A micro robot for turbine blade damage monitoring of an aeroengine

Abstract

The application discloses a micro robot for turbine blade damage monitoring of an aero-engine and belongs to the mechanical field.The micro robot comprises a flexible section, an extension section, a longitudinal motion section and a transverse motion section.The flexible section is connected with the extension section, and a plurality of sensor modules can be installed on the flexible section to realize detection functions.Electrostatic adhesion pieces are arranged on the lower surfaces of the flexible section and the transverse motion section, and the adhesion and separation of the specified sections of the robot are realized by the on-off of voltage.The extension section is designed for controlling the forward and backward motions of the robot inspired by the movement of a worm.The longitudinal motion section is designed for controlling the micro robot to rotate perpendicularly to the initial motion plane to realize the wall climbing and obstacle surmounting functions by imitating the motion posture of a caterpillar.The transverse motion section is designed for controlling the robot to turn in the initial motion plane to effectively bypass obstacles inspired by the movement form of an earthworm.

Description

Technical Field

[0001] This invention relates to the field of industrial robot technology, and in particular to a micro-robot for monitoring surface damage on aero-engine turbine blades. Background Technology

[0002] The reliability of turbine blades, a core component of aero-engines, is directly related to the safe flight of the aircraft. Turbine blades operate in extremely harsh environments, including high speed, high stress, and high temperature, making them one of the components with the highest failure rate in an engine. Therefore, achieving efficient and reliable inspection of engine turbine blades is crucial. Currently, inspection methods for core components such as engine turbine blades mainly include disassembly inspection and visual inspection. However, disassembly inspection is complex and inefficient, while visual inspection suffers from blind spots and is expensive. Using motion-mode biomimetic microrobots for aero-engine turbine blade inspection offers the following advantages compared to traditional methods:

[0003] (1) High detection efficiency, reliable and comprehensive: Micro robots have higher flexibility and environmental adaptability, and can observe the blind spots of traditional detection methods, effectively improving detection efficiency.

[0004] (2) Multifunctional and intelligent: Micro robots can be equipped with complex functions such as lighting and image acquisition, and combined with deep learning algorithms to perform unattended image processing and recognition, thereby realizing intelligent detection of turbine blade damage in aero-engines.

[0005] (3) Miniaturization: Due to their miniaturization and lightweight design, micro-robots can easily reach narrow and complex areas to perform designated tasks. These robots are highly attractive for applications in engineering fields such as disaster search and rescue, pipeline gas detection, and aircraft engine inspection.

[0006] (4) Low cost: Due to the miniaturization and integration of microrobots, the cost of the system can be reduced, which is conducive to large-scale preparation and promotion.

[0007] Based on the above advantages, micro-robots have great potential for application in the field of aero-engine damage monitoring. They represent a combination of industrial robots and non-destructive testing technology and are one of the future development directions in the field of aero-engine damage monitoring.

[0008] Rolls-Royce and Harvard University are collaborating on research into robots capable of rapid movement inside engines. A bee-like quadrupedal micro-robot can be concealed within the abdomen of a snake-like robot to enter the interior of an aircraft engine without disassembling it. The University of Southern California has developed RoBeetle, an insect-sized autonomous crawling robot powered by the catalytic combustion of methanol; its high energy-to-weight ratio gives it good mobility. The University of California, Berkeley has designed the electrically driven VelociRoACH cockroach-inspired robot, powered by a lithium polymer battery, which can rapidly tumble on surfaces of varying roughness; however, its size limits its application in confined spaces. Robot-based intelligent defect detection for turbine blades generally suffers from low maturity, low integration, and several performance indicators that require further improvement. Summary of the Invention

[0009] In view of the above problems, this patent discloses a microrobot for monitoring damage to turbine blades of aero-engines, which aims to solve the problems of complex operation, low efficiency, blind spots and high cost in the prior art.

[0010] This patent discloses a micro-robot for monitoring damage to turbine blades in aero-engines, comprising: a flexible segment, a telescopic segment, a longitudinal motion segment, and a lateral motion segment;

[0011] The flexible segment further includes: a front cover, a rear cover, a support plate, a vision sensor, a protective shell, an integrated circuit, a power supply, and a flexible shell. The support plate connects the front cover and the rear cover. The vision sensor is located on the front side of the front cover. The protective shell is a transparent shell that covers the vision sensor. The integrated circuit and the power supply are located on the support plate. The flexible shell covers the entire flexible segment. A telescopic rod is fixed to the tail end of the flexible segment.

[0012] The telescopic section includes: a front cover, a motor reducer assembly, a gear set, a nut, a lead screw, a guide rod, a support plate, and a rear cover. The support plate connects the front cover and the rear cover, forming the frame of the entire telescopic section. The motor reducer assembly, lead screw, and guide rod are all cylindrical, with both ends connected to the front cover and the rear cover. The output end of the motor reducer assembly drives the lead screw to rotate via the gear set, which is mounted on the front cover. The nut is fitted onto the lead screw and guide rod, and the rotation of the lead screw causes the nut to move back and forth. The end of the telescopic rod of the flexible section is fixed to the nut. A longitudinal rotating rod is fixed on the rear cover of the telescopic section. Electrostatic adhesion plates are provided at the bottom of the flexible section and the transverse movement section.

[0013] The longitudinal motion section includes: a front cover, a turbine, a worm gear, a motor, a support plate, and a rear cover. The support plate connects the front cover and the rear cover, forming the framework of the entire longitudinal motion section. The motor is vertically mounted on the rear cover, with a first bevel gear nested at its output end. The axial direction of the worm gear is consistent with the axial direction of the longitudinal motion section. One end of the worm gear is mounted on the front cover via a bearing, and the other end is nested with a second bevel gear. The connection point between the worm gear and the second bevel gear is mounted on the support plate via a bearing, and the first bevel gear meshes with the second bevel gear. The turbine gear is longitudinally mounted and mounted on the support plate via a bearing. The helical threads on the worm gear mesh with the turbine gear. The longitudinal rotating rod is fixed to the turbine gear, driving the longitudinal motion rod to rotate longitudinally. A transverse motion rod is fixed to the longitudinal motion forging tail section.

[0014] The transverse motion section structure is exactly the same as the longitudinal motion forging structure. Rotating the longitudinal motion section by 90 degrees results in the transverse motion section, and the transverse motion rod rotates laterally.

[0015] The integrated circuit module controls all the motors and processes the data acquired by the vision sensor.

[0016] Furthermore, the telescopic section, longitudinal movement section, and lateral movement section are all equipped with outer shells, which are fixed to the front cover and the rear cover by pins.

[0017] This patent disclosure has at least the following advantages over the prior art:

[0018] 1. Possesses multiple motion modes and strong environmental adaptability. The biomimetic microrobot has three basic motion modes, can reach any position in a plane, and can switch motion planes through longitudinal motion segments, providing a guarantee for the controllable movement and task execution of the microrobot in complex environments.

[0019] 2. It possesses electrostatic adhesion capability, exhibiting good stability and fast response. The aforementioned multi-motion mode biomimetic microrobot offers an electrostatic adhesion method as an option, which is more reliable and easier to control compared to other common adhesion methods. Furthermore, it is non-destructive to moving surfaces, making it suitable for in-situ non-destructive testing of aero-engine turbine blades.

[0020] 3. High degree of modularity, simple manufacturing, and small size. Compared with known continuum inspection robots, the multi-motion mode biomimetic microrobot described in this patent is easy to miniaturize through modular design, making it simple to manufacture and assemble, and smaller in size. In the application of aero-engine turbine blade damage monitoring, it is no longer limited by the reserved probe hole position and size, and can realize defect inspection of various engine models. Attached Figure Description

[0021] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0022] Figure 1 This is a schematic diagram of the overall structure of a multi-motion-mode biomimetic microrobot;

[0023] Figure 2 This is a three-dimensional structural diagram of the flexible segment of a multi-motion-mode biomimetic microrobot;

[0024] Figure 3 This is a three-dimensional structural diagram of the telescopic segment of a multi-motion-mode biomimetic microrobot;

[0025] Figure 4 This is a three-dimensional structural diagram of the transverse / longitudinal motion segments of a multi-motion-mode biomimetic microrobot;

[0026] Figure 5 This is a schematic diagram of the motion performance mode of a multi-motion-mode biomimetic microrobot.

[0027] Figure 6 This is a schematic diagram of the motion of a multi-motion-mode biomimetic microrobot in a space-constrained environment;

[0028] Figure 7 This is a schematic diagram of the movement of a multi-mode biomimetic microrobot in safe retrieval mode. Detailed Implementation

[0029] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0030] The present invention will now be described in conjunction with the accompanying drawings.

[0031] The flexible section is connected to the telescopic section via a connecting rod, the movement of which is controlled by a worm gear and nut. The telescopic section is connected to the longitudinal motion section via a longitudinal rotating rod, driven by a worm wheel and worm gear. The lateral motion section is connected to the longitudinal motion section via a lateral rotating rod, and the robot's complex movements are achieved by the adsorption and detachment of the electrostatic adhesive sheets on the underside of the flexible section and the lateral motion section.

[0032] The microrobot's flexible and lateral movement segments are equipped with electrostatic adhesive patches. When no voltage is applied to the electrostatic adhesive patches on the lower surfaces of the flexible and lateral movement segments, the patches detach from the movement surface and can be driven by the telescopic and rotating segments to generate movement. After voltage is applied, the electrostatic adhesive patches generate electrostatic adsorption force, fixing the designated movement segment to the movement surface, and cooperating with the other movement segments to achieve resting and dynamic movement on non-horizontal surfaces. By applying different combinations of voltage signals to the lower sides of the flexible and lateral movement segments, and controlling the movement in conjunction with the selection of movement modes and gait, complex movements on tilted, vertical, and even inverted planes can be achieved, ultimately realizing the monitoring of surface damage on aero-engine turbine blades.

[0033] The longitudinal and lateral motion segments are connected by a worm gear structure to achieve motion in a plane perpendicular to the initial motion direction and within the initial motion plane. By switching the electrostatic adhesion sheet on and off, the robot can adhere to and detach from designated motion segments. The longitudinal motion segment allows for switching between different motion surfaces of the microrobot, while the lateral motion segment enables the microrobot to turn on the same surface.

[0034] The telescopic section achieves its telescopic function through a lead screw and nut assembly, driving the robot to crawl in a worm-like manner. Combined with the switching on and off of the electrostatic adhesion plate, it enables the robot's designated joints to adhere to and detach from the moving surface, thus achieving high-efficiency crawling. By combining the longitudinal and lateral movement sections, three modes of movement can be achieved and switched; these three modes are referred to in this patent as the motion performance mode, the space-constrained mode, and the safe recovery mode.

[0035] like Figure 1The diagram shows the overall structure of a multi-motion-mode bionic microrobot. The overall structure of the multi-motion-mode bionic microrobot 1, from left to right, includes: a flexible segment 10, a telescopic segment 20, a longitudinal motion segment 30, and a lateral motion segment 40. The flexible segment 10 and the telescopic segment 20 are mechanically interconnected via a telescopic rod 201; the telescopic segment 20 and the longitudinal motion segment 30 are mechanically interconnected via a longitudinal rotating rod 301; and the longitudinal motion segment 30 and the lateral motion segment 40 are mechanically interconnected via a lateral rotating rod 403. The main electronic components of the flexible segment 10 include a vision sensor 101 and an integrated circuit module 102, enabling functions such as illumination, visual sensing, and image acquisition. The telescopic segment 20 is connected to the flexible segment 10 via the telescopic rod 201. As the screw 202 rotates, the nut 203 undergoes axial displacement, driving the telescopic rod 201 to move. The longitudinal motion segment 30 and the lateral motion segment 40 have similar structures and are connected to the preceding structural segment via longitudinal (lateral) rotating rods 301. The longitudinal (transverse) rotating rod is fixed to the turbine 302 and rotates with the turbine. The worm gear 403 is connected to the motor 404 through a bevel gear. The motor 404 drives the worm gear 403 to rotate, which in turn drives the turbine and the longitudinal (transverse) rotating rod to move.

[0036] like Figure 2 The diagram shows a three-dimensional structural schematic of the flexible segment of a multi-motion-mode biomimetic microrobot. The flexible segment 10 is the main functional segment for the robot to perform turbine blade inspection tasks in aero-engines, and its axial movement is achieved through the telescopic rod 201 of the telescopic segment 20. As the lead screw 203 of the telescopic segment 20 rotates, the nut 202 undergoes axial displacement, driving the telescopic rod 201 to move, thereby controlling the robot's flexible segment to move back and forth along the axial direction. The vision sensor 101 and the integrated circuit module 102 are the main electronic components of the flexible segment 10, enabling functions such as visual sensing, illumination, image acquisition, and transmission. The integrated circuit module is encased in a flexible shell 103, which passively changes shape according to terrain changes and movement posture. Its bottom surface includes an electrostatic adhesion sheet made of polyimide, which can be controlled by switching voltage on and off. The protective shell 104 is made of a rigid material to protect the vision sensor 101.

[0037] like Figure 3The diagram shows a three-dimensional structural schematic of the telescopic section of a multi-motion-mode biomimetic microrobot. The telescopic section 20 mainly includes a telescopic rod and matching hole 201, a nut 202, a lead screw 203, a motor and reducer 204, a rear cover 205, a pin 206, a guide rod 207, a support 208, a Hall element 209, a gear set 210, and a front cover 211. The motor and reducer 204 transmits rotational motion to the lead screw 203 via the gear set 210, thereby causing the nut 202 to shift along the guide rod 207, thus enabling the telescopic rod 201 to extend and retract. This, combined with the electrostatic adhesion sheet, allows the robot to move in a plane.

[0038] like Figure 4 The diagram shows a three-dimensional structural schematic of the horizontal / vertical motion segments of a multi-motion-mode biomimetic microrobot. The vertical motion segment 30 has a similar structure to the horizontal motion segment 40, except that the horizontal motion segment 40 is a 90° rotation of the vertical motion segment 30. Taking the vertical motion segment as an example, a motor 305 is connected to the rear cover of the vertical motion segment 30. The motor transmits rotational motion to the worm gear 303 via a bevel gear 304. The vertical rotation rod is fixed to the worm wheel 302. When the motor 305 rotates, it drives the worm gear 303 and the worm wheel 302 to rotate, thereby achieving a specified angle rotation of the vertical motion segment.

[0039] like Figure 5 The diagram illustrates the motion of a multi-motion-mode bionic microrobot in inchworm-like (motion performance mode). In inchworm-like motion mode, the multi-motion-mode bionic microrobot 1 can move in complex environments and overcome obstacles. In the obstacle-crossing embodiment, initially, the multi-motion-mode bionic microrobot 1 is positioned in front of an obstacle. The electrostatic adhesion sheet at the bottom of the longitudinal motion segment 30 is energized, and the flexible segment 10 contacts the side surface of the obstacle via the longitudinal rotating rod 301. At this time, the electrostatic adhesion sheet at the bottom of the flexible segment 10 is energized, while the electrostatic adhesion sheet at the bottom of the longitudinal motion segment 30 is de-energized. Through the repeated extension and retraction of the telescopic rod 201 of the telescopic segment 20, the horizontal and vertical motion surfaces are switched. When the multi-motion-mode bionic microrobot 1 is entirely in the vertical plane, the vertical plane motion is achieved by switching the voltage applied to the electrostatic adhesion sheet in conjunction with the movement of the telescopic segment 20. Using this mechanism, the multi-motion-mode bionic microrobot 1 can switch between horizontal-vertical-horizontal motion surfaces and achieve climbing motion by combining the electrostatic adhesion function.

[0040] like Figure 6The diagram illustrates the motion of a multi-motion-mode biomimetic microrobot in a worm-like (space-constrained) configuration. When space is limited, the multi-motion-mode biomimetic microrobot 1 can achieve flexible movement within a plane via its lateral motion segment. When turning is required, the electrostatic adhesion plate at the bottom of the lateral motion segment 40 is energized and adheres to the moving surface, and the robot's front end rotates to a specified angle via the lateral rotation rod 401. The telescopic rod 201 of the telescopic segment 20 rotates axially via a motor-driven lead screw nut. When the flexible segment 10 reaches the designated position, the electrostatic adhesion plate at the bottom of the flexible segment is energized, the electrostatic adhesion plate at the bottom of the lateral motion segment 40 is de-energized, and the telescopic rod 201 retracts, causing the robot to complete the turning motion.

[0041] like Figure 7 The diagram shows the motion of the multi-motion-mode bionic microrobot in pupa-like (safe recovery mode). After testing, the multi-motion-mode bionic microrobot 1 needs to be recovered via a traction rope to minimize its size and facilitate retrieval. The longitudinal rotating rod 301 rotates 180° to achieve complete folding of the robot. The flexible segment 10 is longer than the lateral movement segment 40; therefore, during the traction and recovery process, it is the flexible outer shell 103 of the flexible segment that contacts the internal structure of the engine, without affecting the internal structure.

[0042] It should be noted that the materials and dimensions of the above-described structural components are merely illustrative examples and do not constitute a limitation of the disclosed examples. In other examples, the materials and dimensional parameters may be different.

Claims

1. A microrobot for monitoring damage to aero-engine turbine blades, comprising: Flexible segment, telescopic segment, longitudinal movement segment, lateral movement segment; The flexible segment further includes: a front cover, a rear cover, a support plate, a vision sensor, a protective shell, an integrated circuit, a power supply, and a flexible shell. The support plate connects the front cover and the rear cover. The vision sensor is located on the front side of the front cover. The protective shell is a transparent shell that covers the vision sensor. The integrated circuit and the power supply are located on the support plate. The flexible shell covers the entire flexible segment. A telescopic rod is fixed to the tail end of the flexible segment. The telescopic section includes: a front cover, a motor reducer assembly, a gear set, a nut, a lead screw, a guide rod, a support plate, and a rear cover. The support plate connects the front cover and the rear cover, forming the frame of the entire telescopic section. The motor reducer assembly, lead screw, and guide rod are all cylindrical, with both ends connected to the front cover and the rear cover. The output end of the motor reducer assembly drives the lead screw to rotate via the gear set, which is mounted on the front cover. The nut is fitted onto the lead screw and guide rod, and the rotation of the lead screw causes the nut to move back and forth. The end of the telescopic rod of the flexible section is fixed to the nut. A longitudinal rotating rod is fixed on the rear cover of the telescopic section. Electrostatic adhesion plates are provided at the bottom of the flexible section and the transverse movement section. The longitudinal motion section includes: a front cover, a worm gear, a worm, a motor, a support plate, and a rear cover. The support plate connects the front cover and the rear cover, forming the framework of the entire longitudinal motion section. The motor is vertically mounted on the rear cover, with a first bevel gear nested at its output end. The axial direction of the worm is aligned with the axial direction of the longitudinal motion section. One end of the worm is mounted on the front cover via a bearing, and the other end is nested with a second bevel gear. The connection point between the worm and the second bevel gear is mounted on the support plate via a bearing, and the first bevel gear meshes with the second bevel gear. The worm gear is longitudinally mounted and is mounted on the support plate via a bearing. The helical threads on the worm mesh with the worm gear. The longitudinal rotating rod is fixed to the worm gear, driving the longitudinal motion rod to rotate longitudinally. A transverse motion rod is fixed to the longitudinal motion forging tail section. The transverse motion section structure is exactly the same as the longitudinal motion forging structure. Rotating the longitudinal motion section by 90 degrees results in the transverse motion section, and the transverse motion rod rotates laterally. The integrated circuit module controls all the motors and processes the data acquired by the vision sensor; After the inspection is completed, the micro-robot needs to be retrieved by a traction rope. The longitudinal rotating rod rotates 180° to achieve complete folding of the robot, and the flexible section is longer than the lateral movement section.

2. The microrobot for monitoring turbine blade damage in aero-engines as described in claim 1, characterized in that, The telescopic section, longitudinal movement section, and lateral movement section are all equipped with outer shells, which are fixed to the front cover and the rear cover by pins.

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