Method for repairing component of continuous flow engine

Abstract

A method of repairing a component of a continuous flow engine. The invention relates to an improved method for repairing continuous flow engine components using an automated system. The invention further relates to an inspection device to be used in such a method and to an evaluation system using such an inspection device and method. In addition, the invention relates to a computer program product adapted to be able to implement the method of the invention.

Description

Technical Field

[0001] The invention relates to a method for repairing a continuous flow engine component having damage. In addition, the invention relates to an inspection device to be used in such a method. In addition, the invention relates to an evaluation system comprising such an inspection device to perform such a method. In addition, the invention relates to a computer program product adapted to be able to implement the method of the invention. Background Art

[0002] Continuous flow engines (such as gas turbines, steam turbines and compressors) are particularly complex and very specialized technical equipment. They represent highly reliable and flexible equipment that represents the backbone of modern industry. However, these engines have the problem that their use brings about continuous changes in the engine itself and spontaneous changes based on maintenance and upgrade processes, etc., which on the one hand make them highly reliable and durable, but at the same time also make them constantly deviate from the initial state. At the same time, the requirements for such continuous flow engines are constantly increasing, requiring that their utilization rate is always optimized and the theoretical limits of the former are increased, making them closer to the actual limits of real life.

[0003] Although the components used in such continuous flow engines are very durable and can withstand even very harsh conditions, they can usually be repaired many times before some replacement is needed. However, based on the above-mentioned changes in usage, this assessment becomes even more difficult. There is also a need for wear patterns that vary over time, making it difficult or impossible for even experts with ten years of experience to assess. However, replacing some components too early is prone to significant losses. For example, the insufficient supply of replacement parts makes immediate replacement very difficult or impossible. However, based on the costs associated with this, it is impossible to simply stockpile large quantities of corresponding spare parts. Therefore, there is a need to improve insight and assessment, preferably to improve the possibility of predicting future demand for such components.

[0004] These problems are solved by the methods and products disclosed below and in the claims. Further advantageous embodiments are disclosed in the dependent claims and in the further description. These benefits can be used to adapt the respective solution to specific needs or to solve further problems. Summary of the invention

[0005] According to one aspect, the invention relates to a method for repairing a continuous flow engine component having damage,

[0006] The method comprises the following steps:

[0007] - Identify continuous flow engine components based on unique identifiers;

[0008] - retrieving inspection data of the continuous flow engine component from an inspection database comprising damage data of the continuous flow engine component;

[0009] - retrieving component data from at least one continuous flow engine component database;

[0010] -Automated damage assessment of continuous flow engine components;

[0011] - automatically generating an output, wherein the output includes data on whether the continuous flow engine component is repairable and / or an estimated number of possible subsequent repairs before the continuous flow engine component is unrepairable.

[0012] Providing this method is very beneficial for continuous flow engine parts. Continuous flow engines are mature equipment used in industry. Examples are compressors used in large-scale industrial production processes (such as refineries) or turbines used in energy production (such as gas turbines or steam turbines). Such equipment unexpectedly benefits significantly from the method of the present invention. For example, in the case where the problem identified later makes the repair unsuccessful or even only damages the characteristics of such continuous flow engine parts and is unsatisfactory, the losses are significant. Even the temporary use of such parts will pose a serious threat, even causing catastrophic failure and serious damage. Therefore, the method of the present invention allows to significantly reduce the risk of loss and damage, so that the additional workload paid for such application is basically insignificant. Even if only corresponding highly specialized inspection equipment is provided for this purpose, it is only a small problem based on the benefits obtained, the value to be protected and the risks to be reduced or even avoided.

[0013] According to another aspect, the invention relates to a computer program product tangibly embodied in a machine-readable storage medium, comprising instructions operable to cause a computing entity to perform the method of the invention.

[0014] According to another aspect, the invention relates to a storage device for providing the computer program product of the invention, wherein the device stores the computer program product and / or provides the computer program product for further use.

[0015] According to another aspect, the present invention relates to an inspection device comprising at least one processing unit, wherein the inspection device is adapted to be able to scan a continuous flow engine component having damage and provide inspection data to be used in the method of the present invention, wherein the inspection device is adapted to be able to receive output, wherein the inspection device is adapted to be able to provide the output to an interface to be used by an operator.

[0016] According to another aspect, the invention relates to an evaluation system comprising the inspection device of the invention, an inspection database, at least one continuous flow engine component database and at least one processing unit, wherein the processing unit is adapted to be able to perform the evaluation of the method of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to simplify the understanding of the present invention, reference is made to the following detailed description and the accompanying drawings and their descriptions. Here, the drawings should be understood not to limit the scope of the present invention, but to disclose preferred embodiments to further explain the present invention.

[0018] Figure 1 A scheme of the method of the present invention is shown.

[0019] Figure 2 An evaluation system according to the invention is shown for implementing the method according to the invention. DETAILED DESCRIPTION

[0020] Preferably, unless otherwise stated, the embodiments below include at least one processor and / or data storage unit for implementing the method of the present invention.

[0021] Unless otherwise specified, terms such as "compute", "process", "determine", "generate", "configure", "reconstruct" and similar terms refer to actions and / or processes and / or steps of modifying data and / or creating data and / or transforming data, where the data is rendered as physical variables or is itself usable.

[0022] The term "data storage" or similar terms as used herein refers, for example, to a temporary data storage like a RAM (Random Access Memory) or a long-term data storage like a hard drive or a data storage unit like a CD, DVD, USB stick, etc. Such a data storage may additionally comprise or be connected to a processing unit to allow processing of the data stored on the data storage.

[0023] The term "continuous flow engine" as used herein refers to a device that utilizes a continuous flow of a fluid (e.g., a gas or liquid). Here, such a continuous flow engine generally provides a rotor that is located in a fluid and interacts with the fluid. Here, such a fluid can be used to provide a rotational motion of the rotor, and the rotational motion of the rotor can be converted into, for example, electrical energy. Examples of such continuous flow engines are gas turbines and steam turbines. Alternatively, the rotor can be actively rotated to allow, for example, compression of the fluid. Examples of such applications are compressors, for example, for oil refineries.

[0024] According to one aspect, the invention relates to a method as described above.

[0025] Note that the inspection and evaluation provided by the method of the present invention is particularly useful for repair processes that use additive manufacturing. According to another embodiment, preferably, the repair uses additive manufacturing, preferably 3D printing. This repair process allows flexible repair of continuous flow engine components, however, a significant amount of work is required to achieve such a repair. In particular for the field of continuous flow engines, which strongly depends on the reliability of the components used, it is extremely advantageous to identify unsuccessful repairs in advance, and unexpectedly the method of the present invention can be used. In particular for methods such as 3D printing that, for example, provide a very good end result to be determined and introduce heat into the component to be repaired, this prediction is unexpectedly reliable and allows components of significant value (such as blades) to be reliably scrapped even before attempting a repair.

[0026] The inventors have also noted that for continuous flow engines such as gas turbines and steam turbines, it is generally preferred to use detailed data collected during their use. According to another embodiment, preferably, the method includes a step of retrieving sensor data from a sensor database, wherein damage to the continuous flow engine component (11) is assessed based on the inspection data (2), the component data (5) and the sensor data. Continuous flow engines (such as gas turbines and steam turbines, in particular high strain gas turbines) can advantageously utilize sensor data, such as sensor data of blades and impellers collected during their use. For example, vibration data can be advantageously combined with inspection data of the continuous flow engine component to assess whether the assessed integrity or corresponding damage includes cracks exceeding the amount recorded during the inspection. This can not only trigger a secondary inspection, but also identify severe damage based on component data of similar damaged continuous flow engine components, and even based on expected deviations from the sensor data and the collected inspection data. Because some deviations can be attributed to, for example, deep cracks extending deep into the continuous flow engine component, which endanger the subsequent use of the continuous flow engine component even after a large number of repair steps.

[0027] Furthermore, it is noted that not only can it be determined whether the component cannot be repaired by the intended additive manufacturing method, but suggestions for changing the repair process can also be automatically provided. According to another embodiment, preferably, the evaluation includes the step of evaluating potential subtractive manufacturing methods in the event that the repair cannot be performed using additive manufacturing methods alone.

[0028] Typically, preferably, the evaluation also includes the results of combining the required subtractive and additive manufacturing steps to repair the continuous flow engine component. Here, the results include an evaluation of the amount of work required, the time required and / or the impact on the characteristics of the continuous flow engine component when performing such a repair. Use of the method of the present invention allows to avoid unnecessary performance of multiple repair steps in a component that no longer meets the expected usage requirements. For example, the required subtractive manufacturing steps may easily introduce too much heat into the component, thereby affecting the microstructure and reducing the overall strength of the component. Therefore, complex repairs are performed by first removing material and then adding material, but the resulting continuous flow engine component cannot provide the overall required mechanical stability at the expected use temperature, which may lead to the scrapping of the component after measuring its performance, or even to catastrophic failure of such a component in a continuous flow engine when in use.

[0029] Furthermore, it is noted that it is of long-term benefit to provide a system of continuous flow engine components that have been provided with unique identifiers. According to a further embodiment, preferably, the continuous flow engine components include unique identifiers. This allows to significantly reduce the risk of human error based on confusing two similar continuous flow engines. For the method of the present invention, which is intended to process a large number of components in a short period of time, this becomes particularly important. And distinguishing the difference of such damage that is not visible to the naked eye makes this feature very important.

[0030] In addition, it is generally beneficial to use a virtual model of the continuous flow engine component. According to a further embodiment, preferably, the method includes the step of using a virtual model of the continuous flow engine component to simulate its behavior during later use to provide an assessment of the damaged continuous flow engine component. Although this requires significant additional processing power, for many applications, the further improvement achieved in reliability assessments in cases that are at the border of being repairable or non-repairable justifies this additional workload. In particular, in the case where the continuous flow engine component is a turbine impeller or turbine blade, such a virtual model unexpectedly facilitates further improved insight.

[0031] Although the entire method can be performed at a desired location, a more decentralized approach is generally preferred. According to a further embodiment, it is preferred that the evaluation is performed at a location remote from the inspection. For example, such an arrangement allows for the utilization of a centrally located higher processing power and / or a central database that is not readily available via the Internet. Generally, it is preferred that the evaluation is performed at a central processing unit that receives inspection data for a plurality of continuous stream engine components from a plurality of remotely located inspection databases. Such an arrangement reduces the total processing power required while making optimal use of an already available central database that includes relevant data.

[0032] It is also possible to collect all required data at a single location. However, for typical applications this is not necessarily the best approach. According to a further embodiment, preferably the inspection database and the component database are different databases, preferably wherein the component database is a remote database. In particular, splitting these databases in this way allows optimal use of already available databases, while the inspection data are usually preferably stored locally, enabling reliable and time-saving data collection, for example, to unexpectedly smooth the entire process.

[0033] Such a component database preferably includes component specific data, such as technical specifications, manufacturing data, previous inspection data of the component, etc. However, it is generally also preferred to include generic component data, such as generic collected data of the same component and its wear, repair, etc. collected over time. In addition, it may be preferred to include data of different continuous flow engine components. For example, gas turbine blades and gas turbine impellers made of similar materials, have similar shapes and designs, show similar wear behavior and / or similar behavior.

[0034] Note that for many applications it is beneficial to use some behavior related data. According to a further embodiment, preferably the component data comprises component data of different continuous flow engine components, wherein the component data of the different continuous flow engine components are selected based on the wear behavior of the components. Such wear behavior may be based on crack development and / or life reduction, since its use may cause several components of the same or different gas turbines (such as different gas turbine impellers and gas turbine blades) to show similar wear during their life. This allows to very easily identify the source of the relevant component data with very little required processing power.

[0035] Although many types of component data may be used beneficially, it is noted that certain component data are generally particularly useful for this purpose. According to further embodiments, preferably, the component data comprises at least one of the group consisting of a CAD model of a continuous-flow engine component, and usage data of a continuous-flow engine component. These types of data are generally particularly useful for performing the method of the present invention. Generally, preferably, the component data comprises at least two of the above types of component data, and more preferably all three.

[0036] The term "usage data" as used herein refers to data relating to the expected usage of a continuous flow engine component. For example, such data may be based on general criteria for usage. Typically, and preferably, the usage data is "component specific usage data". Such component specific usage data as used herein refers to specific requirements for the expected usage of a component based on a very specific use. For example, a continuous flow engine, in which the continuous flow engine component is expected to be used. Even specific expected operating conditions may be used to further optimize the evaluation of the continuous flow engine component.

[0037] In addition, it is noted that the use of the method of the present invention can significantly improve the management of general spare parts. According to a further embodiment, preferably, the output includes an estimated number of subsequent repairs that are possible before the continuous flow engine component is unrepairable, wherein the estimated number of subsequent repairs that are possible before the continuous flow engine component is unrepairable is stored in a database together with the unique identifier of the continuous flow engine component, and / or the estimated number of subsequent repairs that are possible before the continuous flow engine component is unrepairable is stored in or on the continuous flow engine component during the subsequent repair. Unexpectedly, it is noted that such an embodiment effectively utilizes the additional data provided by the method of the present invention. At the same time, it solves the needs that have been solved in the past by the expertise of experts at this point and the estimation of how many subsequent repairs some components may undergo before they need to be replaced based on years of experience and expertise. For continuous flow engines that require very high reliability, such as gas turbines, it is particularly important that the required spare parts are available, while the corresponding replacement parts are not easily available and each part is usually very expensive, which is a challenge that needs to be noted for some operators.

[0038] Although the output can be stored or forwarded directly to a specific person or interface, it is noted that at least its additional storage in a distributed database provides certain benefits. According to a further embodiment, preferably, the output is stored in a distributed database, preferably in a blockchain, together with the unique identifier of the continuous flow engine component. Note that this allows the safety and security of the repair and the utilization rate of the repaired continuous flow engine component to be effectively improved. In addition, based on the fact that failures can be subsequently identified, the possibility of tracking such evaluations is considered to provide significantly increased interest based on insurance and safety requirements. Therefore, storing the output in such a database allows for very efficient use in such applications.

[0039] Furthermore, it is noted that for typical embodiments, an interface is preferably provided for such an inspection device. According to another aspect, the present invention relates to an inspection device comprising at least one processing unit, wherein the inspection device is adapted to be able to scan a continuous flow of engine components with damage and provide inspection data to be used in the method of the present invention, wherein the inspection device is adapted to be able to receive outputs, wherein the inspection device is adapted to be able to provide the outputs to an interface to be used by an operator. Surprisingly, it is noted that an assessment of whether a component is repairable can be provided very quickly. Communication means and protocols are provided for the inspection so that, for example, some remotely located processing units are used using a wireless network to perform the assessment and return only the outputs. This allows an operator to immediately start a repair process or mark a component for scrapping.

[0040] According to a further embodiment, preferably, the inspection device is adapted to be able to encrypt data transmitted from the inspection device and to decrypt data received from the network to which the inspection device is connected. Typically, preferably, the encryption is based on hardware encryption, such as a blockchain chip included in the inspection device. Note that the inclusion of such means for encrypting the data of the inspection device is unexpectedly beneficial, since it is noted that the need to protect the security of the data is very important. For example, on the one hand, it is noted that the data should not be easily stolen by a third party to understand the components used and possible shortcomings. Furthermore, it is noted that such encryption allows to ensure that the data has not been tampered with. Thereby, significant benefits are provided for future business relationships that require enhanced insight and closer cooperation.

[0041] According to another aspect, the invention relates to a computer program product tangibly embodied in a machine-readable storage medium, comprising instructions operable to cause a computing entity to perform the method of the invention.

[0042] According to another aspect, the invention relates to a storage device for providing a computer program product of the invention, wherein the device stores the computer program product and / or provides the computer program product for further use.

[0043] According to another aspect, the invention relates to an evaluation system comprising the inspection device of the invention, an inspection database, at least one continuous flow engine component database, at least one processing unit, wherein the processing unit is adapted to be able to perform the evaluation of the method of the invention.

[0044] Note that such systems are often advantageously established by locating the inspection equipment and processing unit at a remote location. In particular, it is unexpectedly beneficial to use such a centralized evaluation, which utilizes central processing and utilizes a database located at such a location.

[0045] The following detailed description of the drawings uses the drawings to discuss illustrative embodiments and their features and other advantages, which illustrative embodiments should not be construed as limiting.

[0046] Figure 1 Schematic diagram of the method of the present invention is shown. Here, the inspection data 2 of the damaged continuous flow engine component is retrieved from the inspection database 1 by the processing unit 3 based on the unique identifier of the continuous flow engine component. The processing unit 3 retrieves the component data 5 from the continuous flow engine component database 4. Figure 1 The illustrated example of the method of the invention also comprises data 6 retrieved by the processing unit 3 on the usage of the components of the continuous-flow engine.

[0047] Based on the acquired data, the processing unit 3 assesses the damage of the continuous flow engine component. Based on the assessment, the processing unit 3 creates an output 7 comprising data whether the continuous flow engine component can be repaired and an estimated number of possible subsequent repairs before the continuous flow engine component becomes unrepairable.

[0048] Figure 2 2 shows an evaluation system of the invention for implementing the method of the invention. Here, an inspection device 12 is used to scan a continuous flow engine component 11. The acquired inspection data 2 are stored in an inspection database 1. Figure 2 The inspection database 1 of the example shown is integrated into an inspection device 12 .

[0049] The system further comprises a continuous flow engine component database 4 comprising component data 5 and additional data 6 on the usage of the continuous flow engine components.

[0050] The processing unit 3 and the data retrieved from the inspection database 1 and the continuous flow engine component database 4 are located in the cloud environment 13. The inspection device 12 exchanges data with the cloud part of the system using an Internet connection. This allows, for example, to rely on the expertise of a continuous flow engine manufacturer who can provide continuous updates of the evaluation system and detailed expertise and insight into such systems in order to flexibly adapt the evaluation system to even very unusual situations.

[0051] The evaluation results are stored in the evaluation database 14 so that they can be flexibly retrieved by the owner 15 of the continuous flow engine component 11 as needed. For example, a series of corresponding data on the estimated remaining number of possible repairs can be retrieved to stock up spare parts and customize the existing inventory of components as needed. In addition, the output is sent to the inspection device 12. Information on whether the component can be repaired is displayed on the interface 16 to allow the operator of the inspection device to assign a repair task to the continuous flow engine component 11 or trigger a scrapping process.

[0052] The present invention is further described in detail for the purpose of explanation only. However, the present invention should not be understood to be limited to these embodiments, as they represent embodiments that provide benefits to solve specific problems or meet specific needs. The scope of protection should be understood to be limited only by the attached claims.

Claims

1. A method for repairing a continuous flow engine component (11) having damage, The method comprises the following steps: - identifying said continuous flow engine component (11) based on a unique identifier; - retrieving inspection data (2) of the continuous flow engine component (11) from an inspection database (1), the inspection database (1) comprising damage data of the continuous flow engine component (11); - retrieving component data (5) from at least one continuous flow engine component database (4); - automatically assessing damage to the continuous flow engine component (11) based on the inspection data (2) and the component data (5); - automatically generating an output (7), wherein the output (7) comprises data on whether the continuous flow engine component (11) can be repaired and / or an estimated number of possible subsequent repairs before the continuous flow engine component (11) is unrepairable.

2. The method according to claim 2, wherein: The repair uses additive manufacturing, preferably 3D printing.

3. The method according to any one of claims 1 to 2, wherein: The method comprises the step of retrieving sensor data from a sensor database, wherein damage to the continuous flow engine component (11) is assessed based on the inspection data (2), the component data (5) and the sensor data.

4. The method according to any one of claims 1 to 3, wherein: The evaluation includes the step of evaluating potential subtractive manufacturing methods in the event that the repair cannot be performed using additive manufacturing methods alone.

5. The method according to any one of claims 1 to 4, wherein: The continuous flow engine component (11) comprises the unique identifier.

6. The method according to any one of claims 1 to 5, wherein: The method comprises the steps of using a virtual model of the continuous flow engine component (11) to simulate its behavior during subsequent use to provide an assessment of a damaged continuous flow engine component (11).

7. The method according to any one of claims 1 to 6, wherein: The evaluating is performed at a location remote from the examining.

8. The method according to any one of claims 1 to 7, wherein: The inspection database (1) and the component database (4) are different databases, preferably wherein: The component database (4) is a remote database.

9. The method according to any one of claims 1 to 8, wherein: The component data (5) includes at least one from the group consisting of a CAD model of the continuous flow engine component (11), and usage data (6) of the continuous flow engine component (11).

10. The method according to any one of claims 1 to 9, wherein: The output (7) includes an estimated number of possible subsequent repairs before the continuous flow engine component (11) is unrepairable, wherein an estimated number of possible subsequent repairs before the continuous flow engine component (11) becomes unrepairable is stored in a database together with a unique identifier of the continuous flow engine component (11), and / or an estimated number of possible subsequent repairs before the continuous flow engine component (11) becomes unrepairable is stored in or on the continuous flow engine component (11) during a subsequent repair.

11. A computer program product tangibly embodied in a machine-readable storage medium, the computer program product comprising instructions operable to cause a computing entity to perform the method according to any one of claims 1 to 10.

12. A storage device for providing a computer program product according to claim 11, wherein the device stores the computer program product and / or provides the computer program product for further use.

13. An inspection device (12), comprising at least one processing unit (3), wherein the inspection device (12) is adapted to be able to scan a continuous flow engine component (11) having damage and to provide inspection data (2) to be used in a method according to any one of claims 1 to 10, wherein the inspection device (12) is adapted to receive the output (7), Wherein the inspection device (12) is adapted to provide the output (7) to an interface (16) to be used by an operator.

14. The inspection device (12) according to claim 13, wherein: The inspection device (12) is adapted to be able to encrypt data transmitted from the inspection device (12) and to decrypt data received from a network to which the inspection device (12) is connected.

15. An evaluation system, comprising an inspection device (12) according to any one of claims 13 to 14, an inspection database (1), at least one continuous flow engine component database (4), at least one processing unit (3), The processing unit (3) is adapted to be able to perform an evaluation of the method according to any one of claims 1 to 10.

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