Extension tool

Abstract

An extension tool includes a base link including a proximal end, wherein the base link includes a first bend. The extension tool includes a transition section coupled to the base link and including a second bend and a plurality of sequentially arranged links coupled to the transition section and movable relative to each other and including a third bend. The extension tool includes a support member including a distal end, the support member including a wheel disposed at the distal end, where the support member includes a fourth bend. A first bend of the base link extends in a first direction with respect to the longitudinal centerline, while a second bend and a fourth bend extend substantially along the longitudinal centerline in a second direction, curved downward, and a third bend of the plurality of sequentially arranged links extends in a third direction with respect to the longitudinal centerline, curved upward.

Description

Technical Field

[0001] These teachings generally relate to tools for inspecting an environment and / or performing maintenance, cleaning, or other operations within an environment. Background Art

[0002] Robotic arm assemblies are useful in various industries for performing operations in remote locations, hazardous locations, and the like. At least some robot arm assemblies include a robot arm formed from a plurality of links joined together at corresponding joints. In addition, a plurality of control wires may extend through the robot arm, wherein each wire terminates at a separate link for moving such link relative to a rearwardly adjacent link. The control wires may be coupled to one or more motors within a base of the robot arm assembly, such that the robot arm assembly can control movement of the robot arm by increasing and / or decreasing tension on the plurality of control wires.

[0003] In this way, robotic arms can be used to reach locations beyond line of sight in a variety of environments. However, for some applications, robotic arms can often be cost-prohibitive and / or more complex than necessary. Therefore, a tool that can allow users to reach remote locations in an environment in a more cost-effective manner would be useful. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Various needs are at least partially satisfied by providing the extended tools described in the following detailed description, particularly when studied in conjunction with the accompanying drawings. A full and enabling disclosure of the various aspects of the present disclosure, including the best mode thereof, is set forth in the description with reference to the accompanying drawings, wherein:

[0005] Figure 1 includes a top plan view of an extension tool according to various embodiments of these teachings;

[0006] Figure 2 includes perspective views of extension tools according to various embodiments of these teachings;

[0007] Figure 3 includes side views of extension tools according to various embodiments of these teachings;

[0008] Figure 4 includes a bottom view of an extension tool according to various embodiments of these teachings;

[0009] Figure 5 includes a rear view of an extension tool according to various embodiments of these teachings;

[0010] Figure 6 a perspective view of a connecting rod including an extension tool according to various embodiments of these teachings;

[0011] Figure 7a perspective view of a portion of a connecting rod including an extension tool according to various embodiments of these teachings;

[0012] Figure 8 a perspective view of a connecting rod including an extension tool according to various embodiments of these teachings;

[0013] Figure 9 a top perspective view of a support member including an extension tool according to various embodiments of these teachings;

[0014] Figure 10 a bottom perspective view of a support member including an extension tool according to various embodiments of these teachings;

[0015] Figure 11 a top view of a support member including an extension tool according to various embodiments of these teachings;

[0016] Figure 12 including schematic diagrams of a gas turbine engine and extension tool according to various embodiments of these teachings;

[0017] Figure 13 a perspective view of a portion of a connecting rod including an extension tool according to various embodiments of these teachings;

[0018] Figure 14 a perspective view of a connecting rod including an extension tool according to various embodiments of these teachings;

[0019] Figure 15 a perspective view of a connecting rod including an extension tool according to various embodiments of these teachings;

[0020] Figure 16 including a flow chart of a method of inserting an extension tool according to various embodiments of these teachings; and

[0021] Figure 17 A top perspective view of a support member including an extension tool according to various embodiments of these teachings.

[0022] The elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative position of some elements in the drawings may be exaggerated relative to other elements to help improve understanding of the various embodiments of the present teachings. In addition, common but well-understood elements that are useful or necessary in commercially feasible embodiments are generally not described to facilitate less obstructed observation of these different embodiments of the present teachings. Certain actions and / or steps may be described or depicted in a specific order of occurrence, but those skilled in the art will understand that such specificity regarding sequence is not actually required. DETAILED DESCRIPTION

[0023] Generally speaking, various aspects of the present disclosure relate to selectively flexible extension tools. More specifically, the present subject matter relates to extension tools having one or more features for facilitating insertion of the extension tool into a component and / or one or more features for facilitating communication between an internal passage of the extension tool and an environment external to the extension tool. In various embodiments, the selectively flexible extension tool includes a plurality of sequentially arranged links that are movable relative to each other and a support member that defines a distal end of the extension tool. The support member includes a wheel disposed at the distal end. In addition, the extension tool includes: a first bend at the base link and a second bend at a transition section between the base link and the transition link, the second bend being different from the first bend; a third bend along the plurality of sequentially arranged links; and a fourth bend at the support member, the fourth bend being different from or similar to the first bend, the second bend, and the third bend.

[0024] Additionally or alternatively, the selectively flexible extension tool includes a plurality of windows defined in a plurality of sequentially arranged links. The windows of the plurality of windows can be periodically defined along and around the plurality of sequentially arranged links, such that the periodicity of the windows corresponds to the periodicity of the plurality of features of the component. The extension tool as disclosed herein provides benefits such as: positive control of the insertion direction of the tool without external hairlines, etc., that can get stuck on protrusions; reduced friction between the tool and the component into which the tool is inserted; and / or consistent, controllable positioning of instruments for illumination, imaging, etc., of one or more features of the component. For example, one or more of these benefits can reduce inspection time while improving inspection quality.

[0025] The extension tool disclosed herein also provides access to remote locations within a component, such as a gas turbine engine. For example, an extension tool having a curved portion disclosed and described herein facilitates insertion through an opening, such as a borescope opening, that is angled in a non-perpendicular direction relative to the longitudinal centerline of the component. While the angle of the borescope opening may be angled in a non-perpendicular direction relative to the longitudinal centerline of the gas turbine engine, the curved portion allows at least a portion of the extension tool to be positioned substantially perpendicular to the longitudinal centerline about the longitudinal centerline. Furthermore, the wheels of the extension tool avoid dragging the extension tool along the surface of the component, while reducing the cost of producing the extension tool by utilizing a single wheel.

[0026] Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meanings assigned to them by those skilled in the art. Unless otherwise specifically indicated, the word "or" as used herein should be interpreted as having a disjunctive structure, not a conjunctive structure. Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment and indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0027] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0028] The terms "fore" and "aft" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, the front position refers to the position closer to the engine inlet, while the aft position refers to the position closer to the engine nozzle or exhaust.

[0029] The terms "upstream" and "downstream" refer to relative directions of fluid flow in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, while "downstream" refers to the direction toward which the fluid is flowing.

[0030] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0031] As used herein throughout the specification and claims, approximating language is applied to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Accordingly, values ​​modified by terms such as "about," "approximately," and "substantially" are not limited to the precise values ​​specified. In at least some cases, approximating language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may mean within a 10% margin.

[0032] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0033] The above and other benefits may become more apparent after a thorough review and study of the following detailed description. Referring now to the drawings, in which like numerals indicate like elements throughout, Figure 1An extension tool 100 is shown according to an embodiment of the present disclosure. The extension tool 100 is shown in a tensioned or rigidified position, however, the extension tool 100 can be in a relaxed or unstuck position. In this manner, the extension tool 100 can also be referred to as a selectively rigidifiable guide tube.

[0034] As used herein, a relaxed or unstuck position can encompass a variety of different shapes of the extension tool 100. In this manner, a relaxed or unstuck position can be considered any position other than a tensioned or rigidized position. In the tensioned or rigidized position, as described in greater detail below, the plurality of sequentially arranged links 106 are tensioned by a portion of the extension tool 100 such that each of the plurality of sequentially arranged links 106 is compressed against one another. When in the tensioned or rigidized position, the extension tool 100 can have a predefined shape. In some embodiments, the predefined shape can reflect the shape of the component in which the extension tool 100 is deployed.

[0035] As described in greater detail herein, extension tool 100 defines one or more passageways therethrough. Such passageways can receive a borescope or other device capable of transmitting images captured by an imaging device, such as a camera (which may generally be referred to herein as an "imaging device"). Alternatively or additionally, one or more passageways defined through extension tool 100 can convey cleaning fluids (e.g., liquid or foam detergents or other cleaning agents), cooling fluids or other fluids, and / or can provide conduits for materials, tools, instruments, or other devices for repair, maintenance, and / or cleaning to be delivered to one or more locations within a component into which extension tool 100 is deployed. For example, extension tool 100 can be deployed within a component, assembly, system, equipment, etc., and a borescope can be inserted through extension tool 100. Defects in a feature of the component can be detected through the borescope, and the borescope can be retracted so that repair material and / or devices (e.g., a manipulator for positioning the repair material and a heat source such as a laser, a resistance welding device, a brazing device, etc.) can be delivered through extension tool 100 to the defect to repair the defect. As another example, the extension tool 100 can be used to deliver coatings, patches, fluids, cleaning materials, tools, utensils, etc. to one or more features of a component in which the extension tool 100 is deployed. The extension tool 100 is a maneuverable device that can be used for a variety of applications, such as by using various features described in more detail below. For example, the component can be a gas turbine engine that includes various borescope openings for inserting and using the extension tool 100 as described above.

[0036] refer to Figures 1 to 5, the extension tool 100 generally includes a base or handle 102 at a proximal end 112, a plurality of sequentially arranged links 106, and a support member 130 at a distal end 114. The extension tool 100 also generally includes a base link 124, a root 108 (such as an extension of the base link 124), and a plurality of wires 109 (as part of a wire guide assembly 110) and / or a spine 121 extending from the root 108 and / or base link 124, the root 108 being coupled at one end to an end of the base 102 and at an opposite end to an end of the base link 124. As will be understood from the discussion herein, via the wire guide assembly 110 and / or the spine 121, the base 102 is operable with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a tensioned position and a relaxed position.

[0037] When in the relaxed position, the plurality of sequentially arranged links 106 are under no pressure or marginal pressure to allow the plurality of sequentially arranged links 106 to pivotally move relative to each other, for example, through hinged connections between adjacent links 106. For example, the marginal pressure may be less than 20% of the tensioning pressure. The tensioning pressure is the amount of pressure applied to the links 106 to move the tool 100 to a predefined tensioning state. When the tensioning pressure is approximately 90% or greater of the maximum tensioning pressure, the tool 100 achieves a predefined tensioning state. For example, in the relaxed position, the plurality of links 106 may be spaced apart from each other or not subject to a specific pressure to hold the links 106 in a specific position. In contrast, when in the tensioned position, the plurality of sequentially arranged links 106 are pressed against each other to rigidly fix the plurality of sequentially arranged links 106 to each other. As Figure 1 As shown, the wire guide assembly 110 and / or the spine 121 can be used as a hinge. The spine 121 can be selectively rigid and / or semi-flexible. Therefore, the wire guide assembly 110 and / or the spine 121 described in more detail below can be used as a hinge element between two adjacent links 106.

[0038] for Figures 1 to 5In at least some embodiments, it will be understood that each of the plurality of links 106 is designed to produce a specific rigidified shape, i.e., the predefined shape discussed above, when the plurality of links 106 are moved to the tensioned position. For example, a first link in the plurality of links 106 defines a first geometry (i.e., length, curvature, etc.), and a second link in the plurality of links 106 defines a second geometry (i.e., length, curvature, etc.). The first geometry may be different from the second geometry. In at least some embodiments, in order to form the plurality of links 106 having a specific geometry to facilitate the desired shape of the plurality of links 106, each of the plurality of links 106 may be formed by an additive manufacturing process (sometimes also referred to as 3D printing). This may facilitate forming a specifically shaped link 106 to fit within the plurality of links 106 of the extension tool 100, thereby producing the desired shape when moved to the tensioned position, yet still maintaining sufficient flexibility to accommodate the intended environment, as described below with reference to Figure 16 Described in more detail.

[0039] Furthermore, in at least some embodiments, the plurality of links 106 can be formed from one or more materials to optimize the material properties of each link 106, for example, based on the function of the corresponding link 106 in the extension tool 100. For example, the links 106 closer to the base 102 (such as the link from the base link 124 to the transition link 123) can be formed from a stiffer material than the links 106 distal to the transition link 123 because, for example, the proximal link 106 can be more curved or have a smaller radius of curvature, can withstand greater stress during insertion and / or tensioning of the extension tool 100, etc. In some embodiments, the proximal link 106 can be formed from a first material (e.g., steel, etc.), while the link 106 distal to the transition link 123 is formed from a second material that is a lighter and / or less stiff material, such as plastic, etc. Other suitable materials can also be used, and it will be understood that, in at least some embodiments, the plurality of links 106 can be formed from the same material rather than different materials.

[0040] Furthermore, with respect to the wire guide assembly 110 and / or spine 121, it will be understood that each of these may be configured as a cable, a rope, a thin wire, etc. Thus, it will be understood that the wire guide assembly 110 includes the following references to Figures 13 to 151 and 176. Wire 109 and wire guide channels 174 and 176 are described in greater detail. Wire 109 is generally flexible (i.e., does not significantly prevent the plurality of sequentially arranged links 106 from pivotally moving relative to each other in a relaxed position). It will further be understood that spine 121 may be semi-flexible (i.e., does not significantly prevent the plurality of sequentially arranged links 106 from pivotally moving relative to each other in a relaxed position) or may be rigidified by base 102. Furthermore, one or more of wire 109 and / or spine 121 may be formed from a metallic material (such as steel, tungsten, NiTiNOL, etc.). However, alternatively, wire 109 and / or spine 121 may be formed from any other suitable material.

[0041] In at least some embodiments, it will be understood that Figures 1 to 5 The extend tool 100 depicted in FIG can include a tooling instrument coupled to one of a plurality of links 106. For example, the tooling instrument can be coupled to the link 106 at the distal end 114 of the extend tool 100. In certain embodiments, the tooling instrument can include one or more sensors, cameras, or both, and can additionally or alternatively include one or more drill bits, laser tools, welding instruments, rotatable instruments (e.g., Phillips head screwdriver bits, flat head screwdriver bits, Torx bits, Allen bits, Pozidrives, etc.), etc. In this manner, the extend tool 100 can facilitate mechanical manipulation of a part at a remote location or along ambiguous vectors within an environment (e.g., along a non-linear path within the environment) that would otherwise be more difficult.

[0042] However, it will be further understood that in other embodiments, the extension tool 100 may be configured in any other manner to perform operations at a remote location within an environment or along a blur vector.

[0043] For example, for one or more configurations, the extension tool 100 can include an implement, device, or the like that extends through the interior of the plurality of links 106, and more specifically, through a tube defined along the length of the plurality of links 106. Specifically, for the illustrated embodiment, the extension tool 100 is configured such that when the plurality of sequentially arranged links 106 are tensioned together, the plurality of sequentially arranged links 106 define one or more channels 116 therethrough. In various embodiments, the channels 116 can be fluid flow channels, can be configured, for example, to serve as guide tubes for a tool, implement, or other device, or can be a combination of different types of channels, such as a fluid flow channel surrounding a guide tube.

[0044] It will be understood that, as used herein, the term "fluid flow channel" refers to any substantially continuous channel 116 through the plurality of sequentially arranged links 106 when the plurality of sequentially arranged links 106 is in a tensioned position, capable of providing a flow of gas or liquid to a position near the distal end 114 of the plurality of sequentially arranged links 106, or extracting a flow of gas or liquid from a position near the distal end 114 of the plurality of sequentially arranged links 106.

[0045] exist Figures 1 to 6 In the depicted embodiment, a plurality of sequentially arranged links 106 together define a channel 116 ( Figure 6 ), for the embodiment shown, the passage 116 is a guide tube 116. Thus, with or without the tool implements described above, the plurality of links 106 define openings for receiving one or more implements and / or devices (e.g., borescopes, maintenance or repair tools, cleaning implements, or other devices). It will be appreciated that to form the passage or guide tube 116, each link 106 of the plurality of links 106 defines an opening 118 therethrough, such as Figure 13 As best shown in FIG. Each link 106 may define an opening 118 along its length. The openings 118 of adjacent links 106 in the plurality of sequentially arranged links 106 align in a tensioned position to define a passageway or guide tube 116 for one or more instruments and / or devices to pass through or travel therethrough. A borescope may be used to provide rigidity or stiffness to the plurality of sequentially arranged links 106. In this manner, the plurality of sequentially arranged links 106 may be selectively rigidified or stiffened by the borescope extending through the passageway 116.

[0046] Furthermore, while only one channel 116 is depicted, in other embodiments, the extension tool 100 may include two or more channels. For example, when the plurality of sequentially arranged connecting rods 106 are in the tensioned position, the extension tool may include a second channel separate from channel 116. Thus, channel 116 is a first or inner channel, while the second channel is an outer channel, for example, an outer fluid flow channel for flowing fluid along the outer surface of the channel or guide tube 116. In this manner, the inner channel is positioned radially inwardly of the outer channel, with the outer channel substantially completely surrounding the inner fluid flow channel. Thus, the outer channel may define a generally annular shape surrounding the inner fluid flow channel. The inner and outer channels may be coaxial and / or concentric. However, in other embodiments, the two or more channels may be arranged in any other suitable manner. For example, the first and second channels may alternatively extend parallel and adjacent to each other, but may be arranged non-concentrically (e.g., one of the first or second channels extends along one side of the plurality of connecting rods 106, while the other of the first or second channels extends along the other side of the plurality of connecting rods 106).

[0047] Reference again Figures 1 to 5 It will be appreciated that the wire guide assembly 110 can operate with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a relaxed position and a tensioned position. Figure 15 As shown, the wire 109 can pass through the connecting link 129 at the distal end 114 of the plurality of links 106 (hereinafter referred to as Figure 9-11 106 ). The plurality of links 106 are arranged around the base 102 (described in greater detail). When the wires 109 are tensioned (such that a certain amount of slack is taken out of the wires) by applying a tensioning force to the wires in the wires 109, the tension or pressure in the wires 109 presses each of the plurality of sequentially arranged links 106 against each other, securing the plurality of sequentially arranged links 106 in position to form a substantially rigid extension. Notably, for the embodiment shown, the plurality of links 106 includes a base link 124 secured to the base 102, thereby allowing the wires 109 to be tensioned.

[0048] Further references Figures 1 to 5 It will be appreciated that the spine 121 can operate in conjunction with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a relaxed position and a tensioned position. Specifically, the spine 121 can include a rigidifiable structure such that when the spine 121 is tensioned by applying a tensioning force to the spine 121, the tensioning force pulls each of the plurality of sequentially arranged links 106 toward each other, securing the plurality of sequentially arranged links 106 in position to form a substantially rigid extension tool. Similar to the wire guide assembly 110, the base link 124 secured to the base 102 allows the spine 121 to be tensioned. In further embodiments, the spine 121 can include a rigidifiable structure such that when a compressive force is applied to the spine 121, the compressive force pushes each of the plurality of sequentially arranged links 106 toward each other, securing the plurality of sequentially arranged links 106 in position to form a substantially rigid extension tool.

[0049] The wires 109 and spines 121 can operate together or separately with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a relaxed position and a tensioned position. The wires 109 and spines 121 can be tensioned by applying a tensioning force. The spines 121 and wires 109 can be provided on opposite sides of the plurality of sequentially arranged links 106 to allow the extension tool 100 to be rigidified on one side opposite the other.

[0050] In some embodiments, the ridges 121 can be used to maintain a certain rigidity of the extension tool 100, while the wires 109 can operate with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a relaxed position and a tensioned position. Conversely, in some embodiments, the wires 109 can be used to maintain a certain rigidity of the extension tool 100, while the ridges 121 can operate with the plurality of sequentially arranged links 106 to move the plurality of sequentially arranged links 106 between a relaxed position and a tensioned position.

[0051] Return Reference Figure 6 , showing a base link 124. The base link 124 includes a base link extension 127, a first bend 115, and a transition link 123 (at the end thereof) coupled to the base link 124 or the base link extension 127. Figures 1 to 5 shown and referenced herein Figure 7 and Figure 8 ). The base link extension 127 and the first bend 115 allow the extension tool 100 to be inserted into openings of various angles and depths in a component. By selecting and / or varying the length of the base link extension 127, the extension tool 100 can be properly inserted into the opening and the plurality of sequentially arranged links 106 can be properly tensioned to align with the interior surface of the component. The first bend 115 of the base link 124 allows the extension tool 100 to be inserted into angled openings while allowing the plurality of sequentially arranged links 106 to extend substantially aligned with one another, as shown. Figure 4 shown.

[0052] refer to Figures 6 to 8 , showing the distal end of the base link 124 and the transition link 123. The transition link 123 is coupled to the transition section 104 (eg, Figures 2 to 4 ). The transition section 104 extends between the base link 124 and the transition link 123. The transition section 104 includes a second plurality of sequentially arranged links 107 at one end and a plurality of sequentially arranged links 106 at an opposite end. The transition link 123 includes a geometry such that the base link 124 transitions to the plurality of sequentially arranged links 106. In this manner, the extension tool 100 can include an off-plane transition from the base 102 to the plurality of sequentially arranged links 106 via the transition section 104, and further via the second plurality of sequentially arranged links 107, and / or the transition link 123. The second plurality of sequentially arranged links 107 can be similar to the links in the plurality of sequentially arranged links 106 described below.

[0053] The transition link 123 is positioned between links having significantly different directions of curvature. In this way, the transition link 123 allows the hinge to be arranged to accommodate different directions of curvature and also allows the wire assembly 110, including the wire 109 and the wire guide channels 174 and 176, to be repositioned to apply compression to the link 106 in the proper arrangement about the axis of the link 106 relative to the hinge or joint 128 or spine 121. Relatively small changes or continuous changes in direction may not require a transition link 123 having different characteristics than any other link. Figure 2 In the case of the transition link 123 in FIG, the wire assemblies 110 are guided in opposite directions around the link 106 to be positioned approximately 180 degrees relative to their original position, so that the arrangement of the wires 109 and hinges 128 is different along the length of the transition link 123, as shown. Figure 8 In some embodiments, the link 106 or transition link 123 may require less change in direction of curvature to produce a changed configuration suitable for a desired direction of curvature and / or shape.

[0054] Now refer to Figures 9 to 11 In various embodiments, the extension tool 100 further includes a support member 130 defining a distal end 114. The support member 130 includes wheels 132 for controlling the insertion direction of the extension tool 100. More specifically, for the depicted embodiment, the support member 130 includes wheels 132 disposed at the distal end 114 of the tool and at the distal end 122 of the support member 130. The wheels 132 are freely rotatable about respective transversely extending axes 131. For example, compared to a tool 100 without wheels at its distal end, the wheels 132 at the distal end 114 help guide the tip of the extension tool 100 with reduced friction. For example, when the extension tool 100 is inserted into a component, the wheels 132 can roll along the surface of the component. The support member 130 is connected to a plurality of sequentially arranged links 106 via connecting links 129. The connecting links 129 define the proximal end 120 of the support member 130. The wheels 132 define the distal end 122 of the support member 130. Support member 130 includes hinge 128 similar to the hinge described above to tension the distal end of support member 130 relative to proximal end 120. Hinge 128 connects a first flexible member 153 coupled to distal end 114 of extension tool 100 to a second flexible member 155 including wheels 132.

[0055] Support member 130 also includes a fourth bend 145 extending from connecting link 129 of support member 130 to distal end 122 of support member 130. Fourth bend 145 and wheels 132 help prevent dragging of support member 130 when support member 130 begins to transition to an offset position relative to link 106 adjacent to support member 130. For example, support member 130 may have a curved tip or distal end 122. Without wheels 132 and fourth bend 145, extension tool 100 may drag along the component, and an operator or automated machine (e.g., a robot) may have difficulty pushing and overcoming friction between extension tool 100 and the component. Furthermore, if extension tool 100 is used on a coated component, the friction and dragging caused by the tool without at least wheels 132 or fourth bend 145 may scratch the coated component.

[0056] In some embodiments, support member 130 or components thereof (such as wheel 132 and shaft 131) can be formed by an additive manufacturing process (e.g., a 3D printing process) such that wheel 132 and shaft 131 are integral with one another. In some embodiments, shaft 131 is integrally formed with distal end 122 of support member 130. In further embodiments, shaft 131 is a separately produced through-shaft that passes through wheel 132 at distal end 122 of support member 130.

[0057] like Figures 9 to 11 As shown, the support member 130 extends along the support member longitudinal centerline CL such that the distal end 114 defined by the support member 130 and the distal end 122 of the support member 130 is bent or biased away from the support member longitudinal centerline CL. Figure 9 As best shown in the illustrated embodiment, support member 130 is biased in a direction opposite to the direction of curvature R4, as described in greater detail below, such that the plurality of sequentially arranged links 106 resulting in curvature R4 together form an arcuate shape for use in traversing annular or circular components, assemblies, systems, etc. In other embodiments, the plurality of links 106 may define other shapes when tensioned, depending on the shape of the component, assembly, system, etc. into which the extension tool 100 is inserted. It will be appreciated that support member 130 is biased in a direction that facilitates insertion of the extension tool 100 into a device or apparatus undergoing inspection, maintenance, cleaning, etc. The distal end 114 of the extension tool 100, along with wheels 132 positioned at and near the distal end 114, helps control the insertion direction of the extension tool 100. This positive control of insertion direction provided by the biased support member 130 may be particularly advantageous for insertion into annular objects, and more specifically, insertion "upwards" or against the force of gravity into annular objects.

[0058] like Figure 17As shown, in some embodiments, support member 130 can be inserted and removed through channel 116, as described above with reference to FIG. Figures 1 to 5 Describe in detail and Figure 6 . In this manner, a distal link (such as connecting link 129) in the plurality of sequentially arranged links 106 includes an actuatable mechanism or collar. For example, an extension tool 100 including support member 130 can be inserted into an engine. Once in place, the actuatable mechanism of the distal link can be actuated, releasing support member 130 from connecting link 129. Support member 130 can then be removed through passage 116 to allow a borescope or other structure, mechanism, or fluid to pass therethrough. Support member 130 can be inserted back through passage 116 of the plurality of sequentially arranged links 106, reattached to connecting link 129, and the extension tool 100 can be removed. In such an embodiment, connecting link 129 can function as a collar to hold support member 130 to the distal link. In some embodiments, connecting link 129 functioning as a collar can include an actuatable mechanism that allows support member 130 to be removed from the distal link, i.e., support member 130 can be removably coupled to extension tool 100.

[0059] like Figure 2 and Figure 3 As shown, a plurality of sequentially arranged links 106 define a plurality of windows 150. Windows 150 define openings in links 106 for communication between the internal passage 116 defined by links 106 and the environment external to extension tool 100. Windows 150 in the plurality of windows 150 are periodically defined along the plurality of links 106. The periodicity of windows 150 can be defined by windows 150 and correspond to the periodicity of various features of the component, assembly, system, device, apparatus, etc., in which extension tool 100 is deployed. That is, the position of each window 150 corresponds to a periodic feature of the component, etc., in which extension tool 100 is deployed for inspection, maintenance, cleaning, etc. In further embodiments, the plurality of windows 150 can be arranged in a spiral around the plurality of sequentially arranged links 106. That is, the position of each window 150 can vary from link to link to provide a variety of different perspectives on the deployment of extension tool 100. In such embodiments, the pitch of the spiral can correspond to the periodic feature of the component, etc.

[0060] For example, reference Figure 12 , an application of various extension tools disclosed herein will be described. Specifically, Figure 12 An extension tool 100 according to an embodiment of the present subject matter is depicted being used to navigate a non-linear path within an environment, which for the embodiment shown is a gas turbine engine 10. Specifically, for Figure 12In the embodiment of FIG. 1 , the gas turbine engine 10 is configured as a turbofan engine. A turbofan engine generally includes a fan section 14 and a turbine 16 .

[0061] The turbine 16 generally includes a compressor section having a low-pressure ("LP") compressor 22 and a high-pressure ("HP") compressor 24; a combustion section 26; a turbine section including an HP turbine 28 and an LP turbine 30; and an exhaust section (not shown). The compressor section, combustion section 26, turbine section, and exhaust section are each arranged in a serial flow order. The LP compressor 22 and the LP turbine 30 are coupled by an LP shaft 36, and similarly, the HP compressor 24 and the HP turbine 28 are coupled to the HP shaft 34. Furthermore, the turbine 16 includes a casing 18 that at least partially encloses the aforementioned components of the turbine 16. Furthermore, for the illustrated embodiment, the fan section 14 includes a fan 38 having a plurality of fan blades 40, wherein the fan 38 and the plurality of fan blades 40 are driven by the LP shaft 36.

[0062] In the highlighted portion shown by the dashed lines and circles, an orthogonal close-up schematic diagram of a portion of the combustion section 26 of the gas turbine engine 10 is provided. The combustion section 26 generally includes an inner liner 42 and an outer liner 44 that together at least partially define a combustion chamber or combustor 46. The combustion section 26 also includes a plurality of deflectors 48 disposed in a periodic arrangement about the longitudinal centerline axis 12 of the gas turbine engine 10. More specifically, the deflectors 48 may be disposed at the forward end of the combustor 46 between the annular inner liner 42 and the annular outer liner 44. Each deflector 48 has an opening 50 into which a fuel nozzle 52 is disposed when the engine 10 is assembled. It will be appreciated that the deflectors 48 and the fuel nozzles 52 are disposed in a regular periodic arrangement about the annular forward end of the combustor 26.

[0063] After a period of operation, an undesirable amount of coke buildup may form on or within the fuel nozzle 52. For example, during a shutdown of the gas turbine engine 10, fuel may remain within the fuel nozzle 52, and residual heat within the gas turbine engine 10 may cause the remaining fuel to coke. The extend tool 100 may be used to remove coke buildup on or within the fuel nozzle 52, for example, during a maintenance interval. Additionally, the extend tool 100 may be used to inspect the deflector 48, repair any damage to the deflector 48, apply or re-apply a coating to the deflector 48, and / or clean the deflector 48. In further embodiments, the extend tool 100 may be used to inspect the aft heat shield of the fuel nozzle 52, repair any damage to the aft heat shield of the fuel nozzle 52, apply or re-apply a coating to the aft heat shield of the fuel nozzle 52, and / or clean the aft heat shield of the fuel nozzle 52.

[0064] Figure 12The extension tool 100 depicted in FIG. 1 can be constructed according to one or more embodiments described herein. For example, the extension tool can generally include a plurality of connecting rods 106 movable to a tensioned position (as shown), with the plurality of connecting rods 106 having a non-linear, two-dimensional, or three-dimensional shape when in the tensioned position. Notably, the ability to additionally move to a relaxed position can facilitate moving the plurality of connecting rods 106 through the gas turbine engine 10 environment and through ports in, for example, the combustor 46 through which the extension tool 106 is inserted.

[0065] Furthermore, the extension tool 100 can define windows 150 in the plurality of links 106 such that, in some embodiments, the windows 150 have a periodic arrangement similar to that of the deflectors 48 and the fuel nozzles 52. In the depicted embodiment, the periodicity of the windows 150 matches or is identical to the periodicity of the fuel nozzles 52 (and / or the deflectors 48 and / or the openings 50), such that, for example, a borescope or other instrument passing through the plurality of links 106 can inspect, perform maintenance, clean, or otherwise repair each periodic feature (e.g., the deflectors 48 and / or fuel nozzles 52 received therein). That is, one of the plurality of windows 150 is aligned with a corresponding one of the plurality of features (e.g., a corresponding deflector 48 and / or a corresponding fuel nozzle 52) to facilitate inspection, maintenance, cleaning, repair, etc. of each feature. In still further embodiments, the windows 150 have a periodic arrangement that may be spiral along a plurality of sequentially arranged links 106, allowing for several different views along the extension tool 100 during insertion, removal, and in place.

[0066] The corresponding periodicity between the windows 150 and the features helps ensure that each feature is inspected or otherwise repaired. To further ensure that no feature is overlooked, or to help provide dedicated repairs to one or more specific features, each window 150 defined in the extension tool 100 can be labeled and indexed to a corresponding feature in the plurality of features. In addition, the extension tool 100 can be developed for a specific component that includes the feature (e.g., the burner 26), so that it can be easily determined, for example, by the periodicity of the features and the corresponding periodicity of the windows 150, which window 150 aligns with which feature when the extension tool 100 is inserted into the component in a given direction at a given location.

[0067] It will be understood that in various embodiments, the plurality of features may be a plurality of turbine nozzle airfoils of the engine 10, a plurality of compressor blades of the engine 10, a weld line of a pressure vessel, an internal structural member of a fuel tank, etc. The extension tool 100 may be used with a particular component, device, apparatus, etc. such that the periodicity of the windows 150 is adapted to the periodicity of the associated features. Furthermore, the periodicity of the windows 150 need not necessarily correspond to a plurality of connecting rods 106, i.e., the windows 150 may not be defined in every connecting rod 106, the windows 150 may not be defined at the same location along every connecting rod 106, etc. For example, Figure 12 As shown, the window 150 is defined only in each fourth link 106. Additionally, the length of each link 106 can be defined to optimize the navigation of the extension tool through the component. Therefore, no specific relationship is required between the length of the link 106 and the periodicity of the window 150.

[0068] Furthermore, while the links 106 depicted throughout the figures include a pair of windows 150 defined opposite each other along a transverse direction of the links 106, the windows 150 need not be defined in pairs. More specifically, the links 106 may define only one window 150 without a second window 150 defined transversely opposite the one window. Furthermore, the windows 150 may be defined at different locations along the perimeter or edge of one or more links 106. For example, for the plurality of links 106 having a generally circular cross-sectional shape as shown, a first link 106 may define a first window 150 at a first circumferential location along the first link 106, and a second link 106 may define a second window at a second circumferential location along the second link 106, where the second circumferential location is different from the first circumferential location. In other embodiments, the first link 106 may define first and second windows 150, the first and second windows being defined at different circumferential locations relative to the first link 106. In this manner, the positions of the windows 150 may be further customized to the locations of corresponding features or elements of a component in which the extend tool 100 is deployed, e.g., for inspection, maintenance, cleaning, etc. of various features or elements. The periodicity of one of the windows 150 may be defined relative to one component or feature of the gas turbine engine 10, while the periodicity of the second set of windows may be different than the first set of windows and may be defined relative to a second component or feature of the gas turbine engine 10.

[0069] Now refer to Figures 13 to 15 , a single link in the plurality of sequentially arranged links 106 has a shape at each end of the link. It will be understood that the above reference Figures 9 to 11The distal ends 122 of the links define protruding alignment features 180 that mate with or are received by the intruding alignment features 178 of the adjacent links. Thus, when the extension tool 100 is tensioned into the tensioning configuration, the alignment features 180 and 178 align the adjacent links 106 with each other.

[0070] Now refer to Figures 3 to 6 、 Figure 9 and Figure 10 In at least some embodiments, base link 124 includes a first bend 115 defining a first radius of curvature R1 or a first direction relative to longitudinal centerline CL. The first direction can be substantially horizontal or outward relative to the longitudinal centerline. Furthermore, the plurality of sequentially arranged links 106 include one or more transition links 123, wherein the position of extension tool 100 along transition section 104 defines a second radius of curvature R2 between base link 124 and transition link 123, including link 107 that creates second bend 125 extending between base link 124 and transition link 123; a third radius of curvature R3 defined along the plurality of sequentially arranged links 106 from transition link 123 to connecting link 129, terminating at proximal end 120 of support member 130; and a fourth radius of curvature R4 defined at support member 130. Second bend 125, third bend 135, and fourth bend 145 extend substantially along longitudinal centerline CL. The second curved portion 125 and the fourth curved portion 145 extend in a second direction relative to the longitudinal centerline CL and are curved downward to allow the extension tool 100 to be inserted into the gas turbine engine 10 and contact the inner surface of the gas turbine engine 10, thereby preventing the plurality of sequentially arranged connecting rods 106 from being dragged along the surface. The third curved portion extends in a third direction relative to the longitudinal centerline CL and is curved upward to allow the extension tool 100 to be inserted around the inner surface of the gas turbine engine 10. In addition, as Figure 3 and Figure 4 As shown, the extension tool 100 in the tensioned position is bent in four different directions. Generally, when in the tensioned position, the extension tool 100 includes at least four arcs or curves that are curved or bent in different directions, and the at least four arcs or curves can have the same or different radii of curvature. The corresponding radius and curvature of each curved portion can be the same or different. Figure 3 and Figure 4 As shown, the first radius of curvature R1 is similar to the second radius of curvature R2 , both of which are smaller than the third radius of curvature R3 , and the fourth radius of curvature R4 may be similar to R1 and R2 .

[0071] The first arc or first bend 115 is curved in a first direction. Figure 4As specifically shown in FIG, the first direction can be substantially parallel to or horizontal to the longitudinal centerline CL. The second arc or second bend 125 bends in a second direction different from the first direction. As described above, the second direction can be substantially downward. The third arc of the third bend 135 bends in a third direction, which can be substantially upward. Figure 4 As shown, the third bend 135 can be substantially aligned with (in line with) the second bend 125, and in some embodiments, along the same or substantially similar plane, with the first bend 115 extending outwardly from the plane, for example, in a substantially perpendicular direction. Figure 5 As shown, third bend 135 can be in a different direction than second bend 125. Fourth bend 145 bends in the second direction. Fourth bend 145 can be substantially aligned with centerline CL, with distal end 122 of support member 130 bending downward relative to centerline CL, similar to second bend 125. Thus, in some cases, the planes associated with each bend may not be parallel, while in other cases, at least two of the planes associated with each bend may be parallel to each other.

[0072] Return Reference Figure 14 , which shows one of the plurality of sequentially arranged links 106 including the ridge channel 160, the opening 118, and the wire guide channels 174 and 176 associated with the wire guide assembly 110. As shown, the ridge channel 160 extends along the length of each link in the plurality of sequentially arranged links 106. Similarly, Figure 14 and Figure 15 In comparison, wire guide channels 174 and 176 extend the length of each of the plurality of sequentially arranged links 106. Although ridge channel 160 and wire guide channels 174 and 176 are shown as being opposite to each other (i.e., on opposite sides of the plurality of sequentially arranged links 106) with window 150 therebetween, the present disclosure contemplates that the aforementioned elements spiral down the plurality of links 106. In this manner, a joined link may have slightly different positions of associated elements, resulting in an offset of the elements compared to a joined link. In these embodiments, the intrusive alignment feature 178 and the protruding alignment feature 180 may or may not be offset from each other on the same link. With the intrusive alignment feature 178 and the protruding alignment feature 180 aligned with each other, the wire guide channels 174 and 176 can rotate about the periphery of the end of each of the plurality of sequentially arranged links 106.

[0073] The extension tool 100 may also include other features or elements. For example, a plurality of sequentially arranged links 106 may include light elements for illuminating the environment external to the plurality of links 106, such as light emitting diodes (LEDs), light pipes, etc., for providing light within the component into which the extension tool 100 is inserted. The light elements may be embedded in the outer opening 156 or in the outer side surface of one or more links 106. Alternatively or additionally, one or more light elements may be included within the links 106, for example, to illuminate the channel 116, as described above with reference to FIG. Figures 1 to 5 Describe in detail and Figure 6 174 or 176.

[0074] Furthermore, in at least some embodiments, the extension tool 100 also includes features for providing one or more fluid flows therethrough. For example, the channel 116 may be, in whole or in part, a fluid flow channel for providing a fluid flow therethrough. In embodiments, the channel 116 defined by the walls 177 of the plurality of connecting rods 106 is a cooling channel for receiving a cooling fluid within the plurality of sequentially arranged connecting rods 106. In some embodiments, the channel 116 may receive a cooling fluid flow in addition to receiving one or more implements, tools, or other devices. For example, the cooling fluid may flow through the channel 116 to cool the one or more implements, tools, or other devices and / or to cool the extension tool 100 and / or its surrounding environment. This cooling may allow the extension tool 100 to be deployed within a component, system, device, or equipment, for example, without having to wait for the component, etc., to cool to a threshold temperature. It will be appreciated that the cooling fluid may exit through the plurality of windows 150, and in embodiments including diverging window walls, the windows 150 may define nozzles for delivering the cooling fluid flow to an environment external to the extension tool 100.

[0075] As an example, the flow of cooling fluid through the passage 116 may allow the extension tool 100 to be deployed on a gas turbine engine (e.g., a conventional engine) sooner after engine shutdown than an uncooled extension tool 100. Figure 12The flow of cooling fluid through the extension tool 100 can keep the extension tool 100 and / or implements, tools, and / or other devices used therewith cool enough to be used within the engine 10, even if the engine 10 has not yet cooled to a threshold temperature.

[0076] In other embodiments, channel 116 may receive a cooling fluid stream without receiving one or more appliances, tools, or other devices. That is, channel 116 may serve solely as a cooling channel. In yet other embodiments, multiple connecting rods 106 may define one or more channels in addition to channel 116. In addition to or in lieu of channel 116 receiving a cooling fluid, other channels may receive a cooling fluid stream. In yet another embodiment, one or more channels defined by multiple connecting rods 106, including channel 116, may receive one or more different fluid streams, such as a heated gas stream, a pressurized gas stream, a heated liquid stream, a pressurized liquid stream, a cleaning foam or other cleaning material stream, and the like. The different fluid streams may have different temperatures, pressures, and / or compositions. For example, one channel may receive a cooling fluid stream F, while another channel may receive a liquid detergent stream, and the like. As another example, a channel may be configured to receive different fluid streams at different times while extension tool 100 is deployed in a component. For example, one channel may receive a cooling fluid stream at one time, a liquid detergent stream at another time, and a heated gas stream at yet another time. As described above, windows 150 defined in the plurality of links 106 may act as nozzles for directing fluid (e.g., washing fluid or foam, detergent, gas, etc.) external to the extension tool 100, such as to specific features of a component or the general external environment.

[0077] It will also be appreciated from the above discussion that for the depicted and described embodiments, adjacent links 106 are sealed together by mating geometries at their respective ends that are complementary in shape to the mating geometries of adjacent links. The walls 177 of the links 106 are pressed together, and the contact pressure applied by the wires 110 can form a contact seal therebetween to provide a seal between the links 106. In some embodiments, the links 106 can be sealed together by using a sealing element (such as an O-ring around the opening 118) on each end of the links 106.

[0078] In general, the embodiments of the extension tool 100 described herein can be manufactured or formed using any suitable process. However, according to several aspects of the present subject matter, the extension tool 100 can be formed using an additive manufacturing process, such as a 3D printing process. The use of such a process can allow, for example, each link 106 and support member 130 to be formed as a single, unitary component, or as any suitable number of subcomponents. In particular, the manufacturing process can allow each link 106 and support member 130 to be integrally formed and to include various features that are not possible using existing manufacturing methods. For example, the additive manufacturing methods described herein are capable of manufacturing links 106 of any suitable size and shape, with one or more configurations of lumens, passageways, sight lines and wire guides, as well as windows, end geometries, and other features that are not possible using existing manufacturing methods. Some of these novel features are described herein.

[0079] As used herein, the terms "additive manufacturing" or "additive manufacturing techniques or processes" generally refer to a manufacturing process in which successive layers of material are provided upon one another to "build up" a three-dimensional component layer by layer. The successive layers are typically fused together to form a unitary component that may have a variety of integral subcomponents. Although additive manufacturing techniques are described herein as being capable of manufacturing complex objects by building up the object point by point, layer by layer, typically in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, while the discussion herein relates to adding material to form successive layers, it will be understood by those skilled in the art that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present disclosure may use a layer-additive process, a layer-subtractive process, or a hybrid process.

[0080] Suitable additive manufacturing techniques according to the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (e.g., by inkjet and laser jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shape (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM) and other known processes.

[0081] In addition to using a direct metal laser sintering (DMLS) or direct metal laser melting (DMLM) process, in which an energy source is used to selectively sinter or melt portions of a powder layer, it will be understood that, according to an alternative embodiment, the additive manufacturing process can be a "binder jetting" process. In this regard, binder jetting involves continuously depositing layers of additive powder in a manner similar to that described above. However, rather than using an energy source to generate an energy beam to selectively melt or fuse the additive powder, binder jetting involves selectively depositing a liquid binder onto each powder layer. The liquid binder can be, for example, a photocurable polymer or another liquid binder. Other suitable additive manufacturing methods and variations are intended to fall within the scope of the present subject matter.

[0082] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be a plastic, a metal, concrete, a ceramic, a polymer, an epoxy resin, a photopolymer resin, or any other suitable material that can be in a solid, liquid, powder, sheet, wire, or any other suitable form. More specifically, according to embodiments of the present subject matter, the additively manufactured parts described herein can be formed partially, in whole, or from some combination of materials including, but not limited to, pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt-based superalloys (e.g., available from Special Metals Corporation under the name These materials are examples of materials suitable for use in the additive manufacturing processes described herein and may generally be referred to as "additive materials."

[0083] In addition, the additive manufacturing processes disclosed herein allow a single component to be formed from multiple materials. Thus, the components described herein can be formed from any suitable mixture of the above-mentioned materials. For example, a component can include multiple layers, segments, or parts formed using different materials, processes, and / or on different additive manufacturing machines. In this way, components with different materials and material properties can be constructed to meet the needs of any specific application. In addition, while the additive manufacturing processes used to form the components described herein are described in detail, it should be understood that in alternative embodiments, all or a portion of these components can be formed by casting, machining, and / or any other suitable manufacturing process. In fact, any suitable combination of materials and manufacturing methods can be used to form these components.

[0084] It is noteworthy that in embodiments, several features of the components described herein were previously impossible due to manufacturing limitations. Although the present disclosure is generally not limited to using additive manufacturing to form these components, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced costs, greater accuracy, etc.

[0085] In this regard, using additive manufacturing methods, even multi-part components can be formed as a single, continuous piece of material and, therefore, may include fewer subcomponents and / or joints than existing designs. Integrating these multi-part components through additive manufacturing can advantageously improve the overall assembly process. For example, integration reduces the number of individual parts that must be assembled, thereby reducing the associated time and overall assembly costs. Furthermore, existing issues related to, for example, leakage, the quality of the joints between individual parts, and overall performance can be advantageously reduced.

[0086] Furthermore, the aforementioned additive manufacturing methods enable the realization of more complex and intricate shapes and contours of the components described herein. For example, such components may include thin additively manufactured layers, unique mating or complementary geometries, customized cooling cavity sizes and shapes, and / or customized passageway numbers, shapes, and paths. As a specific example, using additive manufacturing methods such as those described herein, one or more of the plurality of links 106 may be formed with unique wire guide channels and sight paths defined therein. Furthermore, each of the plurality of links 106 may have a unique geometry, including various passageways, wire guides, and / or wire guide segments 110, 174, 176, windows 150, and / or other features that may be defined therein, allowing the extension tool 100 to be customized in size, shape, and other aspects for use with a specific component, assembly, system, device, apparatus, or the like. Furthermore, additive manufacturing methods may allow for the manufacture of such customized extension tools 100, including, for example, a plurality of unique links 106, with reduced manufacturing time, cost, and complexity compared to other manufacturing methods.

[0087] Furthermore, while additive manufacturing can produce a single, unitary component, such as the one described herein, from a single material, the additive manufacturing process can also produce a single component with different materials, so that different portions of the component can exhibit different performance characteristics. The continuous, additive nature of the manufacturing process enables the construction of these novel features. As a result, the components described herein can exhibit improved performance and reliability.

[0088] It should be understood that the extension tool 100, including the plurality of connecting rods 106 and support members 130, described herein is merely for the purpose of explaining various aspects of the present subject matter. For example, the extension tool 100 is used herein to describe various configurations, structures, and methods of manufacturing the extension tool 100. It should be understood that the additive manufacturing techniques discussed herein can be used to manufacture other extension tools, connecting rods, or similar components for use in any suitable device, for any suitable purpose, and in any suitable industry. Therefore, the components and methods described herein are merely for the purpose of illustrating various aspects of the present subject matter and are not intended to limit the scope of the present disclosure in any way.

[0089] The present subject matter also includes methods of insertion, i.e., methods of inserting the extension tool 100 into a component or the like. The extension tool 100 can be constructed according to any of the various embodiments described herein. For example, Figure 16 As shown, the method 200 includes (202) generating a signal by a component (such as a gas turbine engine 10 ( Figure 12 )) is inserted into a support member 130 that defines the distal end 114 of the extension tool 100. The method 200 also includes (204) pushing the extension tool 100 to guide the plurality of links 106 through the port. As described herein, the distal end 122 of each link 106 can include a protruding alignment feature 180 that helps guide the link 106 through the port, for example, by "catching" the structure defining the aperture and then sliding into the aperture. As the links 106 move through the port, adjacent links 106 close at their mating (intrusive alignment feature 178 and protruding alignment feature 180), for example, to help prevent the links 106 from getting stuck on any protrusion or vertical surface of the component during the insertion path of the extension tool 100.

[0090] Furthermore, as the extension tool 100 is advanced to guide the plurality of connecting rods 106 into the component, the support member 130, including the wheels 132, guides the connecting rods 106 through the component. The first bend 115, the second bend 125, the third bend 135, and the fourth bend 145, or the curved tip shape of the support member 130, along with the wheels 132, can be particularly helpful in facilitating insertion into curved components, such as annular gas turbine engine combustors, annular gas turbine engine turbine or compressor stages, spherical or cylindrical pressure vessels or tanks, or the like, or along non-linear insertion paths. More specifically, for example, the curved shape of the support member 130 and the wheels 132 help prevent the connecting rods 106 from becoming stuck or obstructed on features or surfaces of the component, as compared to the relatively blunt distal ends of the connecting rods 106.

[0091] The method 200 also includes (206) tensioning or rigidifying the extension tool 100 to cause it to assume a predetermined shape, such as Figures 2 to 5 In some embodiments, the extension tool 100 can be manually tensioned or rigidified, e.g., a person can manually manipulate elements of the base 102 to tighten the wire guide assembly 110 and draw the connecting rod 106 and support member 130 together. In other embodiments, the extension tool 100 can be automatically tensioned or rigidified; e.g., the base 102 can be coupled to or integrated with an automated machine (e.g., a robot) to tension the wire 110 using numerical control, computer control, etc.

[0092] When the extension tool 100 is inserted into the component, for an extension tool 100 including a plurality of windows 150, the windows 150 are aligned along the length of the plurality of sequentially arranged links 106. One or more implements, tools, and / or devices can be inserted into the extension tool 100 individually (e.g., sequentially) or in combination with one another to perform inspection, maintenance, cleaning, repair, maintenance, or other activities. In addition, while the one or more implements, tools, and / or devices are inserted into the tool 100 or before or after the implements, tools, and / or devices are within the tool 100, one or more fluids can flow along one or more channels defined in the extension tool 100. After completing the activity involving the extension tool 100, the tool 100 can be returned to its relaxed position and removed from the component.

[0093] It will be appreciated that while examples of the present subject matter are described herein with respect to aircraft gas turbine engines, particularly turbofan engines, the present subject matter may also be used in other environments. For example, the extend tool 100 described herein may be used in other gas turbine engines and turbines. As a further example, the extend tool 100 described herein may be used for inspection, maintenance, cleaning, and / or other activities on tanks, pressure vessels, and the like, such as those found in oil and gas applications. The present subject matter may also have other applications.

[0094] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0095] 1. An extension tool, comprising: a base link at the proximal end of the extension tool, wherein the base link includes a first bend; a transition section, the transition section including a second bend and connected to the base link; a plurality of sequentially arranged links, the plurality of sequentially arranged links being movable relative to each other, the plurality of sequentially arranged links being connected to the transition section and including a third bend; and a support member having a wheel at the distal end of the extension tool, wherein the support member includes a fourth bend; wherein the first bend of the base link extends in a first direction relative to a longitudinal centerline of the extension tool, wherein the second bend and the fourth bend extend in a second direction along the longitudinal centerline and bend downward, and wherein the third bend of the plurality of sequentially arranged links extends in a third direction along the longitudinal centerline and bends upward.

[0096] The extension tool of any preceding clause, wherein the plurality of sequentially arranged links includes a distal link, and wherein the distal link is the support member such that the distal link includes the distal end and includes the wheel.

[0097] An extension tool according to any preceding clause, wherein the wheel is integrally formed with the distal link.

[0098] An extension tool as claimed in any preceding clause, wherein the support member comprises an integrated shaft to integrally couple the wheel to the support member.

[0099] An extension tool according to any preceding clause, wherein the support member is removably coupled to the plurality of sequentially arranged links such that the wheel can be removed from the extension tool.

[0100] The extension tool of any preceding clause, wherein the support member comprises a first flexible member for coupling to a distal link of the plurality of sequentially arranged links, and a second flexible member comprising the wheel.

[0101] An extension tool according to any preceding clause, wherein the first and second flexible members are coupled together via a joint.

[0102] An extension tool as claimed in any preceding clause, wherein the plurality of sequentially arranged links include an internal passage therethrough for receiving a borescope.

[0103] An extension tool as claimed in any preceding clause, wherein the stiffness of the extension tool is controlled by the borescope.

[0104] An extension tool according to any preceding clause, wherein the plurality of sequentially arranged links are coupled together via a semi-flexible spine.

[0105] An extension tool according to any preceding clause, wherein the stiffness of the plurality of sequentially arranged links is controlled by moving the semi-flexible spine.

[0106] An extension tool according to any preceding clause, wherein the plurality of sequentially arranged links are coupled together via at least one wire guide assembly.

[0107] An extension tool according to any preceding clause, wherein a link of the plurality of sequentially arranged links includes a window.

[0108] The extension tool of any preceding clause, further comprising: a plurality of windows defined in the plurality of sequentially arranged links, wherein each window of the plurality of windows is periodically defined along the plurality of sequentially arranged links.

[0109] 1. An extension tool including a proximal end and a distal end, the extension tool comprising: a base link defining the proximal end, wherein the base link includes a first bend bent in a first horizontal direction; a transition section connected to the base link and including a second bend bent in a second downward direction; and a plurality of sequentially arranged links capable of moving relative to each other, wherein each of the plurality of sequentially arranged links includes an internal channel to form a channel therethrough, and wherein the plurality of sequentially arranged links include a third bend bent in a third upward direction, the third bend being substantially aligned with the second bend; a distal link defining the distal end; and a support member including a wheel and an axial ring disposed at the distal end, wherein the support member is capable of being inserted through the channel of the plurality of sequentially arranged links, and wherein the axial ring contacts the distal link to hold the wheel in place.

[0110] An extension tool as claimed in any preceding clause, wherein the support member comprises a fourth bend curved in the second downward direction, the fourth bend being substantially aligned with the second and third bends.

[0111] An extension tool according to any preceding clause, wherein the first bend of the base link extends substantially perpendicular to the second, third and fourth bends such that the first bend curves outwardly relative to a longitudinal centreline.

[0112] An extension tool as claimed in any preceding clause, wherein the support member comprises an integrated shaft to integrally couple the wheel to the support member.

[0113] An extension tool as claimed in any preceding clause, wherein the support member comprises a first flexible member for extending through the plurality of sequentially arranged links; and a second flexible member comprising the wheel.

[0114] An extension tool according to any preceding clause, wherein the first and second flexible members are coupled together via a joint.

[0115] An extension tool according to any preceding clause, wherein the plurality of sequentially arranged links are coupled together via a semi-flexible spine.

[0116] It will be understood that those skilled in the art may make various changes to the details, materials, and arrangements of parts and components described and illustrated herein to illustrate the nature of the present disclosure within the spirit and scope of the appended claims. In addition, although various features have been described with respect to specific embodiments, it will be understood that features described with respect to one embodiment may also be combined with other described embodiments.

Claims

1. An extension tool, characterized in that: include: a base link at a proximal end of the extension tool, wherein the base link includes a first bend; a transition section including a second bend and coupled to the base link; a plurality of sequentially arranged links movable relative to each other, the plurality of sequentially arranged links coupled to the transition section and including a third bend; as well as a support member having a wheel at a distal end of the extension tool, wherein the support member includes a fourth bend; wherein the first bend of the base link extends in a first direction relative to a longitudinal centerline of the extension tool, wherein the second bend and the fourth bend extend in a second direction along the longitudinal centerline and bend downward, and wherein the third bend of the plurality of sequentially arranged links extends in a third direction along the longitudinal centerline and bends upward.

2. The extension tool according to claim 1, wherein: in, The plurality of sequentially arranged links includes a distal link, and wherein the distal link is the support member such that the distal link includes the distal end and includes the wheel.

3. The extension tool according to claim 2, characterized in that in, The wheel is integrally formed with the distal link.

4. The extension tool according to claim 1, wherein: in, The support member includes an integrated shaft to integrally couple the wheel to the support member.

5. The extension tool according to claim 1, wherein: in, The support member is removably coupled to the plurality of sequentially arranged links such that the wheel can be removed from the extension tool.

6. The extension tool according to claim 1, wherein: in, The support member comprises: a first flexible member for coupling to a distal link of the plurality of sequentially arranged links; and A second flexible member includes the wheel.

7. The extension tool according to claim 6, characterized in that in, The first flexible member and the second flexible member are coupled together via a joint.

8. The extension tool according to claim 1, wherein: in, The plurality of sequentially arranged links include an internal passage therethrough for receiving a borescope.

9. The extension tool according to claim 8, characterized in that in, The stiffness of the extension tool is controlled by the borescope.

10. The extension tool according to claim 1, wherein: in, The plurality of sequentially arranged links are coupled together via a semi-flexible spine.

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