Apparatus and method for automatically inspecting mechanical components

Abstract

The inspection device (100) allows automatically determining the status of a used mechanical part (900) by means of multiple inspection steps. The device (100) comprises a computer unit (120), a 3D scanner (130) and multiple inspection sensors (141, 142, 143) for performing multiple inspection steps on the part (900), the computer unit (120) interacting with the scanner (130) and the sensors (141, 142, 143) for generating an annotated 3D model of the part (900), the computer unit (120) configured to run a simulation on the mechanical part (900) for determining the status of one or more areas of the mechanical part (900), the computer unit (120) may further comprise a check engine for applying one or more criteria (122, 124) to the results of the simulation to automatically determine whether the part (900) is usable and / or repairable and generating a status report accordingly.

Description

[Technical Field]

[0001] The subject matter disclosed herein particularly relates to an apparatus and method for automatically inspecting components, or so-called "working parts," after a period of machine operation. [Background technology]

[0002] Components of machinery, for example, machinery for the oil and gas industry (especially turbomachinery), may need to be inspected after the machinery has been in operation for some time, and such checks are usually repeated periodically, in order to avoid machinery failures and downtime. This is particularly true for components that are subject to wear and / or damage that may result from, for example, high temperatures, high pressures, high mechanical stresses, corrosion, and erosion.

[0003] To perform certain checks, the machine may need to be disassembled, either in whole or in part, so that a part (or parts) can be removed and inspected.

[0004] The outcome of such an action may be that the part is in good condition, i.e. "usable", and can be reinstalled in the machine as is; that the part is not "usable" and needs to be repaired (in some way) before it can be reinstalled in the machine; or that the part is neither "usable" nor "repairable", and a new part must be installed in the machine.

[0005] Systems for performing specific inspection steps are known. For example, patent document U.S. Patent Application Publication No. 2017 / 0176342 (A1) discloses a system for inspecting turbine blades. A computer can compare the difference between the input from the scanner and a predetermined ideal blade surface with a predetermined threshold. The computer can generate a report describing the predicted change in efficiency or performance (corresponding to the difference between the actual efficiency or performance and the ideal efficiency or performance) that may occur after pursuing recommended repairs to the blade surface. Additionally, software systems for assisting human inspectors in visually inspecting machine parts by building an annotated 3D model of the part and presenting it to the inspector on a computer screen are known, for example, from U.S. Patent Application Publication No. 2007 / 217672 (A1) and U.S. Patent Application Publication No. 2014 / 207419 (A1). Typically, the point-based assessment of the part's condition is manual and based on the inspector's training and experience. Summary of the Invention [Problem to be solved by the invention]

[0006] However, the overall inspection and evaluation procedure remains essentially manual, even though some specific inspection steps may be automated.

[0007] It is therefore desirable to provide improved inspection procedures, particularly for parts of machines, that are automatically performed. It should be understood that, in this specification, the term "part" should be interpreted broadly to include any portion of a machine that may be subjected to inspection after operation of the machine. The solutions described herein are most advantageously used for mechanical objects.

[0008] According to a first aspect, the subject matter disclosed herein relates to an inspection apparatus that enables automatic determination of the status of a used mechanical part through multiple inspection stages. The apparatus includes a computer unit, a 3D scanner, and multiple inspection sensors for performing the multiple inspection stages on the part, where the computer unit interacts with the scanner and sensors to generate an annotated 3D model of the part. The computer unit is configured to run a simulation on the mechanical part to determine the status of one or more regions of the mechanical part. Furthermore, the computer unit includes a check engine for applying one or more criteria to the results of the simulation, allowing automatic determination of whether the part is usable and / or repairable. Based on such determination, a status report can be issued by the computer unit for a user of the inspection apparatus. For example, the status report can be output via a user interface of the computer unit and / or stored in a memory of the computer unit for future use.

[0009] According to a second aspect, the subject matter disclosed herein relates to a method for inspecting a used mechanical part, the method including an initial stage followed by one or more different inspection stages, during which the part is scanned and a 3D model of the part is created, and the inspection stage allows for creating an annotated 3D model of the part. Further, the method may include a final stage in which a simulation is performed to determine the condition of one or more regions of the mechanical part, and then one or more criteria are applied to the results of the simulation to determine whether the part is usable and / or repairable. [Brief explanation of the drawings]

[0010] A complete understanding of the disclosed embodiments of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. [Figure 1]Figure 1 shows a very general schematic diagram of an inspection device. [Figure 2] FIG. 2 shows a schematic diagram of a first embodiment of an inspection device. [Figure 3] FIG. 3 shows a schematic diagram of a second embodiment of the inspection device. [Figure 4] FIG. 4 shows a flow chart of an embodiment of the inspection method. DETAILED DESCRIPTION OF THE INVENTION

[0011] An innovative inspection device allows the automatic determination of the condition of a used machine part, e.g., whether the part is worn or damaged, through multiple inspection steps performed one after the other. The device includes a computer-controlled scanner and multiple sensors to automatically create a computerized (scanner-derived) representation of the part with associated information (sensor-derived) about the condition of various parts of the part. In this way, an "annotated 3D model" of the part can be generated. Such an "annotated 3D model" is easily processed automatically by a computer. Such an "annotated 3D model" of the part can be used, for example, to determine whether the part is usable and / or repairable by performing a simulation, e.g., a mechanical or thermal simulation, on the part and then automatically "applying" one or more criteria to the simulation results. In this way, a comprehensive assessment of the part's (as-is) mechanical or thermal condition is possible, even under machine operating conditions, while the part is removed from the machine.

[0012] Reference will now be made to embodiments of the present disclosure, illustrated in the drawings. The embodiments are provided by way of illustration and not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure.

[0013] The innovative inspection device is useful for determining the condition of machine components (which may also be called "machine parts") that have already been used in a machine over a period of time during the machine's operation, i.e., so-called "used parts." Such condition can refer, for example, to any deformation of the part (e.g., a change in overall shape and / or overall size) and / or any change in the surface shape (e.g., a local loss of material, e.g., due to erosion or corrosion, or a local deposition of material, e.g., total or partial closure of a hole) and / or any change in the surface or subsurface layer (e.g., a reduction in the thickness of a protective layer or superficial or deep cracks) and / or a change in the core of the part, as well as the corresponding effect(s) on the mechanical state (e.g., shear stress, tensile stress, torsion), thermal state (e.g., temperature), and / or chemical state (e.g., oxidation) of one or more regions of the part, especially when the part is under machine operating conditions. It should be noted that other conditions can be considered, for example, electrical, magnetic, optical, electromagnetic states. The part that was initially inspected and then evaluated was previously removed from the machine.

[0014] 1, 2, and 3, a machine part 900 to be inspected is shown schematically, such as, but not limited to, a turbine blade including a base portion and an airfoil portion. It should be understood that the innovative apparatus and method according to the present disclosure can be used to inspect other machine parts, such as so-called "gas turbine hot gas path parts" ("HGPPs") and so-called "combustion parts" ("CCs").

[0015] According to these embodiments, one part 900 at a time is introduced into an inspection chamber 111 of a vessel 110 before being inspected. The vessel 110 has walls and an opening, typically with a door 112, for accessing the inspection chamber 111 and introducing the part 900. The vessel 110 may be equivalent to or similar to a freight container and may be transportable to allow for direct inspection of the machine parts at the location where the machine will be installed, for example, at an oil and gas processing plant. Note that according to some embodiments, a vessel may be avoided.

[0016] FIG. 1 schematically illustrates an inspection apparatus 100 including at least a computer unit 120, a 3D scanner 130, a plurality of inspection sensors 141, 142, and 143, and an industrial robot 160 having an articulating arm. The computer unit 120 may include a processor, controller, microprocessor, or the like (not shown), a data memory (not shown), a program memory (not shown), and a user interface 126 for a user, shown schematically as 90 in FIG. 1 . As shown, all of these elements may be housed within a container 110. As shown in the figure, the computer unit 120 may be electrically coupled to an external computer system 190 via wired and / or wireless connections, including, for example, the Internet or another computer network. The large arrows emanating from the unit 120 in the figure indicate the possibility for the computer unit 120 to control, for example, the scanner 130, the inspection sensors 141, 142, and 143, and the industrial robot 160, but also include the possibility for the computer unit 120 to receive data and / or information therefrom, particularly from the scanner and the inspection sensors. It should be noted that even though the scanner is shown in the figures as a separate and distinct device from the inspection sensor, according to some embodiments the scanner may correspond to an optical inspection sensor configured to move relative to the mechanical part. There are three possibilities: 1) only the sensor undergoes absolute movement, 2) only the part undergoes absolute movement, or 3) both the sensor and the part undergo absolute movement. In the following, the expression "configured to" is used when referring to functions performed by the inspection apparatus by one or more programs, which may essentially be "software" or "firmware" stored in a program memory of a computer unit.

[0017] 1 shows three test sensors 141, 142, 143 that differ from one another (this is represented by the different shapes of their symbols). However, different numbers may be considered, with the minimum number being 1, but a typical number being greater than 1. Any of these sensors may be, for example: optical sensors, in particular white light interferometric or laser sensors -Borescope sensor -Electromagnetic wave sensors, especially microwave probe sensors -inductive sensors, especially eddy current sensors -Inductive or infrared thermography sensors -Ultrasonic sensors -Fluorescence sensors, especially X-ray fluorescence sensors For example, sensor 141 may be a borescope sensor, for example, to assess the integrity of a cavity (e.g., a hole), sensor 142 may be a thermography sensor, for example, to assess the integrity of a thermal barrier, and sensor 143 may be an eddy current sensor, for example, to assess the integrity of the surface and / or subsurface layers from a mechanical point of view (e.g., the presence of cracks or voids).

[0018] In general, innovative inspection devices (such as device 100 of FIG. 1) a computer unit (such as unit 120 in FIG. 1); a scanner (which may be laser or white light, e.g., like the 3D scanner 130 of FIG. 1 ) configured to scan a mechanical part (e.g., like the part 900 of FIG. 1 ), wherein a computer unit is coupled to the scanner and configured to create a 3D model of the part based on the scanning of the part; - a plurality of inspection sensors (such as, for example, sensors 141, 142, 143 in Figure 1) configured to perform a corresponding plurality of inspection steps on the part, and a computer unit configured to be coupled to each of the inspection sensors, typically one after the other, and configured to create an annotated 3D model of the part based on the 3D model of the part and the data received from the inspection sensors.

[0019] For example, considering FIG. 1, the operation can be considered as follows. The computer unit 120 is connected to the scanner 130, controls the scanner 130, receives the scan data, and is able to create a 3D model of the part based on the scan data. Typically, the scan data is received while there is relative movement between the scanner and the part, and then The computer unit 120 is capable of connecting to the first sensor 141, controlling the first sensor 141, receiving the first sensory data, generating first inspection information from the first sensory data, and associating the first inspection information with a current 3D model of the part to create a 3D model of the part with added first annotations (e.g., diameter and depth of each hole in the part). Typically, the first sensory data is received while there is a relative movement between the first sensor and the part, and then: The computer unit 120 can connect to the second sensor 142, control the second sensor 142, receive second sensory data, generate second inspection information from the second sensory data, and associate the second inspection information with a current 3D model of the part to create a 3D model of the part with added second annotations (e.g., the quality of the thermal barrier at each point where there is a thermal barrier on the surface of the part). Typically, the second sensory data is received without substantial movement between the second sensor and the part, and then: The computer unit 120 can connect to the third sensor 143, control the third sensor 143, receive the third sensory data, generate third sensory information from the third sensory data, and associate the third sensory information with a current 3D model of the part to create a 3D model of the part with added third annotations (e.g., subsurface missing material at each point on the surface of the part). Typically, the third sensory data is received while relative movement occurs between the third sensor and the part. Thus, considering FIG. 1 , the resulting annotated 3D model of the part can include the exact outer shape of the part under inspection and three types of annotations associated with various positions on the part. Such an annotated 3D model can be easily processed automatically by a computer later.

[0020] A computer unit of the innovative inspection apparatus (e.g., unit 120 in FIG. 1 ) is configured to receive and / or acquire a design model of a mechanical part to be evaluated (e.g., part 900 in FIG. 1 ). The design model is acquired if it is stored in a memory device of the computer unit, e.g., a hard disk, or received if it is stored in a memory device of a different, remote computer system, e.g., a hard disk. The design model is used to acquire detailed information about the mechanical part (e.g., ideal surface shape and / or internal structure and / or materials and manufacturing steps and / or processes and / or operating conditions and / or relationships with other mechanical parts). The acquiring and receiving may require that the mechanical part be previously identified based on, e.g., input received from a user.

[0021] The computer unit of the innovative inspection apparatus (e.g., unit 120 in FIG. 1 ) is configured to perform, for example, mechanical, thermal, or chemical simulations on a machine part (e.g., part 900 in FIG. 1 ) to determine, for example, the mechanical state (e.g., shear stress, tensile stress, torsion), thermal state (e.g., temperature), or chemical state (e.g., oxidation) of one or more regions of the machine part. Such simulations take into account a created 3D model of the machine part (e.g., the actual surface geometry of the entire part), inspection data generated from at least one inspection stage (e.g., the actual non-visible characteristics of the part), and a received and / or acquired design model of the machine part (e.g., idealized surface geometry and / or internal structure and / or materials and manufacturing steps and / or processes and / or operating conditions and / or relationships with other machine parts). Such simulations are preferably performed under machine operating conditions if the results of the simulation are affected by these conditions.

[0022] The computer unit of the innovative test device (e.g., unit 120 in FIG. 1) includes a check engine, which is typically one or more pieces of firmware and / or software, to which configuration data may be provided and / or which may be stored, for example, in a program memory of the computer unit. The configuration data may include one or more usability criteria (e.g., see box 122 in FIG. 1) and / or one or more repairability criteria (e.g., see box 124 in FIG. 1) and / or which may be stored, for example, in a data memory of the computer unit.

[0023] The check engine may be configured to apply one or more criteria to the results of the performed simulation and determine whether the machine component is usable based on the application of such criteria. It is expected that such usability criteria will be determined by the designer / manufacturer of the machine and its components. However, a user of the machine (e.g., the manufacturer's customer) may contribute at least some of the usability criteria. The usability criteria (e.g., shown as 122 in FIG. 1 ) may be stored in the computer unit during machine manufacture and / or machine installation. According to some embodiments, they may be modified after installation. The check engine may be configured to, for example, generate a status report of the machine component for a user (exemplarily shown as 90 in FIG. 1 ) based on the usability determination. The status report, including the usability data, may be output through a user interface (e.g., shown as 126 in FIG. 1 ) of the computer unit, e.g., its display, and / or may be stored in the computer unit's memory for future use.

[0024] Alternatively or additionally, the check engine may be configured to apply one or more criteria to the results of the performed simulation and determine whether the machine part is repairable based on the application of such criteria. It is expected that such repairability criteria will be determined by the designer / manufacturer of the machine and its parts. However, a user of the machine (e.g., the manufacturer's customer) may contribute to at least some of the repairability criteria. The repairability criteria (e.g., shown as 124 in FIG. 1 ) may be stored in the computer unit during machine manufacture and / or machine installation. According to some embodiments, they may be modified after installation. The check engine may be configured to generate a status report of the machine part for a user (exemplarily shown as 90 in FIG. 1 ), for example, based on the repairability determination. The status report including the repairability data may be output through a user interface (e.g., shown as 126 in FIG. 1 ) of the computer unit, e.g., its display, and / or may be stored in the computer unit's memory for future use.

[0025] It should be noted that, according to the prior art, inspection information is evaluated (manually) on a point-by-point basis and compared with reference information. For example, if a lack of thermal barrier coating is detected at a first point on the surface of a part, its size is compared with two thresholds, and the part is determined to be usable, repairable, or scrapped depending on the comparison of the two. If a lack of thermal barrier coating is subsequently detected at a second point on the surface of the part, the same procedure is repeated. However, according to the prior art, the overall effect of various lacks of thermal barrier coating is not taken into account. In contrast, as disclosed herein, it is possible to (automatically) consider the effect of all lacks of thermal barrier coating, for example, by (automatically) simulating the temperature distribution of the machine part (i.e., the actual part as scanned and inspected with all its lacks) under machine operating conditions, and the simulated temperature at one or more points on the part can be (automatically) compared with, for example, two thresholds (which may be different for each point).

[0026] As is apparent from FIG. 1 , the functionality of the check engine can be variously divided between an internal computer unit (e.g., unit 120) and an external computer system (e.g., system 190), depending on the embodiment. Thus, according to some embodiments, the internal computer unit is configured to create an annotated 3D model of the part and transmit it to the external computer system, which is configured to receive the annotated 3D model, perform simulations, and apply one or more criteria. Alternatively, the annotated 3D model may be shared between the internal and external computer units. In this manner, usability and / or repairability result data can be derived from collaboration between the internal computer unit and the external computer system. The external computer system can be considered part of the innovative inspection apparatus.

[0027] Typically, a computer unit (such as, for example, unit 120 in FIG. 1 ) may be configured to identify a particular part to be inspected (e.g., a turbine blade part number, e.g., SMH48303) or a category of part to be inspected (e.g., “blade for a high-power turbine”). Indeed, it is expected that the inspection steps to be performed and / or the order of the steps and / or the criteria applied will depend on either or both of them. Such identification may be based on input received by the apparatus from a user (see, for example, 90 in FIG. 1 ). For example, before introducing a part into the inspection chamber of the apparatus, an operator can finger-press a corresponding code on the keyboard of the computer unit (see, for example, 126 in FIG. 1 ). Such identification may be based on input received by a code reader configured to read a code marked on the part to be inspected. Such identification may also be based on scanning and automatically recognizing the part to be inspected.

[0028] A computer unit (e.g., unit 120 in FIG. 1 ) may be configured to receive and / or acquire a design model of the part to be inspected. For example, referring to FIG. 1 , unit 120 may communicate with system 190 and acquire the design model from a design database that stores models of several different machine parts as originally designed by a design engineer. Note that the term “design model” should not be construed as being limited to the shape of the part, but may also include other characteristics such as tolerances and / or materials and / or manufacturing processes and / or test procedures and / or inspection procedures. For example, “model-based engineering (MBE)” is an approach to engineering that uses models as an integral part of a technology baseline that includes the requirements, analysis, design, implementation, and verification of a function, system, and / or product throughout the acquisition lifecycle.

[0029] A computer unit (such as, for example, unit 120 in FIG. 1) may be configured to correlate a 3D model of the part derived from its scanning in the inspection device with its design model. For example, by comparing the 3D model with the design model (which is a form of correlation), it is possible to determine any deformations in the part that have occurred due to its use in the machine. The inspection phases performed and / or the order of the phases and / or the criteria applied may depend on the design model of the part being inspected.

[0030] A computer unit (such as unit 120 in FIG. 1) may be configured to apply criteria based on simulations performed on the particular part under inspection. The simulations may be performed by an internal computer unit or by an external computer system that provides the results of the simulation to the internal computer unit. The simulations may be based on analytical and / or statistical models to evaluate the durability of the particular part under inspection in terms of oxidation or creep or LCF or HCF or crack propagation life or FMEA.

[0031] It should be noted that one or more of the criteria may be based on the duration and / or conditions of the period of machine operation of the machine part being accessed. For example, if a part has been in use for several years, it is expected that the thickness of any of its coatings will be reduced relative to their design values, or that the sealing of any of its gaskets will be reduced relative to their design values. Such changes will depend not only on the operating time but also on the operating conditions.

[0032] It should be noted that one or more of the criteria may be multiple criteria, for example, such a criterion may correspond to a combination (e.g., a logical combination) of a first check on test information from a first test stage and a second check on test information from a second test stage.

[0033] Advantageously, some or all of the inspection sensors of the plurality of inspection sensors are non-contact, i.e., the sensors do not need to contact the surface of the part being inspected. In any case, contact with the surface may be accepted (even if not required) so that sensor positioning requires less precision. It is not excluded that one or more of the inspection sensors may be contact-type. However, in this case, not only may a degree of precision in positioning be required, but also a degree of control over the pressure applied to the part surface may be required.

[0034] Typically, the plurality of inspection sensors includes at least one inspection sensor for inspecting the surface shape and at least one inspection sensor for inspecting the surface layer or the sub-surface layer. It is not excluded that the plurality of inspection sensors may also include at least one inspection sensor for inspecting the core, i.e., a portion of the internal volume, of the part.

[0035] 2 and 3 respectively show a first embodiment of an innovative inspection apparatus 200 and a second embodiment of an innovative inspection apparatus 300. However, before going into such details, the inspection method will be explained using the flowchart 400 of FIG. 4 and the block diagram of FIG.

[0036] The method is useful for inspecting parts after a period of machine operation, such as part 900 in FIG. 1 (although it can also be used to inspect new parts), and includes an initial stage 401 (sometimes called a “modeling stage”), followed by one or more different inspection stages 402 (considering FIG. 1 , three inspection stages would typically be performed one after the other), and then a final stage 403 (sometimes called a “checking stage”). Note that the method may be performed near the machine on which the part was used, or may be performed remotely. Additionally, note that final stage 403 may be performed well after the inspection stage, at a location different from where the part being inspected is located. Finally, note that final stage 403 may be performed by a different inspection device than the inspection device that performed initial stage 401 and inspection stage 402. Such inspection device may be the same as or similar to the inspection device disclosed herein and may include a computer unit.

[0037] According to the embodiment of FIG. 4, the initial stage 401 includes: A) scanning a machine part removed from the machine (block 410); B) creating a 3D model of the mechanical part based on the scan of the mechanical part (block 420); C) identifying a mechanical part or a category of mechanical parts based on input received from a user (block 430); D) receiving and / or acquiring a design model of the mechanical part (block 440).

[0038] 1, the initial stage 401 is essentially carried out through the unit 120 and the scanner 130. The robot 160 may also contribute.

[0039] According to the embodiment of FIG. 4, the inspection stage 402 includes: E) inspecting the mechanical part via at least one inspection sensor (Block 450); F) generating inspection information based on at least one inspection step (block 460); G) Associating the inspection information with the 3D model of the mechanical part (block 470) to create an annotated 3D model of the mechanical part, where, as previously described, the 3D model is typically annotated incrementally based on inspection information from several inspection stages.

[0040] Considering FIG. 1, the inspection step 402 is essentially performed by the unit 120, the robot 160 and any of the sensors 141, 142 and 143.

[0041] According to the embodiment of FIG. 4, the final step 403 is: I) performing, for example, a mechanical or thermal or thermal simulation on the mechanical component to determine, for example, a mechanical, thermal or chemical state of one or more regions of the mechanical component taking into account the created 3D model of the mechanical component, the inspection data generated from the at least one inspection step, and the received and / or acquired design model of the mechanical component (block 475); H) applying one or more criteria to the results of, for example, mechanical, thermal or chemical simulations performed to determine whether the machine part is usable (block 480); and / or L) Applying one or more criteria to the results of, for example, mechanical, thermal, or chemical simulations performed to determine whether the machine part is repairable (block 490).

[0042] 1 , final step 403 is essentially performed through unit 120 and / or system 190 based on test criteria 122 and / or 124. According to the embodiment of FIG. 1 , all criteria are stored in unit 120. The usability and / or repairability determination may be used to issue a status report with usability and / or repairability data, for example in the form of a list of various test results. The status report may be output to a user, for example by the computer unit, in particular by its display, and / or may be stored, for example, in the memory of the computer unit, after which, possibly, all or part of the status report may be transferred to an external computer system. It should be noted that according to some embodiments, the status report may include only a selection of usability and / or repairability data, for example only positive test results or only negative test results.

[0043] Preferably and advantageously, the simulation performed in step I is performed under machine operating conditions. Furthermore, advantageously, at least one of the criteria in steps H and / or L may be based on the duration and / or conditions of a period of machine operation. Finally, at least one of the criteria in steps H and / or L may be a plurality of criteria, the plurality of criteria being based on at least two inspection steps.

[0044] A first embodiment 200 of the innovative inspection apparatus will now be described with reference to Figure 2. It should be noted that elements 210, 211, 212, 220, 230, 241, 242, 243, 260, and 290 in Figure 2 may be the same as or similar to, and perform the same or similar functions as, elements 110 (container), 111 (inspection chamber), 112 (door), 120 (internal computer unit), 130 (scanner), 141 (first inspection sensor), 142 (second inspection sensor), 143 (third inspection sensor), 160 (robot), 162 (articulating arm), and 190 (external computer system) in Figure 1, respectively.

[0045] The apparatus 200 of Fig. 2 includes a support element 250, in particular a table, for supporting the part 900 to be inspected. The support element 250 may include fixtures 252 dedicated to the part to be inspected. For example, in Fig. 2, the base portion of the turbine blade fits completely between, for example, four fixtures 252 of the support element 250. The support element 250 may be rotatable and / or tiltable.

[0046] The support element 250 may be rotatable and / or tiltable. If the support element 250 is movable, the computer unit 220 may be configured to control the movement of the support element 250. If the support element 250 is movable, it may contribute to the scanning of the part 900. For example, scanning may be performed during a rotation and / or tilt of the support element 250 and a corresponding rotation and / or tilt of the supported part 900.

[0047] The apparatus 200 of FIG. 2 includes at least one industrial robot 260 having an articulated arm 262, preferably a five- or six-axis articulated arm. The articulated arm 262 is configured to carry an inspection sensor, and the computer unit 220 is configured to control the movement of the articulated arm 262. The robot 260 may also participate in scanning the part 900. For example, the arm 262 may carry an optical sensor and move around the part 900 to scan it. In this case, the scanner 230 may correspond to the optical sensor carried by the robot's articulated arm. According to a preferred embodiment, the apparatus includes only one robot for inspecting parts. According to a preferred embodiment, the apparatus includes only one robot for repairing parts.

[0048] Typically, the articulating arm 262 is configured to alternately carry two or more inspection sensors, and the computer unit 220 is configured to control the changing of the sensors carried by the arm. In Figure 2, the dashed lines connecting the sensors to the ends of the arm members schematically indicate the action of picking up the sensor from its rest position, performing an inspection of a part, and returning the sensor to its rest position.

[0049] The computer unit 220 is configured to move the inspection sensor along an inspection path (which may be part and sensor dependent).

[0050] A second embodiment 300 of the innovative inspection apparatus will now be described with reference to Figure 3. It should be noted that elements 310, 311, 312, 320, 330, 341, 342, 343, 360, and 390 in Figure 3 may be the same as or similar to, and perform the same or similar functions as, elements 110 (container), 111 (inspection chamber), 112 (door), 120 (internal computer unit), 130 (scanner), 141 (first inspection sensor), 142 (second inspection sensor), 143 (third inspection sensor), 160 (robot), 162 (articulating arm), and 190 (external computer system) in Figure 1, respectively.

[0051] The apparatus 300 of Fig. 3 includes at least one industrial robot 360 having an articulated arm 362, preferably a five- or six-axis articulated arm. The articulated arm 362 is configured to carry a part 900 to be inspected, and the computer unit 320 is configured to control the movement of the articulated arm 362. The articulated arm 362 may include a fixture 350 dedicated to the part to be inspected. For example, in Fig. 3, a base portion of a turbine blade fits completely between, for example, four fixture members 352 of the fixture 350. In this way, the industrial robot, and in particular the articulated arm, may be configured to grip, move, and / or manipulate mechanical parts.

[0052] The articulating arm 362 may be configured to carry (fixedly or movably) the mechanical part 900 to be inspected as the scanner 330 performs a scan of the part.

[0053] According to the embodiment of FIG. 3, some or all of the test sensors 341, 342, 343 are fixedly attached to the frame or structure of the device 300 at different locations (in FIG. 3, they are depicted, for example, adjacent the wall of the container 310).

[0054] According to the embodiment of Figure 3, the computer unit 320 is configured to move the mechanical part 900 to be inspected along an inspection path. Note that a first portion of the inspection path may be movement of the part proximate to the inspection sensor, a second portion of the inspection path (which may depend on the part and the sensor) may be movement of the part within the zone of the inspection sensor while the sensor is active to perform the desired inspection, and a third portion of the inspection path may be movement of the part away from the inspection sensor. In Figure 3, dashed lines connecting the sensors and fixtures schematically indicate various first and third portions of the inspection path for the inspection sensors 341, 342, and 343.

[0055] The essential difference between the first embodiment of Figure 2 and the second embodiment of Figure 3 is that during the inspection phase, according to the first embodiment the part is fixed (apart from possible rotation and / or tilting of the support element) and the sensor moves, whereas according to the second embodiment the sensor is fixed and the part moves. It is clear that other embodiments may correspond to a combination of these two alternatives.

[0056] In light of the above, it is clear that the innovative devices and methods disclosed herein offer inspection possibilities that are quite different from those offered by prior art devices and methods that are specifically aimed at assisting human inspectors, which compare inspection results directly with reference data.

Claims

1. 1. An inspection apparatus for automatically determining the condition of a machine component after a period of machine operation based on a plurality of inspection stages, the machine component having been used in a machine, the apparatus comprising: a computer unit, a scanner configured to scan the machine part removed from the machine, the computer unit being coupled to the scanner and configured to create a 3D model of the machine part based on the scanning of the machine part; a plurality of inspection sensors configured to perform a plurality of inspection stages corresponding to the mechanical part, wherein the computer unit is configured to be coupled to each of the inspection sensors and configured to generate inspection information from each of the inspection stages and to associate the inspection information with the 3D model of the mechanical part accordingly to create an annotated 3D model of the mechanical part; the computer unit is configured to receive and / or acquire a design model of the mechanical part; the computer unit is configured to perform a simulation of the mechanical component to determine a state of one or more regions of the mechanical component taking into account the created 3D model of the mechanical component, the inspection information generated from at least one inspection stage, and the received and / or acquired design model of the mechanical component; The computer unit includes a check engine including one or more enablement criteria, the check engine comprising: - applying one or more of said enabled criteria to the results of said performed simulations, - determining whether the machine part is usable based on application of the usability criteria; an inspection device configured to generate a status report for a user of the machine part based on the availability determination.

2. the check engine includes one or more repairability criteria; - applying one or more of said repairability criteria to the results of said simulations performed; - further configured to determine whether the machine part is repairable based on application of the repairability criteria; The inspection device of claim 1 , wherein the status report of the machine part is also based on the repairability determination.

3. 2. The inspection apparatus of claim 1, wherein the computer unit is configured to perform a mechanical, thermal or chemical simulation of the mechanical component to determine a mechanical, thermal or chemical state of one or more regions of the mechanical component.

4. The inspection apparatus of claim 1 , wherein at least one of the enablement criteria is pre-determined and associated with the mechanical component or a category of the mechanical component.

5. The inspection device of claim 2 , wherein at least one of the repairability criteria is pre-determined and associated with the mechanical component or a category of the mechanical component.

6. The inspection apparatus of claim 1 , wherein at least one of the enabled criteria is based on a design model of the mechanical part.

7. The inspection apparatus of claim 2 , wherein at least one of the repairability criteria is based on a design model of the mechanical component.

8. The inspection device of claim 1 , wherein at least one of the enablement criteria is based on a duration and / or condition of the period of machine operation.

9. The inspection apparatus of claim 2 , wherein at least one of the repairability criteria is based on the duration and / or condition of the period of machine operation.

10. 10. The inspection apparatus of claim 1, wherein at least one of the enabled criteria is multi-criteria, the multi-criteria being based on at least two inspection stages.

11. The inspection system of claim 2 , wherein at least one of the repairability criteria is multi-criteria, the multi-criteria being based on at least two stages of inspection.

12. 2. The inspection apparatus of claim 1, wherein the computer unit is configured to determine an order of inspection steps based on the mechanical parts or categories of the mechanical parts.

13. The inspection apparatus of claim 1 , wherein the computer unit is configured to identify the mechanical component and / or a category of the mechanical component based on input received from a user of the inspection apparatus.

14. The inspection apparatus of claim 1 , wherein the simulation is performed under machine operating conditions.

15. The inspection apparatus of claim 1 , wherein the computer unit is configured to correlate the 3D model of the mechanical part with the design model of the mechanical part.

16. The testing device of claim 1 , wherein some or all of the test sensors of the plurality of test sensors are non-contact and / or contact type.

17. The plurality of test sensors include: at least one inspection sensor for inspecting the surface shape of said mechanical part; at least one inspection sensor configured to inspect a surface layer or a subsurface layer or a core of the mechanical part.

18. a support element configured to support said mechanical part to be inspected; at least one industrial robot having an articulated arm, preferably a 5- or 6-axis articulated arm, The support element is preferably rotatable and / or tiltable; the articulating arm is configured to carry a test sensor; 2. The inspection device of claim 1, wherein the computer unit is configured to control the support element and / or the articulated arm.

19. - at least one industrial robot having an articulated arm, preferably a 5- or 6-axis articulated arm, configured to grip, move and / or manipulate said mechanical part to be inspected, the computer unit is configured to control the articulating arm; The testing device of claim 1 , wherein some or all of the plurality of test sensors are fixedly attached to a frame or structure of the testing device at different locations.

20. - further comprising a container, the container houses at least the computer unit, the scanner, the plurality of inspection sensors, and preferably at least one industrial robot having an articulating arm; the container has an opening for introducing the machine part to be inspected into the inspection chamber; 10. The testing device of claim 1, wherein the container is preferably configured to be portable.

21. 1. A method for automatically inspecting a machine part after a period of machine operation by an inspection device comprising a computer unit and the computer unit containing inspection criteria, said method comprising an initial stage followed by one or more different inspection stages followed by a final stage, The initial stage comprises: A) scanning the machine part removed from the machine; B) creating a 3D model of the mechanical part based on the scanning of the mechanical part; D) receiving and / or acquiring a design model of the mechanical part; The inspection stage is E) inspecting the mechanical part with at least one inspection sensor; F) generating inspection information based on at least one of said inspection steps; G) associating the inspection information with the 3D model of the mechanical part to create an annotated 3D model of the mechanical part; The final step is I) performing a simulation of the mechanical component to determine a state of one or more regions of the mechanical component, taking into account the created 3D model of the mechanical component, the inspection information generated from at least one inspection step, and the received and / or acquired design model of the mechanical component; H) applying one or more inspection criteria to the results of the performed simulation to determine whether the machine part is usable.

22. The final step is 22. The method of claim 21, further comprising the step of: L) applying one or more inspection criteria to results of the performed simulation to determine whether the machine part is repairable.

23. In step I, the simulation carried out is a mechanical, thermal or chemical simulation of the mechanical component, aimed at determining the mechanical, thermal or chemical state of one or more regions of the mechanical component, or 22. The method of claim 21, wherein in step I, the simulation performed is performed under machine operating conditions.

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