Insertion tool and method

Abstract

An insertion tool is provided for an engine that defines an inlet port and includes a component that at least partially defines a cavity. The insertion tool includes: an insertion tool arm having a plurality of segments, the insertion tool arm being configured to be inserted into the cavity through the access port, and the plurality of segments being configured to be in a fixed position relative to each other within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and move the insertion tool arm in at least two degrees of freedom.

Description

[0001] This application is a divisional application of the invention patent application with application number 202110643037.6 filed on June 9, 2021 and invention name “Insertion tool and method”. Technical Field

[0002] The present subject matter generally relates to tools and methods for inspecting a cavity through an access port, such as an annulus in a turbine engine through an inspection port. Background Art

[0003] At least some gas turbine engines include in a serial flow arrangement: a compressor section including a low-pressure compressor and a high-pressure compressor for compressing air flowing through the engine; a combustor for mixing fuel with the compressed air so that the mixture can be ignited; and a turbine section including a high-pressure turbine and a low-pressure turbine that provide power to the compressor section.

[0004] In one or more sections, at least some of the gas turbine engines define annular openings. Some of these annular openings may vary in size. An inspection tool for inspecting one or more of these annular openings may be beneficial. Summary of the invention

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

[0006] In one aspect of the present disclosure, an insertion tool for an engine is provided, the engine defining an access port and including a component at least partially defining a cavity. The insertion tool includes: an insertion tool arm including a plurality of segments, the insertion tool arm being configured to be inserted into the cavity through the access port, and the plurality of segments being configured to be in a fixed position relative to each other within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.

[0007] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A full and enabling disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification, which refers to the accompanying drawings, in which:

[0009] Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary aspect of the present disclosure.

[0010] Figure 2 is along the axial direction and the radial direction, including the insertion tool according to the exemplary embodiment of the present disclosure Figure 1 A close-up cross-sectional view of a combustion section of an exemplary gas turbine engine.

[0011] Figure 3 is along the radial direction and the circumferential direction, including the exemplary insertion tool Figure 1 Another close-up cross-sectional view of the combustion section of an exemplary gas turbine engine.

[0012] Figure 4 is a close-up view of an insertion tool in a first position according to another exemplary embodiment of the present disclosure.

[0013] Figure 5 It is in the second position Figure 4 A close-up view of an exemplary insertion tool.

[0014] Figure 6 Is in the first position Figure 4 Radial view of an exemplary insertion tool.

[0015] Figure 7 It is in the second position Figure 4 Radial view of an exemplary insertion tool.

[0016] Figure 8 is a flow chart of a method for inserting a tool into an interior of an engine according to an exemplary aspect of the present disclosure. DETAILED DESCRIPTION

[0017] Reference will now be made in detail to the present embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Similar or similar designations have been used to refer to similar or similar parts of the present invention in the drawings and description.

[0018] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the respective components.

[0019] The terms "front" and "rear" refer to relative positions within a component or system and refer to the normal operating posture of a component or system. For example, for a gas turbine engine, the front refers to a position near the inlet of the gas turbine engine, while the rear refers to a position near the exhaust of the gas turbine engine.

[0020] The terms “coupled to,” “fixed to,” “attached to,” and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features unless otherwise stated.

[0021] The singular forms "a", "an" and "the" include plural forms unless the context clearly dictates otherwise.

[0022] As used herein throughout the specification and claims, approximating language is used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to within 10%.

[0023] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein include the endpoints, and the endpoints are independently combinable with each other.

[0024] In some gas turbine engines, one or more annular openings are defined, and the sizes of these annular openings may vary within a particular brand / model of gas turbine engines, as well as between different brands / models of gas turbine engines, such that each annular opening must use a dedicated special inspection tool to extend around and through the annular opening. Maintaining an inspection tool for each of the various annular openings may be expensive and inconvenient.

[0025] Therefore, the present disclosure provides an inspection tool for inspecting annular openings of varying sizes, for example, within a single gas turbine engine or within a variety of gas turbine engines. In particular, certain aspects of the present disclosure provide an insertion tool, the insertion tool comprising: an insertion tool arm having a plurality of segments, and a base coupled to the insertion tool arm. The insertion tool arm is configured to be inserted into a cavity through an access port of a gas turbine engine. The plurality of segments are configured to be in fixed positions relative to each other within the cavity. The base is configured to be positioned outside the cavity and is also configured to move the insertion tool arm along at least two degrees of freedom.

[0026] In this manner, it will be appreciated that the base is capable of moving an insertion arm that, when in a fixed position, defines a radius of curvature that is different than the radius of curvature of the annular opening, thereby allowing the inspection tool to be used with a variety of different sized annular openings / gas turbine engines.

[0027] Referring now to the drawings, wherein like reference numerals refer to like elements throughout, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure. More particularly, Figure 1 In the embodiment of the present invention, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as a "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to the longitudinal centerline 12 for reference) and a radial direction R. The turbofan engine 10 also defines a circumferential direction C (see Figure 3 ). Generally, the turbofan 10 includes a fan section 14 and a turbine 16 arranged downstream of the fan section 14 .

[0028] The illustrated exemplary turbine 16 is generally enclosed within a generally tubular casing 18 defining an annular inlet 20 and an annular exhaust 21. The casing 18 encloses, in serial flow relationship: a compressor section, including a boost or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section, including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22. The compressor section, combustion section 26, turbine section, and nozzle section 32 together define a core air flow path 37 therethrough.

[0029] For the illustrated embodiment, the fan section 14 includes a fixed pitch fan 38 having a plurality of fan blades 40. Each of the fan blades 40 is attached to a disk 42, wherein the fan blades 40 and the disk 42 are rotatable together about a longitudinal axis via the LP shaft 36. For the illustrated embodiment, the turbofan engine 10 is a direct drive turbofan engine such that the LP shaft 36 directly drives the fan 38 of the fan section 14 without using a reduction gearbox. However, in other exemplary embodiments of the present disclosure, the fan 38 may alternatively be a variable pitch fan, and the turbofan engine 10 may include a reduction gearbox, in which case the LP shaft 36 may drive the fan 38 of the fan section 14 across the gearbox.

[0030] Still refer to Figure 1In the exemplary embodiment of the present invention, the disk 42 is covered by a rotatable front hub 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. In addition, the exemplary turbofan engine 10 includes an annular nacelle assembly 50 that circumferentially surrounds at least a portion of the fan 38 and / or the turbine 16. For the illustrated embodiment, the nacelle assembly 50 is supported relative to the turbine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the nacelle assembly 50 extends over an outer portion of the outer casing 18 to define a bypass airflow passage 56 therebetween. The ratio between a first portion of the air passing through the bypass airflow passage 56 and a second portion of the air passing through the inlet 20 of the turbine 16 and through the core air flow path 37 is generally referred to as a bypass ratio.

[0031] It will be understood that although not Figure 1 1 , but the turbofan engine 10 may further define a plurality of openings to allow inspection of various components within the turbine 16. For example, the turbofan engine 10 may define a plurality of borescope openings at various axial locations within the compressor section, the combustion section 26, and the turbine section. Additionally, as will be discussed below, the turbofan engine 10 may include, for example, one or more igniter ports within the combustion section 26 of the turbine 16, which may allow inspection of the combustion section 26.

[0032] It will also be understood that Figure 1 The exemplary turbofan engine 10 shown is exemplary only, and in other exemplary embodiments, the turbofan engine 10 may have any other suitable configuration, any other suitable number of shafts or spools, turbines, compressors, etc. Additionally or alternatively, in other exemplary embodiments, any other suitable turbine engine may be provided. For example, in other exemplary embodiments, the turbine engine may not be a turbofan engine, but may be configured as a turboshaft engine, a turboprop engine, a turbojet engine, etc.

[0033] Reference now Figure 2 , provides Figure 1 1 is a close-up schematic diagram of a combustion section 26 of a turbine 16 of an exemplary gas turbine engine 10 .

[0034] As depicted, the combustion section 26 generally includes a burner 60 positioned within a combustor casing 62. In addition, the burner 60 includes an inner liner 64, an outer liner 66, and a dome 68, which together at least partially define a combustion chamber 70. It will be understood that for the illustrated embodiment, the dome 68 is an annular dome and the combustion chamber 60 is configured as an annular burner. In this way, the combustion chamber 70 is generally defined as an annular. At the front end 61, the burner 60 defines, or more precisely, the dome 68 defines a nozzle opening 72, and the combustion section 26 also includes a fuel-air mixer 74 or nozzle positioned within the nozzle opening 72. The fuel-air mixer 74 is configured to provide a mixture of fuel and compressed air to the combustion chamber 70 during operation of the turbofan engine 10 to produce combustion gases. The combustion gases flow from the combustion chamber 70 to the HP turbine 28, more specifically through a plurality of inlet guide vanes 76 of the HP turbine 28.

[0035] It is worth noting that although Figure 2 A single nozzle opening 72 and fuel-air mixer 74 are shown in FIG. 6 , but the combustor 60 may further include a plurality of circumferentially spaced nozzle openings 72 and a corresponding plurality of fuel-air mixers 74 located within the nozzle openings 72 .

[0036] To initiate combustion of the fuel and compressed air provided to the combustion chamber 70 by the fuel-air mixer 74, the combustion section 26 typically includes an igniter (not installed or shown) extending through one or more igniter openings 78 defined in the combustor casing 62 and the outer liner 66 of the combustor 60. However, when the turbofan engine 10 is not operating, the igniter may be removed and the igniter openings 78 may be used to inspect, for example, the combustion chamber 70, the inlet guide vanes 76 of the HP turbine 28, and / or other components.

[0037] More specifically, for Figure 2 , an insertion tool for inserting one or more instruments into an engine interior according to an exemplary embodiment of the present disclosure is shown. In particular, for the illustrated embodiment, the insertion tool is a tool 100 for inspecting an annular cross-section of an engine according to an exemplary embodiment of the present disclosure, and is depicted extending through a pair of igniter openings 78 defined in the combustor casing 62 and the outer liner 66 of the combustor 60. Now also see Figure 3 , which provides Figure 2 FIG. 1 is a partial axial cross-sectional view of the combustion section 26 . It will be appreciated that the tool 100 generally includes an insertion tool arm 101 generally formed by a plurality of segments 102 and an insertion tube 104 , through which the plurality of segments 102 of the insertion tool arm 101 can be moved into the combustion chamber 70 .

[0038] More specifically, for the exemplary embodiment shown, the insert tube 104 includes a bend 106. In at least some embodiments, the bend 106 can be a bend of approximately 90 degrees, or can be greater or less than 90 degrees. For example, the insert tube 104 includes a radial portion 108 extending generally in a radial direction R and a circumferential portion 110 extending generally in a circumferential direction C. The radial portion 108 and the circumferential portion 110 are joined at the bend 106. The plurality of segments 102 are fed through the radial portion 108, pivoted in a first angular direction relative to each other to pass through the bend 106, and then pivoted in a second opposite angular direction relative to each other and coupled to each other so that they are configured to be in a fixed position relative to each other as they move through the circumferential portion 110. The segments 102 extend from the circumferential portion 110 through the annular combustion chamber 70. As used herein, the term "configured to be in a fixed position relative to each other" means that during the intended operation of the tool 100, other than the actual insertion operation, the segments 102 are not configured to bend or flex significantly at the joints between adjacent segments 102. In this manner, it will be understood that the segments 102 may be biased toward a fixed position with sufficient biasing force to hold the segments in place during the intended operation of the tool 100, but some deflection may be permitted as the tool 100, for example, encounters an object in the environment, or is inserted into or removed from the environment.

[0039] As will be described in more detail below, the tool 100 also includes an insertion tool arm position sensor, or simply a position sensor 111, located near the distal end of the insertion tool arm 101. Specifically, for the illustrated embodiment, the position sensor 111 is located in the frontmost segment 102' of the multiple segments 102 of the insertion tool arm 101. In at least some exemplary embodiments, the position sensor 111 may include one or more cameras. For example, as will be described in more detail below, one or more cameras may include two or more sensors that provide stereo feedback data (e.g., information from two separate locations that can be combined to provide relatively accurate distance / positioning data). For a further example, the position sensor 11 may include a camera so that the position sensor 111 can be further used as an instrument for inspecting the interior of the engine. For example, the camera can additionally or alternatively provide a video feed for inspecting one or more components of the engine, such as for inspecting various components of the combustor 60 and / or the high-pressure turbine 28. It will be further appreciated that the insertion tool arm 101 may additionally or alternatively include any other suitable position sensor 111 for sensing data indicative of the position of the insertion tool arm 101 within a cavity.

[0040] As will be described in more detail below, the plurality of segments 102 of the tool 100 extending through the annular combustion chamber 70 together define an average arc 112 (i.e., an average arc line). In addition, the annular combustion chamber 70 defines an inspection radius 114, which is a distance along the radial direction R from which an annular cross-section of the turbofan engine 10, i.e., the annular combustion chamber 70, is expected to be viewed. For example, the inspection radius 114 may be a radial midpoint within the combustion chamber 70. Likewise, for the illustrated embodiment, the average arc 112 of the plurality of segments 102 extending through the annular combustion chamber 70 (i.e., the plurality of segments 102 coupled to each other within the combustion chamber 70) defines a radius 116 (or "radius of curvature") of the segment 102. In certain exemplary embodiments, the radius 116 of the segment 102 of the average arc 112 may not be substantially equal to the inspection radius 114, in which case the insertion tool arm 101 may be movable in various degrees of freedom from a base 120 located outside of the interior of the gas turbine engine. Such operation will be described in more detail below.

[0041] Notably, the radius of curvature / radius 116 of a segment 102 refers to the radius of a circle aligned with the average arc 112 of the plurality of segments 102 extending through an annulus of the engine 10 , which for the depicted embodiment is the annular combustion chamber 70 .

[0042] It will therefore be understood that although Figure 2 and Figure 3 While tool 100 is depicted as being used to inspect combustion chamber 70, in other exemplary embodiments, tool 100 may additionally or alternatively be used to inspect other areas of turbofan engine 10 having different inspection radii 114. For example, tool 100 may be used to inspect an annular portion of a compressor section or a turbine section, or alternatively, other engines or systems.

[0043] In at least some exemplary embodiments, the various segments 102 of the insertion tool arm 101 can be constructed in a manner similar to the segments 102 of the tool described in U.S. Patent Application No. 2019 / 0360794, entitled “INSPECTION TOOL AND METHOD,” filed on May 23, 2018, in which Andrew Crispin Graham is listed as the primary inventor, which is hereby incorporated by reference in its entirety. In this manner, it will be understood that in certain exemplary embodiments, the plurality of segments 102 may include an adjustment member (in advance or in response to sensed real-time data) for changing the average arc 112 of the plurality of segments 102. Alternatively, however, in other exemplary embodiments, the segments 102 of the insertion tool arm 101 may be configured in any other suitable manner. For example, in other embodiments, the segments 102 may be non-adjustable so that they have only one geometry when they are moved to a fixed position inside the engine. Additionally or alternatively, less than all of segments 102 may be adjustable, or one or more segments 102 may be adjustable in any other suitable manner.

[0044] Now special reference Figure 3 As described above, it will be further understood that the insertion tool also includes a base 120 connected to the insertion tool arm 101 and in communication with the position sensor 111. The base 120 is located outside the cavity and is configured to move the insertion tool arm 101 along at least one degree of freedom in response to data received from the position sensor 111.

[0045] In particular, for Figure 3 In the exemplary embodiment, the base 120 is mounted to the casing 18 of the engine surrounding the combustion section 26 of the engine. Figure 4 and 5 As explained in more detail in the embodiments of the present invention, the base 120 can provide the insertion tool arm 101 with movement along at least two degrees of freedom, such as along at least four degrees of freedom, such as along at least six degrees of freedom. Figure 3 The various degrees of freedom with which the base 120 can move the insertion tool arm 101 are depicted as a longitudinal direction L1, a lateral direction L2, a transverse direction T, an orientation about the longitudinal direction L1', an orientation L2' about the lateral direction, and an orientation T' about the transverse direction.

[0046] In addition, the tool 100 also includes a controller 150. The controller 150 has one or more processors 152 and a memory 154. The memory 154 stores data 156. The data 156 may include instructions that, when executed by the one or more processors 152, cause the tool 100 to perform certain functions. The one or more functions may be one or more functions described below with reference to, for example, the exemplary method 200. In addition, the controller 150 includes a network interface 158. The network interface 158 may utilize any suitable wired or wireless communication network 160 to communicate with other components of the tool 100 and / or other components.

[0047] like Figure 3 As shown in dashed lines, the controller 150 is operably coupled to the position sensor 111 and the base 120. In this manner, the base 120 can receive data indicating the position of the plurality of segments 102 of the insertion tool arm 101 within a cavity (i.e., the combustion chamber 70 for the illustrated embodiment), data indicating a desired position of the insertion tool arm 101 within the cavity (e.g., a desired position of the forward-most segment 102' and / or the sensor 111 in the cavity), and control the insertion tool arm 101 to move the insertion tool arm 101 to the desired position within the cavity while avoiding collisions with components that at least partially define the cavity. As used herein, the term "collision" refers to any undesired contact between the insertion tool arm 101 and a component.

[0048] In this manner, it will be appreciated that the controller 150 can operate with the base 120 to facilitate movement of the insertion tool arm 101, the sensor 111, or both within a cavity of the engine (e.g., within the combustion chamber 70 of the engine) to move the insertion tool arm 101, the sensor 111, or both to a desired position within the cavity of the engine. The controller 150 can operate on a feedback loop based on data sensed by the sensor 111.

[0049] In addition, the base 120 can be configured to control the length of the insertion tool arm 101 within the cavity. In this manner, the exemplary base 120 shown includes a feeding mechanism 122 that is configured to move the plurality of segments 102 through the insertion tube 104 and into the annular combustion chamber 70. The feeding mechanism 122 also communicates with the controller 150 via the network 160. In certain embodiments, the feeding mechanism 122 can feed the segments 102 into the insertion tube 104 using a rotating wheel having a gripper surface (e.g., an elastomeric surface or a gear surface corresponding to a gear surface of the segment 102).

[0050] In addition, although not shown, the insertion tool 100 may include any suitable implement for performing one or more maintenance, repair or inspection operations inside the engine. For example, in certain exemplary embodiments, as described above, the position sensor 111 may include one or more cameras for inspecting the interior of the engine. Additionally or alternatively, the insertion tool arm 101 may include one or more implements, such as one or more of a drill, a heater, a welder, etc., to perform maintenance and / or repair operations in which material is added to a component of the engine, material is removed from a component of the engine, or a physical property of a component of the engine is changed.

[0051] Reference now Figure 4 and 5 , an insertion tool 100 for an engine 10 according to another exemplary embodiment of the present disclosure is provided. Figure 4 and Figure 5 The exemplary insertion tool 100 may be used in the same manner as described above with reference to Figure 2 and Figure 3 The exemplary insertion tool 100 is configured in substantially the same manner as described above and may be used in conjunction with the exemplary insertion tool 100 of the embodiment of the present invention. Figures 1 to 3 One or more exemplary embodiments of the gas turbine engine 10 are described to operate together. For example, the engine 10 can be a gas turbine engine 10 that defines an inlet port and includes a component that at least partially defines a cavity. For the illustrated embodiment, the inlet port is an igniter port 78 or a borescope port, and the component is a combustor liner 64, 66, a combustor dome 68, a fuel nozzle 74, or a combination thereof. Therefore, it will be understood that for the illustrated embodiment, the cavity is a combustion chamber 70 of the engine 10.

[0052] In addition, with the above reference Figure 2 and Figure 3 As with the exemplary insertion tool 100 described above, Figure 4 and 5 The exemplary insertion tool 100 generally includes an insertion tool arm 101 and a base 120, the insertion tool arm 101 having a plurality of segments 102 and a position sensor 111. For the illustrated embodiment, the position sensor 111 is located near the distal end of the insertion tool arm 101, more specifically, at the frontmost segment 102' of the plurality of segments 102 of the insertion tool arm 101.

[0053] However, for the illustrated embodiment, the base 120 of the insertion tool 100 is configured to be mounted at a location separate from the engine 10, and more specifically, the base 120 of the insertion tool 100 is configured to be mounted to a ground location 124. The term "ground location" generally refers to any location separate from the engine 10 or the structure (e.g., an aircraft) on which the engine 10 is mounted. For example, the ground location can be the actual ground, such as below the engine 10, a stand or cart separate from the engine 10 located near the engine 10, and the like.

[0054] To accommodate any relative movement between the engine 10 and the ground location 124, the insertion tool 100 also includes a second position sensor 126, which is configured to sense data indicating the position of one or more aspects of the insertion tool 100 relative to the engine 10 outside the interior of the engine 10. Specifically, for the illustrated embodiment, the second position sensor 126 is included in the base 120 and is configured to sense data indicating the position of the base 120 relative to the engine 10 (e.g., data indicating a relative distance and / or orientation). In certain exemplary embodiments, the insertion tool 100 may include one or more features discussed in U.S. Application No. 16 / 008,475, filed on January 14, 2018, which is incorporated herein in its entirety for all purposes.

[0055] As about Figure 2 and Figure 3 As pointed out in the embodiments, Figure 4 and Figure 5 The base 120 of the exemplary embodiment is coupled to the insertion tool arm 101 and is in communication with the position sensor 111 of the insertion tool arm 101. The base 120 is configured to move the insertion tool arm 101 along at least two degrees of freedom in response to data received from the position sensor 111. More specifically, for the illustrated embodiment, the base 120 is configured to move the insertion tool arm 101 along at least four degrees of freedom in response, at least in part, to data received from the position sensor 111. More specifically, further, the base 120 is configured to move the insertion tool arm 101 along at least six degrees of freedom, plus one degree of freedom for changing the length of the insertion tool arm 101 using the feed mechanism 122, in response, at least in part, to data received from the position sensor 111.

[0056] For the illustrated embodiment, the base 120 is configured to move the insertion tool arm 101 in degrees of freedom including one or more of the following: a longitudinal direction L1, a lateral direction L2, a transverse direction T, an orientation L1' around the longitudinal direction, an orientation L2' around the lateral direction, and an orientation T' around the transverse direction. In order to achieve such movement along these degrees of freedom, the exemplary base 120 shown includes a plurality of members pivotally coupled to each other around respective pivot points. In particular, for the illustrated embodiment, the base 120 includes: a first member 130 pivotally coupled to a second member 132 around a first pivot point 134; a second member 132 pivotally coupled to a third member 136 around a second pivot point 138; and a third member 136 pivotally coupled to a fourth member 140 around a third pivot point 142.

[0057] In addition, for the illustrated embodiment, one or more of these members 130, 132, 136, 140 may allow rotation about its length. Specifically, in the illustrated embodiment, the first member 130 allows rotation about the length of the first member 130, the second member 132 allows rotation about the length of the second member 132, the third member 136 similarly allows rotation about the length of the third member 136, and the fourth member 140 allows rotation about the length of the fourth member 140. These respective rotational directions are depicted with arrows and are not labeled for clarity.

[0058] In certain exemplary embodiments, the base 120 may include one or more motors operable with the members 130 , 132 , 136 , 140 and / or the pivot points 134 , 138 , 142 to provide relative movement and rotation.

[0059] However, it will be appreciated that in other exemplary embodiments, the base 120 may have any other suitable configuration for providing movement of the insertion tool arm 101 along the desired degrees of freedom. For example, in other exemplary embodiments, the base 102 may include a pair of linear actuators to move the insertion tool arm 101 only along the transverse direction T and the longitudinal direction L1. Other configurations are also contemplated.

[0060] In this manner, the insertion tool arm 101 may be moved by the base 120 (eg, at the direction of the controller 150 ) to substantially any desired position and / or orientation within the cavity of the engine 10 .

[0061] Obviously, this may be beneficial to allow the insertion tool arm 101 to travel through annular spaces having different radii of curvature 114 within the same engine 10 or different engines 10. For example, although the insertion tool arm 101 is manufactured to define a radius of curvature 114 that is different from the radius of curvature of the annular space through which it is inserted, the ability to manipulate the insertion tool arm 101 to various positions and orientations along specific degrees of freedom may still allow the insertion tool arm 101 to travel through such annular space without collision.

[0062] In addition, it will be appreciated that, although the movement of the insertion tool arm 101 is constrained by the fixed position of the entry port of the engine 10 through which the insertion tool arm 101 is inserted, the ability to move with various degrees of freedom can facilitate the use of the insertion tool arm 101 in various annular geometries (e.g., having various radii of curvature 114). It will be appreciated from the discussion herein that the ability to move with various degrees of freedom can facilitate the use of the insertion tool arm 101 in various annular geometries while maintaining a desired clearance with the components defining the entry port. For example, the insertion tool 100 may be able to move the insertion tool arm 101 to the interior and exterior of the entry port while pivoting the insertion tool arm 101 at the entry port and / or changing the orientation of the insertion tool arm 101 to position, for example, a sensor 111 at a desired location within a cavity (combustion chamber 70 or other annular space within the engine 10) without colliding with any components.

[0063] For example, now also refer to Figure 5 It will be appreciated that the distal end of the insertion tool arm 101 is moved from the first position ( Figure 4 ;exist Figure 5 ) moves to the second position ( Figure 5 ). As part of this movement, the insertion tool arm 101 moves along the longitudinal direction L1 and the lateral direction L2, and also changes orientation about the transverse direction T. Notably, this movement of the insertion tool arm 101 is performed while maintaining clearance with the components defining the access port, and includes pivoting the insertion tool arm 101 at the access port. This can facilitate movement of the distal end of the insertion tool arm 101 from the first position to the second position despite a mismatch between the radius of curvature of the insertion tool arm 101 and the cavity of the engine 10.

[0064] Furthermore, it will be appreciated that the ability to move the insertion tool arm 101 about various degrees of freedom may also allow the distal end of the insertion tool arm 101 to be positioned at various locations along the length of the engine. Figure 6 and 7 , each providing a radial direction of the engine 10 viewed from the inside out. Figure 4 and 5101, respectively, it will be appreciated that changing the orientation of the insertion arm tool 101 about one or more degrees of freedom may allow the distal end of the insertion tool arm 101 to be positioned further along the length of the engine (e.g., along Figure 1 The axial direction A of the engine, Figure 6 and 7 In various directions (shown as lateral direction L2).

[0065] However, it will be appreciated that in other embodiments, in addition to moving the insertion tool arm 101 via the base 120, the base 120 may further increase or decrease the length of the insertion tool arm 101 within the cavity by adding or removing segments 102 within the cavity. Thus, there may be a variety of potential ways in which the distal end of the insertion tool arm 101 is moved from a first position to a second position. The insertion tool 100 may utilize any method that provides the lowest risk of collision or alternatively meets some other design goal.

[0066] It will be understood that the exemplary insertion tool 100 and base 102 are provided by way of example only. In other exemplary embodiments, the insertion tool 100 and base 102 may have any other suitable configuration. For example, in some exemplary embodiments, the base 102 may not include a Figure 4 and Figure 5 Each of the various degrees of freedom discussed has its own characteristics. For example, although Figure 4 Seven degrees of freedom are depicted, but one or more of the members 132 , 136 , 140 may not allow rotation about its length, and / or the base 102 may not include every one of the members 132 , 136 , 140 .

[0067] Furthermore, it will be understood that while the exemplary insertion tool 100 described above includes a position sensor 111 on the insertion tool arm 101, and the base 102 is constructed to move the insertion tool arm 101 in response to data received from the position sensor 111 on the insertion tool arm 101, in other embodiments, other constructions are contemplated. For example, in other exemplary embodiments, the position sensor 111 may be separated from the insertion tool arm 101 and inserted, for example, through a separate entry port of an engine. Additionally or alternatively, the base 102 may be constructed to be manually operated to move the insertion tool arm 101 along various degrees of freedom in response to sensed data from, for example, the position sensor 111, or in response to a visual inspection of the position of the insertion tool arm 101 within a cavity of an engine.

[0068] Reference now Figure 8, a method 200 for inserting an insertion tool into a cavity of a gas turbine engine is provided. In certain exemplary aspects, the insertion tool includes a base having a position sensor and a base coupled to the insertion tool arm. For example, in certain exemplary aspects, the method 200 can utilize the above reference Figures 1 to 7 One or more exemplary insertion tools are described.

[0069] The method 200 includes receiving data indicating the position of an insertion tool arm within a cavity of a gas turbine engine from a position sensor at (202). The data may be image data from, for example, one or more cameras, distance data from one or more distance sensors, etc. In addition, the data may be one-dimensional distance data, or may be two-dimensional data, or may be three-dimensional data. For example, the data may be image data received from at least two cameras, so that three-dimensional distance data may be determined for the environment.

[0070] Method 200 further includes, at (204), based at least in part on data received from a position sensor at (202), moving the insertion tool arm along at least two degrees of freedom using a base located outside the cavity of the gas turbine engine to avoid collision between the insertion tool arm and a component that at least partially defines the cavity.

[0071] In certain exemplary aspects, moving the insertion tool arm along at least two degrees of freedom at (204) includes maintaining a clearance between the insertion tool arm and a component defining an access port of the gas turbine engine at (206). For example, in the exemplary aspects shown, moving the insertion tool arm along at least two degrees of freedom at (204) includes changing a position of the insertion tool arm relative to the access port and changing an orientation of the insertion tool arm relative to the access port at (208). In this manner, it will be appreciated that movement of the insertion tool arm is constrained by the size and position of the access port. Thus, method 200 can ensure that this constraint is appropriately accounted for when moving the insertion tool arm at (204).

[0072] In addition, it will be understood that for the exemplary method 200 shown, moving the insertion tool arm along at least two degrees of freedom using a base located outside the cavity of the gas turbine engine at (204) also includes moving the insertion tool arm along at least four degrees of freedom using a base located outside the cavity of the gas turbine engine at (210), and more specifically includes moving the insertion tool arm along at least six degrees of freedom using a base located outside the cavity of the gas turbine engine at (212).

[0073] In addition, it will be understood that in addition to moving the insertion tool arm based on feedback from the position sensor, the method 200 can also move the insertion tool arm based on other task objectives (e.g., inspecting a specific component, performing a specific repair, etc.). Specifically, for the exemplary aspects depicted, the method 200 further includes receiving data indicating the desired position of the insertion tool arm at (214). The data received at (214) can be coordinate data of a position within a cavity, and can further include orientation data for the position. In addition, the data received at (214) can include a series of coordinates and corresponding orientations. For such exemplary aspects, moving the insertion tool arm at (204) using a base located outside the cavity of the gas turbine engine based at least in part on the data received from the position sensor also includes moving the insertion tool arm at (216) based at least in part on the received data indicating the desired position of the insertion tool arm. This enables the method 200 to achieve certain tasks.

[0074] In this manner, it will be appreciated that for the exemplary aspects shown, method 200 further includes inspecting one or more components defining the cavity using an insertion tool at (218). Inspecting the one or more components at (218) may include receiving an image from a sensor, such as a camera used as a position sensor, a separation sensor, or both. The image may be analyzed by a controller to determine, for example, a condition of the one or more components and / or one or more aspects of the one or more components.

[0075] Although not shown, method 200 may additionally or alternatively be capable of performing other functions. For example, in other exemplary aspects, the insertion tool may include one or more additional tools (e.g., a drill, a welder, a fluid nozzle, etc.). In this case, method 200 may include performing one or more repair operations.

[0076] Additionally, it will be appreciated that in certain exemplary aspects, the pedestal may not be fixed to the engine. For such exemplary aspects, method 200 may further include receiving data indicating a position of the pedestal relative to the engine at (222). In such exemplary aspects, moving the insertion tool arm using the pedestal located outside the cavity of the gas turbine engine based at least in part on the data received from the position sensor at step (204) may also include moving the insertion tool arm based at least in part on the received data indicating a position of the pedestal relative to the engine at (220).

[0077] However, it will be appreciated that in other exemplary aspects, method 200 may be configured in any other suitable manner to perform any other suitable steps, and that the above-described process is merely an example.

[0078] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any device or system and performing any combined methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims, then these other examples are intended to be included within the scope of the claims.

[0079] Further aspects of the invention are provided by the subject matter of the following clauses:

[0080] An insertion tool for an engine, the engine defining an access port and including a component that at least partially defines a cavity, the insertion tool comprising: an insertion tool arm, the insertion tool arm including a plurality of segments, the insertion tool arm being configured to be inserted into the cavity through the access port, and the plurality of segments being configured to be in fixed positions relative to each other within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.

[0081] An insertion tool of one or more of these clauses, wherein the insertion tool arm further comprises a position sensor configured to sense a position of the insertion tool arm within a cavity, and wherein the base is configured to move the insertion tool arm along at least two degrees of freedom in response to data received from the position sensor.

[0082] The insertion tool of one or more of these clauses, wherein the base is configured to move the insertion tool arm along at least four degrees of freedom in response, at least in part, to data received from the position sensor.

[0083] The insertion tool of one or more of these clauses, wherein the base is configured to move the insertion tool arm along at least six degrees of freedom in response, at least in part, to data received from the position sensor.

[0084] The insertion tool of one or more of these clauses, further comprising: a controller operably coupled to the position sensor and the base for receiving data from the position sensor and providing control decisions to the base in response to the data received from the position sensor.

[0085] An insertion tool as claimed in one or more of these clauses, wherein the base is configured to be mounted to an engine.

[0086] An insertion tool as claimed in one or more of these clauses, wherein the base is configured to be mounted at a location separate from the engine.

[0087] An insertion tool of one or more of these clauses, wherein the base includes a base position sensor configured to sense data indicative of a position of the base relative to the engine, and wherein the base is further configured to move the insertion tool arm in response to data received from the base position sensor.

[0088] The insertion tool of one or more of these clauses, further comprising: an insertion tube extending at least partially through the access port, wherein the insertion tool is configured to feed multiple segments of the insertion tool arm into the cavity through the insertion tube, and wherein the multiple segments of the insertion tool arm are in fixed positions relative to each other within the cavity.

[0089] The insertion tool of one or more of these clauses, wherein the base is further configured to change the length of the insertion tool arm within the cavity in response to data received from the position sensor.

[0090] The insertion tool of one or more of these clauses, wherein the access port is an igniter port or a borescope port, wherein the component is a combustor liner, a combustor dome, a combustion nozzle, or a combination thereof, and wherein the cavity is a combustor.

[0091] A method for inserting an insertion tool into a cavity of a gas turbine engine, the insertion tool comprising an insertion tool arm having a position sensor and a base connected to the insertion tool arm, the method comprising: receiving data indicating the position of the insertion tool arm in the cavity of the gas turbine engine from the position sensor; and moving the insertion tool arm along at least two degrees of freedom using a base located outside the cavity of the gas turbine engine based at least in part on the data received from the position sensor to avoid collision between the insertion tool arm and a component that at least partially defines the cavity.

[0092] The method of one or more of these clauses, wherein moving the insertion tool arm along at least two degrees of freedom includes maintaining a clearance between the insertion tool arm and a component defining an access port of the gas turbine engine.

[0093] The method of one or more of these clauses, wherein moving the insertion tool arm along at least two degrees of freedom comprises changing a position of the insertion tool arm relative to the access port and changing an orientation of the insertion tool arm relative to the access port.

[0094] The method of one or more of these clauses further includes: receiving data indicating a desired position of the insertion tool arm; wherein, moving the insertion tool arm using a base located outside the cavity of the gas turbine engine based at least in part on the data received from the position sensor includes moving the insertion tool arm based at least in part on the received data indicating the desired position of the insertion tool arm.

[0095] The method of one or more of these clauses, wherein moving the insertion tool arm along at least two degrees of freedom using a base located outside the cavity of the gas turbine engine includes moving the insertion tool arm along at least four degrees of freedom using a base located outside the cavity of the gas turbine engine.

[0096] The method of one or more of these clauses, wherein moving the insertion tool arm along at least two degrees of freedom using a base located outside the cavity of the gas turbine engine includes moving the insertion tool arm along at least six degrees of freedom using a base located outside the cavity of the gas turbine engine.

[0097] The method of one or more of these clauses, further comprising: receiving data indicating the position of a base relative to the engine, and wherein moving an insertion tool arm using a base located outside the cavity of the gas turbine engine is based at least in part on the data received from the position sensor, including moving the insertion tool arm based at least in part on the received data indicating the position of the base relative to the engine.

[0098] The method of one or more of these clauses further comprises: using an insertion tool to perform an inspection operation, a maintenance operation, or a repair operation on one or more components defining the cavity.

[0099] A gas turbine engine assembly includes: a section defining an access port; a component at least partially defining a cavity; and an insertion tool, the insertion tool including: an insertion tool arm including a plurality of segments, the insertion tool arm being configured to be inserted into the cavity through the access port, and the plurality of segments being configured to be in fixed positions relative to each other within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.

Claims

1. A system for operating an insertion tool arm in a cavity of a gas turbine engine, characterized in that The system comprises: an insertion tool arm having a first position sensor; a base coupled to the insertion tool arm, the base being located outside of a cavity of a gas turbine engine, the base having at least two degrees of freedom; and a controller operably coupled to the first position sensor and the base, the controller being configured to: receiving first data from the first position sensor, the first data indicating a position of the insertion tool arm within the cavity of the gas turbine engine; and The insertion tool arm is moved in at least two degrees of freedom via the base based at least in part on the first data to avoid collision between the insertion tool arm and components defining the cavity by maintaining a clearance between the insertion tool arm and one or more components defining an access port of the gas turbine engine or one or more components defining the cavity.

2. The system according to claim 1, characterized in that The controller is further configured to: receiving second data indicating a desired position of the insertion tool arm; Wherein the controller is configured to move the insertion tool arm based at least in part on the second data.

3. The system according to claim 1, characterized in that The controller is further configured to: receiving third data indicative of a position of the base relative to the gas turbine engine; Wherein the controller is configured to move the insertion tool arm based at least in part on the third data.

4. The system according to claim 3, characterized in that Wherein the controller is configured to receive the third data from a second position sensor configured to sense data indicative of a position of the pedestal relative to the gas turbine engine.

5. The system according to claim 1, characterized in that The controller is further configured to: At least one of an inspection operation, a maintenance operation, or a repair operation is performed on at least one component defining the cavity using the insertion tool arm.

6. The system according to claim 1, characterized in that Wherein the controller is configured to move the insertion tool arm by moving at least one of a plurality of components of the base, the plurality of components being pivotably coupled to each other about respective pivot points.

7. The system according to claim 1, characterized in that Wherein the controller is configured to move the insertion tool arm by rotating at least one of the plurality of components of the base via at least one pivot point coupling the plurality of components to one another.

8. The system according to claim 1, characterized in that Wherein the controller is configured to move the insertion tool arm by translating at least one of the plurality of members of the base via one or more motors operable with the plurality of members.

9. The system according to claim 1, characterized in that Wherein the controller is configured to move the insertion tool arm by pivoting the insertion tool arm at the access port to maintain the gap with the component.

10. The system according to claim 1, characterized in that The base includes a plurality of members pivotably coupled to one another about respective pivot points, at least one of the plurality of members being allowed to rotate about its length.

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