Insertion tool

Abstract

An insertion tool for performing an operation on a device, the insertion tool comprising: a plurality of segments, each of the plurality of segments comprising a body, the body comprising: a first hinge; and a second hinge, the first hinge of the first segment being coupled to the second hinge of the second segment adjacent to the first segment via an interface, wherein the interface comprises a powder gap, a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof, wherein the insertion tool is constructed to be selectively rigidifiable using a strength member engaged with the plurality of segments.

Description

Technical Field

[0001] The present subject matter generally relates to tools for inspecting an environment and / or performing maintenance operations on components within the environment, such as within an annulus in a turbine engine. Background Art

[0002] At least some gas turbine engines include in a serial flow arrangement: a compressor section including a low-pressure compressor and a high-pressure compressor for compressing air flowing through the engine; a combustor for mixing fuel with the compressed air so that the mixture can be ignited; and a turbine section including a high-pressure turbine and a low-pressure turbine for providing power to the compressor section.

[0003] At least some gas turbine engines define annular openings within one or more sections. Some of these annular openings may vary in size, such that a dedicated, specialized insertion tool must be used for each annular opening to extend around and through such annular openings.

[0004] The inventors of the present disclosure have proposed an insertion tool that can be inserted into an annular opening. The insertion tool proposed by the inventors can benefit from the inclusion of relatively complex geometric shapes and features. Therefore, an insertion tool formed in a manner that meets these needs will be useful. Summary of the invention

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] In an exemplary embodiment of the present disclosure, an insertion tool for performing an operation on a device comprises: a plurality of segments, each of the plurality of segments comprises a body, the body comprising: a first hinge member; and a second hinge member, the first hinge member of the first segment being connected to the second hinge member of the second segment adjacent to the first segment via an interface, wherein the interface comprises a powder gap, a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof.

[0007] According to another exemplary embodiment, an insertion tool for performing an operation on a device comprises: a plurality of segments, each of the plurality of segments comprising a body, the body comprising: a first hinge member; and a second hinge member, the first hinge member of the first segment being connected to the second hinge member of the second segment adjacent to the first segment via an interface, wherein the interface comprises a powder gap, a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof; and a strength member, the strength member intersecting the interface.

[0008] According to another exemplary embodiment, a method of forming an insert tool includes: additively forming a body of a segment of the insert tool; and flexing adjacent segments of the insert tool relative to each other so that powder contained at an interface between adjacent segments of the insert tool can pass from the interface through a powder gap.

[0009] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings.

[0011] Figure 1 is a cross-sectional schematic diagram of a high bypass turbofan jet engine according to an exemplary embodiment of the present disclosure.

[0012] Figure 2 A method of inserting a tool according to an exemplary embodiment of the present disclosure is provided. Figure 1 Close-up cross-sectional views of a combustion section of an exemplary gas turbine engine in axial and radial directions.

[0013] Figure 3 An exemplary insertion tool is included Figure 1 Another close-up cross-sectional view of the combustion section of an exemplary gas turbine engine along radial and circumferential directions.

[0014] Figure 4 is a perspective view of an insertion tool according to an exemplary embodiment of the present disclosure.

[0015] Figure 5 is a perspective view of an insertion tool according to an exemplary embodiment of the present disclosure.

[0016] Figure 6 is an enlarged view of one end of a segment of an insertion tool according to an exemplary embodiment of the present disclosure.

[0017] Figure 7 is an enlarged view of the other end of a segment of an insertion tool according to an exemplary embodiment of the present disclosure.

[0018] Figure 8 is a perspective view of an insertion tool according to an exemplary embodiment of the present disclosure.

[0019] Fig. 9 is an enlarged view of the distal end of an insertion tool according to an exemplary embodiment of the present disclosure.

[0020] Fig.10 is a perspective view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure as seen in a non-rigidified configuration.

[0021] Fig.11 is a perspective view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure as seen in a non-rigidified configuration.

[0022] Fig.12 is a perspective view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure as seen in a rigidified configuration.

[0023] Fig.13A is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a rigidified configuration.

[0024] Fig. 13B is an enlarged schematic illustration of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure, seen in a rigidified configuration.

[0025] Fig.14A is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a rigidified configuration.

[0026] Fig. 14B is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure as seen in a non-rigidified configuration.

[0027] Fig.15A is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a rigidified configuration.

[0028] Fig. 15B is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a disconnected configuration.

[0029] Fig.16A is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a rigidified configuration.

[0030] Fig. 16B is a side view of an interface between adjacent segments of an insertion tool according to an exemplary embodiment of the present disclosure seen in a disconnected configuration.

[0031] Fig. 16C According to the embodiment Fig.16A Cross-sectional view of the interface between adjacent segments seen through line CC.

[0032] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0033] Reference will now be made in detail to the present embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and letter references to refer to features in the drawings. The same or similar reference numerals in the drawings and description have been used to refer to the same or similar parts of the present invention.

[0034] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided to illustrate the invention, not to limit the invention. In fact, it will be apparent to those skilled in the art that various modifications and changes can be made to the invention without departing from the scope of the invention. For example, features shown or described as part of one embodiment can be used with another embodiment to produce yet another embodiment. Therefore, the invention is intended to cover such modifications and changes as come within the scope of the appended claims and their equivalents.

[0035] As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of the respective components. Unless the context clearly dictates otherwise, the singular forms "a," "an," and "the" include plural references. Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment and indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0036] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle, and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, front refers to a position closer to the engine inlet, while rear refers to a position closer to the engine nozzle or exhaust. The terms "upstream" and "downstream" refer to relative directions relative to the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" refers to the direction toward which the fluid is flowing.

[0037] As used herein throughout the specification and claims, approximate language is used to modify any quantitative representation that can be permitted to vary without resulting in a change in the basic function to which it is related. Therefore, values ​​modified by terms such as "about," "approximately," and "substantially" are not limited to the precise values ​​specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to within 10%.

[0038] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0039] In general, an insertion tool according to one or more embodiments described herein may be configured to allow an operator or robotic assembly to maintain (e.g., inspect and / or repair) a cavity, such as the interior volume of a gas turbine engine. The insertion tool may typically include a plurality of adjacent segments that may be selectively rigidified relative to one another to allow the distal end of the insertion tool to enter a confined cavity of the device through a complex path. The adjacent segments may define a hinge member that together forms an interface between the adjacent segments. The hinge member may include features for enhancing the operation of the insertion tool during use (e.g., when inserting the insertion tool into the interior volume of a gas turbine engine).

[0040] Referring now to the drawings, wherein like numerals refer to like elements throughout, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure. More specifically, Figure 1 In the embodiment of the present invention, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as a "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 provided for reference) and a radial direction R. The turbofan engine 10 also defines a circumferential direction C (see FIG. 1 ) extending circumferentially about the axial direction A. Figure 3 ). Generally, the turbofan engine 10 includes a fan section 14 and a turbine 16 disposed downstream of the fan section 14 .

[0041] The depicted exemplary turbine 16 is generally enclosed within a substantially tubular outer casing 18 defining an annular inlet 20 and an annular exhaust port 21. The outer casing 18 encloses, in serial flow relationship: a compressor section including a supercharger or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22. The compressor section, combustion section 26, turbine section, and nozzle section 32 together define a core air flow path 37 therethrough.

[0042] For the depicted embodiment, the fan section 14 includes a fixed pitch fan 38 having a plurality of fan blades 40. The fan blades 40 are each attached to a disk 42, and the fan blades 40 and disk 42 together can be rotated about the longitudinal axis 12 by the LP shaft 36. For the depicted embodiment, the turbofan engine 10 is a direct drive turbofan engine, so that the LP shaft 36 directly drives the fan 38 of the fan section 14 without using a reduction gearbox. However, in other exemplary embodiments of the present disclosure, the fan 38 can alternatively be a variable pitch fan, and the turbofan engine 10 can include a reduction gearbox, in which case the LP shaft 36 can drive the fan 38 of the fan section 14 across the gearbox.

[0043] Still refer to Figure 1 In the exemplary embodiment of the present invention, the disk 42 is covered by a rotatable forward hub 48 that is aerodynamically shaped to facilitate airflow through the plurality of fan blades 40. In addition, the exemplary turbofan engine 10 includes an annular nacelle assembly 50 that circumferentially surrounds the fan 38 and / or at least a portion of the turbine 16. For the depicted embodiment, the nacelle assembly 50 is supported relative to the turbine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the nacelle assembly 50 extends over an outer portion of the casing 18 to define a bypass airflow passage 56 therebetween. The ratio between a first portion of air passing through the bypass airflow passage 56 and a second portion of air passing through the inlet 20 of the turbine 16 and through the core air flow path 37 is generally referred to as a bypass ratio.

[0044] It should be understood that although not Figure 11, the turbofan engine 10 may also define a plurality of openings to allow inspection of various components within the turbine 16. For example, the turbofan engine 10 may define a plurality of borescope openings at various axial locations within the compressor section, the combustion section 26, and the turbine section. Additionally, as will be discussed below, the turbofan engine 10 may include one or more igniter ports within, for example, the combustion section 26 of the turbine 16, which may allow inspection of the combustion section 26.

[0045] It should be further understood that Figure 1 The exemplary turbofan engine 10 depicted in the drawings is merely an example, and in other exemplary embodiments, the turbofan engine 10 may have any other suitable configuration, including, for example, any other suitable number of shafts or spools, turbines, compressors, etc. Additionally or alternatively, in other exemplary embodiments, any other suitable turbine engine may be provided. For example, in other exemplary embodiments, the turbine engine may not be a turbofan engine, but may instead be configured as a turboshaft engine, a turboprop engine, a turbojet engine, etc.

[0046] Reference now Figure 2 , Figure 1 A close-up schematic diagram of the combustion section 26 of the turbine 16 of an exemplary gas turbine engine 10 is provided together with a tool 100 for insertion into an annular section of the engine 10. It should be understood that although the tool 100 is Figure 2 1 is depicted as being inserted into the combustion section 26, but in other exemplary embodiments, the tool 100 may additionally or alternatively be inserted into other areas of the turbofan engine 10 having an annular shape or other shapes. In other embodiments, the tool 100 may be inserted into an annular section of a compressor section or a turbine section, or alternatively, into other engines or systems. For example, Figure 3 An embodiment of a tool 100 for insertion into a high pressure (HP) turbine, such as the previously described HP turbine 28, is shown. The tool 100 may be inserted into a bore of the engine 10 and through the fan section 14, including the fan blades 40, until reaching the interior of the engine 100 corresponding to the HP turbine 2 stage C-clip 80. Certain tool geometries may allow the tool 100 to reach a desired maintenance location through the HP turbine 28. The tool 100 may inspect and / or operate the HP turbine 2 stage C-clip 80, which may fail prematurely, resulting in excessive aircraft downtime. Still additionally or alternatively, the tool 100 may be inserted into a non-annular section. For Figure 3 In the embodiment of FIG. 1 , a tool 100 capable of being inserted into an annular section of an engine is depicted extending through a borescope into the HP turbine 28 .

[0047] Now also refer to Figure 4, provides Figure 3 28, it will be appreciated that the tool 100 generally includes a plurality of segments 102 that can be moved into the engine 10. Each of the plurality of segments 102 can be aligned to form a continuous tool 100. In a rigidized configuration, the plurality of segments 102 can be coupled together such that the tool 100 has a generally rigid structure. That is, the plurality of segments 102 can act like a rigid body, exhibiting sufficient structural rigidity to maintain a desired shape while moving and / or operating within the engine 10 (e.g., the HP turbine 28). Figure 4 As shown and in accordance with certain embodiments, the tool 100 may be maintained in a one-dimensional or two-dimensional spatial arrangement. That is, the tool 100 may not be twisted, for example, helically, in the third dimension of a Cartesian coordinate system. In other embodiments described herein, the tool 100 may exhibit three-dimensional bending. In one or more embodiments, the tool 100 may be inserted into the engine 10 while having a semi-relaxed configuration. In this way, the tool 100 may more easily pass through one or more obstacles in the engine 10. Once through the obstacle, the tool 100 may be fully rigidified.

[0048] In some cases, the tool 100, when in use, can define one or more linear portions 104 and one or more curved portions 106. The curved portions 106 can be created, for example, at interfaces 108 between adjacent segments 102. Alternatively, the curved portions 106 can be internal to the shape of at least some of the segments 102. That is, for example, one or more of the segments 102 can define a curved shape that creates a bend in the tool 100 when in a rigidized configuration. The curved portion 106 can define a radius of curvature, such as R1. The radius of curvature of the curved portion 106 shown can be set within a single plane. That is, for example, as described above, the radius of curvature of the curved portion 106 of the tool 100 can be defined by a single plane.

[0049] The distal end 110 of the tool 100 may include an instrument, which for the depicted embodiment is a camera 112, to allow inspection of various components of the high pressure turbine 28, such as the aforementioned C-clip 80, etc. However, it should be understood that the insertion tool 100 may include any other suitable instrument, so that the insertion tool 100 can be used for any suitable purpose. For example, the insertion tool 100 can be used to inspect the interior of the engine using, for example, the camera 112. Additionally or alternatively, the insertion tool 100 may include various other tools and instruments to perform one or more maintenance operations (e.g., drilling, welding, heating, cooling, cleaning, spraying, etc.) inside the engine.

[0050] In addition, the exemplary insertion tool 100 may include a drive assembly 114 for driving the insertion tool 100 into or out of the engine, and more specifically, for the illustrated embodiment, to or out of the HP turbine 28. The drive assembly 114 may be operably coupled to a controller or other control device so that the length of the insertion tool 100 inside the engine 10 can be relatively accurately controlled by the drive assembly 114. In certain embodiments, the drive assembly 114 may include a motor, a servo motor, etc. configured to drive the tool 100 relative to the engine 10. In other cases, the drive assembly 114 may include a manual interface configured to allow an operator to manually move the tool 100. As described below, the drive assembly 114 may be a selective rigidifier configured to selectively rigidify the tool 100 into a desired shape.

[0051] Figure 5 A perspective view of a tool 100 is shown according to an exemplary embodiment, the tool 100 being in a relaxed (e.g., non-rigid) configuration. The tool 100 includes segments 102, such as a first segment 102A, a second segment 102B, a third segment 102C, a fourth segment 102D, a fifth segment 102E, a sixth segment 102F, a seventh segment 102G, and an eighth segment 102H. Although the illustrated embodiment depicts the tool 100 as including eight segments 102, the number of segments 102 may vary. For example, the tool 100 may include at least two segments, such as at least three segments, such as at least four segments, such as at least five segments, such as at least six segments, such as at least seven segments, such as at least eight segments, such as at least nine segments, such as at least ten segments, such as at least fifteen segments, such as at least twenty segments, such as at least thirty segments, such as at least forty segments, etc. In an embodiment, at least two of the plurality of segments 102 may have the same or similar shape compared to each other. That is, for example, at least two of the segments 102 may have a body 114 that defines the same or similar sidewalls 116 and / or ends 118 as compared to one another. In a more specific embodiment, all of the plurality of segments 102 may share a common body shape, or particular aspects of the body shape. For example, all of the plurality of segments 102 may have the same sidewall length, as measured between opposing ends 118, all of the plurality of segments 102 may have the same general sidewall shape, etc. In another embodiment, at least two of the plurality of segments 102 may have a different shape as compared to one another. For example, the bodies 114 of at least two of the segments may have different lengths as compared to one another, different circumferential dimensions as compared to one another, different ends 118, etc. As a non-limiting example, Figure 5The length L7 of the seventh segment 102G depicted in FIG is less than the length L6 of the sixth segment 102F. As another non-limiting example, the first segment 102A may be formed of a first material and the second segment 102B may be formed of a second material different from the first material. As yet another non-limiting example, the first segment 102A may be formed using a specific manufacturing process or manufacturing tolerance that is different from the manufacturing process or tolerance of the second segment 102B. For example, the first segment 102A may have a lower tolerance or resolution than the second segment 102B. In some cases, the segment 102 may be formed using an additive manufacturing process (e.g., three-dimensional printing). The first segment 102A may have a lower printing resolution than the printing resolution of the second segment 102B, the third segment 102C, etc. For example, this may occur in the case where the first segment 102A is a handle or outermost segment that does not require high surface finish properties to slide over or pass over features of the engine 10 during navigation.

[0052] In one or more embodiments, each pair of adjacent (i.e., neighboring) segments 102 may be attached together via an interface 120. The interface 120 may be disposed at or adjacent to the ends 118 of the adjacent segments 102. For example, referring to the interface 120 between the fourth segment 102D and the fifth segment 102E, each interface 120 may be formed by a first hinge member 122 associated with one of the segments (e.g., the fourth segment 102D) and a second hinge member 124 associated with the adjacent segment (e.g., the fifth segment 102E). The first hinge member 122 and the second hinge member 124 may be coupled together to allow relative movement between adjacent segments 102 (e.g., between the fourth segment 102D and the fifth segment 102E). For example, the first hinge member 122 and the second hinge member 124 may allow relative movement of the segments 102 in one or more planes, such as rotational movement. In a particular embodiment, the interface 120 between a pair of adjacent segments 102 may allow the segments 102 to move within a single plane. For example, as Figure 5 As shown, the fourth segment 102D and the fifth segment 102E can move relative to each other along a plane corresponding to arrow 126. That is, the fourth segment 102D and the fifth segment 102E can pivot relative to each other in the direction indicated by arrow 126 while remaining within a single relative movement plane.

[0053] In the illustrated embodiment, the interfaces 120 formed between at least two pairs of adjacent segments 102 may be different from each other. For example, the interface 120 formed between the fourth segment 102D and the fifth segment 102E is arranged in a first rotational plane, while the interface 120 formed between the second segment 102B and the third segment 102C is arranged in a second rotational plane different from the first plane. Therefore, the rotation angle of the interface 120 formed between the third segment 102C and the fourth segment 102C may be different from the rotation angle of the interface 120 formed between the fourth segment 102D and the fifth segment 102E. In a non-rigid configuration, for example, Figure 5 As shown, such a multi-plane interface may not substantially affect the relaxed shape of the tool 100. However, when rigidified, Figure 5 The multi-planar interface depicted in may result in the tool 100 having a three-dimensional shape for accessing certain areas of the engine 10 or similar structures being maintained (inspected and / or operated).

[0054] The distal segment of the tool 100 (e.g., the eighth segment 102H in the depicted embodiment) can have a different shape than the other segments 102 to allow for maintenance operations. In the illustrated embodiment, the eighth segment 102H is depicted as having a tapered profile having a minimum width disposed at or adjacent to the distal end 110 of the tool 100. In this manner, the tool 100 can be more easily fed into the equipment being maintained (e.g., an aircraft engine). In addition, the tapered profile can allow an implement (e.g., camera 112) to exit the interior volume of the tool 100 (described in more detail below) to perform operations during maintenance without requiring changes to the diameter of the tool 100.

[0055] Figure 6 and 7 The ends 118 of the adjoining (ie, adjacent) segments 102 are shown. The ends 118 may mate with each other so that the interface 120 (ie, the interface 120 between the ends 118) is formed more closely than other interfaces 120 formed between other pairs of segments 102. Figure 5 ) moves in a predetermined manner, for example in a predetermined plane.

[0056] In embodiments, the body 114 of at least one of the segments 102 may be formed by an additive manufacturing process, such as, for example, a three-dimensional printing process, as a non-limiting example. The body 114 according to some embodiments described herein may therefore include indicia of the three-dimensional printing manufacturing process in the form of indicia, including strata, such as layers formed in the body 114 corresponding to individual step-printed layers. In certain embodiments described herein, all of the segments 102 of the tool 100 may be formed using an additive manufacturing process, such as a three-dimensional printing technique. In certain embodiments, the segments 102 may be additively manufactured simultaneously when already in an engaged configuration. That is, adjacent segments 102 may be additively formed in an engaged position relative to each other.

[0057] First reference Figure 6 , the exemplary segment 102 depicted may refer to any one or more of the above-described segments 102 (e.g., the first segment 102A, the second segment 102B, the third segment 102C, etc.). The body 114 of the segment 102 defines a first hinge member 122 ( Figure 5 ). The first hinge member 122 is laterally offset from the central axis 128 of the body 114 in the radial direction. That is, the first hinge member 122 may not be centrally disposed relative to the body 114. Figure 6 In the particular embodiment depicted in FIG, the first hinge member 122 generally includes a central structure 130 and a channel 132 disposed adjacent thereto. The channel 132 is a splitter channel and includes a first channel portion 132A and a second channel portion 132B. The central structure 130 is disposed between the first channel portion 132A and the second channel portion 132B. In an embodiment, the first channel portion 132A and the second channel portion 132B may have the same or similar shapes and / or sizes as compared to each other. In another embodiment, the first channel portion 132A and the second channel portion 132B may have different shapes and / or sizes as compared to each other. The central structure 130 may define opposing surfaces 134A and 134B that are separated from each other by the thickness of the central structure 130. The opposing surfaces 134A and 134B may form end walls of the first channel portion 132A and the second channel portion 132B. As described below with respect to Figure 7 As depicted, the opposing surfaces 134A and 134B may engage with complementary surfaces of the second hinge member 124 to form the interface 120 between adjacent segments 102 .

[0058] Figure 6The body 114 of the illustrated segment 102 also includes a cavity 136. The cavity 136 extends through the length of the segment 102 and can emerge from the body 114 at two or more exit locations, such as at an exit location 138. In the illustrated embodiment, the exit location 138 is shown as intersecting the first hinge member 122. That is, for example, the exit location 138 can emerge from the body 114 through the first hinge member 122 at an exit location that is transverse or substantially transverse to the axis of rotation of the interface 120. A second exit location (not shown) of the cavity 136 can exit the body 114 of the segment 102 through the second hinge member of the segment 102. In this manner, at least one of the bodies 114 can include the first hinge member 122 and the second hinge member 124, and the cavity 136 can exit the body 114 through the first hinge member 122 and the second hinge member 124. The cavity 136 can define a constant or substantially constant cross-sectional shape along the length of the body 114. In some cases, the cavity 136 can be linear, or substantially linear. That is, the longitudinal axis of the cavity 136 can be placed along a straight line or a substantially straight line. As described in more detail below, the cavity 136 can be configured to receive a strength member. The strength member can form the backbone of the tool 100, which deviates from the central axis 128 of the segment 102 and therefore deviates from the central axis of the tool 100. In some embodiments, the strength member can include a flexible member, such as a tension bearing element, a rope, a material that defines a load-bearing memory of a predefined shape, etc. The strength member can allow the tool 100 to flex while allowing the tool 100 to return to, for example, a predefined shape. For example, in a non-rigid configuration, the tool 100 can slide through a predefined volume of an aircraft engine until a desired position is reached. The tool 100 may have to undergo deformation (e.g., bending) to navigate the predefined volume of an aircraft engine. For example, the tool 100 may have to slide around a corner and through a shaped passage to reach a desired position. The strength member can allow the tool to remain in a single operable piece to slide into the aircraft engine while preventing the tool from being stuck or stopped in the predefined volume. Once the tool is positioned in the desired location to allow operation on the engine, strength members may place the tool 100 in a predefined shape.

[0059] In an embodiment, the strength member may occupy less than the entire area size of the cavity 136. For example, the strength member may be a hollow tube extending through the cavity 136. As another example, the strength member may have a cross-sectional shape different from the cavity 136 and / or a size smaller than the cavity 136. In this way, the cavity 136 can further define a space to receive equipment, such as the aforementioned camera 112 therethrough.

[0060] In an embodiment, the strength member may include a shape memory alloy (SMA) material. In a more specific embodiment, the strength member may be formed entirely of an SMA material. In another specific embodiment, the strength member may be formed at least in part of an SMA material. SMA is generally an alloy that can recover its original shape after deformation. In addition, SMA can be used as a lightweight solid-state substitute for traditional materials. For example, certain SMAs can be heated to restore the deformed SMA to its shape before deformation. SMA can also provide a variable stiffness in a predetermined manner in response to a certain temperature range. The stiffness change of the shape memory alloy is due to a temperature-related solid-state microstructural phase transition, which can cause the alloy to change from one physical shape to another physical shape. The change in SMA stiffness can be produced by processing and annealing the preform of the alloy at a temperature equal to or higher than the solid-state microstructural phase transition of the shape memory alloy. The temperature at which this phase transition occurs is generally referred to as the critical temperature or transition temperature of the alloy.

[0061] Some shape memory alloys used herein are characterized by phase changes that depend on temperature. These phases include martensite and austenite. Martensite generally refers to a lower temperature phase, while austenite generally refers to a higher temperature phase. Martensite is generally more deformable, while austenite is generally not easily deformed. When the shape memory alloy is in the martensite phase and heated to a temperature higher than a certain temperature, the shape memory alloy begins to transform into the austenite phase. The temperature at which this phenomenon begins is called the austenite start temperature (As). The temperature at which this phenomenon ends is called the austenite finish temperature (Af). When the shape memory alloy in the austenite phase cools, it begins to transform into the martensite phase. The temperature at which this transformation begins is called the martensite start temperature (Ms). The temperature at which the transformation to the martensite phase ends is called the martensite finish temperature (Mf). As used herein, the term "transition temperature" without any further modifiers may refer to any one of the martensite transformation temperature and the austenite transformation temperature. Furthermore, “below the transformation temperature” without the modifiers “start temperature” or “finish temperature” generally refers to a temperature below the martensite finish temperature, and “above the transformation temperature” without the modifiers “start temperature” or “finish temperature” generally refers to a temperature above the austenite finish temperature.

[0062] In some embodiments, the strength member has a first stiffness at a first temperature and a second stiffness at a second temperature, wherein the second temperature is different from the first temperature. In addition, in some embodiments, one of the first temperature and the second temperature is below the transition temperature, and the other may be equal to or above the transition temperature. Thus, in some embodiments, the first temperature may be below the transition temperature and the second temperature may be equal to or above the transition temperature, while in some other embodiments, the first temperature may be equal to or above the transition temperature and the second temperature may be below the transition temperature.

[0063] Exemplary but non-limiting examples of SMAs may include nickel titanium (NiTi) and other nickel titanium-based alloys, such as nickel titanium hydrogen fluoride (NiTiHf) and nickel titanium palladium (NiTiPd). However, it should be understood that other SMA materials may be equally applicable to the present disclosure. For example, in certain embodiments, the SMA may include a nickel aluminum-based alloy, a copper aluminum nickel alloy, or an alloy containing zinc, copper, gold, and / or iron. The alloy composition may be selected to provide the desired stiffness effect for the application, such as but not limited to damping capacity, transformation temperature and strain, strain hysteresis, yield strength (of martensite and austenite phases), oxidation resistance and hot corrosion resistance, ability to change shape through repeated cycles, ability to exhibit one-way or two-way shape memory effect, and / or many other engineering design criteria. Suitable shape memory alloy compositions that can be used with embodiments of the present disclosure may include, but are not limited to, NiTi, NiTiHf, NiTiPt, NiTiPd, NiTiCu, NiTiNb, NiTiVd, TiNb, CuAlBe, CuZnAl, and some iron-based alloys. In some embodiments, a NiTi alloy is used that has a transformation temperature between 5° C. and 150° C. The NiTi alloy may transform from austenite to martensite upon cooling.

[0064] The body 114 also includes one or more auxiliary cavities 140. In an exemplary embodiment, the auxiliary cavity 140 can be disposed on an opposite side of the central axis 128 compared to the cavity 136. The one or more auxiliary cavities 140 can include, for example, at least one auxiliary cavity, such as at least two auxiliary cavities, such as at least three auxiliary cavities. In an embodiment, the auxiliary cavities 140 can have one or more properties that are the same or similar to each other. For example, the auxiliary cavities 140 can all share the same radial offset distance from the central axis 128. In another embodiment, the auxiliary cavities 140 can have one or more different properties compared to each other. For example, the auxiliary cavities 140 can have different diameters compared to each other. As described in more detail below, in some embodiments, the auxiliary cavity 140 can be configured to receive one or more support members. In some cases, one or more selectively rigidifying elements (e.g., support members and / or strength members) can operate to selectively rigidify the tool 100 and / or help support the tool 100 in a non-rigid (i.e., relaxed) configuration. For example, in the case where the support member includes a tension-bearing material (e.g., a rope), tensioning the support member can cause the tool 100 to adopt a rigidified configuration. During tensioning of the support member, adjacent segments of the tool 100 may pivot relative to (e.g., about) the interface 120 until the support member reaches a critical tension, thereby rigidifying the tool. In some cases, the strength member may also be rigidified by applying tension thereto (e.g., Fig.11) and selectively rigidizable. In other embodiments, the selectively rigidizable element can be selectively rigidizable using a non-tensioning method. For example, selective rigidification can occur through phase shifting, chemical and / or electrical stimulation, etc.

[0065] The hole 142 can be disposed within the body 114 of at least one of the segments 102 (e.g., all segments 102) and is configured to receive an instrument (e.g., the camera 112 described above) for performing operations at a desired location. In an embodiment, the hole 142 can be centered or substantially centered relative to the central axis 128 of the body 114. In some cases, the hole 142 can be disposed at a radial position between the cavity 138 and at least one of the auxiliary cavities 140. The hole 142 can define a non-circular cross-section. For example, the hole 142 can define an oval cross-sectional profile, a rectangular cross-sectional profile, or other shapes other than a circle. In some cases, the hole 142 can be configured to receive an instrument having a non-circular cross-section, such as a cable connected to a tool (e.g., camera 112). For example, the cable can be a ribbon cable or another flat or substantially flat cable. The cable can be configured to bend on a single or substantially single axis. That is, for example, the cable can define a planar shape. The planar shape can be bent in a direction perpendicular to the planar shape. The hole 142 can be relative to the interface 120 ( Figure 5 ) is shaped and / or oriented so that the planar cable bends in a direction associated with the direction of movement (eg, rotation) at the interface 120. In an embodiment, as shown by the maximum relative width W of the hole 142 H The maximum relative height H with respect to the hole 142 H Compared to the defined aspect ratio [W H :H H ] is at least 1.5:1, such as at least 2:1, such as at least 3:1, such as at least 4:1, such as at least 5:1, such as at least 7.5:1, such as at least 10:1, such as at least 15:1, such as at least 20: 1. In certain embodiments, the width and height of the hole 142 can be oriented to be substantially perpendicular relative to each other.

[0066] Figure 7 The diagram shows Figure 6 An exemplary embodiment of segments 102 in which segments 102 are arranged adjacent to each other is illustrated in FIG. Figure 7 The illustrated segment 102 includes an end portion 118 having a second hinge member 124 configured to engage with the hinge member 124. Figure 6 The second hinge member 124 may be complementary in shape and / or size to the first hinge member 122 to allow for the second hinge member 124 to be engaged with the first hinge member 122 as shown in FIG. Figure 6 and 7The second hinge member 124 can include a central structure 144 and a ridge 146. The central structure 144 can be centrally disposed along the ridge 146. The central structure 144 can divide the ridge 146 into a first ridge 146A and a second ridge 146B. The central structure 144 can be retracted into the ridge 146 to receive the central structure 130 of the first hinge 120. The central structure 144 can define opposing surfaces 144A and 144B that are configured to couple with the surfaces 134A and 134B of the first hinge 120 to form the interface 120.

[0067] The body 114 of the segment 102 may further define a cavity 148 configured to receive a strength member exiting the cavity 138 of the adjacent segment 102. The cavity 148 may extend through the length of the segment 102 and emerge from the body 114 at two or more exit locations, such as at an exit location 150. In the illustrated embodiment, the exit location 150 is shown as intersecting the second hinge member 124. That is, for example, the exit location 150 may emerge from the body 114 through the second hinge member 124 at an exit location that is transverse or substantially transverse to the axis of rotation of the interface 120. The second exit location (not shown) of the cavity 148 may exit the body 114 of the segment 102 through the first hinge member 122 of the segment 102. In this manner, the cavity 148 may exit the body 114 through the first hinge member 122 and the second hinge member 124. The cavity 148 may define a constant or substantially constant cross-sectional shape along the length of the body 114. In some cases, the cavity 148 can be linear, or substantially linear. That is, the longitudinal axis of the cavity 148 can lie along a straight line or a substantially straight line.

[0068] The body 114 also includes one or more auxiliary cavities 152. In an exemplary embodiment, the auxiliary cavity 152 can be arranged on the opposite side of the central axis 154 compared to the cavity 148. The one or more auxiliary cavities 152 may include, for example, at least one auxiliary cavity, such as at least two auxiliary cavities, such as at least three auxiliary cavities. In an embodiment, the auxiliary cavities 152 may have one or more properties that are the same or similar to each other. For example, the auxiliary cavities 152 can all share the same radial offset distance from the central axis 154. In another embodiment, the auxiliary cavities 152 may have one or more different properties compared to each other. For example, the auxiliary cavities 152 may have different diameters compared to each other. The auxiliary cavities 152 may be configured to receive the above-mentioned one or more support members.

[0069] The hole 156 may be disposed within the body 114 of the segment 102 and configured to receive the aforementioned instrument, such as a cable, extending through the hole 142 of the adjacent segment 102. In an embodiment, the hole 156 may be centered or substantially centered relative to the central axis 154 of the body 114. In some cases, the hole 156 may be disposed at a radial position between the cavity 148 and at least one of the auxiliary cavities 152. The hole 156 may define a non-circular cross-section. For example, the hole 156 may define an oval cross-sectional profile, a rectangular cross-sectional profile, or other shapes other than circular. In some cases, the hole 156 may be configured to receive an instrument having a non-circular cross-section, such as a cable connected to a tool (e.g., camera 112). For example, the cable may be a ribbon cable or another flat or substantially flat cable. The cable may be configured to bend on a single or substantially single axis. That is, for example, the cable may define a planar shape. The planar shape may be bent in a direction perpendicular to the planar shape. The hole 156 may be relative to the interface 120 ( Figure 5 ) is shaped and / or oriented so that the planar cable bends in a direction associated with the direction of movement (eg, rotation) at the interface 120. In an embodiment, as indicated by the maximum relative width W of the aperture 156 H The maximum relative height H with respect to the hole 156 H Compared to the defined aspect ratio [W H :H H ] is at least 1.5:1, such as at least 2:1, such as at least 3:1, such as at least 4:1, such as at least 5:1, such as at least 7.5:1, such as at least 10:1, such as at least 15:1, such as at least 20: 1. In certain embodiments, the width and height of the hole 156 can be oriented to be generally perpendicular relative to each other.

[0070] Although the above description refers to cavities 136 and 150, auxiliary cavities 140 and 152, and holes 142 and 156, respectively, it should be understood that these aspects may share any common geometry and / or shape compared to each other. Specifically, the cavities, auxiliary cavities, and holes can be configured to operate together to perform the above-mentioned functions of the tool. Therefore, these features can be, but do not have to be, common to all segments 102 of the tool 100. Therefore, reference to a particular aspect regarding one but not all of these elements, as it relates to one segment 102, can refer to that same aspect related to all segments 102. In addition, in another embodiment, cavities 136 and 150 can be part of the same cavity, each auxiliary cavity 140 and 152 can be part of the same auxiliary cavity, and holes 142 and 156 can be part of the same hole. That is, Figure 6 and Figure 7 Different ends, such as opposite ends, of the same segment 102 may be shown.

[0071] Figure 8 An embodiment of the tool 100 is shown in a rigidified configuration. The tool 100 is contained within a frame 158. Figure 8 As seen in FIG. 1 , according to some embodiments of the present disclosure, tool 100 may define a complex geometric shape extending through a three-dimensional Cartesian coordinate system. That is, tool 100 may extend in the X-axis, Y-axis, and Z-axis simultaneously. The particular shape of tool 100 may be viewed in response to the shape of the environment in which the tool will be used.

[0072] The tool 100 may also include an elongated portion 160 shown in frame 162. The elongated portion 160 may be connected to the tool 100 to extend the tool 100 so as to be inserted into certain engine components. The elongated portion 160 may be coupled to the tool 100 at a joint 164. The joint 164 may be a removable joint so that the operator can install the tool 100 on a plurality of different elongated portions 160 of variable size, shape or configuration. In some embodiments, the elongated portion 160 may include a multi-piece configuration. For example, the elongated portion 160 may include a first elongated segment 166 and a second elongated segment 168 coupled together. Thus, the operator may select various segments of various shapes, sizes and / or configurations based on the specific application or requirements of the intended use. A handle 170 may be coupled to the proximal end 172 of the elongated portion 160 to allow the operator to keep the tool 100 at a desired position. The handle 170 may include an interface 174 to be engaged with the elongated portion 160. In embodiments not shown, the handle 170 may be directly coupled to the tool 100. That is, according to one or more embodiments, the elongated portion 160 may be omitted.

[0073] The handle 170 may include one or more elements configured to allow selective rigidification of the tool 100. For example, the handle 170 may include a trigger 176 configured to selectively rigidify the tool 100. The trigger 176 may be rotatable, pivotable, translatable, etc. between a disengaged configuration in which the tool 100 is loose (i.e., non-rigid) and an engaged configuration in which the tool is rigid. In a particular embodiment, the trigger 176 may include a finger grip (not shown) that allows an operator to maintain secure contact with the trigger 176 while pushing and pulling the trigger between the engaged and disengaged positions. In another particular embodiment, the trigger 176 may include multiple contact positions, such as two discrete finger grip positions. In an embodiment, the trigger 176 may be selectively lockable in an engaged and / or disengaged position. Thus, an operator may rigidify the tool 100 and release the trigger 176 during a maintenance operation. In yet another embodiment, the trigger 176 may be operated by a motor or other power device so that rigidification of the tool 100 does not require the generation of manual pressure. When the tool 100 is inserted into the engine, the handle 170 can remain exposed outside the engine. In this way, the operator can maintain control of the tool 100 without having to directly access the tool 100.

[0074] The handle 170 may include an aperture 178 or other interface configured to receive an implement for insertion into the engine. The aperture 178 may include, for example, an opening through which an operator may insert an implement (e.g., the aforementioned camera 112 on a cable) into the engine. In certain embodiments, the aperture 178 may be selectively sealable or closable to prevent dust and other contaminants from entering the tool 100. Once opened, the operator may feed an implement into the aperture 178 and / or move the implement relative to the aperture 178 to allow maintenance operations to be performed as needed.

[0075] Fig. 9An embodiment of a distal end 110 of a tool 100 is shown. A final segment 102 of the tool 100 disposed at the distal end 110 may include an opening 180 (which may be similar or identical to cavities 136 and / or 148) through which a camera 112 may extend. In this manner, the camera 112 may monitor the leading edge of the tool 100 as the tool 100 enters an engine and as the tool 100 performs maintenance operations including engine inspection and / or repair operations. As previously described, the camera 112 may be disposed within the circumferential boundaries of the tool 100. That is, according to an embodiment, the camera 112 may be disposed within the outer diameter of the segment 102 such that the camera does not create a larger leading edge diameter than the diameter of the segment 102. The aforementioned holes 142 and 156 may be in communication with the final hole 182 through which an implement (e.g., a flat cable) may be passed. As described above, the implement may be manual or machine, through the orifice 178 ( Figure 8 ) is fed to the remote end 110 for performing maintenance operations.

[0076] Fig.10 and 11 An embodiment of an insertion tool 1000 is shown in which a strength member 1002 extends through a lumen 1004 of an adjacent segment 1006 . Fig.10 and 11 The strength member 1002 shown in the figure includes a plurality of strength members, such as at least two strength members, such as at least three strength members. However, the strength member 1002 may alternatively include a single strength member. The insertion tool 1000 is shown in a non-rigidized configuration, wherein the segments 1006 are not coupled together at a fixed angle. That is, adjacent segments 1006 can easily move relative to each other. Fig.12 Insertion tool 1000 is shown in which segments 1006 are fixedly coupled together by strength members 1002. For example, selectively rigidifying tool 1000, i.e., from Fig.10 and 11 The non-rigidized structure shown transitions to Fig.12 When tension is applied, the length of the strength member 1002 and / or the support member 1016 within the tool 1000 can be reduced, thereby Fig.11) effectively pulls adjacent segments 1006 together in the direction shown in the figure. As the segments 1006 contact each other, the internal tension within the strength member 1002 and / or the support member 1016 increases, thereby maintaining the segments 1006 connected together and effectively rigidifying the tool 1000. The ends 1010 of the segments 1006 can be keyed together to prevent relative movement in the rigidified configuration. The keyed ends 1010 can include complementary surface features that, when combined, prevent relative movement, such as rotation, between adjacent segments 1006. As non-limiting examples, the keyed ends 1010 can include complementary posts and recesses, complementary undulating features, complementary tooth profiles, etc. As the complementary features cooperate with each other, the adjacent segments 1006 can become fixed relative to each other and maintained in their fixed relative positions by the tension within the strength member 1002.

[0077] In the illustrated embodiment, adjacent pairs of depicted segments 1006 include complementary ridges 1012 and channels 1014 configured to align with each other in a rigidified configuration. When the strength member 1002 is less than fully tensioned, in addition to securing the segments 1006 in a relatively fixed position relative to each other, the ridges 1012 and channels 1014 can act as hinges for the segments 1006. That is, for example, when the tension on the strength member 1002 is reduced, the segments 1006 can deflect relative to each other. If the tension is maintained above a certain amount so that the ridges 1012 and channels 1014 do not completely disengage from each other, the segments 1006 can move relative to each other within the guide track around the pivot axis formed by the ridges 1012 and channels 1014. This may be advantageous during the insertion of the tool 1000 into the engine 10, as the tool 1000 may be forced to navigate complex geometries within the engine, which requires the tool 1000 to bend while maintaining a certain amount of rigidity.

[0078] As previously described, selective rigidification of the tool 1000 can occur through the use of one or more support members 1016. One or more support members 1016 can extend through the auxiliary cavity 1018 of the segment 1006. For example, when the strength member 1002 is in a non-fully tensioned state, the support member 1016 can help hold the segment 1006 together. The support member 1016 can further help guide the tool 1000 within the engine 10 during the tool insertion process. The support member 1016 can also be used to selectively rigidify the tool 1000, while the strength member 1002 forms the flexible backbone of the tool 1000.

[0079] As about Figure 6 and 7As described above, adjacent segments 102 of the tool can be coupled together at the interface 120 by one or more hinge members (e.g., a first hinge member 122 and a second hinge member 124). The first hinge member 122 and the second hinge member 124 can work together to connect the segments 102 while allowing relative movement therebetween, particularly when the tool 100 is not rigidified. Figure 6 and Figure 7 The depicted first hinge member 122 and second hinge member 124 are held together by an interference fit. Specifically, surfaces 134A and 134B engage surfaces 144A and 144B, respectively, to dynamically hold adjacent segments 102 together. Figures 13A to 16C Alternative embodiments of interface 120 and associated hinges 122 and 124 are depicted.

[0080] Fig.13A An enlarged view of an interface 120 formed between adjacent segments 102 is shown in accordance with an exemplary embodiment. Fig. 13B Shown along Fig.13A A magnified cross-sectional view of the interface as seen through line AA in FIG. Fig.13A , the segments 102 may define a first hinge member 122 and a second hinge member 124 as described above. The first hinge member 122 and the second hinge member 124 may cooperate with each other to allow for selective flexure between the segments 102.

[0081] In one or more embodiments, the first hinge member 122 and the second hinge member 124 can be integrally formed with the body 114 of the segment 102. In a particular embodiment, the segment 102 including the first hinge member 122 and the second hinge member 124 can be formed using an additive manufacturing process (e.g., three-dimensional printing) that results in a hierarchy including multiple layers. In yet another more specific embodiment, the segment 102 can be formed in an assembled state so that adjacent segments 102 are, for example, additively manufactured, while the resulting interface 120 is formed and ready for use in the manufacturing process. Although additively manufacturing the interface 120 when assembling the first hinge member 122 and the second hinge member 124 can reduce the introduction of weaknesses into the body 114 caused by flexing the body to mount the first hinge member 122 and the second hinge member 124 relative to each other, some additive manufacturing processes may also result in excess material being formed at the interface 120. For example, some three-dimensional printing processes use printing powder to form the final shape of the printed structure. Not all printing powders can be cured, resulting in the powder being trapped in the interface 120. Such loose powder may reduce the effectiveness of the tool 100, may cause premature wear and / or failure when the tool 100 is disposed within the engine 10, or may even cause the powder to be deposited in the engine as the tool 100 is passed through the engine during insertion.

[0082] To mitigate powder pooling within the interface 120, the first hinge member 122 and the second hinge member 124 may be formed with a powder gap 184 configured to allow powder to pass therethrough. In particular, the powder gap 184 may allow powder to pass through the powder gap 184 when the tool 100 is flexed or otherwise deformed. Fig. 13B , the powder gap 184 may be formed by the gap between the first hinge member 122 and the second hinge member 124. The powder 186 may leave the interface 120 through the powder gap 184 in a direction corresponding to, for example, arrow 188. To further enhance the removal of powder from the interface 120, in some cases, at least one of the first hinge member 122 and the second hinge member 124 may have a tapered interface profile. For example, the inner sidewall 190 of the second hinge member 124 may have a profile that tapers outwardly. As measured relative to the normal axis 194, the cone angle β that the inner sidewall 190 may define is at least one degree, such as at least two degrees, such as at least three degrees, such as at least four degrees, such as at least five degrees, such as at least six degrees, such as at least seven degrees, such as at least eight degrees, such as at least nine degrees, such as at least ten degrees, such as at least fifteen degrees. In another embodiment, the outer sidewall 192 of the first hinge member 122 may have a profile that tapers inwardly. As measured relative to the normal axis 194, the outer sidewall 194 may define a cone angle α of at least one degree, such as at least two degrees, such as at least three degrees, such as at least four degrees, such as at least five degrees, such as at least six degrees, such as at least seven degrees, such as at least eight degrees, such as at least nine degrees, such as at least ten degrees, such as at least fifteen degrees. In some cases, α may be equal to or approximately equal to β. In other cases, α and β may be different from each other. In an embodiment, the inner sidewall 190 and the outer sidewall 192 may be angularly offset from each other.

[0083] Fig.14A An enlarged view of an interface 120 formed between adjacent segments 102 according to another exemplary embodiment is shown when the tool 100 is in a rigid or semi-rigid configuration. Fig. 14B 1 shows when the tool is in a non-rigid configuration (ie, the segments 102 are not rigidly held together and have moved relative to each other). Fig.14A An enlarged view of the interface 120 is shown. Fig.14A14B is multimodal. The multimodal interface can include instances of tight fit and other instances of loose fit. In a rigid configuration, the first hinge member 122 and the second hinge member 124 have a tight fit arrangement so that precise alignment occurs between the segments 102. In a non-rigid configuration, the first hinge member 122 and the second hinge member 124 can have a loose fit so that the interface 120 is loose. The tight fit arrangement can be a result of the hinge geometry. For example, the first hinge member 122 can define an elongated length L1, and the second hinge member 124 can define an elongated length L2. In a rigid configuration, L1 and L2 can deviate from each other. For example, L1 and L2 can be rotationally offset from each other by at least one degree, such as at least two degrees, such as at least three degrees, such as at least four degrees, such as at least five degrees, such as at least six degrees, such as at least seven degrees, such as at least eight degrees, such as at least nine degrees, such as at least ten degrees, such as at least fifteen degrees, such as at least twenty degrees, such as at least thirty degrees, such as at least forty degrees, such as at least fifty degrees, such as at least sixty degrees, such as at least seventy degrees, such as at least eighty degrees, such as at least ninety degrees. In a non-rigid configuration, L1 and L2 can deviate from each other by an amount less than in a rigid configuration. As a non-limiting example, in a particular embodiment, L1 and L2 can deviate from each other by ninety degrees in a rigid configuration and by less than ninety degrees in a non-rigid configuration.

[0084] In an embodiment, the first hinge member 122 includes a post 210 and the second hinge member 124 includes a recess 212 into which the post 210 can be inserted. At least one of the post 210 and the recess 212 can have an aspect ratio different from 1:1, where the aspect ratio is defined by the length (e.g., L1) of the post 210 and / or the recess 212 relative to its width, the width being measured perpendicular to the length. That is, for example, at least one of the first hinge member 122 and the second hinge member 124 can have an elongated shape.

[0085] Fig.15A An enlarged view of an interface 120 formed between adjacent segments 102 is shown according to another exemplary embodiment. Fig. 15BAn enlarged view of the interface 120 between adjacent segments 102 seen in a disconnected configuration is shown for the purpose of observing the first hinge member 122 and the second hinge member 124. In an embodiment, the first hinge member 122 and the second hinge member 124 can be configured to connect to each other when the adjacent pairs of segments 102 are arranged in a first orientation relative to each other. After the adjacent pairs of segments 102 are adjusted to a second orientation different from the first orientation, the adjacent pairs of segments 102 can remain coupled together. This type of engagement can be described as a displacement locking engagement. As an example, the displacement can include an angular displacement. The angular displacement between the first orientation and the second orientation can be at least 1°, such as at least 2°, such as at least 3°, such as at least 4°, such as at least 5°, For example, at least 10°, such as at least 20°, such as at least 30°, such as at least 40°, such as at least 50°, such as at least 60°, For example, at least 70°, such as at least 80°. The displacement can also include translation, pivoting, etc., or any combination thereof.

[0086] exist Fig. 15B In the illustrated embodiment, the first hinge member 122 includes a receiving structure 196 including a first side surface 198 and a second side surface 200. The first side surface 198 and the second side surface 200 can extend from at least one of the opposing side surfaces 134A and 134B of the first hinge member 122. The first side surface 198 and the second side surface 200 define a gap 202 extending therebetween. The second hinge member 124 includes a protrusion 204 configured to pass through the gap 202 when the segments are oriented in a first orientation relative to each other, and to be retained between the first side surface 198 and the second side surface 200 when the segments 102 are oriented in a second orientation relative to each other. When the first hinge member 122 and the second hinge member 124 are coupled together in the first orientation, a retaining element 206 can additionally pass through the gap 202. In the connected (i.e., engaged) configuration resulting from reorienting the segments 102 to the second orientation, the retaining element 206 can interface with the first side surface 198 to further support and maintain engagement between the segments 102. In an embodiment, the receiving structure 196 can be approximately identical on the opposing side surfaces 134A and 134B of the first hinge member 122. In another embodiment, the protrusion 204 and the retaining element 206 can be approximately identical on both opposing side surfaces 144A and 144B of the second hinge member 124.

[0087] Fig.16A An enlarged view of an interface 120 formed between adjacent segments 102 is shown according to another exemplary embodiment. Fig. 16B An enlarged view of the interface 120 between adjacent segments 102 as seen in the disconnected configuration is shown for purposes of viewing the first and second hinge members. Fig. 16C The diagram shows Fig.16A 1. A cross-sectional view of the interface 120 between adjacent segments 102 as viewed from line CC in FIG. The interface 120 includes a compliant feature 208 disposed between opposing side surfaces 144A and 144B of the second hinge member 124. During assembly of the segment 102, the compliant feature 208 may allow expansion between the opposing side surfaces 144A and 144B. In an embodiment, the compliant feature 208 may include a slit extending into the body 114 of the segment. The slit may define a length of at least 0.1 mm, such as at least 0.2 mm, such as at least 0.3 mm, such as at least 0.4 mm, such as at least 0.5 mm, such as at least 1 mm, such as at least 2 mm, such as at least 3 mm, such as at least 4 mm, such as at least 5 mm. When the first hinge member 122 and the second hinge member 124 are brought together to engage each other, the diameter of the slit may increase, allowing the opposing surfaces 134A and 134B to pass over and onto the opposing side surfaces 144A and 144B. In an embodiment, the opposing surfaces 134A and 134B of the first hinge member 122 can be complementary to the opposing side surfaces 144A and 144B of the second hinge member 124. The complementary side surfaces can include, for example, flat surfaces, conical surfaces, hemispherical surfaces, etc. that fit together to keep the first hinge member 122 and the second hinge member 124 coupled together at the interface 120.

[0088] According to one or more embodiments described herein, the first hinge member 122 and the second hinge member 124 can be configured to float relative to each other. As used herein, "floating relative to each other" refers to an interface whereby two or more members (e.g., the first hinge member 12 and the second hinge member 124 of adjacent segments 102) are not fixedly coupled together and can move relative to each other, e.g., in a relaxed state. In contrast, the adjacent segments 102 are held together, e.g., by strength members and / or support members, i.e., in a selectively rigidified state. In contrast, in some cases, when tension is removed, the adjacent segments 102 can separate from each other when the first hinge member 122 and the second hinge member 124 float relative to each other.

[0089] This written description uses examples to disclose the invention, including the best mode, and also to enable those skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0090] Further aspects of the invention are provided by the subject matter of the following clauses:

[0091] Embodiment 1. An insertion tool for performing an operation on a device, the insertion tool comprising: a plurality of segments, each of the plurality of segments comprising a body, the body comprising: a first hinge member; and a second hinge member, the first hinge member of the first segment being connected to the second hinge member of the second segment adjacent to the first segment via an interface, wherein the interface comprises a powder gap, a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof.

[0092] Embodiment 2. An insertion tool according to any one or more embodiments, wherein the body of at least one of the segments comprises a hierarchy comprising a plurality of layers.

[0093] Embodiment 3. An insertion tool according to any one or more embodiments, wherein the insertion tool comprises a strength member that transversely intersects the interface.

[0094] Embodiment 4. The insertion tool according to any one or more embodiments, wherein the powder gap is disposed between an outer side wall of the first hinge member and an inner side wall of the second hinge member.

[0095] Embodiment 5. An insertion tool according to any one or more embodiments, wherein the inner side wall and the outer side wall are angularly offset from each other.

[0096] Embodiment 6. An insertion tool according to any one or more embodiments, wherein the multimodal interface comprises a tight fit when the adjacent segments are rigidified by the strength member, and the multimodal interface comprises a loose fit when the adjacent segments are not rigidified by the strength member.

[0097] Embodiment 7. An insertion tool according to any one or more embodiments, wherein the first hinge member comprises a post, and the second hinge member comprises a recess into which the post can be inserted, and wherein at least one of the post and the recess has an aspect ratio different from 1:1.

[0098] Embodiment 8. An insertion tool according to any one or more embodiments, wherein the first hinge member includes a first outer surface and a second outer surface, wherein the second hinge member includes a first inner surface and a second inner surface, and wherein the interface includes a hemispherical interface between the first outer surface and the first inner surface, and a hemispherical interface between the second outer surface and the second inner surface.

[0099] Embodiment 9. In the insertion tool according to any one or more embodiments, the displacement locking interface comprises a protrusion of the second hinge member, the protrusion being configured to pass through a gap between adjacent side surfaces of the receiving structure of the first hinge member.

[0100] Embodiment 10. An insertion tool for performing an operation on a device, the insertion tool comprising: a plurality of segments, each of the plurality of segments comprising a body, the body comprising: a first hinge member; and a second hinge member, the first hinge member of the first segment being connected to the second hinge member of the second segment adjacent to the first segment via an interface, wherein the interface comprises a powder gap, a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof; and a strength member, the strength member intersecting the interface.

[0101] Embodiment 11. An insertion tool according to any one or more embodiments, wherein the reinforcement member comprises a trunk of the insertion tool, the trunk being configured to keep the plurality of segments coupled together when the insertion tool is not rigidified.

[0102] Embodiment 12. A method of forming an insert tool, the method comprising: additively forming a body of a segment of the insert tool; and flexing adjacent segments of the insert tool relative to each other so that powder contained at an interface between adjacent segments of the insert tool can pass through a powder gap from the interface.

[0103] Embodiment 13. The method of any one or more embodiments, wherein flexing adjacent segments of the insertion tool is performed by tensioning a strength member extending between the adjacent segments.

[0104] Embodiment 14. A method according to any one or more embodiments, wherein the adjacent segments include a first segment having a first hinge member and a second segment having a second hinge member, and wherein the first hinge member and the second hinge member define the interface between the first segment and the second segment.

[0105] Embodiment 15. The method of any one or more embodiments, wherein the first hinge member and the second hinge member are configured to move relative to each other when the tool is not rigidified.

[0106] Embodiment 16. The method according to any one or more embodiments, wherein the interface further comprises a multimodal interface, a compliant feature, a displacement locking structure, an interference fit, or any combination thereof.

[0107] Embodiment 17. A method according to any one or more embodiments, wherein additively forming the body comprises three-dimensional printing.

[0108] Embodiment 18. The method according to any one or more embodiments, further comprising rigidifying the insertion tool by applying a force to the strength member.

[0109] Embodiment 19. A method according to any one or more embodiments, wherein the adjacent segments are constructed to rotate by a joint displacement between a rigidified structure and a non-rigidified structure, and wherein flexing the adjacent segments of the insertion tool relative to each other so that powder contained at the interface between the adjacent segments of the insertion tool can pass from the interface through the powder gap is performed by rotating the adjacent segments by a rotational displacement not greater than the joint displacement.

[0110] Embodiment 20. The method according to any one or more embodiments, further comprising coupling the adjacent segments together after additively manufacturing the body of the segment.

Claims

1. An insertion tool for performing an operation on a device, characterized in that The insertion tool comprises: a plurality of segments, each segment of the plurality of segments comprising a body, the plurality of segments comprising adjacent first and second segments connected to each other via an interface, The interface includes: a first hinge member of the first section, and the second hinge member of the second section, wherein the first hinge member is coupled to the second hinge member, wherein the first hinge member includes a post and the second hinge member includes a recess in which the post is received, wherein the post and the recess prevent the first segment and the second segment from separating, wherein the first section and the second section are convertible between a non-rigid configuration in which the post is positioned in the recess with a loose fit and a rigid configuration in which the post is positioned in the recess with a tight fit; wherein the post and the recess are configured to transition between the loose fit and the tight fit by rotating at least one of the first segment and the second segment relative to each other about a rotation axis extending through the post and the recess while the post is retained in the recess; and The post and the recess each have an aspect ratio different from 1:1, so that when at least one of the first segment and the second segment is rotated relative to each other about the rotation axis extending through the post and the recess, the post and the recess are converted from the loose fit to the tight fit.

2. The insertion tool according to claim 1, characterized in that Wherein the insertion tool includes a strength member that transversely intersects the interface.

3. The insertion tool according to claim 1, characterized in that The powder gap is arranged between the outer side wall of the first hinge member and the inner side wall of the second hinge member.

4. The insertion tool according to claim 3, characterized in that Wherein the inner sidewall and the outer sidewall are angularly offset from each other.

5. The insertion tool according to claim 1, characterized in that wherein the first hinge member comprises a first outer surface and a second outer surface, wherein the second hinge member comprises a first inner surface and a second inner surface, and wherein the interface comprises a hemispherical interface between the first outer surface and the first inner surface, and a hemispherical interface between the second outer surface and the second inner surface.

6. The insertion tool according to claim 1, characterized in that The interface includes a displacement locking configuration, wherein the interface includes a protrusion of the second hinge member configured to pass through a gap between adjacent side surfaces of a receiving structure of the first hinge member.

7. An insertion tool for performing an operation on a device, characterized in that The insertion tool comprises: a plurality of segments, each segment of the plurality of segments comprising a body, the plurality of segments comprising adjacent first and second segments connected to each other via an interface, The interface includes: a first hinge member of the first section, and the second hinge member of the second section, wherein the first hinge member is coupled to the second hinge member, wherein the first hinge member includes a post and the second hinge member includes a recess in which the post is received, wherein the post and the recess prevent the first segment and the second segment from separating and allow the first segment and the second segment to pivot relative to each other, wherein the first section and the second section are convertible between a non-rigid configuration in which the post is positioned in the recess with a loose fit and a rigid configuration in which the post is positioned in the recess with a tight fit; wherein the post and the recess are configured to transition between the loose fit and the tight fit by rotating at least one of the first segment and the second segment relative to each other about a rotation axis extending through the post and the recess while the post is retained in the recess; and wherein the post and the recess each have an aspect ratio different than 1:1, such that the post and the recess transform from the loose fit to the tight fit when at least one of the first segment and the second segment is rotated relative to each other about the rotation axis extending through the post and the recess; The body of at least one of the segments comprises a hierarchy comprising a plurality of layers.

8. An insertion tool for performing an operation on a device, characterized in that The insertion tool comprises: a plurality of segments, each segment of the plurality of segments comprising a body, the plurality of segments comprising adjacent first and second segments connected to each other via an interface, a strength member transversely intersecting the interface, The interface includes: a first hinge member of the first section, and the second hinge member of the second section, wherein the first hinge member is coupled to the second hinge member, wherein the first hinge member includes a post and the second hinge member includes a recess in which the post is received, wherein the post and the recess prevent the first segment and the second segment from separating and allow the first segment and the second segment to pivot relative to each other, wherein the first section and the second section are convertible between a non-rigid configuration in which the post is positioned in the recess with a loose fit and a rigid configuration in which the post is positioned in the recess with a tight fit; wherein the post and the recess are configured to transition between the loose fit and the tight fit by rotating at least one of the first segment and the second segment relative to each other about a rotation axis extending through the post and the recess while the post is retained in the recess; and Wherein the post and the recess each have an aspect ratio different from 1:1, so that when at least one of the first segment and the second segment is rotated relative to each other about the rotation axis extending through the post and the recess, the post and the recess are converted from the loose fit to the tight fit.

9. An insertion tool for performing an operation on a device, characterized in that The insertion tool comprises: a plurality of segments, each segment of the plurality of segments comprising a body, the plurality of segments comprising adjacent first and second segments connected to each other via an interface, The interface includes: a first hinge member of the first section, and the second hinge member of the second section, wherein the first hinge member is coupled to the second hinge member, wherein the first hinge member includes a post and the second hinge member includes a recess in which the post is received, wherein the post and the recess prevent the first segment and the second segment from separating and allow the first segment and the second segment to pivot relative to each other, wherein the first section and the second section are convertible between a non-rigid configuration in which the post is positioned in the recess with a loose fit and a rigid configuration in which the post is positioned in the recess with a tight fit; wherein the post and the recess are configured to transition between the loose fit and the tight fit by rotating at least one of the first segment and the second segment relative to each other about a rotation axis extending through the post and the recess while the post is retained in the recess; and wherein the post and the recess each have an aspect ratio different than 1:1, such that the post and the recess transform from the loose fit to the tight fit when at least one of the first segment and the second segment is rotated relative to each other about the rotation axis extending through the post and the recess; and A strength member intersects the interface.

10. The insertion tool according to claim 9, characterized in that Wherein the strength member comprises a backbone of the insertion tool, the backbone being configured to hold the plurality of segments coupled together when the insertion tool is not rigidified.

11. A method of forming an insertion tool according to claim 1, characterized in that: The method comprises: additively forming a body of a segment of the insertion tool; and Adjacent segments of the insertion tool are flexed relative to each other such that powder contained at an interface between adjacent segments of the insertion tool can pass from the interface through a powder gap.

12. The method according to claim 11, characterized in that Wherein flexing adjacent segments of the insertion tool is performed by tensioning a strength member extending between the adjacent segments.

13. The method according to claim 11, characterized in that Wherein the adjacent segments include a first segment having a first hinge member and a second segment having a second hinge member, and wherein the first hinge member and the second hinge member define the interface between the first segment and the second segment.

14. The method according to claim 13, characterized in that Wherein the first hinge member and the second hinge member are configured to move relative to each other when the tool is not rigidified.

15. The method according to claim 11, characterized in that Wherein the interface further comprises a multi-modal interface, a compliant feature, a displacement locking structure, an interference fit or any combination thereof.

16. The method according to claim 11, characterized in that The additive manufacturing of the body includes three-dimensional printing.

17. The method according to claim 12, characterized in that Further comprising rigidifying the insertion tool by applying a force to the strength member.

18. The method according to claim 11, characterized in that wherein the adjacent segments are constructed to rotate by a coupling displacement between a rigidified structure and a non-rigidified structure, and wherein flexing the adjacent segments of the insertion tool relative to each other so that powder contained at the interface between the adjacent segments of the insertion tool can pass from the interface through a powder gap is performed by rotating the adjacent segments by a rotational displacement no greater than the coupling displacement.

19. The method according to claim 11, characterized in that Further comprising coupling the adjacent segments together after additively manufacturing the body of the segment.

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