Composite parts for aircraft turbine engines

Abstract

The present invention relates to a component (10) made of a composite material, particularly for use in aircraft turbine engines, the component comprising: - a body (40) made of three-dimensionally woven fibers (41) impregnated in a resin, particularly an organic or polymeric resin; - at least one crack sensor (50) capable of detecting cracks in the component (10); - at least one connecting element (60) connected to the crack and / or delamination sensor (50) and configured to transmit a signal (S) to a component outside the component (10) in particular when a crack is detected in the component (10). According to the invention, the crack sensor (50) includes at least one wire (51) woven together with the fibers of the body, and the connecting element (60) is configured to measure the resistance of the wire (51) and wirelessly transmit the signal (S).

Description

Technical Field

[0001] The present invention relates to composite components, particularly for aircraft turbine engines, and methods for manufacturing such composite components. Background Technology

[0002] The technical background specifically includes documents WO-A1-2019 / 234 601, EP-A1-3 653 840, FR-A1-2865539, US-A1-2005 / 0198967, EP-A1-3 557 214 and WO-A2-2010 / 092 426.

[0003] In a known manner, a turbine engine extending along its axis enables an aircraft to be displaced by an airflow entering the turbine engine and flowing from upstream to downstream. In the following text, the terms "upstream" and "downstream" are defined relative to the axis of the turbine engine oriented from upstream to downstream. Similarly, the terms "inner" and "outer" are defined radially relative to the axis of the turbine engine.

[0004] In addition, the turbine engine includes at least one compressor, a combustion chamber, and at least one turbine, the at least one turbine driving the compressor to rotate. The turbine engine includes an upstream fan that enables the acceleration of airflow from upstream to downstream within the turbine engine; the upstream fan includes blades that typically extend in the same plane transverse to the turbine engine axis.

[0005] For components such as impellers (especially those made of composite materials), it is important to be able to detect crack formation. This is done using conventional non-destructive methods such as visual inspection, acoustics, thermal measurement, or X-ray tomography. However, visual inspection is limited to defects that can be visually inspected on the surface of the component.

[0006] The disadvantages of these conventional methods are that they are time-consuming to implement, and can take several hours to complete for a single component. Furthermore, when the component is mounted on an engine, these methods may require specialized equipment and / or are difficult to implement.

[0007] Furthermore, this method is implemented periodically, either during component design or after an accident, particularly when a component is suspected of being impacted, especially during inspections of the rotor blades following the ingestion of foreign object debris (FOD). Foreign object debris refers to any type of material, fragment, or component, whether mechanical or non-mechanical, that is entirely foreign to the aircraft but can cause damage. Therefore, this specific inspection requires the component to be disassembled and sent to an approved center for inspection.

[0008] Furthermore, the methods currently used depend on the manufacturing type of the component to be inspected. This application relates to components comprising a body obtained through three-dimensional weaving of fibers and impregnated in resin. Three-dimensional (3D) weaving is a specific technique, for example, performed on a jacquard loom, that enables the manufacture of three-dimensional bodies or preforms with shapes and dimensions closely approximating the shape and dimensions of the final component to be manufactured. Thus, the body comprises weft yarns mixed with warp yarns (both weft and warp yarns are formed from fibers), as is known to those skilled in the art.

[0009] This technique differs from draping, in which fabrics or fiber webs are layered to form the body of a component. It also differs from winding, in which fibers are wound around nodes within a grid.

[0010] This invention provides solutions to at least some of the problems mentioned above. Summary of the Invention

[0011] This invention relates to a component made of composite materials, particularly for use in aircraft turbine engines, the component comprising:

[0012] -The main body is made of three-dimensionally woven fibers impregnated in resin, particularly organic or polymeric resins.

[0013] - At least one crack sensor, capable of detecting cracks in a component, and

[0014] - At least one connecting element, which is connected to the crack sensor and configured to transmit a signal, specifically to a component outside the component, when a crack is detected in the component.

[0015] According to the present invention, a crack sensor includes at least one wire, which is woven together with the fibers of a body and extends into a region of the body where the presence of a crack will be monitored, and a connecting element is connected to an end of the wire, and the connecting element is configured to measure the resistance of the wire and wirelessly transmit a signal when the measured resistance of the wire is higher than a predetermined threshold.

[0016] The wires of the present invention extend to the area of ​​the component where it is desired to determine whether a crack exists. The wires of the present invention enable the detection of the presence of a crack anywhere on the component, and the connecting element enables the transmission of this information.

[0017] Therefore, this invention proposes a method to determine the operability of a component using an in-situ device comprising a crack sensor and a connecting element. Furthermore, this device is non-destructive and does not require disassembly of the component. Moreover, the device has very little impact on the quality of the component.

[0018] On the other hand, the connecting element is a wireless device, which makes it possible to detect crack formation, especially on moving parts such as impellers. In particular, due to RFID technology, wired connections can be eliminated, and solutions with very little impact on quality can be found.

[0019] The wires are woven together with the fibers of the preform, thus integrating the wires into the preform.

[0020] Components according to the invention may include one or more of the following features, either individually or in combination with each other:

[0021] - The fiber is made of carbon, and the conductor is surrounded by an insulating sheath, which is preferably made of the same material as the resin;

[0022] - The diameter of the wire is between 0.05mm and 8mm;

[0023] - The conductor forms at least one C-shaped loop and / or U-shaped loop;

[0024] - The conductors are made of materials selected from copper, aluminum, iron, silver, nickel and their alloys, especially constantan;

[0025] - The threshold is between 1.01×R and 1.10×R, particularly between 1.02×R and 1.08×R, and particularly equal to 1.05×R, where R is the initial resistance of the wire;

[0026] - Connectivity elements include RFID tags, which are specifically configured to operate at frequencies between 860MHz and 960MHz;

[0027] - This component forms impellers, especially fan impellers.

[0028] The present invention also relates to an aircraft turbine engine comprising the components described above. Specifically, the component is a fan blade, and the turbine engine includes a fan housing surrounding the fan blade and carrying a reading device, such as an RFID reader.

[0029] The present invention also relates to a method for manufacturing the component as described above, wherein the method comprises:

[0030] a) Insertion step, which includes inserting a wire into the braided fiber preform, the wire extending along the area of ​​the crack to be monitored.

[0031] b) A joining step, comprising securing the connecting element to the preform or integrating the connecting element into the preform, and connecting the end of the wire to the connecting element such that the connecting element can measure the resistance of the wire, and

[0032] c) Injection step, which includes injecting resin into a preform pre-arranged in a mold to manufacture the body of the component and cure the assembly, wherein the resin is in particular an organic resin or a polymer resin.

[0033] According to an alternative embodiment of the method, prior to injection step c), there is a step of electrically insulating the connection between the connecting element and the wire. Attached Figure Description

[0034] The invention will be better understood from the following detailed description, including embodiments, which are given illustratively with reference to the accompanying drawings and are presented as non-limiting examples. These non-limiting examples can be used to improve the understanding of the invention and its embodiments, and, where appropriate, to aid in the explanation of the invention, in which:

[0035] [ Figure 1 ] Figure 1 This is a schematic diagram of the longitudinal cross-section of a turbine engine;

[0036] [ Figure 2 ] Figure 2 This is a schematic cross-sectional view of the components including a crack sensor and a connecting element according to the present invention;

[0037] [ Figure 3 ] Figure 3 This is a schematic diagram illustrating the steps of reading the connecting element according to the present invention;

[0038] [ Figure 4 ] Figure 4 This is a schematic perspective view of a turbine engine fan with a connecting element and a reading device according to the present invention;

[0039] [ Figure 5 ] Figure 5 This is a schematic side view of a fan blade with a connecting element according to the present invention;

[0040] [ Figure 6 ] Figure 6 This is a schematic diagram viewed from above the connecting element according to the invention;

[0041] [ Figure 7 ] Figure 7 This is a schematic perspective view of a woven prefabricated component according to the present invention, showing a block with connecting elements.

[0042] [ Figures 8a-8c ] Figure 8a , Figure 8b , Figure 8c This is a schematic diagram illustrating the principle of crack formation on the detection component according to the present invention;

[0043] [ Figures 9a-9b ] Figure 9a , Figure 9b A schematic diagram of a method for manufacturing a component according to the present invention; and

[0044] [ Figure 10 ] Figure 10 It is a schematic perspective view of the integrated wire-conducting blocks of the braided prefabricated component. Detailed Implementation

[0045] like Figure 1 As shown, Figure 1 This is a schematic diagram of a longitudinal section of a turbine engine 100 of an aircraft. The present invention specifically relates to a component 10 made of composite material, particularly for use in the turbine engine 100.

[0046] Component 10 may be, for example, a blade 1, particularly the blade 1 of the fan 110 of the turbine engine 100. Specifically, the turbine engine 100 includes a housing 5 of the fan 110 surrounding the blade 1 of the fan 110.

[0047] The turbine engine 100 extends along the turbine engine axis X and enables the aircraft to be displaced by the airflow entering the turbine engine 100 and flowing from upstream to downstream.

[0048] In a known manner, a turbine engine 100 includes at least one compressor, an annular combustion chamber, and at least one turbine (these components are not shown), wherein the at least one turbine drives the rotor of the compressor to rotate.

[0049] The turbine engine 100 includes an upstream fan 110, which enables the acceleration of airflow from upstream to downstream within the turbine engine 100. The fan 110 includes a disc 111 rotatably fixed to the shaft of the compressor, the disc including receptacles distributed on the outer periphery of the disc 111, and impeller blades 1 are respectively mounted in the receptacles by axial insertion along the turbine engine axis X from upstream to downstream.

[0050] The impeller 1 typically extends in a single plane transverse to the turbine engine axis X. In the example of the illustrated embodiment, the turbine engine 100 includes a cone 112 mounted upstream of the disc 111.

[0051] Component 10 is made of a composite material comprising fibers 41 impregnated in a resin (e.g., an organic resin or a polymer resin). Some of the fibers 41 are conductive (and are referred to as conductive fibers), while others are non-conductive (and are referred to as non-conductive fibers). The resin is non-conductive. Preferably, the conductive fibers are metal fibers and / or carbon fibers. Preferably, the non-conductive fibers are glass fibers and / or thermoplastic fibers (aramid, polyethylene, polyester, etc.).

[0052] Fibers 41 are woven together to form at least one three-dimensional preform to be impregnated in resin. In this example, the resin is thermosetting, but resins can have different properties. The resin can be epoxy resin or bismaleimide resin.

[0053] More specifically, the whorl 1 includes a root, a blade 13, a leading edge 1a, and a trailing edge 1b.

[0054] Now refer to Figure 2 , Figure 2 This is a schematic cross-sectional view of component 10, which includes a crack sensor 50 and a connecting element 60. The invention specifically relates to component 10 made of a composite material, such as a wheel blade 1, which includes a body 40 made of woven fibers 41 impregnated in resin. Component 10 also includes at least one crack sensor 50 for detecting cracks in component 10. Component 10 also includes at least one connecting element 60 connected to the crack sensor 50, the connecting element being configured to measure resistance and, specifically, transmit a signal S to a component (not shown) outside component 10 when a crack is detected.

[0055] The crack sensor 50 includes at least one wire 51 present in region Z1 of the body 40, which will be monitored for the generation of cracks, i.e., the area where cracks may occur and therefore should be detected.

[0056] Advantageously, the crack sensor 50 is integrated within the body 40, enabling the sensor to detect cracks in the volume of the component to be monitored. For this purpose, the wire 51 is braided together with the fibers 41 of the body 40. The braiding of the wire 51 allows it to be oriented in different directions and travel along complex paths, thereby enabling optimization of the monitoring area Z1 of the component. According to a more specific example, the fibers 41 are specifically made of carbon, and the wire 51 is surrounded, for example, by an insulating sheath (not shown), to prevent changes in the resistance value of the wire 51 due to electrical contact or short circuits with other conductive elements present in the component 10 (e.g., reinforcements of the preform, particularly the carbon-made fibers 41), which would have the effect of making the wire unsuitable for the sensor's detection function.

[0057] Advantageously, due to the low measuring voltage, the thickness of the insulating sheath can be small, but it must resist abrasion during its passage through the braiding machine that enables the manufacture of component 10. In particular, the material of the insulator used for the insulating sheath can be a polymeric insulator compatible with the material of the preform, preferably made of a polymeric insulator compatible with the resin and ideally selected from the same family as the resin, such as an epoxy insulating sheath when the resin has epoxy groups.

[0058] Specifically, the diameter of the conductor 51 can be between 0.05 mm and 8 mm. This diameter makes the conductor large enough to withstand the voltage of the conductor 51, and small enough to be compatible with the loom that enables the manufacture of component 10. In particular, the conductor 51 can be formed, for example, one or more C-shaped loops and / or U-shaped loops, to enable optimal coverage of the area to be monitored (e.g., area Z1).

[0059] The conductor 51 is made of a conductive material with a known resistance. Specifically, the material is selected from copper, aluminum, iron, silver, nickel, and their alloys, and is made, for example, from constantan. Constantan is an alloy.

[0060] The conductor 51 is made of constantan, for example, an alloy whose resistance is highly independent of temperature, allowing for more accurate values ​​compared to other types of materials. Furthermore, there is no need to compensate for errors through potential temperature increases.

[0061] The connection element 60 is configured to measure the resistance of the wire 51. According to one embodiment, the connection element 60 includes an RFID tag 62, which is used to wirelessly transmit a signal S, specifically information about the change in resistance of the wire 51, particularly when the resistance of the wire 51 is above a predetermined threshold.

[0062] The connecting element 60 (e.g., RFID tag 62) includes an antenna 42 and one or more electronic components 44 (e.g., a chip). Radio Frequency Identification (RFID) refers to a type of identification that supports radio waves.

[0063] The electronic component 44 of the connecting element is configured, for example, to inject current into the wire 51 and measure the voltage across the terminals of the wire. The electronic component of the connecting element may also be configured to compare the measured voltage value with a reference value (e.g., a threshold value) and send a signal when the measured value is greater than the reference value.

[0064] The connecting element 60 (e.g., RFID tag 62) can be integrated into the component 10, for example, integrated into the preform, or the connecting element can be fixed to the preform before resin injection.

[0065] If component 10 cracks, the wire 51 will break due to the crack being "trapped" in the resin. Therefore, wire 51 will also break along with the crack in component 10. This will directly affect the resistance value of wire 51.

[0066] Since the connecting element 60 (especially the RFID tag) has the function of measuring the resistance of the wire 51, if the resistance value of the wire 51 is higher than a predetermined threshold, it can be known that the component 10 is broken or delaminated.

[0067] Specifically, the predetermined threshold is between 1.01×R and 1.10×R, specifically between 1.02×R and 1.08×R, and specifically equal to 1.05×R, where R is the initial resistance of wire 51. If the resistance of wire 51 is constant and varies between 1% and 10% of the initial value, specifically between 2% and 8% of the initial value, and specifically 5% of the initial value, it can be considered that no breakage has occurred in wire 51, and therefore no crack is found in region Z1 of component 10.

[0068] Conversely, if the resistance value of the wire 51 is particularly outside the predetermined range defined above, it can be considered that the integrity of the wire 51 has changed, and therefore a crack exists in the component 10.

[0069] Figure 3 This is a schematic diagram of the reading steps of the connecting element 60 according to the present invention. Figure 3 In the specific example shown, advantageously, in the first instance, the connecting element 60 can be preferably positioned as close as possible to the center of rotation of the system on which the component 10 (in this case, the blade 10) is mounted, i.e., the center of rotation of the turbine engine 100 in this case. In practice, if the component 10 (in this case, the blade 10) is rotating, this particularly enables the operator P to manually use the reading device 6 (in particular, the reader 6, especially the RFID reader 6) positioned close to the center of rotation (which can be easily done) to continuously or simultaneously acquire data from the different connecting elements 60 (in particular, the different RFID tags 62) present on the component 10 (in this case, the blade 1) in a collective manner.

[0070] Figure 4 This is a schematic perspective view of the fan 110 of the turbine engine 100, which is equipped with connecting elements 60 (in particular RFID tags 62) and reading devices 60 (in particular RFID readers 60), corresponding to embodiments of the invention, enabling the collective acquisition of data from different connecting elements 60 (in particular different RFID tags 62) present on the component 10 (in this case, the impeller 1) according to an automated process. Figure 4In the alternative embodiment shown, the coupling element 60 is located in the region of the cone 112 away from the fan 110.

[0071] The connecting element 60 is positioned on the outer end of the component 10, in this case at the far end of the blade 1, so that the connecting element can be easily read by the reading device 6 which is arranged nearby on the immovable part (e.g., attached to the housing 5 of the fan 110).

[0072] Since the reading device 6 is attached to a non-movable part, when the component 10 passes by the reading device 6, the reading device can obtain data sent by the connecting element 60 (e.g., RFID tag 62) from different components 10 (in this case, from the blade 1 of the fan 110).

[0073] Data transmission (especially RFID) is sensitive to electromagnetic interference. However, the conical region of fan 110 includes numerous metal components that provide electromagnetic shielding and form a Faraday cage. The distance of coupling element 60 from the conical region of fan 110 allows electromagnetic interference to be prevented from affecting the transmission of data and signals S from RFID tags.

[0074] In addition, in order to maximize the detection distance of the connecting element 60 (especially the RFID tag 62) through a suitable reading device 6, proximity to conductive elements should be avoided.

[0075] The resin used to manufacture the blades 1 of the fan 110 is inherently insulating, while the carbon used to weave the fibers of the preform is a good electrical conductor. Therefore, according to one aspect of the invention, the connecting element 60 is positioned in the region of the component 10 with the least amount of carbon (in this case, the blades 1).

[0076] More specifically, positioning the connecting element 60 in a location rich in non-conductive or "non-metallic" fibers 41 reduces interference and / or dissipation of the electromagnetic field and / or the antenna 42 of the connecting element 60 caused by the conductive fibers 41 (e.g., carbon fiber 41), and increases the detection distance by several centimeters (particularly between 5 cm and 25 cm, particularly between 10 cm and 20 cm) up to several meters (particularly between 0.5 m and 10 m, particularly between 2 m and 8 m).

[0077] Furthermore, in order to ensure that the connecting element 60 does not have an adverse effect on the mechanical properties of the body 40, the location and design of the connecting element 60 in the component 10 are preferably carefully defined.

[0078] Furthermore, the connecting element 60 (in particular the RFID tag 62) is integrated into the component 10 (specifically impregnated in resin) and is therefore protected from the external environment.

[0079] Now refer to Figure 5 , Figure 5 This is a schematic diagram of component 10 according to the invention, which serves as a blade. Specifically, Figure 5 A side view of the fan 110 with its blades 1 having a connecting element 60 is shown.

[0080] according to Figure 5 In the example of the illustrated embodiment, the root 11 of the blade 1 is formed from a woven preform or a first portion of a woven preform 30 comprising only conductive fibers 41 (particularly braided carbon fibers 41). The same is true for the main portion of the blade 13 (particularly the leading edge 1a), thus the leading edge of the blade is formed from a preform or a second preform portion 32 comprising only conductive fibers 41. The preform is typically single and extends into both the first preform portion 30 and the second preform portion 32.

[0081] Conversely, the section of blade 13 extending along the trailing edge 1b is made of braided fibers 41, which include conductive fibers (especially carbon fibers) and non-conductive fibers (especially glass fibers), and thus the section includes a preform or third preform section 34 made of a composite material.

[0082] The first precast component 30, the second precast component 32, and the third precast component 34 are in Figure 5 The area is defined by a dashed rectangle.

[0083] Therefore, when it is desirable to maximize the detection distance between the reading device and the connecting element 60 (especially the RFID tag 62), in particular to enable the execution of a method for automatically and collectively collecting data from all RFID tags (corresponding to...) Figure 4 When collecting data as shown, preferably, the connecting element 60 is located in the third preform portion 34, which is the portion with the fewest conductive fibers 41. Therefore, in the example shown, the connecting element 60 is positioned near the trailing edge 1b of the impeller 1. This facilitates detection of the connecting element 60 (corresponding to...) from a distance by the reading device 6. Figure 4 The method shown is for collecting data, which is therefore particularly advantageous.

[0084] In one embodiment, the connecting element 60 (in particular the RFID tag 62) is positioned on the component 10 in an area sufficiently close to the reading device 6 such that when the reading device 6 queries the tag, the RFID tag 62 is powered through the RFID tag's antenna: thus the RFID tag's electronics can determine the resistance of the wire 51 integrated in the component 10 and transmit a signal S with corresponding measurement data to the reading device.

[0085] In practice, the connecting element 60 (especially the RFID tag 62) is preferably a passive device, that is, without a battery, but powered by radio waves generated by the reading device 6 (especially the RFID reader 6).

[0086] Alternatively, the connecting element 60 (specifically the RFID tag 62) may include a battery. The presence of a battery will enable, for example, the periodic reading of the resistance of the wires. This also allows for a reduction in the communication distance between the reading device and the tag.

[0087] Preferably, the connecting element 60 (in particular the tag 62) is configured to operate in the Ultra High Frequency (UHF) band, for example, at a frequency particularly between 860 MHz and 960 MHz.

[0088] In cases where the preform is primarily formed of conductive fibers, preferably, the connecting element 60 is insulated from these fibers. Figure 6 This is a schematic diagram viewed from above the connecting element 60 (e.g., RFID tag 62) in such a prefabricated component.

[0089] According to an example of this embodiment, the connecting element 60 (e.g., RFID tag 62) includes a ball portion 43 made of a dielectric material (typically a polymer), the ball portion being designed to protect the tag's electronic chip and its electrical connection to the antenna 42.

[0090] The largest component of the connecting element 60 is the ball portion 43, which preferably has a diameter of 5 mm or less. The ball portion provides isolation from the antenna and electronic components, and the overall size of the ball portion results in a certain thickness of the connecting element.

[0091] In an alternative embodiment, antenna 42 is planar and may extend parallel to the surface of component 10 (e.g., the surface of blade 1 or blade 13), or between two layers or two meshes of fiber 41 of component 10 or preform. The thickness of antenna 42 is, for example, less than or equal to 2 mm, particularly less than or equal to 1 mm, and particularly less than or equal to 0.5 mm.

[0092] As previously mentioned, the connecting element 60 (e.g., RFID tag 62) has the advantages of meeting the requirements for size, thermal stability, and chemical compatibility in the field. Furthermore, the material of the connecting element 60 (e.g., RFID tag 62) is preferably selected as:

[0093] -Does not affect the resin or its curing.

[0094] - It is thermally stable during the possible curing of the resin-impregnated preform and / or during the exothermic polymerization reaction of the resin.

[0095] - The closure of the mold used to manufacture the blades does not interfere with the weaving and preforming, and

[0096] - The size is not very large.

[0097] The ball portion 43 is made of a polymer, for example. Furthermore, the antenna 42 is made of copper or aluminum, for example, and potentially coated with a thermoplastic polymer or epoxy polymer (PET, PC, polyimide, etc.).

[0098] The connecting element 60 (e.g., RFID tag 62) may include a memory. Therefore, identification data and / or feature data ID1, ID2, such as serial number ID1 (referred to as "serial number (SN)") and / or part number ID2 (referred to as "part number (PN)"), can be stored.

[0099] It goes without saying that the memory can store a single piece of data or a set of data, such as deformation data of component 10, resistance of wire 51, excess of resistance threshold of wire 51, a unique identifier that enables the component to be identified in a particular way, or two or more identification data (e.g., manufacturer's identifier (CAGE code, etc.)), manufacturing date, in particular the degree of sensitivity to a particular fluid, operation authorization reference, and data associated with maintenance operations or logistics of component 10 (e.g., operating status, operations performed, etc.).

[0100] like Figure 3 As shown, the antenna 42 of the connecting element 60 (e.g., RFID tag 62) is configured to receive a read request REQ and, in particular, to send back data, especially identification data and / or feature data ID1, ID2 and / or signal S, when the resistance of the wire 51 is higher than a predetermined threshold.

[0101] Tags using RFID technology are known to those skilled in the art. In a known manner, tags according to RFID technology are distinguished as follows: tags for "metallic" environments (polymer ball type as described above), tags for "non-metallic" or non-conductive environments, and tags for "mixed" use. Tags for "metallic" environments have a thickness of at least 1.5 mm for high-frequency or UHF operation, while tags for "non-metallic" or non-conductive environments have a thickness of less than 0.5 mm for UHF applications.

[0102] Choose the type of RFID tag based on the type of impeller and / or the area where the tag will be placed.

[0103] Because of the small thickness of RFID tags used in "non-metallic" environments, and because the application of RFID tags in "non-metallic" environments is of particular interest for blades with thin profiles due to aerodynamic constraints, RFID tag 62 for "non-metallic" environments is advantageous. Therefore, in the case of RFID tag 62 being used for "non-metallic" applications, the preform should include glass fiber 41.

[0104] One advantage of using RFID tags 62 for “metallic” environments is that it relaxes integration constraints regarding the environment, particularly in areas of the woven preform that do not contain or contain very little non-conductive fiber 41 (e.g., glass fiber).

[0105] according to Figure 6 In the example shown, antenna 42 specifically includes at least one communication lobe L1 oriented along the radio axis XR to receive read requests REQ and, for example, to send back data when a crack is detected in component 10, such as identification data and / or feature data ID1, ID2 and / or signal S.

[0106] Specifically, antenna 42 may include two communication lobes L1 aligned along a single radio axis XR. Therefore, coupling element 60 (e.g., RFID tag 62) may be used in two opposite orientations in the same direction.

[0107] Figure 7 This is a schematic perspective view of a section of the woven prefabricated component with connecting elements 60. Specifically, Figure 7 A portion of the woven preform of component 10 (particularly the impeller 1) is shown, along with a space E present within the preform. Space E is adapted to accommodate the ball portion 43 of the connecting element 60 (e.g., RFID tag 62) in a "metallic" environment. Space E is located between the woven fibers 41. Therefore, the ball portion 43, accommodated in one of the spaces within space E, is intended to be impregnated in a resin that permeates the preform, thus achieving complete impregnation without affecting the shape of the preform.

[0108] Using a connecting element 60 (e.g., an RFID tag 62) and integrating the connecting element into the prefabrication has several advantages, including:

[0109] -Since the integration of the connecting element 60 (e.g., RFID tag 62) is carried out during the manufacturing of part 10 (particularly blade 1) and before the resin is injected into the mold used to manufacture part 10 (particularly blade 1), there is no additional specific step for installing the connecting element.

[0110] - Connecting element 60 (e.g., RFID tag 62) is integrated into component 10 (particularly blade 1).

[0111] Therefore, the connecting element is not forgery. The connecting element cannot be removed without the risk of damaging component 10 (especially the impeller 1).

[0112] The connecting element 60 (e.g., RFID tag 62) is impregnated in resin. Therefore, there is no risk of the connecting element 60 accidentally detaching and being lost during operation; and

[0113] - Detect the connecting element 60 (e.g., RFID tag 62) without removing the turbine engine and / or blades.

[0114] The antenna 42 of the connecting element 60 (e.g., RFID tag 62) also has the following advantages:

[0115] - Thin, and therefore easy to arrange and integrate; and

[0116] - Facilitates detection via reading device 6 (e.g., RFID reader 6).

[0117] Reference Figure 3 A method will now be described specifically for reading, individually and collectively, identification data and / or characteristic data ID1, ID2, and transmitted signals S of one or more components 10 (particularly the blades 1 of the fan 110 of a turbine engine 100, particularly an aircraft turbine shaft engine) when cracks are detected on these components 10.

[0118] In this example, operator P uses reading device 6 (specifically RFID reader 6) to ensure radio identification and positions himself at a distance from one or more components 10, i.e., according to... Figure 3 The example shown is located at a distance from the turbine engine 100, specifically upstream of the turbine engine to be close to the fan 110.

[0119] Using the reading device 6, the operator P sends a read request REQ wirelessly, which is received wirelessly by the antenna 42 of the connecting element 60 (e.g., RFID tag 62).

[0120] In response to a read request REQ, specifically when a crack is detected in component 10, antenna 42 transmits radio signals to transmit data, such as identification data and / or feature data ID1, ID2, and signal S. The data transmitted by antenna 42 is read by read device 6. Specifically, the identification data and / or feature data ID1, ID2, and signal S are transmitted by communication lobe L1 of antenna 42. Preferably, the read identification data and / or feature data ID1, ID2, and / or read measurement deformation data DF, as well as the received signal S, are stored in read device 6 in a computerized manner.

[0121] Depending on the transmission power of the reading device 6 and the distance between the reading device 6 and the connecting element 60, the operator can read a single connecting element 60 individually (in this case, a single RFID tag 62 of the impeller 1) (low power and short range), or collectively read multiple connecting elements 60 (in this case, multiple RFID tags 62 of the impeller 1 of the fan 110) (high power and long range). In practice, depending on the connecting element 60, the reading device 6, and the environment, readings can be performed at distances ranging from a few centimeters (5cm to 25cm) to several meters (0.5m to 10m).

[0122] like Figure 8a , Figure 8b , Figure 8c As shown, the present invention also relates to a method for detecting the formation of cracks on the component 10 as described above.

[0123] More specifically, in Figure 8a , Figure 8b , Figure 8c The diagram shows the crack detection process and the transmission of corresponding information in more detail.

[0124] Figure 8a A component 10 (e.g., a blade 1) including a wire 51 is shown. Here, the resistance of the wire 51 is equal to the known resistance value of the material selected for the wire 51.

[0125] exist Figure 8b In this case, crack F appears on component 10. However, crack F does not reach wire 51. Therefore, there is no elongation of wire 51 and no interruption of electrical contact. Therefore, the resistance value of wire 51 remains the same as its initial resistance value.

[0126] exist Figure 8c Crack F reaches wire 51. Therefore, wire 51 integrated in component 10 partially or completely breaks or fractures. Consequently, crack F affects the current flow in wire 51. Therefore, the resistance of wire 51 increases significantly, reaching infinity in the case of complete breakage. This is verified by injecting current into wire 51. Figure 8a and Figure 8b In this case, the current is injected into the connecting element or tag and the voltage is measured through the terminals of wire 51 to infer the resistance of the wire according to Ohm's law. Figure 8c In this case, the current is injected into the connecting element or tag, and zero voltage is measured through the terminal of wire 51 due to the infinite resistance of the wire.

[0127] An increase in the resistance of wire 51 exceeding a predetermined threshold (e.g., corresponding to an increase between 1% and 10%, particularly 2% and 8%, particularly 5% of the initial resistance of wire 51) indicates the presence of a crack in region Z1 of component 10 (particularly blade 1), in which the presence of the crack must be monitored, through which wire 51 passes. Then, upon request / query from an external reading device, connection element 60 specifically transmits signal S to the reading device via radio waves.

[0128] like Figure 9a , Figure 9b As shown, the present invention also relates to a method for manufacturing the component 10 (particularly the impeller 1) as described above.

[0129] The method includes insertion step a), such as Figure 9a As shown, the insertion step includes inserting the wire 51 into the braided fiber preform 41. Advantageously, the wire 51 is present in region Z1 of the braided material, in which the presence or formation of cracks will be monitored. The wire 51 is woven and integrated along a specific path by a braiding machine, specifically to cover most of region Z1, in which the presence of cracks must be monitored. For example, Figure 10 The path of the wire 51, which is wound together with the fibers of the body 40, is shown. The wire 51 is integrated into the volume of the body, i.e., the path of the wire, together with the aforementioned loop, enables coverage of the surface and thickness of the area Z1 to be monitored.

[0130] like Figure 9b As shown, the method includes a joining step b), which includes fixing the connecting element 60 to the preform or integrating the connecting element 60 into the preform, and connecting the end of the wire 51 to the connecting element 60, such that the connecting element can measure the resistance of the wire 51 and compare the resistance of the wire with a predetermined threshold, as described above.

[0131] If the resistance of the wire 51 is greater than a predetermined threshold (particularly greater than the value between 1.01×R and 1.10×R, particularly between 1.02×R and 1.08×R, particularly equal to 1.05×R, where R is the initial resistance of the wire 51), then the connecting element 60 can transmit a signal S to the reading device 6 indicating that the component 10 has been damaged, particularly due to a break.

[0132] The method also includes injection step c), such as Figure 2 As shown, the injection step involves injecting resin (particularly organic or polymeric resin) into a preform pre-arranged in a mold (not shown) to manufacture the body 40 of component 10 (e.g., blade 1). The assembly consisting of the preform, crack sensor 50, and connecting element 60 is then cured.

[0133] However, the crack sensor 50, the connecting element 60, and the connecting elements must be able to withstand the temperature and pressure constraints generated during injection, particularly temperatures between 180°C and 200°C, especially a typical temperature of 180°C and a pressure of 20 bar.

[0134] Before the injection step c) of this method, for example, there may be a step of electrically insulating (not shown) the connection between the connecting element 60 and the wire 51.

[0135] The invention has been described with reference to an embodiment in which component 10 is specifically blade 1, but the invention can certainly be applied to any type of composite component 10, particularly components 10 for aircraft turbine engines.

[0136] Of course, the present invention is not limited to the embodiments described above, which are provided by way of example only. The present invention includes various modifications, alternatives and other variations that can be conceived by those skilled in the art within the framework of the present invention, and in particular all combinations of the various embodiments described above that can be used alone or in combination.

Claims

1. A component (10) made of composite material, said component comprising: - Body (40), which is made of three-dimensionally woven fibers (41) impregnated in resin. - At least one crack sensor (50), said at least one crack sensor being capable of detecting cracks in said component (10), and - At least one connecting element (60) is connected to the crack sensor (50) and configured to transmit a signal (S) when a crack is detected in the component (10). Its features are: - The crack sensor (50) includes at least one wire (51) that is braided together with the fibers of the body and extends into a region (Z1) of the body (40) where the presence of a crack will be detected, and - The connecting element (60) is connected to the end of the wire (51), and the connecting element is configured to measure the resistance of the wire (51) and wirelessly transmit the signal (S) when the measured resistance of the wire (51) is higher than a predetermined threshold.

2. The component (10) according to claim 1, wherein, The fiber (41) is made of carbon, and the conductor (51) is surrounded by an insulating sheath.

3. The component (10) according to claim 1 or 2, wherein The diameter of the conductor (51) is between 0.05 mm and 8 mm.

4. The component (10) according to claim 1 or 2, wherein The conductor (51) forms at least one C-shaped loop and / or U-shaped loop.

5. The component (10) according to claim 1 or 2, wherein The conductor (51) is made of a material selected from copper, aluminum, iron, silver, nickel and their alloys.

6. The component (10) according to claim 1 or 2, wherein The predetermined threshold is between 1.01×R and 1.10×R, where R is the initial resistance of the wire (51).

7. The component (10) according to claim 1 or 2, wherein The connecting element (60) includes an RFID tag (62).

8. The component (10) of claim 1, wherein, The component is used in the aircraft turbine engine (100).

9. The component (10) according to claim 1, wherein, The resin is a polymer resin.

10. The component (10) according to claim 1, wherein, The at least one connecting element is configured to transmit a signal (S) to a component outside the component (10) when a crack is detected in the component (10).

11. The component (10) of claim 2, wherein, The insulating sheath is made of the same material as the resin.

12. The component (10) of claim 5, wherein, The conductor (51) is made of constantan.

13. The component (10) of claim 6, wherein, The predetermined threshold is between 1.02×R and 1.08×R.

14. The component (10) of claim 6, wherein, The predetermined threshold is equal to 1.05 × R.

15. The component (10) of claim 7, wherein, The RFID tag is configured to operate at a frequency between 860MHz and 960MHz.

16. The component (10) of claim 1, wherein, The body (40) includes a three-dimensional preform made of fibers (41) that are three-dimensionally woven.

17. The component (10) of claim 1, wherein, The main body (40) includes a weft yarn made of fiber (41) and a warp yarn made of fiber (41), the weft yarn and the warp yarn being three-dimensionally woven together, the at least one wire (51) of the crack sensor (50) being woven together with the weft yarn and the warp yarn, the at least one wire (51) of the crack sensor (50) including at least a weft portion extending along the weft yarn and a warp portion extending along the warp yarn.

18. The component (10) according to claim 1, wherein, The connecting element (60) includes an RFID tag (62) configured to wirelessly transmit the signal (S) when the measured resistance of the conductor (51) is above a predetermined threshold. The RFID tag (62) includes a ball (43) made of dielectric material that protects the electronic chip of the RFID tag (62) and the electrical connection to the antenna (42) of the RFID tag (62).

19. The component (10) according to claim 9, wherein, The resin is an organic resin.

20. An aircraft turbine engine (100) comprising a component (10) according to any one of claims 1 to 19.

21. The aircraft turbine engine (100) according to claim 20, wherein, The component (10) is the blade (1) of the fan (110), and the aircraft turbine engine (100) includes the housing (5) of the fan (110), the housing of the fan surrounding the blade (1) of the fan (110) and carrying the reading device (6).

22. A method for manufacturing a component (10) according to any one of claims 1 to 19, wherein, The method includes: a) An insertion step comprising inserting the wire (51) into a preform composed of three-dimensionally braided fibers (41), the wire (51) being braided together with the fibers of the preform and extending into a region (Z1) where the presence of cracks will be monitored. b) A joining step comprising securing the connecting element (60) to the preform and connecting the end of the wire (51) to the connecting element (60) such that the connecting element is capable of measuring the resistance of the wire (51), and c) Injection step, which includes injecting the resin into the preform pre-arranged in a mold to manufacture the body (40) of the component (10) and to cure the assembly.

23. The method of claim 22, wherein, Prior to the injection step c), there is a step of electrically insulating the connection between the connecting element (60) and the wire (51).

24. The method of claim 22, wherein, The resin is a polymer resin.

25. The method of claim 22, wherein, The preform includes a weft yarn made of fiber (41) and a warp yarn made of fiber (41), the weft yarn being three-dimensionally woven with the warp yarn by a loom, and the at least one wire (51) of the crack sensor (50) being woven with the weft and warp yarns of the preform by the loom during the insertion step a).

26. The method according to claim 22, wherein, Prior to the injection step c), there is a step of electrically insulating the connecting element (60).

27. The method of claim 22, wherein, The joining step includes integrating the connecting element into the preform.

28. The method of claim 24, wherein, The resin is an organic resin.

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