Device and method for measuring mechanical strain

Abstract

A strain sensing assembly includes a sensor substrate bonded to a strain sensing element, wherein the sensor substrate is captured in a capture pocket formed by first and second fixing pins and a turbine engine component. An adhesive material may be disposed in the capture pocket to adhere the sensor substrate to the turbine engine component and the first / second fixing pin. In some forms, an adhesive material is located between the first fixing pin and the sensor substrate. The compressive strain from the first fixing pin may be transmitted to the sensor substrate through the adhesive material. In other forms, the sensor substrate is in direct mechanical contact with the first fixing pin. The compressive strain from the first fixing pin may be transmitted directly to the sensor substrate.

Description

Technical Field

[0001] This disclosure relates to a strain sensing assembly for measuring mechanical strain. Background Technology

[0002] Gas turbine engines typically consist of a turbine and a rotor assembly. Gas turbine engines, such as turbofan engines, are used for aircraft propulsion and are subjected to loads in this manner, resulting in stress and strain on the components. Measuring the loads on turbine engine components is desirable to ensure safe operation and monitor component health. Improvements in strain sensing systems would be useful in this field. Attached Figure Description

[0003] The complete and enabling disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0004] Figure 1 This is a cross-sectional view of a gas turbine engine for providing propulsion power to an aircraft, according to an exemplary aspect of this disclosure.

[0005] Figure 2 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0006] Figure 3 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0007] Figure 4A This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0008] Figure 4B This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0009] Figure 5A This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0010] Figure 5B This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0011] Figure 6 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0012] Figure 7 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0013] Figure 8 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0014] Figure 9 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0015] Figure 10 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0016] Figure 11 This is a schematic diagram of a sensor substrate and a strain sensing element according to another exemplary aspect of this disclosure.

[0017] Figure 12A This is a schematic diagram of a sensor assembly according to another exemplary aspect of this disclosure.

[0018] Figure 12B This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0019] Figure 13 This is a schematic diagram of a strain sensing component according to another exemplary aspect of this disclosure.

[0020] Figure 14 This is a schematic diagram of a computing device according to another exemplary aspect of this disclosure.

[0021] Figure 15 This is a flowchart describing a method for manufacturing a strain sensing component according to the present disclosure. Detailed Implementation

[0022] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerals and letter reference numerals to denote features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to denote similar or analogous portions of this disclosure.

[0023] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as being more preferred or advantageous than other implementations. Furthermore, unless otherwise specifically indicated, all embodiments described herein should be considered exemplary.

[0024] The singular forms “one,” “a,” and “the” include plural references unless the context clearly indicates otherwise.

[0025] In a context such as “at least one of A, B and C”, the term “at least one” means only A, only B, only C, or any combination of A, B and C.

[0026] The term “turbine” refers to a machine that includes one or more compressors, a heating section (e.g., a combustion section), and one or more turbines that together produce torque output.

[0027] The term "gas turbine engine" refers to an engine that has a turbine as its power source, either entirely or partially. Examples of gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and hybrid electric versions of one or more of these engines.

[0028] The term "combustion section" refers to any heat addition system used in a turbine. For example, the term combustion section can refer to a section that includes one or more of a knock combustion assembly, a rotating detonation combustion assembly, a pulse detonation combustion assembly, or other suitable heat addition assembly. In some example embodiments, the combustion section may include an annular burner, a cylindrical burner, a tubular burner, a vortex burner (TVC), or other suitable combustion systems, or combinations thereof.

[0029] The terms “axial” and “axially” refer to a direction and orientation that extends substantially parallel to the reference axis. Furthermore, the terms “radial” and “radially” refer to a direction and orientation that extends substantially perpendicular to the reference axis. Additionally, as used herein, the terms “circumferential” and “circumferentially” refer to a direction and orientation that extends in an arc about the reference axis.

[0030] The terms “connection,” “fixation,” “attachment,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment via one or more intermediate components or features, unless otherwise specified herein.

[0031] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0032] As used herein, "third stream" refers to a small portion of non-primary airflow that can increase fluid energy to generate total propulsion thrust. The third stream typically receives inlet air (air from a duct downstream of the primary fan) rather than free-flowing air (as with the primary fan). The pressure ratio of the third stream may be higher than that of the primary propulsion stream (e.g., bypass or propeller-driven propulsion stream). Thrust can be generated via dedicated nozzles or by mixing the airflow through the third stream with the primary propulsion stream or core airflow (e.g., into a shared nozzle).

[0033] As used throughout this specification and claims, approximate language is used to modify any quantitative representation that may allow for variation without altering the underlying functionality associated with it. Therefore, a value modified by one or more terms (e.g., “about,” “approximate,” and “substantially”) is not limited to a specified exact value. In at least some cases, approximate 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 part and / or system. For example, approximate language may refer to a margin of 1%, 2%, 4%, 10%, 15%, or 20%. These approximate margins may be applied to a single value, or to the margin defining one or both endpoints of a numerical range and / or the range between those endpoints.

[0034] As will be discussed in more detail below, the subject matter of this disclosure generally relates to a strain sensing assembly for measuring strain in a turbine engine component. The strain measurement can be used to determine temperature, strain, frequency, torque, speed, or combinations thereof, and can be used for engine control or health monitoring. It should be understood that the determined value of any one of temperature, strain, frequency, torque, speed, or combinations thereof can be directly calculated from the strain measurement, wherein such strain measurement is determined by the electrical output of the strain sensing assembly. The strain sensing assembly may include a first retaining pin and a second retaining pin, which form a trapping pocket with the turbine engine component. A sensor substrate may be located in the trapping pocket and secured in place by compressive strain between the first retaining pin, the second retaining pin, and the turbine engine component. A strain sensing element may be bonded to the sensor substrate. In one embodiment, an adhesive material is located between the first retaining pin and the turbine engine component, wherein compressive strain is transferred through the adhesive material. In another embodiment, the sensor substrate is in direct contact with the first retaining pin, such that compressive strain is transferred directly from the first retaining pin to the sensor substrate.

[0035] Referring now to the accompanying drawings, in which the same reference numerals denote the same elements throughout the figures. Figure 1 This is a schematic cross-sectional view of a gas turbine engine according to exemplary embodiments of the present disclosure. More specifically, for Figure 1 In one embodiment, the gas turbine engine is a high-bypass turbofan jet engine, sometimes also referred to as a "turbofan engine." For example... Figure 1 As shown, the gas turbine engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 provided for reference), a radial direction R, and a circumferential direction C extending about the longitudinal centerline 12. Generally, the gas turbine engine 10 includes a fan section 14 and a turbine 16 disposed downstream of the fan section 14.

[0036] The exemplary turbine 16 shown typically includes a generally tubular outer casing 18 defining an annular inlet 20. The casing 18 surrounds, in a series flow relationship, a compressor section including a turbocharger or low-pressure (LP) compressor 22 and a high-pressure (HP) compressor 24; a combustion section 26; a turbine section including a high-pressure (HP) turbine 28 and a low-pressure (LP) turbine 30; and an exhaust nozzle section 32. A high-pressure (HP) shaft 34 (which may additionally or alternatively be a spool) drivesably connects the HP turbine 28 to the HP compressor 24. A low-pressure (LP) shaft 36 (which may additionally or alternatively be a spool) drivesly connects the LP turbine 30 to the LP compressor 22. The compressor section, combustion section 26, turbine section, and exhaust nozzle section 32 together define a working gas flow path 37.

[0037] In the illustrated embodiment, fan section 14 includes a fan 38 having a plurality of fan blades 40 spaced apart and coupled to disk 42. As shown, the fan blades 40 extend outward from disk 42 generally in a radial direction R. Each fan blade 40 is operably coupled to a suitable pitch changing mechanism 44 by means of the fan blades 40, allowing rotation relative to disk 42 about a pitch axis P. The pitch changing mechanism 44 is configured to collectively change the pitch of the fan blades 40, for example, to uniformly change the pitch of the fan blades 40. Gas turbine engine 10 further includes a power gearbox 46, and the fan blades 40, disk 42, and pitch changing mechanism 44 are rotatable together about a longitudinal centerline 12 via an LP shaft 36 across the power gearbox 46. The power gearbox 46 includes a plurality of gears for adjusting the rotational speed of fan 38 relative to LP shaft 36, allowing fan 38 to rotate at a more efficient fan speed.

[0038] Still referencing Figure 1 In an exemplary embodiment, the disc 42 is covered by a rotatable front hub 48 (sometimes referred to as a "rotor") of the fan section 14. The front hub 48 has an aerodynamic profile to facilitate airflow through the multiple fan blades 40.

[0039] Furthermore, the exemplary fan section 14 includes an annular fan housing or outer nacelle 50 that circumferentially surrounds at least a portion of the fan 38 and / or turbine 16. It should be understood that, in the illustrated embodiment, the nacelle 50 is supported relative to the turbine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Additionally, a downstream section 54 of the nacelle 50 extends above the outer portion of the turbine 16, thereby defining a bypass airflow passage 56 between the two.

[0040] During operation of the gas turbine engine 10, a volume of air 58 enters the gas turbine engine 10 through the nacelle 50 and the corresponding inlets 60 of the fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of air 62 is directed or directed into the bypass airflow passage 56, and a second portion of air 64, as indicated by arrow 64, is directed or directed into the working gas flow path 37, or more specifically, into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is commonly referred to as the bypass ratio. The pressure of the second portion of air 64 then increases as it is directed through the HP compressor 24 and into the combustion section 26, where it mixes with fuel and is burned to provide combustion gases 66.

[0041] Combustion gas 66 is directed through HP turbine 28, in which a portion of the thermal and / or kinetic energy from combustion gas 66 is extracted via a successive stage of HP turbine stator blades 68 connected to housing 18 and HP turbine rotor blades 70 connected to HP shaft 34, thereby rotating HP shaft 34, which supports the operation of HP compressor 24. Combustion gas 66 is then directed through LP turbine 30, in which a second portion of the thermal and kinetic energy is extracted from combustion gas 66 via a successive stage of LP turbine stator blades 72 connected to housing 18 and LP turbine rotor blades 74 connected to LP shaft 36, thereby rotating LP shaft 36, which supports the operation of LP compressor 22 and / or the rotation of fan 38.

[0042] Combustion gas 66 is then directed through the injection exhaust nozzle section 32 of turbine 16 to provide propulsive thrust. Simultaneously, the pressure of the first portion of air 62 increases significantly as it is directed through the bypass airflow passage 56 before exiting the fan nozzle exhaust section 76 of gas turbine engine 10, also providing propulsive thrust. HP turbine 28, LP turbine 30, and injection exhaust nozzle section 32 at least partially define the hot gas path 78 for directing combustion gas 66 through turbine 16.

[0043] However, it should be understood that, Figure 1The exemplary gas turbine engine 10 shown is merely an example, and in other exemplary embodiments, the gas turbine engine 10 may have any other suitable configuration. For example, although the gas turbine engine 10 shown is configured as a ducted gas turbine engine (i.e., including the outer nacelle 50), in other embodiments, the gas turbine engine 10 may be a ductless gas turbine engine (such that the fan 38 is a ductless fan, and the outlet guide vane 52 cantilevered out from the housing 18). Additionally or alternatively, although the gas turbine engine 10 shown is configured as a geared gas turbine engine (i.e., including a power gearbox 46) and a variable pitch gas turbine engine (i.e., including a fan 38 configured as a variable pitch fan), in other embodiments, the gas turbine engine 10 may additionally or alternatively be configured as a direct-drive gas turbine engine (such that the LP shaft 36 rotates at the same speed as the fan 38), a fixed-pitch gas turbine engine (such that the fan 38 includes fan blades 40 that cannot rotate about the pitch axis P), or a combination of both. It should also be understood that, in other exemplary embodiments, aspects of this disclosure may be incorporated into any other suitable gas turbine engine. For example, in other exemplary embodiments, aspects of this disclosure may (as the case may) be incorporated into, for example, a turboprop gas turbine engine, a turboshaft gas turbine engine, or a turbojet gas turbine engine.

[0044] In one embodiment, the gas turbine engine 10 can be used as the prime mover of the aircraft 90 to provide propulsion power to the aircraft 161. In another embodiment, the gas turbine engine 10 can be used in other applications, whether related to power facilities for transportation or as an engine for static power generation.

[0045] Now go to Figure 2 Embodiments of the strain sensing assembly 202 are adhered to a turbine engine component 204, which may include a rotatable shaft (e.g., a rotatable shaft such as HP shaft 34 and / or LP shaft 36 and / or any other suitable structure). It is understood that the strain sensing assembly 202 can be adhered to any suitable structure, such as any structure associated with an aerospace propulsion system, a power generation system, or an automotive system (any of which can be considered a propulsion system). In this way, the rotatable shaft to which the strain sensing assembly 202 is adhered can be a shaft of the propulsion system. Additionally and / or alternatively, the rotatable shaft can be any of the gearbox shaft, power output shaft, low-pressure turbine shaft, high-pressure turbine shaft, fan shaft, or engine coupling shaft of the propulsion system.

[0046] The strain sensing component 202 is configured to respond to mechanical strain in the turbine engine component 204 and generate a signal indicating the strain. The signal generated by the strain sensing component 202 can be transmitted to the engine controller 200 or any other suitable device (e.g., a computing device discussed further below) for use and / or further processing. For example, in some embodiments, the signal can represent the strain measured in the turbine engine component 204; while in other embodiments, the signal can be further processed using, for example, a calibration curve to generate the measured strain or torque.

[0047] The strain sensing assembly 202 includes a strain sensing element 206 coupled to a sensor substrate 208. The strain sensing element 206 is configured to respond to a dimensional change associated with strain transmitted from the turbine engine component 204 through the sensor substrate 208 and to the strain sensing element 206. The strain sensing element 206 can take various forms, including a strain gauge. In one form, the strain sensing element 206 is a surface acoustic wave (SAW) strain sensor. In another form, the strain sensing element 206 can be a bulk acoustic wave (BAW) sensor. In some embodiments, the strain sensing assembly 202 can be configured to wirelessly transmit a signal indicating strain, which may include a raw signal generated by the strain sensing element 206 or a calculated signal based on the raw signal.

[0048] In some embodiments, the sensor substrate 208 is made of a material with an elastic modulus close to that of the turbine engine component 204. For example, the sensor substrate 208 may have an elastic modulus within 1% of that of the turbine engine component 204. In other embodiments, the sensor substrate 208 may have an elastic modulus within 5% of that of the turbine engine component 204. In a further embodiment, the sensor substrate 208 may have an elastic modulus within 10% of that of the turbine engine component 204. In one form, the sensor substrate 208 is made of quartz.

[0049] The strain sensing element 206 can be bonded and / or otherwise formed to the sensor substrate using any suitable technique. In one form, the sensing element 206 is bonded to the sensor substrate by means of a fabrication process for depositing the sensing element 206. To give only two non-limiting examples, the sensing element 206 can be deposited using wafer-level processes such as sputtering deposition or photolithography. The sensor substrate 208 can be bonded to the turbine engine component 204 using any suitable technique such as chemical bonding, including adhesive material 210. Regardless of the type of chemical adhesive material used to bond the sensor substrate 208 to the turbine engine component 204, the chemical adhesive material is expected to have a high modulus of elasticity and be applied as a relatively thin layer. For example, the chemical adhesive material used to bond the sensor substrate 208 to the turbine engine component 204 is expected to have an modulus of elasticity between 5 GPA and 200 GPA in some applications, between 50 GPA and 150 GPA in other applications, and between 75 GPA and 125 GPA in still other applications. Furthermore, the chemical adhesive used to bond the sensor substrate 208 to the turbine engine component 204 is expected to have an adhesive thickness between 5 μm and 250 μm in some applications, between 50 μm and 200 μm in other applications, and between 100 μm and 150 μm in still other applications. Additionally, the chemical adhesive used to bond the sensor substrate 208 to the turbine engine component 204 is expected to have a glass transition temperature above 190°C. In some embodiments, the chemical adhesive used to bond the sensor substrate 208 to the turbine engine component 204 can be cured in a zero-stress state at a temperature corresponding to the expected operating temperature of the turbine engine component 204. In other embodiments disclosed elsewhere herein, the sensor substrate 208 can be mechanically held against the turbine engine component 204 without the use of a chemical adhesive.

[0050] The strain sensing assembly 202 includes a first retaining pin 212 and a second retaining pin 214, which facilitate the formation of a capture pouch 215 for capturing and forming a pouch for holding the sensor substrate 208 and / or adhesive material 210. The first retaining pin 212 and / or the second retaining pin 214 may extend entirely or partially along the edge of the sensor substrate 208 (e.g., as shown in the image). Figure 2 As shown (viewed from the direction of entering the page). The first retaining pin 212 may include a first side leg 216 and a first top 218. The second retaining pin 214 may include a second side leg 220 and a second top 222. These pins may also surround all four sides of the sensor and be welded, brazed, or soldered thereto. The pouch may also be filled with solder, brazing compound, epoxy resin, or other moldable materials. Furthermore, these pins may be removable, such as bolts. Figure 2 As can be seen in the illustrated embodiment, the adhesive material 210 can be located not only between the sensor substrate 208 and the turbine engine component 204, but also between both the first top 218 and the second top 222 and the sensor substrate 208. In this way, the adhesive material 210 at least partially encapsulates the sensor substrate 208 without covering the sensing element. Strain applied to the turbine engine component 204 can be transferred in a tensile manner through the adhesive material and to the sensor substrate 208, or in a compressive manner from each of the first top 218 and the second top 222 through the adhesive material 210 and to the sensor substrate 208.

[0051] Now go to Figure 3 This describes alternative and / or additional embodiments of the strain sensing assembly 202, which include a die attachment 224 for coupling a sensor substrate 208 to a turbine engine component 204. In some embodiments, the die attachment 224 is, for example, Figure 2 The adhesive material 210 shown is the same. Figure 3 The use of a cover 226 and a seal 228 for protecting the strain sensing element 206, although not shown, is also depicted; the strain sensing element 206 may be located between the seal 228 and the sensor substrate 208. In one embodiment, the cover may be made of quartz. The sensor substrate may also be made of quartz and have a thickness between 100 and 500 micrometers (μm). Chip attachment 224 shows that the adhesive material is typically in a stretched state rather than a compressed state. Furthermore, as shown, in one form, the turbine engine component may be made of a metal such as steel. Figure 3 In the illustrations, the stacking of components (e.g., the stack of cover 226, seal 228, sensor substrate 208, and chip accessory 224) can have a variety of total thicknesses. For example, in some embodiments, the stack thickness can be any value from 0.25 mm to 1 mm. In other embodiments, the stack thickness can be any value from 0.5 mm to 0.75 mm.

[0052] Now go to Figure 4A and Figure 4BAnother embodiment of the strain sensing assembly 202 is depicted, wherein a first retaining pin 212 and a second retaining pin 214 are used to mechanically capture a sensor substrate 208. The first retaining pin 212 and the second retaining pin 214 may be integral with the turbine engine component 204 (e.g., they may be integral, such as being machined from the material already present in the turbine engine component 204), or they may be integrated (e.g., manufactured separately but joined by mechanical fasteners, chemical adhesives, metallurgical adhesives, etc.). A capture pouch portion 215 may be formed between the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. To mechanically capture the sensor substrate 208, the capture pouch portion 215 may be heated to increase the dimensions between the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204, thereby allowing the sensor substrate 208 to be mounted. In the heated state, the sensor substrate 208 may, for example, be slidably inserted into the capture pouch portion 215. During cooling, the mechanical interaction between the sensor substrate 208, the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204 can act like a dovetail joint, preventing the sensor substrate 208 from being disassembled. Furthermore, the sensor substrate 208 can be made of a material with a coefficient of thermal expansion (CoE) similar to that of any one or more of the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. For example, the CoE of the sensor substrate 208 can be within 1% of the CoE of any one or more of the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. In other embodiments, the CoE of the sensor substrate 208 can be within 5% of the CoE of any one or more of the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. In a further embodiment, the CoE of the sensor substrate 208 can be within 10% of the CoE of any one or more of the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. During elevated operating temperatures, in one case of mismatch in the CoE, the capture bag portion 215 can expand sufficiently to accommodate the expansion of the sensor substrate 208 without applying excessive stress to the sensor substrate 208, or mechanically capturing the sensor substrate 208 in another case of CoE mismatch. It is envisioned that the sensor substrate 208 is captured within the capture bag portion 215 such that compressive stress is applied to it via the first retaining pin 212, the second retaining pin 214, and the turbine engine component 204. The advantage of this is improved reliability, as many materials perform better under compression than under tension.

[0053] The sensor substrate 208 may include a chamfered edge 230 sized to match a substrate capture angle 232 formed between the first retaining pin 212 and the turbine engine component 204 (e.g., between the surfaces of the turbine engine component 204 and the first retaining pin 212 that are mechanically connected to the sensor substrate). It should be noted that another capture angle 232 is also formed between the second retaining pin 214 and the turbine engine component 204 (e.g., between the surfaces of the turbine engine component 204 and the second retaining pin 214 that are mechanically connected to the sensor substrate). The capture angle 232 formed between the second retaining pin 214 and the turbine engine component 204 may be the same as or different from the capture angle 232 formed between the second retaining pin 214 and the turbine engine component 204. Similarly, the sensor substrate 208 may include another chamfered edge to match the capture angle 232 formed between the second retaining pin 214 and the turbine engine component 204. It is understood that the capture angle 232 is formed by the orientation of the first retaining pin 212 (or alternatively the second retaining pin 214) relative to the turbine engine component 204. The first retaining pin 212 (or alternatively the second retaining pin 214) extends away from the turbine engine component 204 in a general direction of the thickness 234 of the sensor substrate 208 (e.g., in the thickness direction of the thickness 234). The angle of the surface of the first retaining pin 212 (or alternatively the surface of the second retaining pin 214) that mechanically connects the sensor substrate 208 is generally away from the turbine engine component 204 and extends toward the interior of the sensor substrate 208. The extension of the surface of the first retaining pin 212 (or alternatively the surface of the second retaining pin 214) toward the interior of the sensor substrate 208 may be in a direction generally along the lateral dimension of the sensor substrate 208 (e.g., in the lateral direction of the lateral dimension of the sensor substrate 208).

[0054] Now go to Figure 5A and Figure 5B Depicting with Figure 4A and Figure 4B Similar embodiments exist, except for cover 226. Cover 226 may include a cover chamfer 236 sized to match the substrate capture angle 232 formed between the first retaining pin 212 and the turbine engine component 204 (e.g., between the surfaces of the turbine engine component 204 and the first retaining pin 212 that are mechanically connected to the sensor substrate). It should be noted that cover 226 may also include the cover chamfer 236 on the side mechanically connected to the second retaining pin 214.

[0055] Figure 6 Depicting and Figure 2Similar embodiments are possible, but include a second adhesive material 238 for at least partially encapsulating the sensor substrate 208. As described above, the adhesive material 210 may be a material having a high modulus and capable of operating at the high temperatures of a gas turbine engine. The adhesive material 210 may have relatively high adhesive strength and low viscosity to provide thinner adhesive lines. In one embodiment, the adhesive material 210 may be made of the same material having the same properties as described above for bonding the sensor substrate 208 to the turbine engine component 204. In one form, the adhesive material 210 and / or the adhesive material for bonding the sensor substrate 208 to the turbine engine component 204 may have a viscosity in the range of 10-100 centipoise. In another embodiment, the adhesive material 210 and / or the adhesive material for bonding the sensor substrate 208 to the turbine engine component 204 may have a viscosity in the range of 25-75 centipoise. In yet another embodiment, the adhesive material 210 and / or the adhesive used to bond the sensor substrate 208 to the turbine engine component 204 may have a viscosity in the range of 40-60 centipoise. Furthermore, in one embodiment, the adhesive material 210 and / or the adhesive used to bond the sensor substrate 208 to the turbine engine component 204 may have an adhesion strength of 1000-3000 pounds per square inch (psi). In another embodiment, the adhesive material 210 and / or the adhesive used to bond the sensor substrate 208 to the turbine engine component 204 may have an adhesion strength of 1500 psi-2500 psi. In yet another embodiment, the adhesive material 210 and / or the adhesive used to bond the sensor substrate 208 to the turbine engine component 204 may have an adhesion strength of 1750 psi to 2250 psi. In another embodiment, the adhesive material 210 and / or the adhesive material used to bond the sensor substrate 208 to the turbine engine component 204 may have a Young's modulus between 0.5 gigapascals and 2 gigapascals. In yet another embodiment, the adhesive material 210 and / or the adhesive material used to bond the sensor substrate 208 to the turbine engine component 204 may have a Young's modulus between 1 gigapascal and 1.5 gigapascals. In yet another embodiment, the adhesive material 210 and / or the adhesive material used to bond the sensor substrate 208 to the turbine engine component 204 may have a Young's modulus between 1.2 gigapascals and 1.32 gigapascals.

[0056] The second adhesive material 238 may be made of a different material than the adhesive material 210. The second adhesive material 238 may have a relatively higher modulus than the adhesive material 210 and may have high compressive strength to transfer compressive forces from the first retaining pin 212 and the second retaining pin 214 to the sensor substrate 208. Further, the second adhesive material 238 may include a filler material, a ceramic paste, and a high-temperature material. The second adhesive material 238 may have a compressive strength between 1 gigapascal and 200 gigapascals. In another embodiment, the second adhesive material 238 may have a compressive strength between 50 gigapascals and 150 gigapascals. In yet another embodiment, the second adhesive material 238 may have a compressive strength between 75 gigapascals and 125 gigapascals. The second adhesive material may have a glass transition temperature up to 500 degrees Celsius. In another embodiment, the second adhesive material may have a glass transition temperature between 450 degrees Celsius and 550 degrees Celsius. The adhesive line thickness may have the same thickness and / or thickness range as the adhesive material 210 and / or the adhesive material used to bond the sensor substrate 208 to the turbine engine component 204. In one embodiment, the adhesive line thickness may have the same lower limit range as the thickness and / or thickness range of the adhesive material 210 and / or the adhesive material used to bond the sensor substrate 208 to the turbine engine component 204, wherein the upper limit range is 250 micrometers. The curing temperature of the second adhesive material 238 may be 200 degrees Celsius. In another embodiment, the curing temperature of the second adhesive material 238 may be 225 degrees Celsius. In yet another embodiment, the curing temperature of the second adhesive material 238 may be 250 degrees Celsius. It should be noted that in many embodiments, the second adhesive material 238 is cured under zero stress. Furthermore, the second adhesive material 238 is cured at a temperature higher than the expected operating temperature of the turbine engine component 204. The second adhesive material 238 may comprise a filler material, such as silica, silicate, or ceramic. In one form, the second adhesive material 238 may be a non-conductive epoxy resin containing inorganic fillers in an organic or inorganic substrate. In one embodiment, the second adhesive material 238 may be a material such as Stycast, manufactured by HENKEL AG&CO.KGAA at HENKELSTRASSE 67, DUSSELDORF GERMANY 40589, Germany. In some forms, the filler material used in the second adhesive material 238 may be calcium carbonate, talc, silica, wollastonite, mica, glass beads, alumina trihydrate, clay, kaolin, and carbon.

[0057] In addition to the above, the strain sensing assembly may include a conduit 240 formed through the first retaining pin 212 for wiring at least one lead 242, which electrically connects the strain sensing element 206 to a suitable receiving device, such as a transmitter, computing device, etc.

[0058] Figure 7 An embodiment is depicted in which a strain sensing element 206 communicates electrically with a sensor transmitter 244 bridged between a first retaining pin 212 and a second retaining pin 214. The sensor transmitter 244 is configured to receive a signal indicating strain from the strain sensing element 206 and process the signal for wireless transmission to any suitable receiving device (e.g., a computing device discussed further below). The sensor transmitter 244 may include any desired electronics and power supply for providing power to the strain sensing element 206. For example, the sensor transmitter 244 may include a battery 246 and power electronics 248 for providing a voltage and / or current suitable for the type of strain sensing element 206 to the strain sensing element 206. The sensor transmitter 244 may have a suitable radio frequency (RF) antenna for transmitting the signal indicating strain (e.g., transmitting the raw signal and / or calculated signal from the strain sensing element 206).

[0059] Figure 8 The first fixing pin 212 and the second fixing pin 214 are depicted having a function for forming a capture bag portion 215, similar to Figure 4A-5B An embodiment of the inclined surfaces of the first fixing pin 212 and the second fixing pin 214. However, in Figure 8 In the illustrated embodiment, the sensor substrate 208 may not include... Figure 4A-5B The chamfered edge 230 is shown. Compressive stress is applied to the sensor substrate 208 via adhesive material 210 from the first retaining pin 212 and the second retaining pin 214.

[0060] Figure 9 An embodiment is depicted where the first retaining pin 212 and the second retaining pin 214 are shot-peened to form the first top 218 and the second top 222. In other embodiments, the first top 218 and the second top 222 may be machined in place or adhered to the respective first leg 216 and second leg 220 via any suitable technique (e.g., mechanical fastening, chemical bonding, metallurgical bonding, etc.). Compressive stress is applied from the shot-peened areas of the first top 218 and the second top 222 to the sensor substrate 208 via the adhesive material 210. This compressive stress can be used to deform the first top 218 and the second top 222.

[0061] Figure 10An embodiment of a strain sensing assembly 202 is depicted. This assembly is modular and can be inserted into a slot 250 formed in a turbine engine component 204. The strain sensing assembly 202 may include chamfered feet 252 that engage the overhanging portion 254 of the slot 250. Similar to the thermal fit of the sensor substrate 208 within the capture bag portion 215, Figure 10 The strain sensing component 202 can be thermally fitted into the groove 250.

[0062] Figure 11 A top view of sensor substrate 208 and sensing element 206 is depicted. As described above, sensor substrate 208 may include a lateral dimension 256 extending in a lateral direction 258. Strain sensing element 206 is located inside the outer periphery of sensor substrate 208. Sensor substrate 208 includes a region 260 that extends laterally beyond the outer periphery of strain sensing element 206. In the various embodiments described herein, compressive forces (direct pressure or indirect pressure via adhesive material 210) from first retaining pin 212 and second retaining pin 214 may be applied to region 260.

[0063] Figure 12A-12B An embodiment of a sensor substrate 208 including an aperture 262 is depicted. While the aperture 262 is located around the entire periphery of the sensor substrate 208, some embodiments may include fewer apertures 262 arranged along fewer edges of the sensor substrate 208. For example... Figure 12B As shown, the adhesive material 210 can be located in the aperture 262 and apply downward compressive stress to the sensor substrate 208 through the inner surface of the aperture 262.

[0064] Figure 13 Depicting and Figure 11 A similar arrangement, except that orifice 262 is not a through hole (e.g., Figure 10 Instead of a through-hole, it is an opening that does not extend through the thickness of the sensor substrate 208. Figure 12B As in the previous embodiment, compressive stress is applied to the sensor substrate 208 via the adhesive material 210 and the orifice 262.

[0065] Now go to Figure 14 Any of the engine controller 200, sensor transmitter 244, etc., used to process, transmit, and / or receive signals indicating strain in turbine engine components may be implemented using computing device 268, one embodiment of which is... Figure 14 As shown in the image. For illustrative purposes, Figure 14Engine controller 200 is depicted, but this description applies to any other controller discussed herein. Computing device 268 may include one or more processors 268A and one or more memory devices 268B. The one or more processors 268A may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, and / or other suitable processing device. The one or more memory devices 268B may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard disk drives, flash drives, and / or other memory devices.

[0066] One or more memory devices 268B may store information accessible to one or more processors 268A, including computer-readable instructions 268C executable by one or more processors 268A. Instructions 268C may be any set of instructions that, when executed by one or more processors 268A, cause one or more processors 268A to perform an operation. In some embodiments, instructions 268C may be executed by one or more processors 268A to cause one or more processors 268A to perform operations, such as any operations and functions configured for the controller and / or computing device 268, operations as described herein for any of the aforementioned systems (e.g., valve 223, etc.), and / or any other operations or functions of one or more computing devices 268 (e.g., as a full authority digital engine controller). Instructions 268C may be software written in any suitable programming language or implemented in hardware. Furthermore, and / or alternatively, instructions 268C may execute on one or more processors 268A in logically and / or virtually independent threads. One or more memory devices 268B may also store data 268D accessible by one or more processors 268A. For example, data 268D may include data indicating external air conditions, power flow, engine / aircraft operating conditions, and / or any other data and / or information described herein. Data 268D may alternatively and / or additionally include data containing signals indicating strain in turbine engine components.

[0067] The computing device 268 may also include a network interface 268E for communicating, for example, with other components of the system described herein (e.g., via a communication network). The network interface 268E may include any suitable components for interfacing with one or more network interfaces, including, for example, a transmitter, receiver, port, controller, antenna, and / or other suitable components. One or more devices may be configured to receive one or more commands from or to provide one or more commands to the computing device 268.

[0068] The network interface 268E may include any suitable components for use with one or more network interfaces, including, for example, a transmitter, receiver, port, controller, antenna and / or other suitable components.

[0069] The techniques discussed herein relate to computer-based systems and the actions taken by and the information sent to and received from them. Those skilled in the art will recognize that the inherent flexibility of computer-based systems allows for a wide variety of possible configurations, combinations, and divisions of tasks and functions between and within components. For example, the processes discussed herein can be implemented using a single computing device or multiple computing devices working in combination. Databases, memory, instructions, and applications can be implemented on a single system or distributed across multiple systems. Distributed components can operate sequentially or in parallel.

[0070] Figure 15 A method 270 for manufacturing a strain sensing assembly is disclosed, comprising inserting a sensor substrate 208 into a capture pouch portion 215 of a strain sensing assembly 202 at step 272. As described above, the sensor substrate 208 may be made of quartz. The sensor substrate 208 can be inserted into the capture pouch portion 215 by various actions, including sliding insertion. Step 274 includes bonding a strain sensing element 206 to the sensor substrate 208. The strain sensing element 206 may be bonded to the sensor substrate 208 using chemical adhesive. The chemical adhesive material may have an elastic modulus between 5 gigapascals (GPA) and 200 GPA in some applications, between 50 GPA and 150 GPA in others, and between 75 GPA and 125 GPA in still others. In one form, the chemical adhesive is expected to have an adhesive thickness between 12 μm and 250 μm. The chemical adhesive used to bond the sensor substrate 208 to the turbine engine component 204 is intended to have a glass transition temperature above 225°C. In some embodiments, the chemical adhesive used to bond the sensor substrate 208 to the turbine engine component 204 can be cured in a zero-stress state at a temperature corresponding to the intended operating temperature of the turbine engine component 204. In other embodiments disclosed elsewhere herein, the sensor substrate 208 can be mechanically held against the turbine engine component 204 without the use of a chemical adhesive. Step 276 includes compressively capturing the sensor substrate in a capture bag portion 215. The capture bag portion may be formed between the turbine engine component and the first and second retaining pins.

[0071] Method 270 may further include heating the first retaining pin of the strain sensing assembly. This heating may be used to increase the size of the capture bag portion 215 to allow the sensor substrate 208 to slide into place. Method 270 may further include engaging the first retaining pin 212 with a chamfered edge 230 of the sensor substrate 208. The chamfered edge 230 may be formed at the same angle as the capture angle 232 formed by the surface of the first retaining pin 212. Method 270 may further include bonding the sensor substrate 208 to the turbine engine component 204. Method 270 may further include coupling a cover portion 226 to the strain sensing element 206 such that the strain sensing element 206 is captured between the cover portion 226 and the sensor substrate 208.

[0072] Embodiments of this disclosure are used to capture a sensor substrate configured to transfer strain from a turbine engine component to a strain sensing element coupled to the sensor substrate. Adhesive materials can be used to assist in strain transfer. The sensor substrate can be captured between a first retaining pin and a second retaining pin. This strain sensing assembly can be used in applications requiring higher strain limits as well as more stringent lifespan and reliability requirements. The higher strain limit also saves component weight during sensor integration. This disclosure improves the accuracy of the sensor system by employing a novel mounting structure to reduce the viscoelastic creep of existing adhesive materials. This structure allows for the use of additional or alternative adhesive materials to attach the sensor.

[0073] Further aspects are provided by the following topics:

[0074] A strain sensing assembly includes: a sensor substrate for coupling to a turbine engine component; a strain sensing element coupled to the sensor substrate and configured to generate a signal indicating strain in the turbine engine component; and a first retaining pin and a second retaining pin configured to apply compressive stress to the sensor substrate, the first retaining pin being positioned on a first side of the sensor substrate and the second retaining pin being positioned on a second side of the sensor substrate, the first side being opposite to the second side.

[0075] A strain sensing assembly includes: a sensor substrate for coupling to a rotatable shaft; a strain sensing element coupled to the sensor substrate and configured to generate a signal indicating strain in the rotatable shaft; and a first retaining pin and a second retaining pin configured to apply compressive stress to the sensor substrate, the first retaining pin being positioned on a first side of the sensor substrate and the second retaining pin being positioned on a second side of the sensor substrate, the first side being opposite to the second side.

[0076] According to the strain sensing assembly described in the foregoing clause, the sensor substrate includes a region that extends laterally beyond the outer periphery of the strain sensing element.

[0077] According to any of the preceding clauses, the strain sensing assembly wherein the retaining pin is oriented to apply compressive stress to the region of the sensor substrate extending laterally beyond the outer periphery of the strain sensing element.

[0078] The strain sensing assembly according to any of the preceding clauses further includes a sensing element cover.

[0079] According to any of the preceding clauses, the strain sensing assembly wherein the sensor substrate and the sensing element cover are made of quartz material.

[0080] According to any of the preceding clauses, the strain sensing assembly includes a surface acoustic wave (SAW) sensor or a bulk acoustic wave (BAW) sensor.

[0081] According to any of the preceding clauses, the strain sensing assembly wherein the sensor substrate includes a thickness in the thickness direction, wherein the sensor substrate includes a lateral dimension in the lateral direction transverse to the thickness direction, wherein the first retaining pin forms a capture angle relative to the sensor substrate and toward the interior of the sensor substrate, thereby capturing the sensor substrate.

[0082] According to any of the preceding clauses, the strain sensing assembly wherein the first retaining pin extends in the thickness direction and the lateral direction.

[0083] According to any of the preceding clauses, in the strain sensing assembly, the first retaining pin forms a capture angle relative to the sensor substrate to form a capture pocket portion configured to capture the sensor substrate.

[0084] According to any of the preceding clauses, the strain sensing assembly, wherein the sensor substrate includes a chamfered edge having a chamfered edge angle that matches the capture angle.

[0085] According to any of the preceding clauses, the strain sensing component wherein the rotatable shaft is the shaft of the propulsion system.

[0086] According to any of the preceding clauses, the rotatable shaft is one of the gearbox shaft, power output shaft, low-pressure turbine shaft, high-pressure turbine shaft, fan shaft, or engine coupling shaft of the propulsion system.

[0087] According to any of the preceding clauses, the strain sensing assembly wherein the first retaining pin is integral with the turbine engine component.

[0088] According to any of the preceding clauses, the strain sensing assembly wherein the first retaining pin is integrated with the turbine engine component.

[0089] According to any of the preceding clauses, the strain sensing assembly wherein the sensor substrate is adhered to the turbine engine component using an adhesive material.

[0090] According to any of the preceding clauses, in the strain sensing assembly, the adhesive material at least partially encapsulates the sensor substrate.

[0091] A method for manufacturing a strain sensing assembly, the method comprising: inserting a sensor substrate into a capture bag portion of the strain sensing assembly; bonding a strain sensing element to the sensor substrate; and compressively capturing the sensor substrate in the capture bag portion.

[0092] The method described in the foregoing clauses further includes heating the first retaining pin of the strain sensing component.

[0093] The method according to any of the preceding clauses further includes engaging the first retaining pin with the chamfered edge of the sensor substrate.

[0094] The method according to any of the preceding clauses further includes bonding the sensor substrate to the turbine engine component.

[0095] According to the method described in any of the preceding clauses, the sensor substrate is inserted into the capture bag after the capture bag portion is heated to a temperature higher than that of the sensor substrate.

[0096] The method according to any of the preceding clauses further includes expanding the adhesive material to apply a compressive force associated with compressively capturing the sensor substrate in the capture bag portion.

[0097] The method according to any of the preceding clauses further includes deforming the first retaining pin to capture the sensor substrate.

[0098] This written description uses examples to disclose this disclosure, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any device or system and performing any combined methods. The patentable scope of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A strain sensing component, characterized in that, include: A sensor substrate for connection to a rotatable shaft; A strain sensing element, the strain sensing element being coupled to the sensor substrate, the strain sensing element being configured to generate a signal indicating strain in the rotatable shaft; as well as A first fixing pin and a second fixing pin are configured to apply compressive stress to the sensor substrate. The first fixing pin is positioned on a first side of the sensor substrate, and the second fixing pin is positioned on a second side of the sensor substrate, with the first side opposite to the second side.

2. The strain sensing component according to claim 1, characterized in that, The sensor substrate includes a region that extends laterally beyond the outer periphery of the strain sensing element.

3. The strain sensing component according to claim 2, characterized in that, The fixing pin is oriented to apply compressive stress to the region of the sensor substrate that extends laterally beyond the outer periphery of the strain sensing element.

4. The strain sensing component according to claim 1, characterized in that, It further includes a sensor element cover.

5. The strain sensing component according to claim 4, characterized in that, The sensor substrate and the sensor element cover are made of quartz material.

6. The strain sensing component according to claim 1, characterized in that, The strain sensing element mentioned above includes a surface acoustic wave (SAW) sensor or a bulk acoustic wave (BAW) sensor.

7. The strain sensing component according to claim 1, characterized in that, The sensor substrate includes a thickness in the thickness direction, and the sensor substrate includes a lateral dimension in the lateral direction transverse to the thickness direction, wherein the first fixing pin forms a capture angle relative to the sensor substrate and toward the interior of the sensor substrate, thereby capturing the sensor substrate.

8. The strain sensing component according to claim 7, characterized in that, The first fixing pin extends in the thickness direction and the transverse direction.

9. The strain sensing component according to claim 1, characterized in that, The first fixing pin forms a capture angle relative to the sensor substrate to form a capture bag portion configured to capture the sensor substrate.

10. The strain sensing component according to claim 9, characterized in that, The sensor substrate includes a chamfered edge having a chamfered edge angle that matches the capture angle.

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