the fifth method comprises determining the coordinates of the feature identified at block 134 in the three-dimensional data using the coordinates of the feature in the two-dimensional data determined at block 126 and the predetermined conversion algorithm 29.

[0129] The fifth method then moves to block 122, and comprises measuring one or more parameters of the feature identified at block 134 using the three-dimensional coordinates of the feature determined at block 128. The fifth method can also comprise controlling storage of the one or more parameters measured at block 122.

[0130] The fifth method can advantageously increase the likelihood of identifying a feature of a component of the engine 12, since the feature analysis and identification is performed on both the two-dimensional data and the three-dimensional data received at block 82.

[0131] Figure 14 A sixth method of inspecting the engine 12 is illustrated. The sixth method is similar to the first method illustrated in Figure 5 the third method illustrated in Figure 8 the fourth method illustrated in Figure 12 and the fifth method illustrated in Figure 13 and uses the same reference numbers where the blocks are similar.

[0132] At block 82, the method comprises receiving data comprising two-dimensional data and three-dimensional data of the engine 12.

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

[0134] At block 138, the sixth method includes determining coordinates of a second volume in the three-dimensional data corresponding to the second region using the determined coordinates of the second region in the two-dimensional data and the predetermined conversion algorithm 29. For example, the controller 14 can apply the conversion algorithm 29 to the two-dimensional coordinates of the second region determined at block 136 to calculate the coordinates of the second volume in the three-dimensional data.

[0135] The sixth method then moves to block 140 and includes identifying a feature of the component using a subset of the three-dimensional data corresponding to the second volume calculated at block 138. It will be appreciated that block 140 is analogous to block 92 in the third method illustrated in Figure 8 and the fifth method illustrated in Figure 13 but differs in that the feature analysis and identification is performed only on the subset of the three-dimensional data (i.e., the three-dimensional data corresponding to the second volume).

[0136] The sixth method then moves through blocks 130, 132, 134, 126, 128, and 122 to provide a measurement of one or more parameters of the identified feature of the component. The sixth method can also include controlling storage of the measured one or more parameters at block 122.

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

[0138] Figure 8 , 12 The methods illustrated in

[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 method for inspecting an engine comprising: inspecting an engine to identify damage by inserting an inspection device into the engine during a first time period, the engine being associated with an aircraft, the inspection device having sensors configured to generate three-dimensional data, wherein the aircraft is not operational and not released by a control tower or repair facility of an airport during the first time period; receiving three-dimensional data of one or more components of the engine, the three- dimensional data being generated during the first time period; determining whether the identified damage exceeds a threshold during the first time period; if the identified damage does not exceed the threshold, providing instructions to release the aircraft for operation for a second time period after the first time period; and inspecting the received three-dimensional data generated during the first time period to measure damage by measuring parameters of features of the components during the second time period, the aircraft being in a flight condition during the second time period.

2. The method of claim 1, wherein inspecting the received three-dimensional data comprises: identifying features of the components using the three-dimensional data; determining coordinates of the features in the three-dimensional data; and measuring parameters of features of the components using the determined coordinates of the features in the three-dimensional data.

3. The method of claim 1, further comprising: receiving data comprising two-dimensional data of components of the engine, the two- dimensional data being generated during the first time period; and wherein inspecting the received three-dimensional data comprises: identifying features of the components using the two-dimensional data; determining coordinates of the features in the two-dimensional data; determining coordinates of the features in the three-dimensional data using the determined coordinates of the features in the two-dimensional data and a predetermined conversion between coordinates in two-dimensional data and coordinates in three-dimensional data; and measuring parameters of features of the components using the determined coordinates of the features in the three-dimensional data.

4. The method of claim 3, wherein prior to identifying features of the components using the two-dimensional data, the method further comprises: identifying features of the components using the three-dimensional data; determining coordinates in the three-dimensional data of a first volume bounding coordinates of the features; determining coordinates of a first region in the two-dimensional data corresponding to the first volume using the determined coordinates of the first volume in the three- dimensional data and the predetermined conversion.

5. The method of claim 4, wherein identifying features of the components using the two- dimensional data comprises using a subset of the two-dimensional data corresponding to the first region.

6. The method of claim 4, wherein determining coordinates in the three-dimensional data of the first volume comprises: identifying the first volume in the three-dimensional data using the identified features of the components; and a three-dimensional model of the components. ​ ​ 7. The method of claim 4, wherein prior to using the three-dimensional data to identify features of the component, the method further comprises: identifying a second region using the two-dimensional data of the component, the second region excluding predetermined components and / or predetermined subcomponents of the engine within the two-dimensional data; determining coordinates of a second volume in the three-dimensional data corresponding to the second region using: the determined coordinates of the second region in the two-dimensional data; and the predetermined conversion.

8. The method of claim 7, wherein using the three-dimensional data to identify features of the part comprises: identifying features of the component using a subset of the three-dimensional data corresponding to the second volume.

9. The method of claim 3, further comprising: controlling storage of the measured parameters.

10. The method of claim 1, wherein inspecting the received three-dimensional data during the second time period is performed by a computer.

11. The method of claim 1, wherein inspecting the received three-dimensional data during the second time period is performed automatically by a computer in response to receiving the three-dimensional data.

12. The method of claim 1, wherein inspecting the received three-dimensional data is performed during a predetermined time period from release of the aircraft for operation.

13. A non-transitory computer-readable storage medium comprising computer-readable instructions that, when executed by a computer, cause the computer to perform the method of any one of claims 1 to 12.

14. An apparatus for inspecting an engine, comprising: a controller configured to perform the method of any one of claims 1 to 12.

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