3D imaging for engine component inspection

Abstract

Systems and methods for imaging an engine are provided. An imaging system includes an optical sensor coupled to an insertion tool and a light source configured to project light onto a component of an engine assembly. The system includes a processor configured to: receive data comprising multiple frames from the optical sensor, the data being captured as the component of the engine assembly rotates; determine the angular displacement of the component between frames; and form a 3D point cloud of the component based on the data in the frames combined with the angular displacement of the component between frames.

Description

Technical Field

[0001] This topic broadly relates to imaging tools, and more specifically, to three-dimensional (3D) imaging tools for the inspection of engine components. Background Technology

[0002] Complex devices, such as jet engines, experience wear and tear during normal use, leading to performance degradation and malfunctions. Wear can occur in various locations within the device, including internal areas that are difficult to access without disassembling the device. Insertion imaging systems, such as borescopes, can be inserted through inspection ports to inspect the interior of jet engines. However, the shape factor and field of view of insertion imaging systems can be limited due to the insertion path and space constraints within the engine. Attached Figure Description

[0003] The complete and feasible disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0004] Figure 1 This is a schematic cross-sectional view of a high-bypass turbofan jet engine according to some embodiments of the present disclosure.

[0005] Figure 2 This is a block diagram of an inspection system according to some embodiments of the present disclosure;

[0006] Figure 3 This is a flowchart of a method according to some embodiments of the present disclosure;

[0007] Figure 4 This is a flowchart of another method according to some embodiments of the present disclosure;

[0008] Figure 5A , 5B 5C are illustrations of an inspection apparatus according to some embodiments of the present disclosure; and

[0009] Figure 6 This is an illustration of processing points in a point cloud according to some embodiments of the present disclosure. Detailed Implementation

[0010] Reference will now be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation and not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the present disclosure without departing from the scope or spirit thereof. For example, features shown or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, the present disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0011] As used herein, the terms “first,” “second,” “third,” etc., are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0012] Unless otherwise stated herein, the terms “connection,” “fixed,” “attached to,” etc., refer to both direct connection, fixation, or attachment, and indirect connection, fixation, or attachment via one or more intermediate components or features.

[0013] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0014] As used herein throughout the specification and claims, approximate language can be applied to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by terms such as “about,” “approximate,” “almost,” and “substantially” are not limited to specified exact values. In some cases, approximate language may correspond to the precision of the instrument used to measure the value. For example, approximate language may refer to a margin of 1%, 2%, 4%, 10%, 15%, or 20%. These approximate margins can be applied to a single value, to either or both endpoints of a range of values, and / or to the margin of a range between endpoints. Herein and throughout the specification and claims, range limitations are combined and interchanged, and such ranges are identified and include all subranges contained herein unless the context or language otherwise indicates otherwise. For example, all ranges disclosed herein include endpoints, and endpoints can be combined independently of each other.

[0015] Typically, borescope inspection (BSI), or more generally, inspection using insert tools, is performed periodically to assess the extent of damage to components inside a fully assembled aircraft engine. This inspection can be conducted under continuous illumination while the component is in motion. Once the inspector identifies damage on the component, they can stop the component's movement and move the component and the BSI device or other insert tool to obtain the desired view of the damage. At this point, the inspector can also convert the BSI from a 2D assessment to 3D point cloud (PC) generation and perform 3D measurements around the point of interest. 3D measurements allow for comparison of the measured dimensions of the damage and tolerance thresholds associated with a specific component. 3D measurements can be performed via a combination of 3D stereo (a dual-camera system or a single camera with a prism view) and / or structured light pattern projection with a vision system to build a 3D point cloud. However, conventional 3D scanning techniques typically require the component being inspected to be static. Therefore, inspectors typically stop component movement (e.g., rotation of a compressor section) during 3D scanning.

[0016] In some embodiments, the systems and methods described herein provide an imaging tool configured to provide a consistent image, unaffected by operator subjectivity or skill level. In some embodiments, the systems and methods described herein provide light projection in conjunction with a consistent imaging tool to generate 3D point clouds as a part moves. The imaging apparatus described herein can reduce inspection time and increase the consistency of data capture performed by different operators and across inspection locations. In some embodiments, the system includes a multicolor (e.g., red, green, blue) light projection system (e.g., laser lines, structured light) offset from the camera when the part is in the camera's field of view. In some embodiments, RGB channels in each frame are processed to obtain a laser projection pattern that is combined into a point cloud. In some embodiments, as video of the moving part is captured along with laser lines, points from each color line are converted into one or more 3D point clouds. In some embodiments, the 3D point cloud is formed based on the position of the imaging system relative to the part from a computer-aided design (CAD) model. In some embodiments, the 3D point cloud of the part is reconstructed by appropriate magnification correction. In some embodiments, the motion of a component can be estimated by video analysis or by external sensors (optical, roller, ultrasonic, infrared, etc.), and a point cloud construction algorithm is used to combine the captured data points.

[0017] Referring now to the accompanying drawings, in which the same numerals indicate the same elements throughout the drawings. Figure 1This is a schematic cross-sectional view of a conventional gas turbine engine 10 for use in an aircraft in which the imaging and inspection system described herein can operate. The engine 10 has a generally longitudinally extending axis or centerline 12 extending from the front 14 to the rear 16. The engine 10 includes the following downstream sequential flow relationships: a fan section 18 comprising a fan 20; a compressor section 22 comprising a supercharger or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26; a combustion section 28 comprising a combustor 30; a turbine section 32 comprising an HP turbine 34 and an LP turbine 36; and an exhaust section 38.

[0018] Fan section 18 includes a fan housing 40 surrounding fan 20. Fan 20 includes a plurality of fan blades 42 arranged radially about centerline 12.

[0019] The HP compressor 26, burner 30, and HP turbine 34 form the core 44 of the engine 10 that generates combustion gases. The core 44 is surrounded by a core housing 46, which can be connected to the fan housing 40.

[0020] An HP shaft or spool 48, coaxially arranged around the centerline 12 of the engine 10, drives the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50, coaxially arranged around the centerline 12 of the engine 10 within a larger diameter annular HP spool 48, drives the LP turbine 36 to the LP compressor 24 and the fan 20.

[0021] LP compressor 24 and HP compressor 26 each include multiple compressor stages 52 and 54, respectively, in which a set of compressor blades 56 and 58 (also referred to as rotating blades) rotate relative to a corresponding set of static compressor impellers 60 and 62 (also referred to as nozzles) to compress or pressurize the fluid flow through the stage. In a single compressor stage 52 or 54, the multiple compressor blades 56 and 58 may be arranged in a ring and extend radially outward from the blade platform relative to the blade tip relative to the centerline 12, while the corresponding static compressor impellers 60 and 62 are positioned downstream of and adjacent to the rotating blades 56 and 58. It should be noted that... Figure 1 The number of blades, impellers, and compressor stages shown is chosen for illustrative purposes only, and other numbers are also possible.

[0022] HP turbine 34 and LP turbine 36 each comprise multiple turbine stages 64 and 66, in which a set of turbine blades 68 and 70 (also referred to as rotating blades) rotate relative to a corresponding set of static turbine blades 72 and 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64 and 66, the multiple turbine blades 68 and 70 may be arranged in a ring and extend radially outward from the blade platform relative to the blade tip relative to the centerline 12, while the corresponding static turbine blades 72 and 74 are positioned upstream of and adjacent to the rotating blades 68 and 70. It should be noted that... Figure 1 The number of blades, impellers, and turbine stages shown is chosen for illustrative purposes only, and other numbers are also possible.

[0023] In operation, the rotary fan 20 supplies ambient air to the LP compressor 24, which then supplies pressurized ambient air to the HP compressor 26, which further pressurizes the ambient air. The pressurized air from the HP compressor 26 is mixed with fuel in the combustor 30 and ignited to generate combustion gases. Some work is extracted from these gases by the HP turbine 34 driving the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the exhaust gas is finally discharged from the engine 10 via the exhaust section 38. The drive of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24.

[0024] It will be understood that engine 10 may further define multiple openings that allow inspection of various components within engine 10. For example, engine 10 may define multiple insertion tool openings at various axial locations within the compressor section, combustion section 28, and turbine section 32. Additionally, as will be discussed below, engine 10 may include, for example, one or more ignition ports within the combustion section 28 of engine 10, which may allow inspection of the combustion section 28.

[0025] It should be further understood that Figure 1 The exemplary engine 10 depicted herein is merely an example, and in other exemplary embodiments, 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 examined using the systems and methods described herein. For example, in other exemplary embodiments, the turbine engine may not be a turbofan engine, but may be configured as a turboshaft engine, turboprop engine, turbojet engine, etc., or may be an industrial gas turbine engine for power generation, fluid pumping, etc.

[0026] Now for reference Figure 2An engine inspection system 200 is shown. The engine inspection system 200 includes an inspection controller 210 and an imaging device 215. The imaging device 215 includes a light source 220, an optical sensor 230, and in some embodiments, a component sensor 240 coupled to one or more insertion tools 250. The component sensor 240 may be a sensor that detects the position, motion flow, and / or velocity of a rotating component being inspected. Typically, the component sensor 240 may output a signal that can be used by a processor 212 to determine / estimate the angular displacement of the rotating component. In some embodiments, the component sensor 240 may generate a signal based on the movement of a component, the movement of another component, and / or signals from another device (such as a rotating tool).

[0027] The inspection controller 210 includes a processor 212 coupled to memory 213. In some embodiments, the inspection controller 210 may further include data and / or network interface means for communicating with the light source 220, optical sensor 230, component sensor 240, and / or one or more databases for image processing and data storage, as described herein. In some embodiments, the inspection controller 210 may include one or more of control circuitry, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC), etc., and may be configured to execute computer-readable instructions stored on the computer-readable storage memory 213. The computer-readable storage memory 213 may include volatile and / or non-volatile memory and stores computer-readable code thereon that, when executed by the processor, causes the inspection controller 210 to receive and process data received from the optical sensor 230 and / or component sensor 240. In some embodiments, the processor 212 may be further configured to control the operation of the light source 220, the optical sensor 230, and the component sensor 240. In some embodiments, the inspection controller 210 may be further configured to control the movement of one or more automated or semi-automated insertion tools 250 (such as snake-arm robots or robotic arms) of the imaging device 215. In some embodiments, the inspection controller 210 may be further configured to control the actuation of one or more mechanical components of the imaging device 215 (such as connectors and tip extenders for spacing and / or angulating the light source 220, optical sensor 230, and / or component sensor 240 relative to each other and / or relative to the body of the insertion tool 250 within the engine interior). In some embodiments, the inspection controller 210 is configured to perform the functions described herein. Figure 3 and Figure 4One or more steps are described. The inspection controller 210 may be located locally or remotely on the engine being inspected and communicates with the light source 220, optical sensor 230, and / or component sensor 240 via a wired connection, a wireless local area network connection, and / or a wide area network. In some embodiments, the inspection controller 210 may communicate with one or more imaging devices 215 in the inspection space for inspecting one or more aircraft components.

[0028] Insertion tool 250 generally refers to a tool configured to insert light source 220 and / or optical sensor 230 through a port on the engine housing to capture images of the engine interior. In some embodiments, insertion tool 250 may be an insertion tool and / or a borescope insertion tool. In some embodiments, insertion tool 250 may include a flexible insertion tool, a rigidifiable insertion tool, a robotic arm, or a snake-arm robot. In some embodiments, insertion tool 250 may be a manually operated tool, a semi-automatic tool, or an automatic tool. In some embodiments, insertion tool 250 may be configured to position optical sensor 230 and / or light source 220 in a predetermined location and orientation within the engine upon insertion. In some embodiments, insertion tool 250 may include one or more channels for guiding wires carrying transmitted signals between inspection controller 210 and one or more of light source 220, optical sensor 230, and / or component sensor 240. In some embodiments, light source 220 is coupled to a second insertion tool separate from optical sensor 230, which may be inserted through a different port of the engine assembly.

[0029] Light source 220 typically includes one or more light emitters for projecting one or more light patterns onto the component being inspected. In some embodiments, light source 220 may include one or more of a laser, a light-emitting diode (LED), etc. In some embodiments, light source 220 and optical sensor 230 may be spaced apart and positioned along the length of insertion tool 250. In some embodiments, light source 220 is configured to project a line pattern onto the component. In some embodiments, light source 220 is configured to project structured light patterns, grids, horizontal bars, and / or vertical bars. In some embodiments, light source 220 may be configured to sequentially project a series of different patterns. For example, light source 220 may project a first line at a first angle during a first rotation of the component and a second line at a second angle during a second rotation of the component. In some embodiments, insertion tool 250 may include two or more distal tips configured to extend separately when inserted into an engine assembly, and optical sensor 230 is positioned on a first distal tip and light source 220 is positioned on a second distal tip.

[0030] In some embodiments, light source 220 includes a plurality of light emitters configured to project light of different wavelengths. In some embodiments, the light emitters are configured to simultaneously project different patterns of different wavelengths onto the component. For example, light source 220 may include a blue laser, a green laser, and a red laser that simultaneously project patterns onto the component. In some embodiments, the light emitters project lines that are angled relative to each other. In some embodiments, the emitters of light source 220 may be configured to project patterns that at least partially overlap each other and are within the field of view of optical sensor 230. In some embodiments, light source 220 includes a plurality of light emitters positioned around optical sensor 230 and coupled to insertion tool 250. In some embodiments, light source 220 includes a plurality of light emitters positioned along the length of insertion tool 250. In some embodiments, light source 220 includes a blue laser, a red laser, and a green laser. In some embodiments, light source 220 may include emitters that emit at wavelengths inside or outside the visible spectrum, such as infrared or ultraviolet.

[0031] Optical sensor 230 typically includes one or more light sensors configured to capture an image of light projected onto a component. In some embodiments, optical sensor 230 may include one or more sensor elements for detecting light within or outside the visible spectrum. In some embodiments, optical sensor 230 may include sensor devices such as MOS, CCD, CMOS sensors, etc. In some embodiments, optical sensor 230 is configured to capture images in multiple color channels. In some embodiments, optical sensor 230 includes a single sensor having an optical filter (e.g., a linear or Bayer filter, or any other color filter array) that separates incident light into a series of colors. In some embodiments, optical sensor 230 includes a separate sensor for each color / wavelength channel, such as a three-chip color CCD camera. For example, optical sensor 230 may include a monochromatic sensor for a first wavelength with a phase difference of 50, 80, or 100 nm and a second monochromatic sensor for a second wavelength. In some embodiments, the color channels of optical sensor 230 correspond to the wavelengths (e.g., red, green, blue) of the light emitter of light source 220.

[0032] In some embodiments, the imaging apparatus 215 further includes a component sensor 240 configured to detect the rotational speed of a component being inspected. In some embodiments, the component sensor 240 is spaced apart from the optical sensor 230 and / or the light source 220. In some embodiments, the component sensor 240 is coupled to an insertion tool 250 that is the same as or different from the light source 220 and / or the optical sensor 230. In some embodiments, the component sensor 240 may be positioned outside the housing of the engine assembly being inspected. For example, the component sensor 240 may monitor the rotation of a fan blade 42, turbine blade 70, or rotator of the engine from the outside of the engine assembly. In some embodiments, monitoring may be based on the detection of optical markings on these components. In some embodiments, the component sensor 240 may be coupled to a rotational device that rotates a component of the engine assembly being inspected, and the output of the rotational device may be used to estimate the rotational speed of the component. In some embodiments, the component sensor 240 measures the rotational speed of the component based on capturing images of the component and / or detecting visual codes on a component or axis of the engine assembly. In some embodiments, component sensor 240 may include a rangefinder configured to determine rotational speed based on oscillations in distance measurements corresponding to measurement points of the airfoil as it moves past the rangefinder. In some embodiments, the speed may be measured based on detecting the lowest point in the distance measurement, which corresponds to the tip of the airfoil passing in front of component sensor 240. The component rotational speed measured by component sensor 240 may be used to determine angular displacement between image frames captured by optical sensor 230 for combining the frames into a 3D point cloud. In some embodiments, component sensor 240 may be omitted, and angular displacement may be determined in other ways, such as based on images captured by optical sensor 230.

[0033] Next reference Figure 3 This illustrates a method for performing engine inspection. In some embodiments, Figure 3 One or more steps can be referenced Figure 2 The engine inspection system 200 described herein shall be used.

[0034] In step 310, an insertion tool (such as insertion tool 250) is inserted into the engine assembly. In some embodiments, the insertion tool may be manually operated, semi-automatic, or automatic. In some embodiments, the insertion tool may include a stiffening tool that is inserted and stiffened to position the optical sensor 230 and / or light source 220 of the inspection tool in a predetermined location and / or orientation. In some embodiments, the insertion tool may be mechanically driven into place by a signal from a controller.

[0035] In step 330, a rotating component, such as component 550, is rotated. In some embodiments, the component may include a compressor airfoil, turbine airfoil, or shaft of an engine assembly. In some embodiments, the component may include a reference... Figure 1 The airfoil and other structures of the LP compressor 24, HP compressor 26, HP turbine 34, LP turbine 36, and / or fan blade 42 are described. In some embodiments, the component may be a cylindrical segment of the engine configured to rotate about the centerline 12 of the engine assembly on its axis. In some embodiments, the component may be rotated by a rotating device configured to drive rotation, such as an auxiliary power unit, an external power source, a device configured to apply mechanical torque to the rotator of the fan blade 42 or the engine assembly, or a device configured to rotate the HP shaft or spool 48 via a gearbox (e.g., an accessory gearbox). In some embodiments, the engine assembly can be inspected while mounted on the aircraft. In some embodiments, the component may be rotated manually, such as by hand or via a crank. In some embodiments, the rotational speed of the component may vary during image capture due to the physical limitations of the rotating device and the engine assembly. For example, the rotational speed of the component may increase and decrease within a single rotation.

[0036] In step 320, the light source 220 projects light onto components of the engine assembly within the field of view of an optical sensor (such as optical sensor 230). In some embodiments, the light projection is a laser projection. In some embodiments, the light projection is a line. In some embodiments, the light projection is a structured light pattern, a grid, horizontal bars, and / or vertical bars. In some embodiments, the light source 220 includes multiple emitters that output multiple projections, each projection at a different peak wavelength. Reference Figure 4 A more detailed description of an embodiment with projections having multiple wavelengths is provided below.

[0037] In step 340, an inspection controller (such as inspection controller 210) receives data from an optical sensor. In some embodiments, the data from the optical sensor includes multiple image frames captured as the components of the engine assembly rotate and light projection is projected onto the engine assembly. In some embodiments, the data received in step 340 can be processed in real-time or near real-time while the insertion tool is still inserted into the engine and the optical sensor is still capturing data to form a 3D point cloud according to steps 350, 360, 370, and 380. In some embodiments, the data received in step 340 can be stored for later processing.

[0038] In step 350, the controller checks the angular displacement between the first and second frames of the plurality of frames received by the component in step 340. In some embodiments, the angular displacement may be measured based on signals from the component sensor 240 described herein. For example, a rangefinder may be used to measure the rotational speed of the component. In some embodiments, the angular displacement of the component is determined based on the detection of visual codes on the component or shaft of the engine assembly in images captured by the optical sensor 230 and / or the component sensor 240. For example, the angular displacement may be measured based on pixel displacement of the visual codes between frames. In some embodiments, the angular displacement of the component is determined based on illuminating the component with broadband light (e.g., white light) and recording the distance and / or orientation of the component in the frame. In some embodiments, the angular displacement of the component is determined by estimating the rotational speed of the component based on the plurality of frames captured by the optical sensor. In some embodiments, the light projection includes a line positioned tangent to a point on the leading edge of the compressor airfoil closest to the optical sensor or light source 220 when the compressor airfoil is in the rotational position closest to the optical sensor or light source 220, and the angular displacement of the component is determined based on detecting the point on the compressor airfoil via the light projection. In some embodiments, the angular displacement of a component between the first and second frames is determined by comparing the first and second frames with a stored 3D model of the component. In some embodiments, the angular displacement between two frames can be estimated based on determining the rotation of the component over a time period (e.g., 2 rpm, 10 rpm, etc.) and removing the measured total angular displacement to the number of frames acquired during that time period (e.g., 60 fps, 120 fps, etc.).

[0039] In step 360, the controller examines a first frame of an image captured by the optical sensor 230 to determine a set of points. In some embodiments, the first set of points includes 3D coordinates determined by triangulation of the distance between the optical sensor 230 and the points on the component based on (1) a known distance and angle between the light source 220 and the optical sensor 230, and (2) the displacement of the projected pixels associated with the points in the first image of the light projection. In some embodiments, the first set of points may include points on a local coordinate system relative to a reference point or plane of the imaging tool. In some embodiments, the first set of points is determined based on magnification correction of the first image of the light projection. In some embodiments, the distance (H) between the points captured by the optical sensor 230 and the reference plane is determined based on the displacement (vH) of the pixels in the first image of the light projection in the first frame, where H = vH / (m*tan(ø)); where ø is the angular offset between the optical sensor 230 and the light source 220, m is the magnification factor, and tan(ø) = d / u; and where d is the distance between the optical sensor 230 and the light source 220, and u is the distance between the optical sensor 230 and the reference plane.

[0040] In step 370, the controller examines a second frame of the image captured by optical sensor 230 to determine a second set of points. Typically, the second set of points is determined based on the same or similar processing described in step 360.

[0041] In step 380, the controller checks that a 3D point cloud is formed based on combining at least a plurality of sets of points determined in steps 360 and 370. In some embodiments, the 3D point cloud can be based on any number of frames. The 3D point cloud of a component can be formed based on combining a first set of points and a second set of points based on the angular displacement of the component between the first and second frames determined in step 350. In some embodiments, forming the 3D point cloud of the component includes converting the local coordinates of the first set of points and the second set of points into global coordinates of the 3D point cloud based on the angular displacement. Figure 6 An example of this conversion is shown in [the image]. Figure 6 In this system, points from the first frame 610 and the second frame 620 are positioned relative to each other based on the angular displacement (Δ) between the two frames. In some embodiments, the displacement between the two frames may include a y-axis (tangential to the direction of component rotation) and a z-axis (perpendicular to the plane of the frame) shift. In some embodiments, the displacement between the set of points may be determined based on the measured angular displacement and the distance between the reference plane or point and the optical sensor 230 and / or the known distance between the optical sensor 230 and the axis of rotation of the component. The system can combine any number of frames based on the same or similar processing to form a 3D model of the component being examined. For example, by rotating the compressor section completely, the system can form a 360-degree 3D model of the compressor section about the axis of rotation.

[0042] In some embodiments, the 3D point cloud is generated based on averaging and / or applying a smoothing function between adjacent points on a first set of points and a second set of points. In some embodiments, the 3D point cloud of a component may be further determined based on outlier removal of the first set of points or the second set of points, or on the resulting 3D point cloud. In some embodiments, the system is configured to determine points in a first set of points and a second set of points associated with stationary components of the engine (e.g., housing, blades). In some embodiments, the system may remove points associated with stationary components from the 3D point cloud of the component. In some embodiments, the system may process points associated with stationary components separately and combine moving and stationary components in the 3D point cloud model. For example, points associated with stationary components may be combined without performing frame shifting based on angular displacement. In some embodiments, points associated with stationary components of the engine are determined based on comparing images of light projections in multiple frames to identify static / invariant points. In some embodiments, points associated with stationary components of the engine are determined based on comparing the 3D model with a stored computer model of a rotating component.

[0043] In some embodiments, the system can be configured to determine that enough data has been captured to form a 3D point cloud. For example, the system can detect that the part has undergone a complete rotation and / or that data has been captured around the entire perimeter of the part. The system can then signal to the inspection tool and / or user interface to terminate the inspection.

[0044] In some embodiments, after step 380, the system may be further configured to detect anomalies on the component based on a 3D point cloud in step 390. In some embodiments, anomalies may be detected based on comparing the 3D point cloud with a stored 3D model of the engine assembly's components. In some embodiments, anomalies may be detected based on the detection of local surface anomalies.

[0045] Next reference Figure 4 This illustrates a method for engine inspection using multiple color channels. In some embodiments, Figure 4 One or more steps can be referenced Figure 2 The inspection system described is used for this purpose. In some embodiments, Figure 4 The steps in can be compared with Figure 3 The steps for sharing the same reference numerals in the accompanying drawings are the same or similar.

[0046] exist Figure 4 In the illustrated embodiment, in step 320B, the light source 220 projects two or more patterns, each with a different peak wavelength / color, onto the component. In some embodiments, the peak wavelengths of the first and second wavelengths differ by at least 50 nanometers. In some embodiments, the wavelength difference is 80 nanometers, 100 nanometers, or greater. In some embodiments, the light projection includes a first line of the first wavelength and a second line of the second wavelength, the second line being angled relative to the first line. In some embodiments, each pattern may include a line, a structured light pattern, a grid, a horizontal bar, and / or a vertical bar. In some embodiments, the patterns at least partially overlap in the field of view of the optical sensor 230. In some embodiments, the first and second patterns are projected simultaneously or sequentially. In some embodiments, the light source 220 projects three patterns of three wavelengths (e.g., red, green, and blue). In some embodiments, the patterns may be lines, structured light patterns, etc.

[0047] In step 340B, an inspection controller (such as inspection controller 210) receives data from optical sensor 230. In some embodiments, the data from optical sensor 230 includes multiple color channels. In some embodiments, optical sensor 230 includes multiple monochromatic sensors, such as a monochromatic sensor for a first wavelength and a second monochromatic sensor for a second wavelength. In some embodiments, the optics include linear or Bayer filters or some other color filter array for separating color channels.

[0048] In step 340A, the system filters frames for a first wavelength. In some embodiments, step 340A may be based on isolating the color channel associated with the first wavelength from the data received from the optical sensor 230. In some embodiments, step 340A may include applying a software color filter to the captured color image. In step 360A, the system determines a first subset of points in a first frame associated with a first pattern having the first wavelength. The determination of the first subset of points may be the same as or similar to the process described with reference to 360. In step 370A, the system determines a first subset of points in a second frame associated with the first pattern having the first wavelength. The determination of the second subset of points may be the same as or similar to the process described with reference to step 370.

[0049] In step 340B, the controller checks the second wavelength filtered frame. In some embodiments, step 340B may be based on isolating the color channel associated with the second wavelength from the data received from the optical sensor 230. In some embodiments, step 340B may include applying a software color filter to the captured color image. In step 360B, the system determines a first subset of points in a first frame associated with the second pattern having the second wavelength. The determination of the second subset of points in the first frame may be the same as or similar to the process described with reference to 360. In step 370B, the system determines a second subset of points in a second frame associated with the second pattern having the second wavelength. The determination of the second subset of points in the second frame may be the same as or similar to the process described with reference to 370. Typically, steps 360A, 370A, 360B, and 370B may be performed in any order and / or simultaneously.

[0050] In step 380B, the controller is checked to form a 3D point cloud based at least on a subset of the points determined in steps 360A, 370A, 360B, and 370B. (See reference...) Figure 3 The discussion focuses on combining subsets of points based on angular displacement between frames. In some embodiments, points from different color channels can be combined or stitched together by averaging or weighted averaging adjacent points. In some embodiments, the overall resolution of the 3D point cloud can be increased by combining data from different color channels of an optical sensor compared to triangulation based on a monochrome image. In some embodiments, projections can have different angles of incidence in the plane of the frame relative to the surface of the component and / or relative to each other to enhance the detection of different surface features / abnormal geometries. For example, a line projection at an angle to linear damage can better detect linear damage than a line projection parallel to the damage line.

[0051] Although reference Figure 4Filtering at two wavelengths is shown and described, but the systems and methods described herein can utilize any number of projected color channels, such as three (e.g., red, green, blue), four, five, or six discrete color channels. This can be based on... Figure 3 and Figure 4 The processing described herein involves filtering, processing, and combining channels.

[0052] Next reference Figure 5A -C illustrates an example of an imaging apparatus construction according to some embodiments. Figure 5A In this configuration, a light source 220A, an optical sensor 230A, and a component sensor 240 are coupled to the distal tip of an insertion tool 250. The insertion tool 250 is inserted through a port of the engine assembly to provide a line of sight to the component 550 being inspected. In some embodiments, the component 550 may be an airfoil of a fan or compressor of a turbine engine 10. The light source 220A is positioned to project a light pattern 510A onto the surface of the component 550, and the optical sensor 230A is positioned to capture the projected image as the component 550 rotates about an axis of the engine assembly segment. As indicated by arrow 551, the airfoil of the component 550 is shown moving downwards. However, it should be understood that the image shows a planar representation of a group of objects (e.g., blades) mounted on a cylindrical support (e.g., a shaft or disc) rotating about the engine centerline.

[0053] exist Figure 5A In the illustrated embodiment, component sensor 240, light source 220A, and optical sensor 230A are positioned along the length of insertion tool 250. In some embodiments, one or more of component sensor 240, insertion tool 250, and optical sensor 230A may be coupled to a pivotable and / or stiffenable segment of insertion tool 250 relative to each other. In some embodiments, insertion tool 250 may include distal tips, wherein light source 220A and optical sensor 230A are mounted on different tips configured to pivot independently relative to a preceding segment. An actuator may actuate the two distal tips to separate upon insertion of insertion tool 250.

[0054] exist Figure 5B In this embodiment, the light source 220 includes three emitters—a red emitter 220B-1, a blue emitter 220B-2, and a green emitter 220B-3 positioned around the optical sensor 230B at the tip of the insertion tool 250. In some embodiments, the emitters may include actuators configured to retract when the insertion tool 250 is inserted into the engine assembly and to extend when the tool is in a data acquisition position. Figure 5BThe position is shown. In some embodiments, the transmitter can retract again to withdraw the insertion tool 250 from inside the engine. In some embodiments, the transmitter actuator may be electrically powered, wire-controlled, and / or spring-loaded. The red transmitter 220B-1, blue transmitter 220B-2, and green transmitter 220B-3 each project a pattern of discrete wavelengths, including red line projection 510B-1, blue line projection 510B-2, and green line projection 510B-3. The optical sensor 230B may include filters for separating the three color channels and / or may include multiple monochrome sensors.

[0055] exist Figure 5C In this design, the light source 220 includes three emitters positioned along the length of the insertion tool 250: a red emitter 220C-1, a blue emitter 220C-2, and a green emitter 220C-3. An optical sensor 230C is positioned at the tip of the component sensor 240. Emitters 220C-1, 220C-2, and 220C-3 are coupled to a first segment of the component sensor 240, and the optical sensor 230C is coupled to a second segment angled relative to the first segment. In some embodiments, the two segments are configured to pivot relative to each other. In some embodiments, each of the emitters 220C-1, 220C-2, and 220C-3 may be located on a different segment of the insertion tool 250 that may pivot and / or be angled relative to each other. The red emitter 220C-1, blue emitter 220C-2, and green emitter 220C-3 each project a pattern of discrete wavelengths, including a red line projection 510C-1, a blue line projection 510C-2, and a green line projection 510C-3. The optical sensor 230C may include filters for separating the three color channels and / or may include multiple monochrome sensors.

[0056] Figure 5A The imaging tool configuration shown in -C is provided as an example only, and it should be understood that the systems and methods described herein utilize a number of imaging tools with different configurations, which at least have the optical sensor 230 and light source 220 described herein.

[0057] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0058] An engine inspection system includes: an optical sensor coupled to an insertion tool configured to be inserted into an engine assembly for inspection; a light source configured to project light onto a component of the engine assembly within the field of view of the optical sensor; and a processor configured to: receive data comprising a plurality of frames from the optical sensor, the data being captured as the component of the engine assembly rotates and the light projection is projected onto the engine assembly; determine an angular displacement of the component between a first frame and a second frame of the plurality of frames; determine a first set of points based on a first image of the light projection in the first frame; determine a second set of points based on a second image of the light projection in the second frame; and combine the first set of points and the second set of points based on the angular displacement of the component between the first frame and the second frame to form a 3D point cloud of the component.

[0059] In any of the foregoing clauses, the light projection is a line.

[0060] According to any of the foregoing clauses, the light projection includes structured light patterns, grids, horizontal bars and / or vertical bars.

[0061] According to any of the foregoing clauses, the angular displacement of the component is determined based on the detection of visual encoding on the axis of the component or the engine assembly.

[0062] According to any of the foregoing clauses of the system, the angular displacement of the component is determined based on illuminating the component and the light source with broadband light and recording the distance and / or orientation of the component.

[0063] The system according to any of the foregoing clauses further includes a component sensor spaced apart from the optical sensor, wherein the angular displacement of the component is determined based on a signal from the component sensor.

[0064] In any of the foregoing clauses, the component sensor is coupled to the insertion tool or a separate insertion tool.

[0065] In any of the foregoing clauses, the component sensor is located outside the housing of the engine assembly.

[0066] According to any of the foregoing clauses, the angular displacement of the component is determined by estimating the rotational speed of the component based on the plurality of frames captured by the optical sensor.

[0067] According to any of the preceding clauses, the system wherein the light projection includes a line positioned tangent to a point on the leading edge of the compressor airfoil closest to the optical sensor or the light source when the compressor airfoil is in a rotational position closest to the optical sensor or the light source, and wherein the processor is configured to determine the angular displacement of the component based on detecting the point on the compressor airfoil via the light projection.

[0068] According to any of the foregoing clauses, the angular displacement of the component between the first frame and the second frame is determined by comparing the first frame and the second frame with a stored 3D model of the component.

[0069] According to any of the foregoing clauses, the first set of points comprises 3D coordinates determined by triangulation based on a known distance between the light source and the optical sensor and the displacement of pixels in the first image projected by the light.

[0070] According to any of the foregoing clauses of the system, the first set of points is determined based on magnification correction of the first image of the light projection.

[0071] According to any of the foregoing clauses, the distance (H) between the point captured by the optical sensor and the reference plane is determined based on the displacement (vH) of the pixel in the first image of the light projection in the first frame, where H = vH / (m * tan(ø)); where ø is the angular offset between the optical sensor and the light source, m is the magnification factor, and tan(ø) = d / u; and where d is the distance between the optical sensor and the light source, and u is the distance between the optical sensor and the reference plane.

[0072] According to any of the foregoing clauses, the 3D point cloud of the component is further determined based on outlier removal.

[0073] According to any of the foregoing clauses, the processor is further configured to determine points associated with stationary components of the engine in the first set of points and the second set of points, and remove the points from the 3D point cloud of the components.

[0074] According to any of the foregoing clauses, the point associated with the stationary component of the engine is determined by comparing images of the light projection in the plurality of frames to identify static points.

[0075] According to any of the foregoing clauses, the 3D point cloud forming the component includes converting the local coordinates of the first set of points and the second set of points into global coordinates of the 3D point cloud based on the angular displacement.

[0076] According to any of the foregoing clauses, the optical projection comprises a plurality of patterns projected sequentially.

[0077] According to any of the foregoing clauses, the insertion tool includes a flexible insertion tool, a rigidifiable insertion tool, a robotic arm, or a snake-arm robot.

[0078] According to any of the preceding clauses, the insertion tool includes two distal tips, at least one of which is configured to extend separately upon insertion into the engine assembly, and the optical sensor is positioned on the first distal tip and the light source is positioned on the second distal tip.

[0079] According to any of the foregoing clauses, the light source is coupled to an insertion tool separate from the insertion tool, and the insertion tool and the insertion tool are inserted through different ports of the engine assembly.

[0080] In any of the foregoing clauses, the system wherein the light source comprises one or more laser emitters.

[0081] According to any of the foregoing clauses, the system wherein the light source includes a plurality of light emitters positioned around the optical sensor and coupled to the insertion tool.

[0082] According to any of the foregoing clauses, the light source includes a plurality of light emitters positioned along the length of the insertion tool.

[0083] According to any of the foregoing clauses, the system wherein the light source is coupled to a first segment of the insertion tool and the optical sensor is coupled to a second segment of the insertion tool, the second segment being at an angle relative to the first segment during the capture of the plurality of frames.

[0084] According to any of the foregoing clauses, the light source includes two or more of blue light, red light, and green light.

[0085] According to any of the preceding clauses, the system includes a first light emitter that outputs a first pattern of light projection at a first wavelength and a second light emitter that outputs a second pattern of light projection at a second wavelength; and wherein the first set of points is determined based on: filtering the first frame for the first wavelength to determine a first subset of points associated with the first pattern; and filtering the first frame for the second wavelength to determine a second subset of points associated with the second pattern.

[0086] According to any of the foregoing clauses, the optical sensor includes a monochromatic sensor for the first wavelength and a second monochromatic sensor for the second wavelength.

[0087] According to any of the foregoing clauses of the system, the filtering of the first frame is based on a linear filter or a Bayer filter.

[0088] According to any of the foregoing clauses, the peak wavelengths of the first wavelength and the second wavelength differ by at least 50 nanometers.

[0089] According to any of the foregoing clauses, the first pattern includes a first line, and the second pattern includes a second line at an angle relative to the first line.

[0090] According to any of the foregoing clauses, the first pattern or the second pattern includes a structured light pattern, a grid, horizontal bars and / or vertical bars.

[0091] According to any of the foregoing clauses, the first pattern and the second pattern at least partially overlap in the field of view of the optical sensor.

[0092] According to any of the foregoing clauses, the first pattern and the second pattern are projected simultaneously.

[0093] According to any of the foregoing clauses, the first pattern and the second pattern are projected sequentially.

[0094] According to any of the foregoing clauses, the system wherein the light source further includes a third light emitter that outputs a third pattern of a third wavelength, and wherein determining the first set of points further includes: determining a third subset of points based on filtering the first frame for the third wavelength.

[0095] According to any of the foregoing clauses, the components of the engine assembly include a compressor or a turbine airfoil.

[0096] According to any of the foregoing clauses, the 3D point cloud is generated based on the average value between adjacent points on the first set of points and the second set of points.

[0097] According to any of the foregoing clauses, the processor is further configured to detect anomalies on the component based on the 3D point cloud.

[0098] According to any of the foregoing clauses, the anomaly is detected based on comparing the 3D point cloud with a stored 3D model of the component of the engine assembly.

[0099] According to any of the foregoing clauses, the anomaly is detected based on identifying outliers in the first set of points compared to the second set of points, and by aligning two or more sets of points to combine them into a point cloud.

[0100] An engine inspection method includes: rotating a component of an engine assembly; projecting light from a light source onto the component of the engine assembly within the field of view of an optical sensor inserted into the engine assembly via an insertion tool; receiving data comprising multiple frames from the optical sensor at a processor, the data being captured as the component of the engine assembly rotates and the light projection is projected onto the component; determining, using the processor, an angular displacement of the component between a first frame and a second frame of the multiple frames; determining, using the processor, a first set of points based on a first image of the light projection in the first frame; determining, using the processor, a second set of points based on a second image of the light projection in the second frame; and forming a 3D point cloud of the component by combining the first set of points and the second set of points based on the angular displacement of the component between the first frame and the second frame.

[0101] According to any of the foregoing provisions, the light projection is a line.

[0102] According to any of the preceding clauses, the light projection includes structured light patterns, grids, horizontal bars and / or vertical bars.

[0103] According to any of the foregoing clauses, the angular displacement of the component is determined based on the detection of visual encoding on the axis of the component or the engine assembly.

[0104] According to any of the preceding clauses of the method, the angular displacement of the component is determined based on illuminating the component and the light source with a broadband light source and recording the distance and / or orientation of the component relative to the optical sensor in multiple frames. According to any of the preceding clauses of the method, the angular displacement of the component is determined based on signals from a component sensor spaced apart from the optical sensor.

[0105] According to any of the foregoing clauses, the component sensor is coupled to the insertion tool or a separate insertion tool.

[0106] According to any of the foregoing clauses, the component sensor is located outside the housing of the engine assembly.

[0107] According to any of the foregoing clauses of the method, the angular displacement of the component is determined by estimating the rotational speed of the component based on the plurality of frames captured by the optical sensor.

[0108] According to any of the foregoing provisions, the light projection includes a line positioned tangent to a point on the leading edge of the compressor airfoil closest to the optical sensor or the light source when the compressor airfoil is in a rotational position closest to the optical sensor or the light source, and the angular displacement of the component is determined based on detecting the point on the compressor airfoil via the light projection.

[0109] According to any of the foregoing clauses, the angular displacement of the component between the first frame and the second frame is determined by comparing the first frame and the second frame with a stored 3D model of the component.

[0110] According to any of the foregoing provisions of the method, the first set of points includes 3D coordinates determined by triangulation based on a known distance between the light source and the optical sensor and the displacement of the light point in the first image of the light projection.

[0111] According to any of the foregoing provisions of the method, the first set of points is determined based on magnification correction of the first image of the light projection.

[0112] According to any of the foregoing provisions, the distance (H) between the point captured by the optical sensor and the reference plane is determined based on the displacement (vH) of the pixel in the first image of the light projection in the first frame, where H = vH / (m * tan(ø)); where ø is the angular offset between the optical sensor and the light source, m is the magnification factor, and tan(ø) = d / u; and where d is the distance between the optical sensor and the light source, and u is the distance between the optical sensor and the reference plane.

[0113] According to any of the foregoing provisions of the method, the 3D point cloud of the component is further determined based on outlier removal.

[0114] The method according to any of the foregoing clauses further includes: determining points from the first set of points and the second set of points associated with stationary components of the engine; and removing the points from the 3D point cloud of the component.

[0115] According to the method described in any of the foregoing clauses, the point associated with the stationary component of the engine is determined by comparing images of the light projection in the plurality of frames to identify static points.

[0116] According to any of the foregoing provisions, the 3D point cloud forming the component includes converting the local coordinates of the first set of points and the second set of points into global coordinates of the 3D point cloud based on the angular displacement.

[0117] The method according to any of the foregoing clauses, wherein the light projection comprises a plurality of patterns projected sequentially.

[0118] The method according to any of the foregoing clauses, wherein the insertion tool includes a flexible insertion tool, a rigidifiable insertion tool, a robotic arm, or a snake-arm robot.

[0119] According to any of the preceding clauses of the method, the insertion tool includes two distal tips configured to extend separately when inserted into the engine assembly, and the optical sensor is positioned on the first distal tip and the light source is positioned on the second distal tip.

[0120] According to any of the foregoing clauses, the light source is coupled to an insertion tool separate from the insertion tool, and the insertion tool and the insertion tool are inserted through different ports of the engine assembly.

[0121] The method according to any of the foregoing clauses, wherein the light source comprises one or more laser emitters.

[0122] According to any of the foregoing clauses of the method, the light source includes a plurality of light emitters positioned around the optical sensor and coupled to the insertion tool.

[0123] According to any of the foregoing clauses of the method, the light source includes a plurality of light emitters positioned along the length of the insertion tool.

[0124] According to any of the foregoing clauses of the method, wherein the light source is coupled to a first segment of the insertion tool and the optical sensor is coupled to a second segment of the insertion tool, wherein the second segment is at an angle relative to the first segment during the capture of the plurality of frames.

[0125] The method according to any of the foregoing clauses, wherein the light source comprises two or more of blue light, red light, and green light.

[0126] According to any of the preceding clauses of the method, wherein the light source includes a first light emitter that outputs a first pattern of the light projection at a first wavelength and a second light emitter that outputs a second pattern of the light projection at a second wavelength; and wherein the first set of points is determined based on: filtering the first frame for the first wavelength to determine a first subset of points associated with the first pattern; and filtering the first frame for the second wavelength to determine a second subset of points associated with the second pattern.

[0127] According to any of the preceding clauses of the method, the optical sensor includes a monochromatic sensor for the first wavelength and a second monochromatic sensor for the second wavelength.

[0128] According to any of the foregoing provisions, the filtering of the first frame is based on a linear filter or a Bayer filter.

[0129] According to any of the foregoing provisions of the method, the peak wavelengths of the first wavelength and the second wavelength differ by at least 50 nanometers.

[0130] According to any of the foregoing provisions of the method, wherein the first pattern includes a first line, and the second pattern includes a second line at an angle relative to the first line.

[0131] According to any of the preceding clauses, the first pattern or the second pattern includes a structured light pattern, a grid, horizontal bars and / or vertical bars.

[0132] According to any of the foregoing provisions of the method, the first pattern and the second pattern at least partially overlap in the field of view of the optical sensor.

[0133] According to any of the foregoing provisions, the first pattern and the second pattern are projected simultaneously.

[0134] According to any of the foregoing provisions, the first pattern and the second pattern are projected sequentially.

[0135] According to any of the foregoing provisions of the method, wherein the light source further includes a third light emitter that outputs a third pattern of a third wavelength, and wherein determining the first set of points further includes: determining a third subset of points based on filtering the first frame for the third wavelength.

[0136] According to any of the foregoing clauses of the method, the components of the engine assembly include a compressor or a turbine airfoil.

[0137] According to any of the foregoing provisions, the 3D point cloud is generated based on the average value of neighboring points on the first set of points and the second set of points.

[0138] The method according to any of the foregoing clauses further includes: detecting anomalies on the component based on the 3D point cloud.

[0139] According to any of the foregoing provisions, the anomaly is detected based on comparing the 3D point cloud with a stored 3D model of the component of the engine assembly.

[0140] This written description uses examples to disclose this disclosure, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any apparatus or system and methods of making any combination. The patentable scope of this disclosure is defined by the claims, and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially indistinguishable from the literal language of the claims.

Claims

1. An engine inspection system, characterized in that, include: An optical sensor, coupled to an insertion tool configured to be inserted into an engine assembly for inspection; A light source configured to project light onto a component of the engine assembly within the field of view of the optical sensor; as well as Processor, the processor being configured as follows: Data comprising multiple frames is received from the optical sensor, the data being captured as the component of the engine assembly rotates and the light projection is projected onto the engine assembly; Determine the angular displacement of the component between the first and second frames in the plurality of frames; The first set of points is determined based on the first image of the light projection in the first frame; The second set of points is determined based on the second image of the light projection in the second frame; and The 3D point cloud of the component is formed by combining the first set of points and the second set of points based on the angular displacement of the component between the first frame and the second frame.

2. The system according to claim 1, characterized in that, in, The light projection includes line patterns, structured light patterns, grids, horizontal bars, or vertical bars.

3. The system according to claim 1, characterized in that, in, The angular displacement of the component is determined based on the detection of visual encoding on the axis of the component or the engine assembly.

4. The system according to claim 1, characterized in that, in, The angular displacement of the component is determined by illuminating the component and the light source with a broadband light source and recording the distance and / or orientation of the component relative to the optical sensor in multiple frames.

5. The system according to claim 1, characterized in that, It further includes a component sensor spaced apart from the optical sensor, wherein the angular displacement of the component is determined based on a signal from the component sensor.

6. The system according to claim 1, characterized in that, in, The angular displacement of the component is determined by estimating the rotational speed of the component based on the plurality of frames captured by the optical sensor.

7. The system according to claim 1, characterized in that, in, The light projection includes a line projection, which is positioned such that when the compressor airfoil is in its rotational position closest to the optical sensor or the light source, it is substantially tangent to the point on the leading edge of the compressor airfoil closest to the optical sensor or the light source. The processor is configured to determine the angular displacement of the component based on detecting the point on the compressor airfoil via the light projection.

8. The system according to claim 1, characterized in that, in, The angular displacement of the component between the first and second frames is determined by comparing the first and second frames with a stored 3D model of the component.

9. The system according to claim 1, characterized in that, in, The first set of points includes 3D coordinates determined by triangulation based on the known distance between the light source and the optical sensor and the displacement of the light point in the first image of the light projection.

10. The system according to claim 1, characterized in that, in, The processor is further configured to determine points associated with stationary components of the engine in the first set of points and the second set of points, and remove the points from the 3D point cloud of the components.

11. The system according to claim 10, characterized in that, in, The point associated with the stationary component of the engine is determined by comparing images of the light projection in the plurality of frames to identify static points.

12. The system according to claim 1, characterized in that, in, The insertion tool includes two distal tips, at least one of which is configured to extend separately when inserted into the engine assembly, and the optical sensor is positioned on the first distal tip and the light source is positioned on the second distal tip.

13. The system according to claim 1, characterized in that, in, The light source includes one or more laser emitters.

14. The system according to claim 1, characterized in that, in, The light source includes a plurality of light emitters positioned around the optical sensor and coupled to the insertion tool, or a plurality of light emitters positioned along the length of the insertion tool.

15. The system according to claim 1, characterized in that, in, The light source includes a first light emitter that outputs a first pattern of the light projection at a first wavelength and a second light emitter that outputs a second pattern of the light projection at a second wavelength; and The first set of points was determined based on the following: Filter the first frame for the first wavelength to determine a first subset of points associated with the first pattern; as well as The first frame is filtered for the second wavelength to determine a second subset of points associated with the second pattern.

16. The system according to claim 15, characterized in that, in, The first pattern includes a first line, and the second pattern includes a second line at an angle relative to the first line.

17. The system according to claim 15, characterized in that, in, The light source further includes a third light emitter that outputs a third pattern of a third wavelength, and wherein determining the first set of points further includes: A third subset of points is determined based on filtering the first frame for the third wavelength.

18. The system according to claim 1, characterized in that, in, The components of the engine assembly include a compressor or a turbine airfoil.

19. The system according to claim 1, characterized in that, in, The processor is further configured to detect anomalies on the component based on the 3D point cloud.

20. An engine inspection method, characterized in that, The method includes: Components of a rotating engine assembly; Within the field of view of the optical sensor inserted into the engine assembly via an insertion tool, light is projected from the light source onto the component of the engine assembly; The processor receives data comprising multiple frames from the optical sensor, the data being captured as the component of the engine assembly rotates and the light projection is projected onto the component; The processor is used to determine the angular displacement of the component between the first and second frames in the plurality of frames; The processor determines a first set of points based on a first image of the light projection in the first frame; The processor determines a second set of points based on a second image of the light projection in the second frame; and The processor uses the combination of the first set of points and the second set of points based on the angular displacement of the component between the first frame and the second frame to form a 3D point cloud of the component.

Images