Method for examining a component

Abstract

The present invention relates to a method for supporting the examination of a component for a turbomachine, in particular for an aircraft engine, comprising the steps of: providing a USB camera; capturing of an image of the component by means of the USB camera while the USB camera is held by hand; comparing and combining the image, which shows an examination site of the component, with a computer model of the component; marking the examination site in the computer model combined with the image and thus determining coordinates of the examination site in the computer model.

Description

[0001] METHOD FOR EXAMINATION OF A COMPONENT

[0002] DESCRIPTION

[0003] Technical area

[0004] The present invention relates to a method for supporting the diagnosis of a component for a turbomachine, in particular for an aircraft engine.

[0005] State of the art

[0006] Due to the potential consequences of failure of a component in a turbomachine or aircraft engine, their quality and testing require particular attention. A visual inspection can be used to examine components for damage, for example, during new production; however, components that have already been used can also be inspected during an overhaul. Any damage, which may result from particle impact or wear during operation during an overhaul, is recorded as a finding for the component during a diagnosis. Depending on the attribute of the finding, e.g., "not OK" or "minor damage, but still OK," the component can then be rejected for further examination or rework, or even as scrap.

[0007] Description of the invention

[0008] The present invention is based on the technical problem of providing an advantageous method for detecting a component for a turbomachine or an aircraft engine.

[0009] This is achieved according to the invention with the method according to claim 1. In this case, an image of the component is taken handheld using a USB camera (steps i and ii), thus using a comparatively simple hardware setup. The image taken with the USB camera is then compared with a computer model of the component (step iii), whereby the computer model is brought into line with the taken image, for example with regard to orientation and zoom. By combining the taken image with the computer model (step iii), the two are linked, for example according to the principle of augmented reality. A tracking algorithm is required for this. The diagnosis point is then marked in the computer model combined with the image, whereby the coordinates of the diagnosis point can be derived from the computer model.

[0010] To illustrate, if, for example, damage is detected in the area of ​​the leading edge of an airfoil in the image, after steps iii) and iv) its coordinates are stored in the computer model or determined from the computer model. Despite the hand-held recording with the USB camera, i.e. the comparatively simple setup without, for example, an automated image recording device with scan guidance, etc., the result still provides reproducible coordinate information for the location of the findings. The method is relatively easy to implement (e.g. no complex hardware acquisition or conversion required), but still produces reproducible diagnosis documentation. With the USB camera, even hard-to-reach areas of the component can be recorded better and more easily than with a scanning device or, for example, a comparatively large and therefore less handy tablet computer.

[0011] Preferred embodiments are found in the dependent claims and the entire disclosure, which is at least implicitly directed to all categories of claims.

[0012] In general, a "defect" can be a damaged area, such as a crack, break, chip, etc. The term generally refers to any deviation from a desired condition, including, for example, discoloration, inclusions, etc. Accordingly, the defect can already be inherent in the material upon receipt of the goods, but it can also arise during production and / or operation.

[0013] In general, the computer model is typically a CAD (computer-aided design) model of the component. The computer model is preferably three-dimensional, whereas the image captured with the USB camera is two-dimensional. The alignment in step iii) aligns the three-dimensional model, i.e., a corresponding view of it, with the two-dimensional image. Since the three-dimensional model is then subject to the two-dimensional image, the coordinates can be determined by marking the location of the diagnosis, e.g., by manually clicking on it.

[0014] In general, method steps iii) and iv) are each at least partially computer-implemented, although they can generally also be fully computer-aided. In a preferred embodiment, however, the computer model in step iii) is first aligned manually, i.e. by an operator using a corresponding input device, e.g. a computer mouse. This can preferably be done by the same operator who also manually captured the image and therefore immediately knows from which direction the view of the computer model must be directed. During this first "rough" alignment, the computer model and the image can be superimposed, for example in a (partially) transparent display. As soon as the first alignment by the operator has resulted in a sufficient match, the overlay "snaps" into place with computer support.This requires an image processing algorithm that compares the image and the computer model and fits, i.e., overlays, corresponding features. Depending on the component, these features can be lines, edges, corners, holes, etc.

[0015] In general, the marking in step iv) can also be carried out computer-aided, e.g., by pattern recognition with an image processing algorithm. In a preferred embodiment, however, the diagnosis point is marked manually, i.e., by the operator using an input device, e.g., a computer mouse. This allows the operator to draw on their wealth of experience in identifying, for example, typical damage or defect locations (e.g., without complex AI training), while the results can still be used digitally later due to the coordinate assignment, e.g., for systematic error analyses or statistical evaluations, etc. After combining, i.e., when the image and computer model have "snapped" into place as described above, the computer model is preferably kept static, i.e., frozen with the recorded image as a still image.In step iv), the diagnosis points are then marked in the freeze frame, whereby the freeze frame can simplify manual marking.

[0016] According to a preferred embodiment, after the coordinates have been marked and determined, a marking is displayed in the computer model for visualization and verification of the coordinates. This makes it possible to check whether the marking was placed in the correct location or whether it was incorrectly placed due to perspective reasons, for example if the image does not show the location to be examined from above, but rather the view falls on the component surface at an angle. After the marking has been placed, the computer model can be moved again using an input device (e.g., a computer mouse), so that a plausibility check can also be performed from other viewing directions. This is preferably carried out by the same operator who previously placed the marking and also took the image of the component.

[0017] The computer model with the marking can be checked from different viewing angles, in particular, by comparing it with the actual component. The correct placement of the marking can therefore be determined by the operator by comparing the computer model and the actual component. Regardless of these details, the marking in the computer model can preferably comprise a line angled to the component surface, particularly perpendicular, i.e., preferably a surface normal.

[0018] According to a preferred embodiment, the computer model is divided into different areas, with different testing and / or exclusion criteria stored for each area. For example, different, particularly stricter, criteria may apply to component surfaces facing the gas duct than to other surfaces. In general terms, different criteria can be defined for different areas depending on the stress and / or potential damage impact, e.g., size specifications (area and / or length, etc.) to differentiate between damage areas that are still acceptable and those that are no longer acceptable.

[0019] In a preferred embodiment, not only the coordinates of the finding location of one component are stored in a finding computer model (“first” finding computer model in the terminology of the claims), but also coordinates of finding locations of the same component type, e.g., other production orders. This finding computer model is typically also a CAD model, i.e., in its basic structure, it is the same model as in step iii). The finding computer model creates comparability and evaluation within a material master data set, i.e., identical components (which have the same computer model) can be referenced to one another. The finding computer model serves, in a sense, as a central storage location in which the coordinates of finding locations of a large number of components are stored. This enables, for example, systematic evaluations; areas with noticeable clusters can be identified, for example.For example, frequently occurring complaints / damages in the same geometric location can be visualized in the manner of a heat map.

[0020] According to a preferred embodiment, in a diagnosis computer model (“second” diagnosis computer model in the terminology of the claims) of the component, in addition to the coordinates of the diagnosis point, coordinates of other diagnosis points are also stored, which are determined on the same component at different times of production and / or use. This diagnosis computer model can also be viewed as a storage location, analogous to the previous paragraph, with different points in time being summarized therein as in a digital life cycle. A diagnosis can, for example, be carried out during a final inspection after initial production, whereby intermediate steps can optionally also be diagnosed beforehand (e.g., before / after the application of a coating, etc.). Further stages of the digital life cycle can then arise during a component revision, i.e., when the used component is removed and inspected, e.g., at defined maintenance intervals.Such a report computer model can also be used for documentation purposes in quality processes, for example.

[0021] The USB camera is preferably wired, meaning the image is transferred to the computer via a USB port. Compared to a wireless camera, this can be advantageous for security reasons, as well as for the camera's design and weight (e.g., no battery is required). As already discussed at the beginning, this improves handling and accessibility.

[0022] In a preferred embodiment, the USB camera is designed without a position, motion, or acceleration sensor, meaning it does not have such a sensor. Reference is made to the above comments on the simple design; the image captured without any information on orientation, etc., is then nevertheless coupled to the coordinate system in step iii). However, the camera preferably has an autofocus function, which can simplify image capture. A shutter release can be provided on the camera itself, directly via keyboard input on the PC, or, for example, in the form of a foot pedal connected to the computer.

[0023] The application also relates to a method for modeling a component for a turbomachine / aero engine using a simulation model. This can be created, for example, from the computer model, for example by appropriately networking the CAD model using FEM simulation software. Mechanical stresses can then be investigated in the simulation model, for example, thermally induced mechanical stresses during production / use and / or stresses induced by the application of force, such as centrifugal and / or gas forces. The simulation computer model can, for example, also depict a damaged area at the relevant coordinates, such as a notch, etc. The application further relates to a method for manufacturing a component for a turbomachine / aero engine, wherein the component is assessed between different manufacturing steps and / or after completion in a manner described herein.

[0024] Furthermore, the application relates to a method for revising a component of a turbomachine / aircraft engine, wherein the used component is removed from the turbomachine and examined in a method described here.

[0025] Short description of the drawings

[0026] In the following, the invention is explained in more detail using an exemplary embodiment, whereby the individual features within the scope of the independent claims can also be essential to the invention in other combinations and no distinction is made in detail between the different claim categories.

[0027] In detail,

[0028] Figure 1 shows a turbomachine, namely an aircraft engine, in a schematic axial section;

[0029] Figure 2a-d various steps in the examination of a component of a turbomachine;

[0030] Figure 3 shows some process steps in a flow chart.

[0031] Preferred embodiment of the invention

[0032] Figure 1 shows a turbomachine 1, specifically a turbofan engine, in an axial section. The section plane thus includes a longitudinal axis 2, around which the rotors rotate during operation. Functionally, the turbomachine 1 is divided into a compressor 1a, a combustion chamber 1b, and a turbine 1c. During operation, air drawn in the compressor 1a is compressed and burned in the downstream combustion chamber 1b with added fuel, particularly kerosene. The resulting combustion or hot gas is expanded in the turbine 1c, driving its rotors, which is also partially converted into rotation of the compressor 1a and the fan.

[0033] Such an engine contains a multitude of components that must meet different requirements depending on their location and purpose. This article focuses on the assessment of such components, both during new production and during overhaul. The procedure is illustrated below using a guide vane or guide vane segment, which is part of a so-called stator in the engine.

[0034] Figure 2a illustrates how an image 30 of a component 20, in this example the guide vane, is captured using a USB camera 25. The USB camera 25 is connected to a computer 27 via a cable 26; this setup forms a workstation 28 for the optical inspection of components 20. The USB camera is a comparatively simple industrial camera and is operated by hand 29 by an operator (not shown in detail here). The image 30 captured by the USB camera 25 shows a location 35 identified by the operator, e.g., a damaged area.

[0035] Figure 2b shows, in addition to image 30 of component 20, a computer model 40 of the component, namely a 3D model. The two are displayed superimposed, i.e., the computer model 40 is superimposed as a GAoV model on image 30. By adjusting, i.e., by appropriate alignment and zooming, the computer model 40 is brought into alignment with the image 30 of component 20; it is fitted to it.

[0036] In Figure 2c, the computer model 40 is already fitted to the image 30 of the component 20; the two are congruent. In this still image 45, the examination point 35 is marked manually by the operator. The corresponding location is then stored in the computer model 40, resulting in the coordinates 50 of the examination point 35. Figure 2d shows the computer model 40 with a marking 55 at the marked examination point 35. The marking 55 can be used to verify the correct position of the examination point 35 or coordinates 50.

[0037] Figure 3 summarizes some process steps and options in a flow chart. The provision 61 of the USB camera allows for handheld recording 62 of the

[0038] Image 30. This is then compared with the computer model 40 and combined 63. The marking 64 of the diagnosis point then takes place in the combined image. The coordinates 50 obtained from this can, for example, be entered into a first diagnosis computer model 71, in which the coordinates of diagnosis points of other components are also stored. Alternatively or additionally, the

[0039] Coordinates 50 are entered into a second findings computer model 72, in which additional coordinates of findings points taken on the same component at different times are stored.

[0040] LIST OF REFERENCE SYMBOLS

[0041] Turbomachine 1

[0042] Compressor la

[0043] Combustion chamber 1b

[0044] Turbine 1c

[0045] Longitudinal axis 2

[0046] Component 20

[0047] USB camera 25

[0048] Cable 26

[0049] Computer 27

[0050] Workplace 28

[0051] Operator 29

[0052] Image 30

[0053] Diagnostic Center 35

[0054] Computer model 40

[0055] Still image 45

[0056] Coordinates 50

[0057] Marking 55

[0058] Provision 61

[0059] Handheld recording 62

[0060] Matching and Combining 63

[0061] Mark 64

[0062] First findings computer model 71

[0063] Second findings computer model 72

Claims

CLAIMS 1. A method for supporting the diagnosis of a component (20) for a turbomachine (1), in particular for an aircraft engine, comprising the steps: i) providing (61) a USB camera (25); ii) manually capturing (62) an image (30) of the component (20) with the USB camera; iii) comparing and combining (31) the image (30), which shows a diagnosis point (35) of the component (20), with a computer model (40) of the component (20); iv) marking (64) the diagnosis point in the computer model (40) combined with the image (30) and thereby determining coordinates (50) of the diagnosis point in the computer model (40).

2. Method according to claim 1, wherein the computer model (40) in step iii) is first manually aligned in coordination with the image (30) and then superimposed with the image (30) in a computer-assisted manner.

3. Method according to claim 1 or 2, wherein the marking (64) of the site of examination (35) in step iv) is carried out manually.

4. The method according to claim 3, wherein the computer model (40) combined with the image (30) in step iv) is static, i.e. the diagnosis site (35) is marked in a still image (45).

5. Method according to one of the preceding claims, wherein after step iv) a marking (55) is displayed in the computer model (40) for visualization at the coordinates of the marking.

6. Method according to one of the preceding claims, in which the computer model (40) is subdivided into different areas, wherein different test and / or exclusion criteria are assigned to the diagnosis point (35) depending on in which of the areas the coordinates (50) are located.

7. Method according to one of the preceding claims, in which the coordinates (50) of the diagnosis point (35) of the component (20) and additionally coordinates of further diagnosis points are stored in a first diagnosis computer model (71) of the component (20), which are determined on identical components in a method comprising steps ii) to iv).

8. Method according to one of the preceding claims, in which the coordinates (50) of the diagnosis point (35) of the component (20) and additionally coordinates of further diagnosis points are stored in a second diagnosis computer model (72) of the component (20), which are determined on the component (20) at different times of manufacture and / or use in a method comprising steps ii) to iv).

9. Method according to one of the preceding claims, in which the USB camera (25) is designed to be wired, i.e. the image in step ii) is transmitted to a computer (27) via a cable (26) and a USB interface.

10. Method according to one of the preceding claims, wherein the USB camera (25) does not have a position sensor, motion sensor or acceleration sensor.

11. Method according to one of the preceding claims, wherein the USB camera (25) has an autofocus function.

12. Method for modeling a component (20) for a turbomachine (1), in particular for an aircraft engine, in which the component (20) is diagnosed in a method according to one of the preceding claims and a simulation model of the component (20) is examined with regard to mechanical stresses at the coordinates (50) of the diagnosis point (35).

13. Method for producing a component (20) for a turbomachine (1), in particular for an aircraft engine, in which the component (20) is inspected between different manufacturing steps and / or after completion in a method according to one of claims 1 to 11.

14. Method for revising a component (20) of a turbomachine (1), in particular of an aircraft engine, in which the component (20) is removed from the turbomachine (1) and in a method according to one of the Claims 1 to 11 are found to be valid.

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