Method and apparatus for servicing engine

Abstract

The snake arm robot and the service device are mechanically coupled. The mechanical coupling is accomplished by longitudinally inserting the snake-arm robot into the maintenance device or longitudinally inserting the maintenance device into the snake-arm robot. An actuator moves the snake-arm robot through a passage in the engine until the snake-arm robot reaches a desired position. Movement of the snake-arm robot moves the maintenance device through the channel at the same time. Subsequently, the snake-arm robot is disconnected from the service device, and the snake-arm robot is removed from the engine while leaving the service device in place within the engine.

Description

Technical Field

[0001] These teachings generally relate to robotic arm navigation within parts to be inspected, examined, processed, or maintained. Background Art

[0002] A snake-like robotic arm is a longitudinally extended mechanical device with a large number of degrees of freedom (referred to herein as a "snake arm robot"), which can be inserted into various environments for inspection, maintenance, or repair purposes. These arms typically include a large number of controlled joints coupled to a camera or other sensor inserted into the part to be inspected.

[0003] For example, a snake-like robotic arm can be inserted into an engine to inspect the internal components of the engine. The large number of degrees of freedom of these devices allows them to be inserted into the cluttered, restricted, and / or otherwise inaccessible or difficult-to-access parts of the engine. The images and other information obtained by the camera can be analyzed to detect signs of damage, wear, or other problems, and repair and maintenance activities can extend the serviceable or useful life of the part. Brief Description of the Drawings

[0004] By providing methods and apparatus for inserting a repair device into an engine using a snake arm robot as described in the following detailed description, various needs are at least partially met, particularly when studied in conjunction with the accompanying drawings. The complete and enabling disclosure of aspects of this description for those of ordinary skill in the art, including its best mode, is set forth in the specification with reference to the accompanying drawings, in which:

[0005] Figure 1 Diagrams of inspection and / or repair systems constructed in accordance with various embodiments of these teachings;

[0006] Figure 2A Diagrams of a snake arm robot and a repair device constructed in accordance with various embodiments of these teachings;

[0007] Figure 2B Cross-sectional views of an apparatus taken along line 103 constructed in accordance with various embodiments of these teachings Figure 2A ;

[0008] Figure 3A Diagrams of a snake arm robot and a repair device constructed in accordance with various embodiments of these teachings;

[0009] Figure 3B Cross-sectional views of an apparatus taken along line 105 constructed in accordance with various embodiments of these teachings Figure 3A ;

[0010] Figure 4A Diagrams of a snake arm robot constructed in accordance with various embodiments of these teachings;

[0011] Figure 4B Part of a snake-arm robot constructed according to various embodiments of these teachings Figure 4A of the figure;

[0012] Figure 5A Figure of a maintenance device in a relaxed state constructed according to various embodiments of these teachings;

[0013] Figure 5B Figure of a maintenance device in a tensioned state constructed according to various embodiments of these teachings;

[0014] Figure 6A Figure of inserting a snake-arm robot and a maintenance device into an engine constructed according to various embodiments of these teachings;

[0015] Figure 6B Figure of further inserting a snake-arm robot and a maintenance device into an engine constructed according to various embodiments of these teachings;

[0016] Figure 6C Figure of removing a snake-arm robot and a maintenance device into an engine constructed according to various embodiments of these teachings;

[0017] Figure 6D Figure of further removing a snake-arm robot and a maintenance device into an engine constructed according to various embodiments of these teachings;

[0018] Figure 7 Flowchart constructed according to various embodiments of these teachings;

[0019] Figure 8 Figure of an engine constructed according to various embodiments of these teachings; and

[0020] Figure 9A and Figure 9B Cross-sectional view of a further example of the arrangement of a snake-arm robot and a maintenance device constructed according to various embodiments of these teachings.

[0021] The elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the sizes and / or relative positions of some elements in the drawings may be exaggerated relative to other elements to help improve the understanding of the various embodiments of these teachings. In addition, common but well-understood elements that are useful or necessary in commercially viable embodiments are generally not described so as to facilitate a less obstructed view of these different embodiments of these teachings. Certain actions and / or steps may be described or depicted in a particular order of occurrence, but those skilled in the art will understand that in practice such specificity of sequence is not required. Detailed Description

[0022] The method described herein provides the ability to repair internal engine parts using a reusable repair device (e.g., a flexible tube, a borescope, or a rigidizable catheter) carried by a snake-arm robot to a desired destination. Once the snake-arm robot reaches the destination, the snake-arm robot is removed from the engine, leaving the repair device in place at the destination. The method provided allows the repair device to be effectively deployed at many locations within the engine that are inaccessible using some prior methods, and at the same time allows the repair device to be precisely positioned at the destination, thereby allowing tasks to be performed accurately and effectively at the destination.

[0023] A repair device (such as a catheter) is a device that can be used to position a tool (such as a borescope) within an aircraft engine to reach a destination. The catheter can be rigid or flexible. A rigid device may have the advantage of being able to be precisely positioned at some destinations because its shape can be precisely defined. However, these rigid devices may also be limited in their availability for passing through or along complex paths (such as inside an engine, typically reached through a borescope inspection (BSI) port), because their rigidity will prevent some types of movement along these paths. On the other hand, a flexible tube may be easier to deploy along complex paths, but may not be able to achieve precise positioning at the destination due to its flexible shape. Whether rigid or flexible, these devices are generally not reusable and typically require a large number of catheters to enable a series of tasks.

[0024] The method provided herein utilizes a snake-arm robot as a catheter or a guide rod to position repair devices (such as a borescope), flexible catheters, rigidizable catheters, and other devices, to provide controllable programmability and the ability to use these tools more flexibly. In some aspects, the snake-arm robot has a suitable scale and size for positioning flexible devices through a BSI port in an aircraft engine. Other uses are also possible.

[0025] In other aspects, the snake-arm robot is used to position a repair device (such as a flexible tube having end hooks or grasping features (e.g., suction, magnetic, etc.)) in place. The snake-arm robot is removed to enable the use of a processing tool or other device through the attached flexible tube. In this case, the snake-arm robot replaces the function of the previously used J-tube and enables the same flexible device to be deployed to different locations in the same engine and different engines. In other words, the current method provides a reusable device.

[0026] In many of these embodiments, the snake-arm robot and the repair device are mechanically coupled together. The snake-arm robot has a distal end and a proximal end. The proximal end is coupled to an actuator. In some examples disclosed herein, the mechanical coupling is accomplished by longitudinally inserting the snake-arm robot into the repair device or longitudinally inserting the repair device into the snake-arm robot.

[0027] The actuator can be actuated to produce movement of the snake-arm robot through the passage within the engine until the distal end of the snake-arm robot reaches the desired position. The movement of the snake-arm robot effectively moves the maintenance device simultaneously through the passage. This movement occurs until the desired positioning of the maintenance device is obtained at the desired position.

[0028] Subsequently, the snake-arm robot is disconnected from the maintenance device. The snake-arm robot is removed from the engine while leaving the maintenance device in place within the engine.

[0029] The maintenance device can take a variety of different forms. In an example, the maintenance device includes a rigidizable conduit (RGT) presenting a single predetermined shape, an RGT presenting any of a plurality of arbitrary shapes, a borescope, or a flexible conduit. Other examples are possible. In a particular example, the maintenance device includes a rigidizable conduit (RGT), and the RGT is locked in shape at the desired position.

[0030] In other aspects, the engine maintenance equipment is released at the desired position. In an example, the desired position is a blade of an aircraft engine, and the engine maintenance equipment includes a blade rider device. Other examples are possible.

[0031] The positioning of the distal end of the snake-arm robot can be accomplished in a variety of ways. For example, the positioning of the distal end of the snake-arm robot can be adjusted based on feedback received from a sensor. For example, an image from a camera can be used to make manual or automatic adjustments.

[0032] The relative positioning of the snake-arm robot and the maintenance device can also vary. For example, the snake-arm robot is deployed within the maintenance device. Alternatively, the maintenance device is deployed within the snake-arm robot.

[0033] The combination of the snake-arm robot and the maintenance device can enter the engine in a variety of different ways. For example, the snake-arm robot and the maintenance device can enter through an inspection port in the engine.

[0034] The movement of the snake-arm robot can be accomplished in different ways. For example, the snake-arm robot and the maintenance device can be automatically guided to the desired position using a previously generated and previously stored description or recipe, which includes, for example, the shape of the snake-arm robot or the path for guiding the snake-arm robot. In other examples, the maintenance device can be automatically guided to the target position while automatically detecting obstacles and avoiding potential collisions using sensors located at or near the distal end of the snake-arm robot. The maintenance device can provide sensor capabilities for this purpose, or the sensors can be separate devices. In other examples, the snake-arm robot and the maintenance device are manually guided.

[0035] In other embodiments among these embodiments, the system includes a snake-arm robot and a maintenance device. The snake-arm robot has a distal end and a proximal end, and the proximal end is coupled to an actuator. The maintenance device is mechanically coupled to the snake-arm robot. The mechanical coupling is accomplished by longitudinally inserting the snake-arm robot into the maintenance device or longitudinally inserting the maintenance device into the snake-arm robot.

[0036] Actuation of the actuator effectively produces movement of the snake-arm robot through the passage of the engine until the distal end of the snake-arm robot reaches the desired position. The movement of the snake-arm robot effectively moves the maintenance device simultaneously through the passage to the desired orientation at the desired position. Subsequently, the snake-arm robot is decoupled from the maintenance device and removed from the engine while leaving the maintenance device in place within the engine.

[0037] Except as otherwise set forth herein with different specific meanings, the terms and expressions used herein have the ordinary technical meanings given to these terms and expressions by those skilled in the above technical field. Unless specifically indicated otherwise, the word "or" as used herein shall be interpreted with a disjunctive construction rather than a conjunctive construction. Unless otherwise stated herein, terms such as "coupled", "fixed", "attached to", etc. refer to both direct coupling, fixing or attachment and indirect coupling, fixing or attachment through one or more intermediate components or features.

[0038] Unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" include plural references.

[0039] As used throughout this specification and the claims, approximating language is applied to modify any quantitative representation that may permit variation without resulting in a change in the basic function associated therewith. Thus, values modified by terms such as "about", "approximately", and "substantially" are not limited to the specified exact values. In at least some instances, the approximating language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the components and / or systems. For example, the approximating language may refer to within a 10% margin.

[0040] The above and other advantages may become more apparent upon a thorough review and study of the following detailed description.

[0041] Now referring Figure 1 , an example of a system 100 for controlling the movement of a snake-arm robot 102 and a maintenance device 104 is described. The system 100 includes a snake-arm robot 102, a maintenance device 104, an actuator 106, and a controller 108. In Figure 1In [the figure], the snake-arm robot 102 and the maintenance device 104 are shown together, but it should be understood that the snake-arm robot 102 is inserted into the maintenance device 104, or the maintenance device 104 is inserted along the length of the snake-arm robot 102 into the snake-arm robot 102. The snake-arm robot 102 has a proximal (or root) end 112 and a distal end 114. The proximal end 112 is coupled to the actuator 106. The distal end 114 may include a camera, a sensor, or other devices (coupled to the maintenance device 104 or associated with the maintenance device 104, or associated with the engine maintenance equipment 115).

[0042] The actuator 106 and the controller 108 are disposed outside 109 of the engine 110. The actuator 106 may be an electric motor or some other drive mechanism. Other examples are possible.

[0043] The engine 110 includes engine components 107. The engine components 107 may be moving and / or non-moving components of an aircraft engine, such as fan blades, frames, or shafts, to name just a few examples.

[0044] The snake-arm robot 102 is configured to have the ability to longitudinally advance along its own length, enabling it to follow a serpentine path. The advantage of this is that this type of device can be used in situations where access to the work site is severely restricted. However, in addition to longitudinally advancing along the path, the snake-arm robot 102 can also move in other modes, for example, by changing the posture and position of the snake-arm robot 102 without moving the base of the drive arm to move the snake-arm robot 102 along the path. Other movements are possible.

[0045] In some aspects, the control of the snake-arm robot 102 is carried out by a plurality of tendons (such as ropes, or more specifically, wire ropes or cables), each rope being connected at one end of the rope at a point within one of the multiple links of the arm and connected to the actuator 106, which is configured to apply force and displacement at the other end of the rope. The actuator 106 is coupled to these structures and controls the movement of these structures, and thus controls the movement and shape of the snake-arm robot 102. In some aspects, wire rope actuation or Bowden cable actuation is provided to achieve a wave-like motion. The wave-like motion can also be achieved without a cable structure. The wave-like motion can be used while simultaneously advancing or retracting the snake-arm robot 102, such that the wave motion has the effect of causing the snake-arm robot 102 to avoid obstacles. In this way, the body of the snake-arm robot 102 can remain close to the nominal path when advancing or retracting forward. The snake-arm robot 102 may include a tip portion (or working head) adapted to carry sensors (or tools or other inspection elements) for work, inspection, or examination of the passage 113.

[0046] The repair device 104 can take various different forms. In some aspects, the repair device includes a rigidizable catheter (RGT) presenting a single predefined shape, an RGT presenting any of a plurality of arbitrary shapes, an endoscope or a flexible catheter. Other examples of repair devices are possible.

[0047] The RGT device can have individual links connected by wires or cables. Initially, the RGT device can be in a flexible or semi-flexible state. However, when the wires or cables are tightened, the links may come together so that the RGT device presents a certain shape.

[0048] In some aspects, the RGT device can be configured to present only a single shape. The shape is predefined, and the connections between the links are shaped to engage to produce only one result, namely the predefined shape. Some of these devices can employ constant joint friction to maintain the shape and have no actuation to change the stiffness. In certain aspects, these devices can utilize ball and cup structures.

[0049] In other examples, the RGT device is a reinforceable device that can be reinforced in any arbitrary shape. One advantage of this is that the snake-arm robot 102 does not have to overcome the high stiffness of the device in order to change shape.

[0050] The repair device 104 can also be a tube made of a material with electroprogrammable stiffness that is vacuum-extruded together, or a sleeve with electrostatically-attracted beads, or a sleeve with beads inside, to name just a few examples. In these configurations, the snake-arm robot 102 is removed so that the rigidizable tube can be used in a fixed but programmable position. In still other examples, the repair device 104 is a series of stainless-steel cups and spheres that are perforated and rigidized internally at the periphery with cords, which have been used to reinforce the passive adjustable base of the snake-arm robot.

[0051] The repair device 104 can also be a flexible catheter having hooks that enable the use of a flexible endoscope. The methods provided herein offer a controllable, programmable solution for positioning such a catheter (and other catheters) along a path that would otherwise not be achievable.

[0052] The servicing device 104 can be used to position the engine servicing equipment 115. In these respects, the engine servicing equipment 115 is carried by, coupled to, attached to, and / or integrated with the servicing device 104. The engine servicing equipment 115 can be any device for providing specialized maintenance operations within the engine 110 and can include devices such as drills, saws, ablation devices, sanders, cameras, sensors, or grinders, to name just a few examples. The engine servicing equipment 115 can also include mechanisms or structures for securing it to parts of the engine 110. The engine servicing equipment 115 can be detached from the servicing device 104 or remain attached to the servicing device 104. The engine servicing equipment 115 can be a blade rider. A blade rider can be an inspection, maintenance, or repair device that is configured to be inserted into a gas turbine engine through a borescope port, an igniter port, or any other suitable orifice that connects an external space adjacent to the engine to the internal volume of the engine and is further configured to attach to or be attached to a moving part of the gas turbine engine (e.g., attach to or be attached to a compressor blade or a turbine blade) so as to be transported within the gas turbine engine by the rotation of the gas turbine engine rotor for the purpose of performing functions such as inspecting, maintaining, or repairing stationary parts of the gas turbine engine (e.g., vanes, stators, nozzles, shrouds, bushings, housings, or seals). The attachment method can include adhesion, suction, magnetic, electromagnetic, mechanical clamping, or frictional connection, such as by configuring the device to fit tightly between two adjacent blades on the engine rotor or by configuring a balloon or spring to urge a portion of the blade rider into contact with the surface of the moving part to create a reaction force and frictional connection between the blade rider and the engine.

[0053] One such application is now described. In this example, the servicing device 104 carries and / or positions the engine servicing equipment 115 within the primary cavity of the turbine assembly of the engine 110.

[0054] In some respects, the engine servicing equipment 115 is positioned between adjacent blades of the turbine assembly of the engine 110. Additionally, the engine servicing equipment 115 is configured to move through the primary flow path of the turbine assembly. Thus, the engine servicing equipment 115 facilitates the maintenance of the turbine assembly. For example, the engine servicing equipment 115 (when used in conjunction with the snake arm robot 102 and the servicing device 104) facilitates the inspection and repair of the turbine assembly at locations within the primary flow path that are difficult to access from outside the turbine assembly by conventional means (such as using a borescope tool).

[0055] As described above, the engine repair device 115 can be positioned within the primary flow path using the repair apparatus 104. In some embodiments, the repair apparatus 104 is used to position the engine repair device 115 adjacent to a rotating component of the turbine assembly, such as a blade of the turbine assembly, and then the rotating component is used to position the engine repair device 115 relative to a stationary component of the turbine assembly.

[0056] During operation and in certain aspects, the engine repair device 115 enters the turbine assembly through any suitable access port or opening of the turbine assembly. For example, in some embodiments, the engine repair device 115 enters and / or exits the turbine assembly with the combination of the snake-arm robot 102 and the repair apparatus 104 through any of an inlet, an exhaust port, and / or an access port, such as an igniter port, a borescope port, or a fuel nozzle port, or any other port that can provide access by temporarily removing a component of the gas turbine engine. In an exemplary embodiment, the engine repair device 115 is sized and shaped to fit within the turbine assembly and travel through the turbine assembly in parallel, such as through the primary cavity of the turbine assembly. For example, the engine repair device 115 has a height, a length, and a width that are less than the clearance required to fit within the primary flow path. The height, the length, and the width define the volume of the engine repair device 115. In alternative embodiments, the engine repair device 115 is any size and shape capable of operating the engine repair device as described herein.

[0057] During operation, the engine repair device 115 can be used to inspect and / or repair any internal component of the turbine assembly. For example, in some embodiments, the engine repair device 115 is positioned adjacent to a portion of the internal surface of the turbine assembly. The internal surface can be any surface within the primary flow path of the turbine assembly. For example, in some embodiments, the internal surface includes, but is not limited to, the surfaces of blades, stator vanes, and shrouds. In some embodiments, the engine repair device 115 detects the characteristics of the internal surface. For example, in some embodiments, the engine repair device 115 is used to generate an image of the internal surface and inspect the image to determine the condition of the turbine assembly and evaluate whether repair is needed. If repair is needed, in some embodiments, the engine repair device 115 is used to repair the internal surface. For example, in some embodiments, the engine repair device 115 removes and / or replaces damaged portions of the internal surface.

[0058] In some aspects, the snake-arm robot 102 includes a hollow internal portion along its longitudinal length that allows the repair apparatus 104 to be inserted through the snake-arm robot 102. In other examples and as described above, the snake-arm robot 102 can be inserted through the repair apparatus 104.

[0059] The actuator 106 can be a motor or other device that pushes the snake arm robot 102 and also actuates the wire ropes or cables of the snake arm robot 102. In some cases, the snake arm robot 102 is pushed by a person (e.g., initially inserting the snake arm robot 102 into the engine 110).

[0060] In some other examples, the actuator 106 receives instructions that define a target (e.g., a destination within a passageway) for the tip portion of the snake arm robot 102. In these aspects, the controller 108 can be coupled to the user interface 121 to allow an operator to input commands specifying the destination. For example, the user interface 121 can include a joystick. In another example, at the start of an operation, the final destination is unknown and the operator can use the user interface 121 to interactively manipulate the snake arm robot 102 in an exploration mode. Other examples of operator inputs are possible.

[0061] The controller 108 is coupled to the snake arm robot 102. In some aspects, the controller 108 is disposed at or within the actuator 106. It should be understood that, as used herein, the term "controller" generally refers to any microcontroller, computer, or processor-based device having a processor, memory, and programmable input / output peripherals that is typically designed to control the operation of other components and devices. It should also be understood to include common ancillary attachment devices, including memory, transceivers for communicating with other components and devices, etc. These architectural options are well known and understood in the art and need not be further described here. The controller 108 can be configured (e.g., by using corresponding programming stored in memory, as would be well understood by those skilled in the art) to perform one or more of the steps, actions, and / or functions described herein.

[0062] It should be understood that the methods used can be for inserting the snake arm robot 102 and the repair device 104 (and the engine repair equipment 115, if used) into the passageway 113 of the engine 110. Additionally, these methods are for controlling the movement of the snake arm robot 102 out of the passageway 113 while leaving the repair device 104 (and potentially the engine repair equipment 115) in place within the passageway 113.

[0063] The snake arm robot 102 is flexible and is inserted into the passageway 113 (to be inspected, examined, machined, maintained, or milled) within the engine 110 at an insertion point (or opening) 131 in the wall or housing of the engine 110. The snake arm robot 102 has multiple degrees of freedom as it moves through the passageway 113.

[0064] In Figure 1In another example of the operation of the system, the snake-arm robot 102 and the repair device 104 are mechanically coupled together. The mechanical coupling is accomplished by longitudinally inserting the snake-arm robot 102 into the repair device 104 (or inserting the repair device 104 into the snake-arm robot 102 longitudinally). The mechanical coupling involves pressing the surface of the snake-arm robot 102 against the surface of the repair device 104.

[0065] The actuator 106 is actuated to produce movement of the snake-arm robot 102 through the passage within the engine until the distal end of the snake-arm robot 102 reaches the desired position. The movement of the snake-arm robot 102 effectively moves the repair device 104 simultaneously through the passage 113. This movement occurs until the desired positioning of the repair device 104 is obtained at the desired position. During these operations, the engine repair equipment 115 is positioned at the desired position as it has been carried and / or moved together with the repair device 104.

[0066] After insertion into the engine 110, the snake-arm robot 102 is disconnected from the repair device 104. The snake-arm robot 102 is removed from the engine 110 while leaving the repair device 104 (and the engine repair equipment 115) in place within the engine 110. The removal can be accomplished by the actuator 106.

[0067] Now briefly turning to Figure 2A and Figure 2B , an example is shown where the snake-arm robot 102 is inserted inside the repair device 104. Figure 2B A cross-section taken along the line marked 103 is shown. Now briefly turning to Figure 3A and Figure 3B , an example is shown where the repair device 104 is inserted inside the snake-arm robot 102. Figure 3B A cross-section taken along the line marked 105 is shown. Regardless of whether the outermost element is the snake-arm robot 102 or the repair device 104, in some aspects, the central channel extends through and along the center of the outer element. As described above, during the insertion operation into the engine 110, the repair device 104 and the snake-arm robot 102 can be held together by mechanical tension (e.g., friction). In these aspects, the diameter of each of the snake-arm robot 102 and the repair device 104 is selected such that one of these elements can be inserted into the other, and when needed, by applying force, the inner element can be moved through the outer element, but when the inner element is not being moved, the inner element and the outer element remain in place due to the mechanical tension between the surfaces of the inner element and the outer element.

[0068] Briefly turning to Figure 9A and Figure 9B , cross-sections showing other examples of fixing the snake-arm robot 102 and the repair device 104 are shown. AsFigure 9A As shown, a mechanical connection is formed between the snake-arm robot 102 and the maintenance device 104, and the extension 117 of the maintenance device 104 is inserted into the cavity 119 of the snake-arm robot 102. Other suitable attachment mechanisms, such as hooks or latches, can also be used. It should also be understood that Figure 9A the configuration of the components shown in

[0069] can be reversed (e.g., the snake-arm robot 102 can have an extension that first enters the cavity of the maintenance device 104). Figure 9B As shown, the snake-arm robot 102 and the maintenance device 104 can be attached by some non-invasive switchable mechanism 123, such as by magnetic coupling or suction coupling. These two components can be attached or detached by actuating or de-actuating the mechanism (e.g., turning on or off the electromagnet that holds the snake-arm robot 102 and the maintenance device 104). Although the switchable mechanism 123 is shown in both the snake-arm robot 102 and the maintenance device 104, it should be understood that the switchable mechanism 124 can be located in only one of the snake-arm robot 102 and the maintenance device 104.

[0070] Now referring to Figure 4A , a snake-arm robot 102 that can be used with the methods provided herein is described. The actuator 106 can include one or more electric motors. The controller 108 is electrically connected to the actuator 106. In addition, the snake-arm robot 102 extends generally between a proximal (or root) end 112 and a distal end 114.

[0071] The depicted snake-arm robot 102 is generally formed by a plurality of links 116 and a plurality of joints 118, where the plurality of links 116 are arranged in sequence and are movably coupled to each other along a length 146 by the plurality of joints 118.

[0072] Now also referring to Figure 4B , the snake-arm robot 102 is shown in more detail. Figure 4B Shown is Figure 4A a close-up schematic view of an adjacent pair of links 116 (i.e., a front link 116A and a rear link 116B) of the snake-arm robot 102 and the joint 118 of the exemplary snake-arm robot 102. For the depicted embodiment, the joint 118 is configured as a bending joint. More specifically, compared to the link 116, the joint 118 is a section with a greatly reduced cross-sectional area, such that two adjacent links 116 can bend relative to each other at the joint 118. In addition, it should be understood that for the depicted embodiment, the snake-arm robot 102 includes a plurality of control lines 120A and 120B extending therethrough. For illustrative purposes, Figure 4BTwo control lines 120A and 120B (a first control line 120A and a second control line 120B) are depicted, where each of the first and second control lines 120A, 120B terminates at the front link 116A of the depicted pair of links 116. Thus, it should be understood that the first and second control lines 120A, 120B can each be movably positioned within the rear link 116B (e.g., slidable relative to the rear link 116B) and fixedly attached to the front link 116A. More specifically, the first control line 120A includes a first anchor 122A fixed to one side of the front link 116A, and the second control line 120B includes a second anchor 122B fixed to the other side of the front link 116A. However, it should be understood that in other exemplary embodiments, the first and second control lines 120A, 120B can be fixedly attached to the front link 116A in any other suitable manner.

[0073] To bend the front link 116A relative to the rear link 116B, one of the first control line 120A or the second control line 120B can be pulled by, for example, the actuator 106. For example, to Figure 4B bend the front link 116A clockwise in the depicted perspective view, the second control line 120B can be pulled by the actuator 106 while the tension can be released in the first control line 120A. Conversely, to Figure 4B bend the front link 116A counterclockwise in the depicted perspective view, the first control line 120A can be pulled by the actuator 106 while the tension can be released in the second control line 120B.

[0074] It should be understood that although Figure 4B only two control lines 120A, 120B are depicted, in other embodiments, each link 116 can have any other suitable number of control lines terminating at that link 116 for controlling that link 116, or alternatively, some links 116 of the snake-arm robot 102 may not have control lines terminating at that link 116 (e.g., the bending applied by a set of ropes can be distributed among several links 116 and associated joints 118). For example, in some embodiments, each link 116 can include three control lines terminating at that link 116 to provide additional degrees of freedom for that link 116. Additionally, although Figure 4BOnly two lines are shown therein, but a relatively large number of additional control lines may extend through the link 116 to control each link 116 in front of the depicted link 116. By way of example only, if the snake-arm robot 102 includes twenty links 116, and each link 116 includes three control lines terminating at that link 116, the link 116 near the root end 112 of the snake-arm robot 102 may include approximately sixty control lines extending therethrough. Additionally, additional lines may extend therethrough, such as for electrical connections for the engine servicing device 115 and / or for providing working fluid for the engine servicing device 115.

[0075] Now referring Figure 5A , a schematic illustration of an example of the servicing device 104 is shown. In the example, the servicing device 104 is a selectively flexible extension tool that can be used to perform various operations within the engine 110 ( Figure 1 ). Figure 5A An exemplary servicing device 104 in a relaxed position is shown. Figure 5B is an exemplary servicing device 104 in a tensioned position Figure 5A of.

[0076] The servicing device 104 includes a base 152, a wire assembly 154, and a plurality of sequentially arranged links 156. The base 152 generally includes a first plate 158, a second plate 160, and one or more extension guides 162. For the depicted example, the one or more extension guides 162 include a pair of extension guides 162 fixedly coupled to the first plate 158 and extending in the longitudinal direction LW. The second plate 160 of the base 152 includes openings 164 corresponding to the pair of extension guides 162 such that the second plate 160 is slidable along the extension guides 162 in the longitudinal direction LW away from and toward the first plate 158.

[0077] The wire assembly 154 generally includes a root 166 coupled to the second plate 160 of the base 152 and a plurality of wires 168 extending from the root 166. The plurality of wires 168 includes a first wire 168A, and the first wire 168A (and the remaining wires 168 in the illustrated embodiment) can operate with the plurality of sequentially arranged links 156 to move the plurality of sequentially arranged links 156 between a relaxed position ( Figure 5A ) and a tensioned position ( Figure 5B ). When in the relaxed position, the plurality of sequentially arranged links 156 are spaced apart from each other to allow the plurality of sequentially arranged links 156 to pivotally move relative to each other. In contrast, when in the tensioned position, the plurality of sequentially arranged links 156 are pressed against each other to rigidly fix the plurality of sequentially arranged links 156 to each other.

[0078] As described above, for the illustrated embodiment, each of the plurality of lines 168 can operate with a plurality of sequentially arranged links 156 to move the plurality of sequentially arranged links 156 between a relaxed position and a tensioned position. It should be understood that each of these lines 168 can be constructed as a cable, rope, wire, etc. Thus, it should be understood that the lines 168 are generally flexible (i.e., do not prevent the plurality of sequentially arranged links 156 from pivoting relative to each other in the relaxed position).

[0079] In short, for the depicted embodiment, it should be understood that Figure 5A and Figure 5B the servicing device 104 depicted in is a tool member including a tool implement 170 (which can be engine servicing equipment 115) coupled to one of the plurality of links 156. More specifically, the servicing device 104 defines a distal end 172, and the tool implement 170 is coupled to the link 156 at the distal end 172. For the illustrated embodiment, the tool implement 170 includes one or more sensors, cameras, or both, and more specifically, includes a sensor 174. One or more sensors, cameras, or both can be operably coupled to a controller or other device (not shown) via one or more electrical wires extending through the plurality of sequentially arranged links 156. Alternatively, the sensor 174 can be incorporated (along with potentially other devices) within the engine servicing equipment 115, as discussed elsewhere herein.

[0080] Now referring to Figure 6A 、 Figure 6B 、 Figure 6C and Figure 6D an example is described of inserting the combined device of the snake arm robot 102 and the servicing device 104 into the engine 110, positioning the snake arm robot 102 and the servicing device 104 within the engine 110, and then removing the snake arm robot 102 from the engine 110 while leaving the servicing device 104 in place. In this example, the snake arm robot 102 has been inserted inside the servicing device 104. However, if the servicing device 104 is inserted inside the snake arm robot 102, the methods described with reference to Figure 6A 、 Figure 6B 、 Figure 6C and Figure 6D will apply.

[0081] Referring to Figure 6A the combination of the servicing device 104 and the snake arm robot 102 to be inserted into the engine 110 is shown when located outside 109 of the engine 110. The combination of the snake arm robot 102 and the servicing device 104 is inserted into the engine 110 through an insertion point or opening 131. The insertion is performed by moving the combination of the snake arm robot 102 and the servicing device 104 in the direction indicated by the arrow labeled 101.

[0082] Reference Figure 6B , the combination of the snake-arm robot 102 and the servicing device 104 has been inserted into the engine 110 near the engine component 107. Movement stops. At this time, the servicing device 104 has been manually or automatically secured, tensioned, and / or locked into the desired position and / or orientation described elsewhere herein.

[0083] It should be understood that the servicing device 104 can include various tools or other devices that can be used to perform operations within the engine or at or on the engine component 107. For example, the servicing device 104 can include engine servicing equipment 115( Figure 1 ), and the engine servicing equipment 115 includes cameras, drills, saws, and other types of sensors described elsewhere herein.

[0084] Reference Figure 6C , the snake-arm robot 102 begins to be removed from the engine 110. The direction of movement is outward from the engine 110 in the direction indicated by the arrow labeled 101.

[0085] Reference Figure 6D , the snake-arm robot 102 is now completely removed from the engine 110, and the movement continues in the direction indicated by the arrow labeled 101. Eventually, the movement stops. The movement can be performed manually by an actuator (e.g., actuator 106) or a combination of these methods.

[0086] Now referring to Figure 7 , an example of a method for moving a servicing device into an engine is described. At step 702, the snake-arm robot 102 and the servicing device 104 are mechanically coupled together. The proximal end 112 of the snake-arm robot 102 is coupled to the actuator 106. The mechanical coupling is accomplished by longitudinally inserting the snake-arm robot 102 into the servicing device 104 or by longitudinally inserting the servicing device 104 into the snake-arm robot 102. In some aspects, the mechanical coupling is provided by friction between the two parts after one part is inserted into the other. The outer element (whether the snake-arm robot 102 or the servicing device 104) can be held while the other is being inserted. The insertion can be done manually or by an automated method (e.g., using a robot).

[0087] At step 704, the actuator 106 is actuated to cause movement of the snake-arm robot 102 through the passage 113 within the engine 110 until the distal end 114 of the snake-arm robot 102 (and / or the distal end of the servicing device 104) reaches the desired position. The movement of the snake-arm robot 102 effectively moves the servicing device 104 through the passage 113 simultaneously. This movement occurs until the desired orientation of the servicing device 104 is obtained at the desired position.

[0088] After insertion and reaching the destination, at step 706, the snake-arm robot 102 is disconnected from the maintenance device 104. The disconnection can be accomplished by applying a force in a direction opposite to the insertion direction to overcome the mechanical connection that holds the two devices together. At step 708, the snake-arm robot 102 is removed from the engine while leaving the maintenance device in place within the engine.

[0089] Now referring Figure 8 , a schematic cross-sectional view of a conventional gas turbine engine 810 for an aircraft in which the imaging and inspection systems described herein can be operated is depicted. The gas turbine engine 810 has a generally longitudinally extending axis or centerline 812 that extends from a front portion 814 to a rear portion 816. The gas turbine engine 810 includes, in a downstream serial flow relationship: a fan section 818 that includes a fan 820; a compressor section 822 that includes a booster or low-pressure (LP) compressor 824 and a high-pressure (HP) compressor 826; a combustion section 828 that includes a burner 830; a turbine section 832 that includes an HP turbine 834 and an LP turbine 836; and an exhaust section 838.

[0090] The fan section 818 includes a fan casing 840 that surrounds the fan 820. The fan 820 includes a plurality of fan blades 842 radially disposed about the centerline 812.

[0091] The HP compressor 826, the burner 830, and the HP turbine 834 form a core 844 of the gas turbine engine 810 that generates combustion gases. The core 844 is surrounded by a core casing 846 that may be coupled to the fan casing 840.

[0092] An HP shaft or spool 848 coaxially disposed about the centerline 812 of the gas turbine engine 810 drivingly connects the HP turbine 834 to the HP compressor 826. An LP shaft or spool 850 coaxially disposed about the centerline 812 of the gas turbine engine 810 within a larger diameter annular HP spool 848 drivingly connects the LP turbine 836 to the LP compressor 824 and the fan 820.

[0093] The LP compressor 824 and the HP compressor 826 each include a plurality of compressor stages 852, 854, where a set of compressor blades 856, 858 rotate relative to a corresponding set of stationary compressor vanes 860, 862 (also referred to as nozzles) to compress or pressurize the fluid flow through the stage. In a single compressor stage 852, 854, the plurality of compressor blades 856, 858 may be arranged in a ring and extend radially outward from a blade platform to a blade tip relative to the centerline 812, while the corresponding stationary compressor vanes 860, 862 are positioned downstream and adjacent to the rotating blades 856, 858. It is noted that, Figure 8The number of blades, vanes, and compressor stages shown is for illustrative purposes only, and other numbers are possible.

[0094] The HP turbine 834 and the LP turbine 836 each include a plurality of turbine stages 864, 866, where a set of turbine blades 868, 870 rotates relative to a corresponding set of stationary turbine vanes 872, 874 (also known as nozzles) to extract energy from the fluid flow through the stage. In a single turbine stage 864, 866, the plurality of turbine blades 868, 870 can be arranged in a ring and extend radially outward from a blade platform to a blade tip relative to a centerline 812, while the corresponding stationary turbine vanes 872, 874 are positioned upstream and adjacent to the rotating blades 868, 870. It is noted that Figure 8 The number of blades, vanes, and turbine stages shown is for illustrative purposes only, and other numbers are possible.

[0095] In operation, the rotating fan 820 supplies ambient air to the LP compressor 824, and then the LP compressor 824 supplies the pressurized ambient air to the HP compressor 826, which further pressurizes the ambient air. The pressurized air from the HP compressor 826 is mixed with fuel and ignited in the combustor 830, thereby generating combustion gases. The HP turbine 834 extracts some work from these gases, which drives the HP compressor 826. The combustion gases are discharged into the LP turbine 836, which extracts additional work to drive the LP compressor 824, and the exhaust gases are finally discharged from the gas turbine engine 810 via the exhaust section 838. The driving of the LP turbine 836 drives the LP spool 850 to rotate the fan 820 and the LP compressor 824.

[0096] It should be understood that although Figure 8 not depicted, the gas turbine engine 810 can also define a plurality of openings that allow inspection of various components within the gas turbine engine 810. For example, the gas turbine engine 810 can define a plurality of access tool openings at various axial positions within the compressor section, the combustor section 828, and / or the turbine section 832. Additionally, as will be discussed below, the gas turbine engine 810 can include, for example, one or more igniter ports within the combustor section 828 of the gas turbine engine 810, which can allow inspection of the combustor section 828.

[0097] Through these openings, the snake-arm robot 102 can be inserted together with the repair device 104 (and potentially the engine repair equipment 115), as described elsewhere herein. For example, one of these openings can be near the turbine section 832 and allow access to the turbine section 832. The snake-arm robot 102 and the repair device 104 can be positioned near the turbine blades 868, 870. The shape of the repair device 104 can be locked, or the repair device or repair equipment can be attached to parts of the engine, and the snake-arm robot 102 can be removed from the engine 110, as described herein. Then, various operations can be performed using the repair device 104 or a device applied through the repair device 104 (e.g., the engine repair equipment 115). It should also be understood that these methods can be performed at any location where an opening is available in the gas turbine engine 810 (such as in the combustion section 828).

[0098] It should be further understood that Figure 8 the exemplary gas turbine engine 810 depicted is only by way of example, and in other exemplary embodiments, the gas turbine engine 810 can have any other suitable configuration, including for example any other suitable number of shafts or spools, turbines, compressors, etc. Additionally or alternatively, in other exemplary embodiments, any other suitable turbine engine can be inspected using the methods described herein. For example, in other exemplary embodiments, the engine can not be a turbofan engine, but can be configured as a turboshaft engine, a turboprop engine, a turbojet engine, etc., or can be an industrial gas turbine engine for power generation, fluid pumping, etc.

[0099] A further aspect of the invention is provided by the subject matter of the following clauses:

[0100] A method, the method comprising: mechanically coupling a snake-arm robot and a repair device, the snake-arm robot having a distal end and a proximal end, the proximal end coupled to an actuator, the mechanical coupling being accomplished by longitudinally inserting the snake-arm robot into the repair device or longitudinally inserting the repair device into the snake-arm robot; actuating the actuator to cause movement of the snake-arm robot through a passage within an engine until the distal end of the snake-arm robot reaches a desired position, the movement of the snake-arm robot effectively moving the repair device simultaneously through the passage, the movement occurring until a desired positioning of the repair device is obtained at the desired position; after reaching the desired position and the desired positioning, disconnecting the snake-arm robot from the repair device; and removing the snake-arm robot from the engine while leaving the repair device in place within the engine.

[0101] According to any of the methods described in the foregoing clauses, wherein the repair device includes a rigidizable conduit (RGT) presenting a single predetermined shape, an RGT presenting any of a plurality of arbitrary shapes, a borescope, or a flexible conduit.

[0102] According to any of the methods described in the foregoing clauses, wherein the repair device includes a rigidizable conduit (RGT), and wherein the RGT is locked in shape at the desired position.

[0103] According to any of the methods described in the foregoing clauses, further comprising carrying an engine repair device to the desired position by the repair device and releasing the engine repair device at the desired position.

[0104] According to any of the methods described in the foregoing clauses, wherein the repair device is a non-rigid or flexible device, and wherein the repair device or the engine repair device is attached to the engine or engine component at the desired position.

[0105] According to any of the methods described in the foregoing clauses, wherein the positioning of the distal end of the snake-arm robot is adjusted based on feedback received from a sensor.

[0106] According to any of the methods described in the foregoing clauses, wherein the snake-arm robot is inserted into the repair device.

[0107] According to any of the methods described in the foregoing clauses, wherein the repair device is inserted into the snake-arm robot.

[0108] According to any of the methods described in the foregoing clauses, further comprising inserting the snake-arm robot and the repair device through an inspection port in the engine.

[0109] According to any of the methods described in the foregoing clauses, wherein the snake-arm robot and the repair device are automatically guided to the desired position via a controller.

[0110] A system, the system comprising: a snake-arm robot having a distal end and a proximal end, the proximal end being coupled to an actuator; and a repair device mechanically coupled to the snake-arm robot, the mechanical coupling being accomplished by longitudinally inserting the snake-arm robot into the repair device or longitudinally inserting the repair device into the snake-arm robot; wherein actuation of the actuator effectively produces movement of the snake-arm robot through a passage of the engine until the distal end of the snake-arm robot reaches a desired position, the movement of the snake-arm robot effectively moving the repair device simultaneously through the passage to a desired orientation at the desired position; wherein the snake-arm robot is then decoupled from the repair device and removed from the engine while leaving the repair device in place within the engine.

[0111] The system according to any of the preceding clauses, wherein the repair device comprises a rigidizable conduit (RGT) presenting a single predetermined shape, an RGT presenting any of a plurality of arbitrary shapes, a borescope, or a flexible conduit.

[0112] The system according to any of the preceding clauses, wherein the repair device comprises a rigidizable conduit (RGT), and wherein the repair device is locked in shape at the desired position.

[0113] The system according to any of the preceding clauses, further comprising engine repair equipment released at the desired position.

[0114] The system according to any of the preceding clauses, wherein the repair device is a non-rigid or flexible device, and wherein the repair device or the engine repair equipment is configured to be attached to the engine or engine component at the desired position.

[0115] The system according to any of the preceding clauses, further comprising a sensor, and wherein the distal end of the snake-arm robot is adjusted based on feedback received from the sensor.

[0116] The system according to any of the preceding clauses, wherein the snake-arm robot is inserted into the repair device.

[0117] The system according to any of the preceding clauses, wherein the repair device is inserted into the snake-arm robot.

[0118] The system according to any of the preceding clauses, wherein the snake-arm robot and the repair device are configured to be inserted through an inspection port in the engine.

[0119] Any of the systems according to the foregoing clauses further includes a controller configured to automatically guide the snake-arm robot and the repair device to the desired position.

[0120] Those skilled in the art will recognize that various modifications, variations, and combinations can be made to the above embodiments without departing from the scope of the present invention, and such modifications, variations, or combinations should be considered within the scope of the inventive concept of the present invention.

Claims

1. A method, characterized in that, The method includes: Mechanically coupling a snake-arm robot and a repair device, the snake-arm robot having a distal end and a proximal end, the proximal end being coupled to an actuator, the mechanical coupling being accomplished by longitudinally inserting the snake-arm robot into the repair device or longitudinally inserting the repair device into the snake-arm robot; Actuating the actuator to effect movement of the snake-arm robot through a passage within an engine until the distal end of the snake-arm robot reaches a desired position, the movement of the snake-arm robot effectively moving the repair device simultaneously through the passage, the movement occurring until a desired positioning of the repair device is obtained at the desired position; After reaching the desired position and the desired positioning, disconnecting the snake-arm robot from the repair device; and Removing the snake-arm robot from the engine while leaving the repair device in place within the engine.

2. The method according to claim 1, wherein Wherein, The repair device includes a rigidizable conduit (RGT) presenting a single predetermined shape, an RGT presenting any of a plurality of arbitrary shapes, a borescope, or a flexible conduit.

3. The method according to claim 1, wherein Wherein, The repair device includes a rigidizable conduit (RGT), and wherein the RGT is locked in shape at the desired position.

4. The method according to claim 1, wherein Further includes carrying an engine repair device to the desired position by the repair device and releasing the engine repair device at the desired position.

5. The method according to claim 1, characterized in that Wherein, The repair device is a non-rigid or flexible device, and wherein the repair device or the engine repair device is attached to the engine or an engine component at the desired position.

6. The method according to claim 1, wherein Wherein, Adjusting the positioning of the distal end of the snake-arm robot based on feedback received from a sensor.

7. The method according to claim 1, wherein Wherein, The snake-arm robot is inserted into the repair device.

8. The method according to claim 1, characterized in that Wherein, The repair device is inserted into the snake-arm robot.

9. The method according to claim 1, characterized in that, Further includes inserting the snake-arm robot and the repair device through an inspection port in the engine.

10. The method according to claim 1, wherein Wherein, The snake-arm robot and the repair device are automatically guided to the desired position via a controller.

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