Nondestructive testing and residual life prediction method and system for aero-engine

Abstract

The invention discloses an aero-engine nondestructive testing and residual life prediction method and system. According to the method, a nondestructive testing device is used for checking a core engine section of an engine, and damage checking of life-limiting pieces such as a disc, a shaft and blades in the engine is completed under the condition that the engine is not issued, disassembled and decomposed; after the nondestructive testing device inspects and records a damage result, the damage result is matched with damage data in the system, and information such as the size and the shape of the damage is obtained; and then, based on results after checking and matching, residual life prediction of the tested object is carried out through a life prediction tool of the system, and a prediction result is reported to a display device.

Description

Technical Field

[0001] The present invention relates to the field of aero - engines, and particularly to non - destructive testing and remaining life prediction of the engine core section during flight operation. Background Art

[0002] The service life of an aero - engine is greatly affected by important components such as life - limited parts. If the service life of life - limited parts meets expectations, the operational reliability and safety of the engine will be guaranteed, and at the same time, the losses of maintenance and operation costs caused by unplanned engine replacement and return to the factory will be reduced. Therefore, during the use process, if the status and damage degree of life - limited parts in the core section can be predicted in advance through regular / irregular inspections, the inspection results can be used by maintenance personnel and engine engineers to determine whether to continue operation.

[0003] After investigation, during the in - flight maintenance process of current civil aero - engines, the commonly used non - destructive testing method is borescope inspection. Borescope inspection is a commonly used non - destructive testing method, which has the advantages of convenience and portability. However, due to the limitations of the detection probe and detection cable, borescope inspection can only inspect rotor blades and some stators, and the degree of damage and its impact highly depend on the experience and judgment of people.

[0004] Therefore, there is a need for methods and systems that can improve the deficiencies in the prior art. Summary of the Invention

[0005] The present invention content is provided to introduce some concepts in a simplified form that will be further described in the following detailed implementation section. The present invention content is not intended to identify the key features or essential features of the claimed subject matter, nor is it intended to be used to help determine the scope of the claimed subject matter.

[0006] Aiming at the technical problems in the prior art, the present invention provides a method and system for non - destructive inspection and product remaining life prediction of the core section of an engine without removing or disassembling the engine during maintenance. The system in the present invention provides a non - destructive testing device during engine commissioning and operation, timely discovers the damage status of life - limited parts in the engine core section; and based on the identified and located damage results, compares with a large number of engine damage characteristics stored in the damage characteristic database in this system to obtain the damage degree of life - limited parts; at the same time, the present invention provides a function for predicting the remaining life of the product based on the damage / failure of life - limited parts, and submits the remaining life and recommended maintenance and repair plans to the display terminal for maintenance personnel and engine engineers to judge and make decisions. Thus, from the perspective of maintenance support, the present invention improves the use reliability and safety of the engine, can identify problems in advance, solve problems, improves economy, and reduces the economic losses caused by engine replacement and return to the factory due to life - limited part failures.

[0007] Specifically, in an embodiment of the present invention, a method for non-destructive testing and remaining life prediction of an aero-engine is provided, including:

[0008] Using a non-destructive testing device to strike the object to be detected and perform surface imaging on the object to be detected to obtain the vibration feedback signal and surface image signal of the object to be detected;

[0009] Analyzing the surface image signal to determine the damage size and damage morphology characteristics, and using the damage morphology characteristics as retrieval conditions to retrieve the surface damage feature database to obtain surface damage feature information;

[0010] Analyzing the vibration feedback signal to determine the vibration signal characteristic values;

[0011] In the case where the damage size is zero, using the vibration signal characteristic values as retrieval conditions to retrieve the internal damage feature database to obtain internal damage feature information;

[0012] In the case where the damage size is not zero, using the surface damage feature information and the vibration signal characteristic values as retrieval conditions to retrieve the comprehensive damage feature database to obtain the internal damage feature information; and

[0013] According to the matching relationship between the surface damage feature information and the internal damage feature information established in the surface damage feature database, the internal damage feature database, and the comprehensive damage feature database and the failure physics model, calculating the remaining life of the object to be detected at the damage size based on the matched failure physics model.

[0014] In an embodiment of the present invention, the non-destructive testing device includes an image scanning unit and a vibration excitation unit, wherein the image scanning unit includes one or more high-definition micro spherical cameras and one or more micro lighting lamps, and the vibration excitation unit includes a driving mechanism, multiple driving connecting rods, and multiple spherical vibration excitation probes, and wherein:

[0015] The one or more high-definition micro spherical cameras are configured to perform surface imaging on the object to be detected,

[0016] Each of the multiple driving connecting rods is configured to connect one end to the driving mechanism and the other end to one of the multiple spherical vibration excitation probes, and

[0017] Each of the multiple spherical vibration excitation probes is configured to actuate with the corresponding driving connecting rod to strike the object to be detected and receive the vibration feedback signal.

[0018] In an embodiment of the present invention, the surface damage feature database includes damage images and corresponding damage types. The attributes of the damage images include the damage size and the damage morphology features for easy identification and comparison, and the damage types include pits, notches, chips, surface spalling, cracks, wear, deformation, and fracture. And the surface damage feature information includes the damage size and the damage type.

[0019] In an embodiment of the present invention, the internal damage feature database includes the vibration signal characteristic values of various detected objects with internal damage, as well as the corresponding damage positions and damage degrees, and the internal damage feature information includes the damage position and the damage degree.

[0020] In the above embodiment of the present invention, the method further includes reconstructing an internal damage image according to the damage position and the damage degree of the detected object.

[0021] In an embodiment of the present invention, the comprehensive damage feature database includes the vibration signal characteristic values of various detected objects with damage both on the surface and inside, as well as the corresponding damage positions and damage degrees.

[0022] In an embodiment of the present invention, the failure physics model includes a stress-strength interference model and a degradation model.

[0023] In an embodiment of the present invention, calculating the remaining life of the detected object under the damage size further includes calculating the remaining life based on the life model using the bathtub curve and giving a life prediction curve. The life model is a function of various factors, and the factors include the surface damage feature information, the internal damage feature information, the environment, and the load.

[0024] In another embodiment of the present invention, a system for non-destructive testing and remaining life prediction of an aero-engine is provided, including:

[0025] A non-destructive testing device configured to tap the detected object and perform surface imaging on the detected object to obtain the vibration feedback signal and the surface image signal of the detected object;

[0026] A damage analysis device configured to:

[0027] Analyze the surface image signal to determine the damage size and the damage morphology features, and retrieve the surface damage feature database with the damage morphology features as the retrieval condition to obtain the surface damage feature information;

[0028] Analyze the vibration feedback signal to determine the vibration signal characteristic values;

[0029] When the damage size is zero, retrieve the internal damage feature database using the eigenvalue of the vibration signal as the retrieval condition to obtain internal damage feature information;

[0030] When the damage size is not zero, retrieve the comprehensive damage feature database using the surface damage feature information and the eigenvalue of the vibration signal as the retrieval condition to obtain the internal damage feature information; and

[0031] A life prediction device configured to calculate the remaining life of the object under test at the damage size based on the matching relationship between the surface damage feature information and the internal damage feature information established in the surface damage feature database, the internal damage feature database, and the comprehensive damage feature database and the failure physics model, and based on the matching failure physics model.

[0032] In an embodiment of the present invention, the damage analysis device is further configured to reconstruct an internal damage image based on the damage position and the damage degree of the object under test.

[0033] In an embodiment of the present invention, the life prediction device is further configured to calculate the remaining life of the object under test at the damage size by the following operations: calculating the remaining life using the bathtub curve based on a life model, and giving a life prediction curve, where the life model is a function of various factors, including the surface damage feature information, internal damage feature information, environment, and load.

[0034] After reading the following detailed description of specific exemplary embodiments of the present invention in conjunction with the accompanying drawings, other aspects, features, and embodiments of the present invention will be apparent to those of ordinary skill in the art. Although the features of the present invention may be discussed below with respect to certain embodiments and drawings, all embodiments of the present invention may include one or more of the advantageous features discussed herein. In other words, although one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used in accordance with the various embodiments of the present invention discussed herein. In a similar manner, although the exemplary embodiments may be discussed below as device, system, or method embodiments, it should be understood that such exemplary embodiments may be implemented in various devices, systems, and methods. Description of the Drawings

[0035] To understand in detail the manner in which the features described above of the present disclosure are used, the above briefly summarized content may be described in more detail with reference to the various aspects, some of which are illustrated in the drawings. However, it should be noted that the drawings only illustrate certain typical aspects of the present disclosure and should not be considered to limit its scope, as the description may allow other equally effective aspects.

[0036] Figure 1Shows a schematic block diagram of a system for non-destructive testing and remaining life prediction of an aero-engine according to an embodiment of the present disclosure.

[0037] Figure 2 Shows a schematic diagram of a non-destructive testing device according to an embodiment of the present disclosure.

[0038] Figure 3 Shows a flowchart of a method for non-destructive testing and remaining life prediction of an aero-engine according to an embodiment of the present disclosure. Detailed implementation manners

[0039] The following will describe each embodiment in more detail with reference to the accompanying drawings that form a part of the present invention and show various specific exemplary embodiments. However, each embodiment can be implemented in many different forms and should not be construed as limiting the embodiments set forth herein; on the contrary, these embodiments are provided so that the present disclosure will be thorough and complete, and the scope of these embodiments will be fully conveyed to those of ordinary skill in the art. Each embodiment can be implemented according to a method, a system or a device. Therefore, these embodiments can adopt a hardware implementation form, a full software implementation form or a form combining software and hardware aspects. Therefore, the following detailed implementation manners are not restrictive.

[0040] The steps in each flowchart can be executed by hardware (e.g., a processor, an engine, a memory, a circuit), software (e.g., an operating system, an application, a driver, machine / processor executable instructions) or a combination thereof. As those of ordinary skill in the art will understand, the methods involved in each embodiment may include more or fewer steps than those shown.

[0041] Aiming at the defects in the prior art, the present invention discloses a method for non-destructive testing and remaining life prediction of an aero-engine. First, a non-destructive testing device is used to obtain the surface image and vibration feedback signal of the object to be detected (such as the aero-engine core engine route), and the surface damage feature database, the internal damage feature database and the comprehensive damage feature database are retrieved based on the surface image and vibration feedback signal to obtain the surface damage feature information and the internal damage feature information. Subsequently, the remaining life of the object to be detected under the current damage size is estimated according to the obtained surface damage feature information and internal damage feature information and the matched failure physics model, and a life prediction curve is given.

[0042] The following will describe various aspects of the present disclosure in more detail and more comprehensively through block diagrams and method flowcharts.

[0043] Figure 1 Shows a schematic block diagram of a system 100 for non-destructive testing and remaining life prediction of an aero-engine according to an embodiment of the present disclosure.

[0044] As Figure 1 shown, system 100 includes a non-destructive testing device 102, a damage analysis device 104, and a life prediction device 106. These devices will be described in detail below.

[0045] In one embodiment of the present invention, the non-destructive testing device 102 may be configured to strike the object to be detected and perform surface imaging on the object to be detected to obtain a vibration feedback signal and a surface image signal of the object to be detected. In this embodiment, the non-destructive testing device 102 may include an image scanning unit and a vibration excitation unit. The image scanning unit may include one or more high-definition micro spherical cameras and one or more micro lighting lamps, and the one or more high-definition micro spherical cameras are configured to perform surface imaging on the object to be detected. The vibration excitation unit may include a driving mechanism, a plurality of driving link rods, and a plurality of spherical vibration excitation probes. Each of the plurality of driving link rods may be configured to connect one end to the driving mechanism and the other end to one of the plurality of spherical vibration excitation probes, and each of the plurality of spherical vibration excitation probes may be configured to actuate with the corresponding driving link rod to strike the object to be detected and receive a vibration feedback signal. More details about the non-destructive testing device 102 will be described below in conjunction with Figure 2 a more detailed description of the non-destructive testing device 102.

[0046] In one embodiment of the present invention, the damage analysis device 104 may be configured to analyze the surface image signal to determine the damage size and damage morphology characteristics and retrieve the surface damage feature database with the damage morphology characteristics as the retrieval condition to obtain surface damage feature information.

[0047] In this embodiment, the damage analysis device 104 may receive and store the vibration feedback signal, the surface image signal, and the detection result signal from the non-destructive testing device 102, and the damage analysis device 104 may be an external independent device and may communicate with the non-destructive testing device 102 by means of wireless communication. In other embodiments of the present invention, the damage analysis device 104 may communicate with the non-destructive testing device 102 by any other suitable means, not limited to the wireless communication means.

[0048] In an embodiment of the present invention, the surface damage feature database may be included in the damage analysis device 104, or in other embodiments, it may be deployed outside the damage analysis device 104. In an embodiment of the present invention, the surface damage feature database may include a large number of damage images and corresponding damage types. The attributes of these damage images may include damage size and damage morphology features for easy identification and comparison. That is, when retrieving the surface damage feature database with the damage morphology features in the surface image signal obtained by the non-destructive testing device 102 as the retrieval condition, the corresponding damage images in the database can be retrieved, and based on the association relationship between the retrieved damage images and the corresponding damage types, the damage type corresponding to the obtained damage morphology features can be determined, and the damage types include pits, notches, chips, surface spalling, cracks, wear, deformation, and fracture. In the above embodiment, the surface damage feature information may include damage size and damage type.

[0049] In an embodiment of the present invention, the damage images in the surface damage feature database may be classified according to the detected objects as disks, shafts, and blades, and the damage images and corresponding damage types in the surface damage feature database, as well as the failure physics models matching the damage types described below, may mainly come from maintenance data and test data. These data are collected and entered into the database, and at the same time, means such as simulation and interpolation can be used to supplement the surface damage feature database.

[0050] In an embodiment of the present invention, the damage analysis device 104 may also be configured to analyze the vibration feedback signal to determine the vibration signal characteristic value, and in the case where the damage size is zero, retrieve the internal damage feature database with the vibration signal characteristic value as the retrieval condition to obtain the internal damage feature information.

[0051] In this embodiment, the internal damage feature database includes the vibration signal characteristic values of various detected objects with internal damage, as well as the corresponding damage positions and damage degrees, that is, generally reflected as the association relationship between the damage position, degree, and amplitude under specific excitation. The vibration signal characteristic value may be the vibration signal characteristic value of different internal damage positions and sizes in the detected object under specific vibration excitation. When retrieving the internal damage feature database with the vibration signal characteristic value as the retrieval condition, the damage position and damage degree can be determined based on the association relationship between the vibration signal characteristic value and the damage position and damage degree, and the internal damage feature information includes the damage position and the damage degree.

[0052] In an embodiment of the present invention, the vibration data in the internal damage feature database can be classified according to the detected objects into disks, shafts, and blades. The manifestation of internal damage is usually cracks. The vibration signal feature values, the corresponding damage positions and degrees of damage in the internal damage feature database, and the physics-of-failure models matching the damage positions and degrees of damage described below can be mainly sourced from maintenance data and test data, collected and entered into the database. Meanwhile, means such as simulation and interpolation can be used to supplement the internal damage feature database.

[0053] In an embodiment of the present invention, the damage analysis device 104 can also be configured to retrieve the comprehensive damage feature database using the surface damage feature information and the vibration signal feature values as retrieval conditions when the damage size is non-zero to obtain the internal damage feature information. In an embodiment of the present invention, the comprehensive damage feature database can include the vibration signal feature values of various detected objects with damage on both the surface and inside, as well as the corresponding damage positions and degrees of damage, that is, generally manifested as the correlation between the damage position, degree, and the amplitude under a specific excitation. In other words, when the damage size is non-zero, that is, when there is surface damage, the damage analysis device 104 uses the damage type, damage size on the surface, and the vibration signal feature values as retrieval conditions to retrieve the comprehensive damage feature database to match and obtain the internal damage position and degree of damage.

[0054] In an embodiment of the present invention, the vibration signal feature values, the corresponding damage positions and degrees of damage in the comprehensive damage feature database, and the physics-of-failure models matching the damage positions and degrees of damage described below can be mainly sourced from maintenance data and test data, collected and entered into the database. Meanwhile, means such as simulation and interpolation can be used to supplement the comprehensive damage feature database.

[0055] In another embodiment of the present invention, the damage analysis device 104 can be further configured to reconstruct the internal damage image according to the damage position and degree of damage of the detected object. In other embodiments, the damage analysis device 104 can be further configured to send the reconstructed damage image, damage type, damage size, damage position, and degree of damage to the corresponding display device to provide interactive information for maintenance personnel.

[0056] In one embodiment of the present invention, the life prediction device 106 may be configured to calculate the remaining life of the object under test at the current damage size based on the matching relationships between the surface damage feature information and the internal damage feature information established in the surface damage feature database, the internal damage feature database, and the comprehensive damage feature database, and the physics-of-failure model. That is, the matching physics-of-failure model can be retrieved based on the relationships between the damage feature information (surface damage feature information and internal damage feature information) established in each damage feature database based on various observed failure phenomena (surface damage features and internal damage features) and the physics-of-failure model, and the matching physics-of-failure model can be used to complete the calculation of the remaining life and life prediction of the object under test with the current damage (damage size) as the initial defect.

[0057] In this embodiment, the physics-of-failure model may include a stress-strength interference model and a degradation model. In the stress-strength interference model, according to reliability mathematical theory, the product failure probability can be regarded as a conditional probability based on stress (considering the structural stress and strength as independent random variables, and then defining the structural reliability as the probability that the strength is greater than the stress), and its probability failure model based on stress can be derived. In the degradation model, one of the performance parameters of the product can be converted into a function of factors such as load and material, and when this parameter degrades beyond its limit value, the product fails. As those skilled in the art can understand, those skilled in the art can set the stress-strength interference model and the degradation model according to their own needs, and other suitable physics-of-failure models other than the stress-strength interference model and the degradation model can also be used.

[0058] In one embodiment of the present invention, the life prediction device 106 may be further configured to calculate the remaining life of the object under test at the current damage size through the following operations: calculate this remaining life based on the life model using the bathtub curve and give a life prediction curve. In this embodiment, the life model can be a function of various factors, and these factors may include the surface damage feature information (damage type, damage size), internal damage feature information (damage location, damage degree), environment, and load. In other embodiments of the present invention, the life prediction device 106 may also be configured to give the current maintenance advice and the next inspection time. As those skilled in the art can understand, any other suitable calculation model can be used to estimate the remaining life in other embodiments of the present invention.

[0059] Figure 2 FIG. shows a schematic diagram of a non-destructive testing device according to an embodiment of the present disclosure.

[0060] As Figure 2As shown, in one embodiment of the present invention, the non-destructive testing device may include a scanning system (2-1), a power supply system (2-2), a signal processing system (2-3), and a transmission system (2-4). The scanning system (2-1) may include the above-mentioned two detection units, namely an image scanning unit (2-1-1) and a vibration excitation unit (2-1-2). The image scanning unit may include an optical high-definition micro-spherical camera (2-1-1-1) and a micro-illuminating lamp (2-1-1-2). The high-definition micro-spherical camera is responsible for imaging the surface of the object to be detected and saving the image signal to the signal processing system (2-3); the micro-illuminating lamp is responsible for providing ambient lighting when the camera is working.

[0061] The vibration excitation unit (2-1-2) may include a driving mechanism (2-1-2-1), a driving connecting rod (2-1-2-2), and a spherical vibration excitation probe (2-1-2-3). The driving mechanism is powered by a motor to drive the corresponding driving connecting rod to complete radial actuation; one end of the driving connecting rod is connected to the driving mechanism, and the other end is connected to the spherical vibration excitation probe; the vibration excitation probe actuates with the actuating connecting rod to strike the object to be detected. After the object to be detected vibrates due to the strike, it will feedback a vibration signal, which is received by the spherical excitation probe and then transmitted back and saved to the signal processing system (2-3).

[0062] The power supply system (2-2) can provide power and voltage signals for the scanning system (2-1), the signal processing system (2-3), and the transmission system (2-4), including the optical high-definition micro-spherical camera, the micro-illuminating lamp, the driving mechanism, the spherical vibration excitation probe, etc.

[0063] The signal processing system (2-3) may include a signal storage unit, a signal transmitting unit, and a signal receiving unit. The signal storage unit is divided into a control instruction storage sub-unit and a detection result storage sub-unit. The main function of the control instruction storage sub-unit may be to store the program files and instructions for the operation of the non-destructive testing device, so as to enable the device to complete the scanning detection according to the established walking route; the main function of the detection result storage sub-unit may be to store the non-destructive testing results, including image signals and vibration signals, for a short time.

[0064] The signal transmitting unit may be divided into a control instruction transmitting sub-unit and a detection result transmitting sub-unit. The control instruction is sent to each unit of the scanning system via the control instruction transmitting sub-unit to complete various actuations; the detection result transmitting sub-unit can send the image signal and the vibration signal to the data analysis device. The signal receiving unit may be divided into a control instruction receiving sub-unit and a detection result receiving sub-unit. The main function of the control instruction receiving sub-unit may be to receive the control instruction program compiled by the data analysis device; the main function of the detection result receiving sub-unit may be to receive the detection results transmitted by the scanning system.

[0065] The transmission system (2-4) may include a driving motor (2-1-2-1), a transmission inner ring (2-4-1), and a transmission outer ring (2-4-2). The driving motor drives the transmission inner ring to rotate, and the transmission inner ring drives the transmission outer ring to move on the surface of the object to be detected through gear meshing. The material of the transmission outer ring is a special adsorption material that can adsorb to the surface of the object to be detected.

[0066] As can be understood by those skilled in the art, any other suitable non-destructive testing device can also be used to obtain the surface image signal and vibration feedback signal of the object to be detected, without being limited to using the above non-destructive testing device.

[0067] Figure 3 The flowchart of a method 300 for non-destructive testing and remaining life prediction of an aero-engine according to an embodiment of the present disclosure is shown.

[0068] As Figure 3 shown, the method 300 starts at step 302, using a non-destructive testing device to strike the object to be detected and perform surface imaging on the object to be detected to obtain the vibration feedback signal and surface image signal of the object to be detected. In an embodiment of the present invention, the non-destructive testing device includes an image scanning unit and a vibration excitation unit, wherein the image scanning unit includes one or more high-definition micro spherical cameras and one or more micro lighting lamps, and the vibration excitation unit includes a driving mechanism, multiple driving link rods, and multiple spherical vibration excitation probes, and wherein each of the one or more high-definition micro spherical cameras is configured to perform surface imaging on the object to be detected, each of the multiple driving link rods is configured to connect one end to the driving mechanism and the other end to one of the multiple spherical vibration excitation probes, and each of the multiple spherical vibration excitation probes is configured to actuate with the corresponding driving link rod to strike the object to be detected and receive the vibration feedback signal.

[0069] Subsequently, the method 300 proceeds to step 304, parsing the surface image signal to determine the damage size and damage morphology characteristics and retrieving the surface damage feature database with the damage morphology characteristics as the retrieval condition to obtain the surface damage feature information. In an embodiment of the present invention, the surface damage feature database includes damage images and corresponding damage types, the attributes of the damage images include the damage size and the damage morphology characteristics for easy identification and comparison, and the damage types include pits, notches, chips, surface spalling, cracks, wear, deformation, and fracture, and wherein the surface damage feature information includes the damage size and the damage type.

[0070] Next, the method 300 proceeds to step 306, parsing the vibration feedback signal to determine the vibration signal characteristic value.

[0071] Next, method 300 proceeds to step 308, where, in the case where the damage size is zero, the vibration signal eigenvalue is used as a retrieval condition to retrieve the internal damage feature database to obtain internal damage feature information. In one embodiment of the present invention, the internal damage feature database includes vibration signal eigenvalues of various detected objects with internal damage, as well as corresponding damage locations and degrees of damage, and the internal damage feature information includes the damage location and the degree of damage.

[0072] Then, method 300 proceeds to step 310, where, in the case where the damage size is not zero, the surface damage feature information and the vibration signal eigenvalue are used as retrieval conditions to retrieve the comprehensive damage feature database to obtain the internal damage feature information. In one embodiment of the present invention, the comprehensive damage feature database includes vibration signal eigenvalues of various detected objects with both surface and internal damage, as well as corresponding damage locations and degrees of damage.

[0073] Finally, method 300 proceeds to step 312. According to the matching relationship between the surface damage feature information and the internal damage feature information established in the surface damage feature database, the internal damage feature database, and the comprehensive damage feature database and the failure physics model, the remaining life of the detected object at the damage size is calculated based on the matched failure physics model. In one embodiment of the present invention, the failure physics model includes a stress-strength interference model and a degradation model, and calculating the remaining life of the detected object at the damage size may further include calculating the remaining life and giving a life prediction curve based on the life model using the bathtub curve. The life model is a function of various factors, and the factors include the surface damage feature information, internal damage feature information, environment, and load.

[0074] In summary, the present invention provides a non-destructive testing and life prediction method for an aero-engine, which supports non-destructive flaw detection of important life-limiting components in the core engine section of the engine without removing or disassembling the engine, timely discovers faults, avoids more serious economic losses, and also establishes a massive damage feature database. After a damage is discovered in the non-destructive testing stage, the damage database in the system is matched, and the damage information can be more accurately determined and the remaining life prediction can be given.

[0075] The embodiments of the present invention have been described above with reference to the block diagrams and / or operational descriptions of methods, systems, and computer program products according to the embodiments of the present invention. The functions / actions noted in the blocks may occur in an order different from that shown in any flowchart. For example, depending on the functions / actions involved, two consecutive blocks shown may actually be executed substantially simultaneously, or these blocks may sometimes be executed in the reverse order.

[0076] As described above, it is only the preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. A method for non-destructive testing and remaining life prediction of an aero-engine, comprising: using a non-destructive testing device to strike a detected object and perform surface imaging on the detected object to obtain a vibration feedback signal and a surface image signal of the detected object; analyzing the surface image signal to determine the damage size and damage morphology characteristics and retrieving a surface damage feature database with the damage morphology characteristics as retrieval conditions to obtain surface damage feature information; analyzing the vibration feedback signal to determine vibration signal characteristic values; when the damage size is zero, retrieving an internal damage feature database with the vibration signal characteristic values as retrieval conditions to obtain internal damage feature information; when the damage size is not zero, retrieving an internal damage feature database with the surface damage feature information and the vibration signal characteristic values as retrieval conditions to obtain the internal damage feature information; and based on the matching relationship between the surface damage feature information and the internal damage feature information and the failure physics model established in the surface damage feature database, the internal damage feature database, and the comprehensive damage feature database, calculating the remaining life of the detected object at the damage size based on the matched failure physics model.

2. The method according to claim 1, wherein the non-destructive testing device comprises an image scanning unit and a vibration excitation unit, the image scanning unit comprises one or more high-definition micro-spherical cameras and one or more micro-illuminators, the vibration excitation unit comprises a driving mechanism, a plurality of driving connecting rods, and a plurality of spherical vibration excitation probes, and wherein: the one or more high-definition micro-spherical cameras are configured to perform surface imaging on the detected object, each of the plurality of driving connecting rods is configured to connect one end to the driving mechanism and the other end to one of the plurality of spherical vibration excitation probes, and each of the plurality of spherical vibration excitation probes is configured to actuate with the corresponding driving connecting rod to strike the detected object and receive the vibration feedback signal.

3. The method according to claim 1, wherein the surface damage feature database comprises damage images and corresponding damage types, the attributes of the damage images include the damage size and the damage morphology characteristics for easy identification and comparison, and the damage types include pits, notches, chunks, surface spalling, cracks, wear, deformation, fractures, and wherein the surface damage feature information comprises the damage size and the damage type.

4. The method according to claim 1, wherein the internal damage feature database comprises vibration signal characteristic values of various detected objects with internal damage and corresponding damage positions and damage degrees, and the internal damage feature information comprises the damage position and the damage degree.

5. The method according to claim 1, wherein the comprehensive damage feature database comprises vibration signal characteristic values of various detected objects with both surface and internal damage and corresponding damage positions and damage degrees.

6. The method according to claim 1, wherein the failure physics model comprises a stress strength interference model and a degradation model.

7. The method according to claim 1, wherein calculating the remaining life of the detected object under the damage size further comprises: calculating the remaining life and giving a life prediction curve by using a bathtub curve based on a life model, the life model being a function of various factors, the factors including the surface damage characteristic information, internal damage characteristic information, environment, and load.

8. A system for non-destructive testing and remaining life prediction of an aeroengine, comprising: a non-destructive testing device configured to strike the detected object and perform surface imaging on the detected object to obtain a vibration feedback signal and a surface image signal of the detected object; a damage analysis device configured to: analyze the surface image signal to determine the damage size and damage morphology characteristics and retrieve a surface damage characteristic database with the damage morphology characteristics as a retrieval condition to obtain surface damage characteristic information; analyze the vibration feedback signal to determine vibration signal characteristic values; retrieve an internal damage characteristic database with the vibration signal characteristic values as a retrieval condition to obtain internal damage characteristic information when the damage size is zero; retrieve an internal damage characteristic database with the surface damage characteristic information and the vibration signal characteristic values as a retrieval condition to obtain the internal damage characteristic information when the damage size is not zero; and a life prediction device configured to calculate the remaining life of the detected object under the damage size based on a matching relationship established between the surface damage characteristic information and the internal damage characteristic information and a failure physics model in the surface damage characteristic database, the internal damage characteristic database, and the comprehensive damage characteristic database, and based on the matching failure physics model.

9. The system according to claim 8, wherein the damage analysis device is further configured to reconstruct an internal damage image according to the damage position and the damage degree of the detected object.

10. The system according to claim 8, wherein the life prediction device is further configured to calculate the remaining life of the detected object under the damage size by the following operations: calculating the remaining life and giving a life prediction curve by using a bathtub curve based on a life model, the life model being a function of various factors, the factors including the surface damage characteristic information, internal damage characteristic information, environment, and load.

Images