Monitoring device, inspection device, monitoring method, and program

Abstract

A monitoring device comprising: an image acquisition unit for acquiring an image including a stationary body and a rotary body of a rotary machine; a ratio calculation unit for calculating the ratio of the size of a prescribed portion of the rotary machine in the image with respect to the actual dimensions thereof on the basis of the positions of both ends of the prescribed portion designated on the image and the actual dimensions of the prescribed portion; a position setting unit for setting a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotary body; a distance estimation unit for estimating, on the basis of the calculated ratio and the circumferential distance between the first position and the second position on the image, the actual circumferential distance between the first position and the second position in a ground coordinate system; and a phase estimation unit for estimating, on the basis of the estimated actual circumferential distance, the phase shift with respect to a reference phase of the rotary body.

Description

Monitoring device, inspection device, monitoring method, and program

[0001] This application claims priority to Japanese Patent Application No. 2023-206242, filed on December 6, 2023, the contents of which are incorporated herein by reference.

[0002] In recent years, devices that monitor and inspect objects using sensors such as cameras have been used. For example, Patent Document 1 describes a system that uses camera image information to detect the position of a loading platform separation jig for the purpose of automating the work of connecting and separating the loading platforms of self-driving trucks. Patent Document 2 describes a technology that uses a slit pattern light source to measure the three-dimensional surface shape of an object photographed for the purpose of object shape recognition.

[0003] Furthermore, in rotary machines such as steam turbines and gas turbines, non-open inspections are performed to inspect the interior without removing the casing. The interior of a rotary machine has a complex and narrow internal shape with multiple blades (stationary blades and rotor blades) arranged inside. As an inspection device for passing through such narrow spaces, Patent Document 3 describes a tubular inspection device that includes a flexible tube with an inspection cable having a sensor at its tip, an attitude actuator that can adjust the attitude of the tube, and an advance / retract actuator that moves the tube forward and backward.

[0004] International Publication No. 2022 / 051329 Japanese Patent No. 6752468 Japanese Patent No. 7059396

[0005] In order to pass through narrow sections without damaging the rotating machine during non-overhaul inspection, it is necessary to further improve the reliability of the inspection device. For example, to improve the reliability of the inspection device, it is necessary to generate a target path that does not interfere (contact) with the inspection device in narrow sections. For example, in a conventional inspection device such as that described in Patent Document 3, a target path is generated assuming that the rotor blades are stopped at a predetermined phase (reference phase). However, the rotor blades do not necessarily stop at the predetermined phase, and it is not possible to detect at which phase the rotor blades actually stopped from outside the rotating machine. Therefore, if the rotor blades are stopped at a phase different from the reference phase, it may be difficult for the inspection device to generate a target path that does not interfere.

[0006] Furthermore, in a narrow space such as the inside of a rotating machine, there may be a limited number of features available for position detection. As a result, in a conventional system such as that disclosed in Patent Document 1, which identifies the position of an object from camera image information, it may be difficult to obtain sufficient features and accurately detect the position of the object (phase of the rotor blade). Furthermore, a system equipped with a slit pattern for position estimation, such as that disclosed in Patent Document 2, is difficult to use in a high-temperature environment such as a rotating machine. In other words, it is difficult to detect the phase of the rotor blade in a narrow space such as a rotating machine using conventional technology.

[0007] An object of the present disclosure is to provide a monitoring device, an inspection device, a monitoring method, and a program that can estimate the amount of phase shift of a rotating body relative to a reference phase during non-open inspection of a rotating machine.

[0008] According to one aspect of the present disclosure, a monitoring device includes: an image acquisition unit that acquires an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; a ratio calculation unit that calculates a ratio of a size of a predetermined part of the rotating machine on the image to the actual dimension based on both end positions of the predetermined part specified on the image and the actual dimension of the predetermined part included in design information of the rotating machine; a position setting unit that sets a first position indicating a circumferential position of the stationary body and a second position indicating a circumferential position of the rotating body based on characteristic points of the stationary body and the rotating body specified on the image; a distance estimation unit that estimates an actual circumferential distance between the first position and the second position in a ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and a phase estimation unit that estimates a phase shift amount of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

[0009] According to one aspect of the present disclosure, the monitoring device includes an image acquisition unit that acquires an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube, a feature point setting unit that accepts designation of a plurality of feature points on the image, and a position and attitude estimation unit that estimates the position and attitude of the sensor in a ground coordinate system based on the positions of the plurality of feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

[0010] According to one aspect of the present disclosure, a monitoring method includes the steps of: acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; calculating a ratio of a size of a predetermined part of the rotating machine on the image to the actual dimension based on both end positions of the predetermined part specified on the image and actual dimensions of the predetermined part included in design information of the rotating machine; setting a first position indicating a circumferential position of the stationary body and a second position indicating a circumferential position of the rotating body based on characteristic points of the stationary body and the rotating body specified on the image; estimating an actual circumferential distance between the first position and the second position in a ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and estimating a phase shift amount of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

[0011] According to one aspect of the present disclosure, a monitoring method includes the steps of acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube, accepting designation of multiple feature points on the image, and estimating the position and attitude of the sensor in a ground coordinate system based on the positions of the multiple feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

[0012] According to one aspect of the present disclosure, the program causes the monitoring device to perform the following steps: acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; calculating a ratio of the size of a specified part of the rotating machine on the image to the actual dimension based on both end positions of the specified part of the rotating machine specified on the image and the actual dimension of the specified part included in design information of the rotating machine; setting a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotating body based on characteristic points of the stationary body and the rotating body specified on the image; estimating an actual circumferential distance between the first position and the second position in a ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and estimating a phase shift amount of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

[0013] According to one aspect of the present disclosure, the program causes the monitoring device to perform the following steps: acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; accepting designation of multiple feature points on the image; and estimating the position and attitude of the sensor in a ground coordinate system based on the positions of the multiple feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

[0014] According to the above aspect, it is possible to estimate the amount of phase shift of the rotor with respect to the reference phase during non-open inspection of the rotary machine.

[0015] 1 is a schematic diagram showing a schematic configuration of a gas turbine having a turbine that is an inspection target of the inspection method in this embodiment. FIG. 1 is a schematic diagram showing a schematic configuration of a combustor and the surrounding area, illustrating an inspection device. FIG. 2 is a schematic diagram showing a schematic configuration of a tube and an attitude actuator. FIG. 3 is an enlarged view of a main part of a tube, showing a tube body and wires. FIG. 4 is a cross-sectional view of a main part of a tube body, showing an attachment position of a wire in a tip tube body. FIG. 5 is a cross-sectional view of a main part of a tube body, showing an attachment position of a wire in another tube body adjacent to the tip tube body. FIG. 6 is a cross-sectional view of a main part showing the structure of an attitude actuator. FIG. 7 is a schematic diagram showing a state in which a tube is inserted deep inside a turbine. FIG. 8 is a schematic diagram explaining the schematic configuration of a guiding jig. FIG. 9 is a schematic diagram explaining a route. FIG. 10 is a diagram showing a hardware configuration of a monitoring device of a first embodiment. FIG. 11 is a block diagram showing the functional configuration of the monitoring device of the first embodiment. FIG. 12 is a first flowchart showing an example of a monitoring method of the first embodiment. FIG. 13 is a second flowchart showing an example of a monitoring method of the first embodiment. FIG. 14 is a diagram for explaining processing in the monitoring method of the first embodiment. FIG. 15 is a block diagram showing the functional configuration of a monitoring device of a second embodiment. FIG. 16 is a first flowchart showing an example of a monitoring method of the second embodiment. FIG. 10 is a second flowchart showing an example of a monitoring method according to a second embodiment. FIG. 11 is a diagram for explaining processing in the monitoring method according to the second embodiment. FIG. 12 is a diagram for explaining the function of a position and orientation estimation unit according to the second embodiment. FIG. 13 is a block diagram showing the functional configuration of a monitoring device according to a third embodiment. FIG. 14 is a flowchart showing an example of a monitoring method according to the third embodiment.

[0016] First Embodiment Hereinafter, the first embodiment will be described in detail with reference to FIGS.

[0017] 1 is a schematic diagram showing a schematic configuration of an inspection object according to the first embodiment. The inspection object in this embodiment is a rotary machine, such as the turbine 3 of a gas turbine 1 shown in FIG.

[0018] As shown in FIG. 1 , the gas turbine 1 includes a compressor 2 that generates high-pressure air, a turbine 3 that is driven by combustion gas, and a plurality of combustors 4 that mix fuel with the high-pressure air and combust it to generate combustion gas and supply it to the turbine 3.

[0019] The turbine 3 has a turbine rotor 31 that rotates about the axis O1 and a turbine casing 35 that covers the turbine rotor 31 from the outer periphery. The turbine rotor 31 has a columnar shape extending along the axis O1. A plurality of turbine blade stages 32 are provided on the outer periphery of the turbine rotor 31 and are arranged at intervals in the direction of the axis O1, which is the direction in which the axis O1 extends. Each turbine blade stage 32 has a plurality of blades 33 that are arranged on the outer periphery of the turbine rotor 31 and are arranged at intervals in the circumferential direction centered on the axis O1.

[0020] The turbine casing 35 has a cylindrical shape centered on the axis O1. A plurality of turbine stator vane stages 36 are provided on the inner peripheral surface of the turbine casing 35, spaced apart in the direction of the axis O1. These turbine stator vane stages 36 are provided upstream of the respective turbine rotor blade stages 32 in a one-to-one correspondence. As a result, the turbine stator vane stages 36 and the turbine rotor blade stages 32 are alternately arranged in the direction of the axis O1. Each turbine stator vane stage 36 has a plurality of stator vanes 37 arranged side by side in the circumferential direction on the inner peripheral surface of the turbine casing 35. In this embodiment, the rotor blades 33 and stator vanes 37 arranged most upstream inside the turbine casing 35 are referred to as first-stage rotor blades 331 and first-stage stator vanes 371. The turbine casing 35 is provided with a plurality of inspection ports 38 for inspecting the interior from the outside. The inspection hatch 38 is formed so as to communicate with a space inside the turbine casing 35 where the rotor blades 33 and the stator blades 37 can be observed.

[0021] The combustor 4 is provided at a connection portion between the compressor 2 and the turbine casing 35. A plurality of combustors 4 are provided at intervals in the circumferential direction around the axis O1. Each combustor 4 of the present embodiment has a hollow cylindrical combustion liner 41.

[0022] Inside the combustion liner 41, a mixture of high-pressure air compressed by the compressor 2 and fuel gas is combusted to generate combustion gas. The combustion liner 41 is a cylindrical member. In a portion including the upstream end of the combustion liner 41, its imaginary central axis O4 extends at an angle so as to approach the axis O1 as it moves from the compressor 2 toward the turbine 3. The downstream end (outlet) of the combustion liner 41 is connected to the inlet of the turbine 3. In the combustion liner 41, the portion including the downstream end is bent so as to follow the direction of the axis O1 relative to the portion including the upstream end.

[0023] The inspection device 5 of this embodiment is a device for performing non-destructive inspection to visually check the inside of the turbine 3 without opening the turbine casing 35. The inside of the turbine 3 is the space inside the turbine casing 35 through which combustion gas flows, and is the space in which the rotor blades 33 and the stator blades 37 are arranged.

[0024] (Configuration of inspection device) Fig. 2 is a schematic diagram showing the general configuration of the combustor and the surrounding area to explain the inspection device. Fig. 3 is a schematic diagram showing the general configuration of the tube and the attitude actuator. Fig. 4 is an enlarged view of a main part of the tube, showing the tube body and wires. Fig. 5 is a cross-sectional view of a main part of the tube body, showing the attachment position of the wire in the tube body at the tip. Fig. 6 is a cross-sectional view of a main part of the tube body, showing the attachment position of the wire in another tube body adjacent to the tube body at the tip. Fig. 7 is a cross-sectional view of a main part showing the structure of the attitude actuator. Fig. 8 is a schematic diagram showing a state in which the tube is inserted deep inside the turbine. Fig. 9 is a schematic diagram showing the general configuration of the guide jig. Fig. 10 is a schematic diagram showing a route.

[0025] The inspection device 5 is a device that can check the inside of the turbine 3 from the outside. By being fixed to the combustor 4, the inspection device 5 can visually check narrow sections and bent sections inside the turbine 3 that are difficult to see through the inside of the combustor 4. The inspection device 5 of this embodiment includes an inspection cable 61, an inspection tube 6, a guide jig 7, a drive control device (drive control device for the inspection tube) 8, a monitoring device 80, a camera image monitor 91, and a self-position display monitor 92.

[0026] The inspection cable 61 has a highly flexible cable main body 611 and a sensor 612 that is provided at the tip of the cable main body 611 and can inspect the inside of the turbine 3. The cable main body 611 can be bent in any direction intersecting the cable extension direction, which is the direction in which the cable main body 611 extends, by an operator operating an operation unit (not shown). The cable main body 611 is a separate member from the tube 62 and is detachably fixed to the tube 62. An actuator (not shown) for moving the cable is provided in the cable main body 611 so that the cable main body 611 can be driven independently of the inspection tube 62.

[0027] The sensor 612 is fixed to the tip of the cable main body 611. The sensor 612 and the cable main body 611 are built into the tube 62. The sensor 612 in this embodiment is a camera that can capture images of the inside of the turbine 3. Images (captured data such as moving images or still images) captured by the sensor 612 are sent to the camera image monitor 91 via a cable extending from the end (rear end) of the cable main body 611 on which the sensor 612 is not provided. As the inspection cable 61 in this embodiment, for example, a borescope (industrial endoscope) that is used to observe and inspect deep areas that cannot be directly observed with the naked eye is used.

[0028] The inspection cable 61 may be any cable that has a bendable structure, and may be, for example, a snake-like robot having a multi-joint structure in which multiple highly flexible members are connected.

[0029] Furthermore, the sensor 612 is not limited to being a camera as in this embodiment. For example, the sensor 612 in this embodiment may be a sensor 612 having a dimension measurement function (e.g., three-dimensional phase measurement) or a sensor 612 capable of measuring temperature or the presence or absence of scratches.

[0030] The inspection tube 6 includes a tube 62 , a posture actuator 65 , and a forward / backward movement actuator 67 .

[0031] As shown in FIG. 3 , the tube 62 has a hollow portion formed therein through which the inspection cable 61 can be inserted. The tube 62 is flexible. The tube 62 has a multi-joint structure that allows it to be bent at multiple locations. Therefore, the tube 62 can be bent in any direction intersecting the tube extension direction, which is the direction in which the tube 62 extends. Note that each joint portion of the tube 62 preferably has a structure that is easy to bend but is resistant to twisting and compression. The outer diameter of the tube 62 is sized to allow it to be inserted into the combustor 4 and into narrow spaces between the rotor and stator blades of the turbine 3. A cable main body 611 is detachably attached to the tube 62. The tube 62 of this embodiment is configured by connecting multiple tube main bodies 63.

[0032] The multiple tube bodies 63 are arranged side by side in the direction in which the tube bodies 63 extend and are connected to each other. The tube bodies 63 are deformable from an initial state in which they extend linearly along their central axis to a deformed state in which they are bent. As shown in FIG. 4 , the tube bodies 63 have a tubular portion 631 with both ends open and flange portions 632 protruding radially outward from the outer peripheral surfaces of both ends of the tubular portion 631. The tubular portion 631 has a cylindrical shape through which the inspection cable 61 can be inserted. The tubular portion 631 has, for example, multiple slits (not shown) formed therein, allowing it to be bent in any direction. The flange portions 632 are annular and integrally formed with the tubular portion 631.

[0033] As shown in Fig. 3, the attitude actuator 65 is capable of adjusting the attitude of the tube 62. Here, the attitude of the tube 62 refers to the position and orientation of the tip of the tube 62 on an imaginary plane intersecting the tube extension direction. The attitude actuator 65 in this embodiment is fixed to the rear end of the tube 62. As shown in Fig. 7, the attitude actuator 65 has a plurality of wires 651, a housing 652, a pulley 653, a wire driver 654, and a wire load detector 655.

[0034] As shown in FIG. 4 , a plurality of wires 651 (e.g., four in this embodiment) are provided for each tube body 63. The tips of the wires 651 are fixed to a flange portion 632 located on the tip side of the tube body 63. As shown in FIG. 5 , the wires 651 are fixed to one flange portion 632 so as to be spaced apart from each other and out of phase with each other (e.g., 90 degrees) with respect to each other. Furthermore, the wires 651 are arranged out of phase with each other for each adjacent tube body 63. Therefore, as shown in FIG. 6 , the fixing position of the wire 651 in one tube body 63 located on the tip side is offset by, for example, 45 degrees from that of another tube body 63 adjacent to the rear end. Therefore, the flange portion 632 of the rear-end tube body 63 has a wire insertion hole 633 formed therein for inserting the wire 651 fixed to a tube body 63 located further tip-side than the tube body 63. Therefore, the tube body 63 located closest to the rear end has more wire insertion holes 633 formed therein.

[0035] 7 , the housing 652 is fixed to the rear end of the tube 62. One end of the wire 651 is housed inside the housing 652. The housing 652 has a housing through-hole 652A formed therein, through which the cable main body 611 protruding from the rear end of the tube 62 can be inserted. The housing through-hole 652A is formed to penetrate the housing 652.

[0036] Pulley 653 is rotatably attached inside housing 652. Pulley 653 reverses the direction in which wire 651 extends inside housing 652. A pulley 653 is provided for each wire 651. In other words, one pulley 653 is provided for each wire 651. A plurality of pulleys 653 are provided spaced apart from each other to surround housing through-hole 652A.

[0037] The wire driving unit 654 is fixed inside the housing 652. A wire driving unit 654 is provided for each wire 651. That is, one wire driving unit 654 is provided for each wire 651. The wire driving unit 654 is connected to the rear end of the wire 651, which is the end of the wire 651 that is not fixed to the tube main body 63, via a wire load detection unit 655. The wire driving unit 654 is capable of moving the wire 651 forward and backward relative to the pulley 653. As the wire driving unit 654, for example, an electric slider, an electric cylinder, or a ball screw is used.

[0038] The wire load detection unit 655 is disposed between the rear end of the wire 651 and the wire driver 654. The wire load detection unit 655 measures the load (wire tensile force) acting on the wire 651 and sends the measurement result to the wire driver 654. If the sent measurement result is equal to or greater than a value determined to be excessive (e.g., a value that may damage the wire 651), the wire driver 654 is driven to loosen the wire 651. If the sent measurement result is equal to or less than a value determined to be insufficient (e.g., a value at which the wire 651 is deemed to be bent), the wire driver 654 is driven to tension the wire 651 to a degree that does not loosen it. The wire load detection unit 655 may be, for example, a load cell capable of directly measuring the load. Alternatively, the load may be measured indirectly based on the motor current value in the wire driver 654.

[0039] Furthermore, the attitude actuator 65 drives some of the multiple tube bodies 63 that are located near the tip. The number of tube bodies 63 driven by the attitude actuator 65 may be one or more. As shown in Fig. 3 , the tube 62 of this embodiment is divided into an active part 62A that is driven by the attitude actuator 65 and a driven part 62B that is not driven (deformed or moved) by the attitude actuator 65.

[0040] In the active section 62A, a wire 651 is fixed to the flange section 632 of each tube body 63. The active section 62A is a region of the tube 62 that has a predetermined length from the tip. Here, the predetermined length is a length that can reach a desired inspection range.

[0041] The driven part 62B moves in accordance with the movement of the active part 62A. In the driven part 62B, the wire 651 is not fixed to the flange part 632 of each tube main body 63. The driven part 62B is the region from the rear end of the tube 62 to the active part 62A. In this embodiment, the driven part 62B is the region sandwiched between the housing part 652 and the active part 62A.

[0042] 2, the advance / retract actuator 67 is capable of advancing and retracting the tube 62. Here, advancing and retracting the tube 62 means moving the tube 62 in the tube extension direction. The advance / retract actuator 67 of this embodiment is capable of moving the housing part 652 to which the tube 62 is fixed. The advance / retract actuator 67 has a guide rail 672 and an advance / retract drive part 671.

[0043] The guide rail 672 can be fixed to the upstream end of the combustor 4 via a guide jig 7. In this embodiment, the guide rail 672, when fixed to the combustor 4, extends parallel to an imaginary central axis O4 of a portion including the upstream end of the combustion liner 41.

[0044] The advancing / retracting drive unit 671 moves on the guide rails 672. The housing unit 652 is fixed to the advancing / retracting drive unit 671. The advancing / retracting drive unit 671 is, for example, an electric slider. As shown in FIG. 8 , the advancing / retracting drive unit 671 moves on the guide rails 672 so as to approach the connection position with the combustor 4, whereby the tube 62 is inserted deep inside (downstream side) the turbine 3. Conversely, as shown in FIG. 2 , the advancing / retracting drive unit 671 moves on the guide rails 672 so as to move away from the connection position with the combustor 4, whereby the tube 62 is moved from deep inside the turbine 3 to near the inlet of the turbine 3 (upstream side).

[0045] The guide jig 7 guides the tubes 62 from the outside of the gas turbine 1 to the inside of the turbine 3. The guide jig 7 of the present embodiment is inserted into the combustion liner 41 from the upstream side of the combustor 4, thereby guiding the tips of the tubes 62 from the outside of the combustor 4 to the outlet of the combustor 4 (near the upstream side of the first stage stator vane 371 inside the turbine 3). As shown in FIG. 9 , the guide jig 7 has a guide pipe 71, a leading pipe 72, a leading pipe rotating portion 73, and a guide pipe rotating portion 74.

[0046] The guide pipe 71 extends along the central axis O7. The guide pipe 71 is a cylindrical member through which the tube 62 can be inserted. The guide pipe 71 is formed to be longer than the length of a portion of the combustion tube 41, including its upstream end, extending along the imaginary central axis O4. A leading pipe 72 is connected to the tip of the guide pipe 71. A guide pipe flange portion 711 is formed at the rear end of the guide pipe 71, opposite the end where the leading pipe 72 is provided. The guide pipe flange portion 711 protrudes radially outward from the outer peripheral surface at the rear end of the guide pipe 71 to form an annular shape. A gear is formed on the outer peripheral surface of the guide pipe flange portion 711. The guide pipe 71 can be fixed to the combustor 4 with the guide pipe flange portion 711 positioned outside.

[0047] Like the guide tube 71, the leading pipe 72 is a cylindrical member through which the tube 62 can be inserted. The rear end of the leading pipe 72 is rotatably supported by the guide tube 71 via a leading pipe rotation shaft 721. The leading pipe rotation shaft 721 extends in a direction perpendicular to the central axis O7. The leading pipe rotation shaft 721 rotatably connects the leading pipe 72 and the guide tube 71. The leading pipe 72 has a free end at its tip. The leading pipe 72 is formed shorter than the guide pipe 71. The leading pipe 72 has a length approximately equal to the length of the portion of the combustion tube 41 that includes the downstream end.

[0048] The leading pipe rotation unit 73 rotates the leading pipe 72 relative to the guide pipe 71. The leading pipe rotation unit 73 has a leading pipe rotation motor 731, a leading pipe side pulley 732, a motor side pulley 733, and a wire unit 734. The leading pipe rotation motor 731 is provided so as to be located outside the combustor 4 when the guide jig 7 is attached to the combustor 4. The leading pipe side pulley 732 is fixed to the leading pipe rotation shaft 721. The motor side pulley 733 is fixed to the drive shaft of the leading pipe rotation motor 731. The wire unit 734 is endless, and is stretched between the leading pipe side pulley 732 and the motor side pulley 733. As a result, when the leading pipe rotation motor 731 is driven, the motor side pulley 733 rotates. The rotation of the motor-side pulley 733 is transmitted to the leading tube-side pulley 732 via the wire portion 734, and the leading tube-side pulley 732 rotates together with the leading tube rotation shaft 721. As a result, the leading tube 72 rotates around the leading tube rotation shaft 721.

[0049] The guide pipe rotation unit 74 rotates the guide pipe 71 around the central axis O7. The guide pipe rotation unit 74 has a guide pipe rotation motor 741 and a guide pipe rotation gear 742. The guide pipe rotation motor 741 is disposed outside the combustor 4 such that, when the guiding jig 7 is attached to the combustor 4, the guide pipe rotation gear 742 meshes with the guide pipe flange portion 711. The guide pipe rotation gear 742 is fixed to the drive shaft of the guide pipe rotation motor 741. As a result, when the guide pipe rotation motor 741 is driven, the guide pipe rotation gear 742 rotates. As the guide pipe rotation gear 742 rotates, the meshed guide pipe flange portion 711 rotates. As a result, the guide pipe 71 rotates together with the leading pipe 72 around the central axis O7.

[0050] As shown in FIG. 2 , the drive control device 8 is capable of sending signals to the attitude actuator 65 and the advance / retract actuator 67 to control the movement of the tube 62. The drive control device 8 determines a route R based on design information including pre-stored three-dimensional shape data of the interior of the turbine 3, and controls the attitude actuator 65 and the advance / retract actuator 67 of the inspection device 5 so that the inspection device 5 moves along the route R. Here, as shown in FIG. 10 , the route R is a path from a start point SP, where the tip of the tube 62 is initially positioned inside the turbine 3, to a target point EP to be inspected (checked). The start point SP is the point where the tip of the tube 62 is located before the start of inspection. In this embodiment, the start point SP is a connection between the inlet of the turbine 3 and the outlet of the combustor 4, near the upstream end of the first-stage stator vane 371. The target point EP is an arbitrary inspection position inside the turbine 3, such as the stator vane 37 or the rotor blade 33 to be inspected. The functional configuration of the drive control device 8 is similar to that of a known functional configuration (e.g., Patent Document 3), and therefore a detailed description thereof will be omitted.

[0051] The camera image monitor 91 displays a video (image) captured by the sensor 612. The image captured by the sensor 612 is input to the camera image monitor 91 via the inspection cable 61. The image input to the camera image monitor 91 is sent to the self-position display monitor 92, the drive control device 8, and the monitoring device 80. The camera image monitor 91 also displays information such as the relative phases of the stator blades 37 and the rotor blades 33 superimposed on the image captured by the sensor 612, based on information input from the monitoring device 80.

[0052] The self-position display monitor 92 displays the route R on the three-dimensional shape data inside the turbine 3, and the current position and attitude of the tube 62. The self-position display monitor 92 displays the current position and attitude of the tube 62 on the route R based on information input from the drive control device 8 and the monitoring device 80.

[0053] The monitoring device 80 estimates the amount of phase shift of the rotor of the turbine 3 relative to a reference phase based on image data captured by a sensor 612 provided at the tip of the inspection device 5. In this embodiment, an example will be described in which the monitoring device 80 is built into the drive control device 8 as shown in FIG. 2 . In other embodiments, the monitoring device 80 may be configured as a device separate from the drive control device 8, or may be implemented as a function executed by the CPU of the drive control device 8.

[0054] (Hardware Configuration of Monitoring Device) Fig. 11 is a diagram showing the hardware configuration of the monitoring device of the first embodiment. As shown in Fig. 11, the monitoring device 80 is a computer including a CPU (Central Processing Unit) 101, a ROM (Read Only Memory) 102, a RAM (Random Access Memory) 103, a storage unit 104, and an interface unit 105. Signals are exchanged via the interface unit 105 with the attitude actuator 65, the advance / retreat actuator 67, and a camera image monitor 91 and a self-position display monitor 92, which will be described later.

[0055] The CPU 101 is a processor that controls the overall operation of the monitoring device 80. The CPU 101 operates according to a program prepared in advance to perform various functions, which will be described later.

[0056] The ROM 102 is a non-volatile memory that cannot be rewritten. The RAM 103 is a volatile memory that can be rewritten. The ROM 102 and RAM 103 are also called main storage devices, and programs that enable the CPU 101 to perform various functions are loaded in the ROM 102 and RAM 103.

[0057] The storage unit 104 is a large-capacity storage device (non-volatile memory) built into the drive control device 8, and is, for example, a hard disk drive (HDD) or a solid state drive (SSD). The storage unit 104 is also called an auxiliary storage device, and stores necessary information in advance, such as design information for the turbine 3 (described later), data acquired and generated by processing in each part of the CPU 101, and programs for operating the CPU 101.

[0058] (Functional Configuration of Monitoring Apparatus) Fig. 12 is a block diagram showing the functional configuration of the monitoring apparatus of Embodiment 1. As shown in Fig. 12, a monitoring apparatus 80 of this embodiment includes an image acquisition unit 81, a reference line setting unit 82, a ratio calculation unit 83, a position setting unit 84, a distance estimation unit 85, and a phase estimation unit 86.

[0059] The image acquisition unit 81 acquires an image including the stationary body and the rotating body of the turbine 3 from the sensor 612. In this embodiment, an example will be described in which the stationary body is the stationary blade 37 and the rotating body is the rotating blade 33. In other embodiments, the stationary body may be another structure such as the turbine casing 35, as long as the relative phase with respect to the rotating body can be detected.

[0060] The reference line setting unit 82 accepts specification of positions on the image that indicate both ends of a line segment extending circumferentially around the turbine 3 in the ground coordinate system (in actual three-dimensional space) and a vertical line perpendicular to this line segment, and sets a first reference line corresponding to the circumferential line segment on the image and a second reference line corresponding to the vertical line.

[0061] The ratio calculation unit 83 receives a specification of the position of a specified part of the turbine 3 on the image, and calculates the ratio of the size (circumferential length) of the specified part on the image to the actual dimensions of the specified part included in the design information of the turbine 3.

[0062] The position setting unit 84 receives specification of the positions of the stator blades 37 and the rotor blades 33 on the image, and sets a first position indicating the circumferential position of the stator blades 37 and a second position indicating the circumferential position of the rotor blades 33.

[0063] The distance estimation unit 85 estimates the actual circumferential distance in the ground coordinate system between the first position and the second position based on the circumferential distance on the image between the first position and the second position and the calculated ratio.

[0064] The phase estimation unit 86 estimates the amount of phase shift of the rotor blade 33 relative to the reference phase based on the estimated actual circumferential distance.

[0065] (Example of processing by the monitoring device) Fig. 13 is a first flowchart showing an example of the monitoring method of the first embodiment. Fig. 14 is a second flowchart showing an example of the monitoring method of the first embodiment. Fig. 15 is a diagram for explaining processing in the monitoring method of the first embodiment. Here, details of the monitoring method S1 using the monitoring device 80 of the first embodiment will be explained with reference to Figs. 13 to 15.

[0066] 13, the worker installs the inspection device 5 on the turbine 3, which is the object to be inspected (step S10). For example, the worker attaches the inspection device 5 to the combustor 4 of the gas turbine 1, as shown in FIG.

[0067] Next, the operator operates the inspection device 5 to insert the tip of the inspection tube 6 to a location where a characteristic point of the inspection object is located (step S11). For example, the operator inserts the inspection tube 6 to a position near the stator blade 37 (first stage stator blade 371) of the turbine 3 and just before the rotor blade 33 (first stage rotor blade 331) provided downstream of the stator blade 37.

[0068] Further, while watching the camera image monitor 91, the operator adjusts the angle of view of the sensor 612 (the direction of the inspection tube 6) so that the characteristic points of the stationary blade 37 and the rotor blade 33 are simultaneously captured (step S12).

[0069] Once the adjustment of the angle of view of the sensor 612 is completed, the monitoring device 80 acquires an image from the sensor 612 that simultaneously includes characteristic points of the stator blade 37 and the rotor blade 33, and performs a process of estimating the phase shift amount of the rotor blade 33 relative to the reference phase (step S13).

[0070] The flow of the process S13 for estimating the amount of phase shift performed by the monitoring device 80 will be described with reference to Figures 14 and 15. First, the image acquisition unit 81 acquires an image captured by the sensor 612 (step S130). Figure 15 shows an example of an image acquired by the image acquisition unit 81. Due to the adjustment in step S12, the image simultaneously includes both the stationary blade 37 and the rotating blade 33, as shown in Figure 15.

[0071] Next, the reference line setting unit 82 sets a first reference line L1 corresponding to a line segment extending in the circumferential direction of the turbine 3 (step S131). The line segment extending in the circumferential direction of the turbine 3 is, for example, a line segment indicating one axial end (contour line) of the inner shroud of the stator vane 37. The inner shroud is a plate-like member provided radially inside the stator vane 37 and extending in the circumferential direction. The operator visually checks the stator vane 37 on the image and specifies first feature points F1 and F1' indicating any two points (both ends) on the contour line extending in the circumferential direction of the inner shroud of the stator vane 37. Then, the reference line setting unit 82 sets a line connecting the first feature points F1 and F1' on the image as the first reference line L1.

[0072] The reference line setting unit 82 also sets a second reference line L2 corresponding to a vertical line perpendicular to the circumferential direction in the ground coordinate system (in actual three-dimensional space) (step S132). The vertical line is a line parallel to the axis O1 and is, for example, a line segment indicating one circumferential end (contour) of the platform of the rotor blade 33. The platform is a plate-like member located radially inside the rotor blade 33 and extending in the circumferential direction. The operator visually checks the rotor blade 33 on the image and specifies second feature points F2 and F2' that indicate any two points (both ends) on the contour extending in the axial direction of the platform of the rotor blade 33. The reference line setting unit 82 then sets the line connecting the second feature points F2 and F2' on the image as the second reference line L2.

[0073] The ratio calculation unit 83 receives designation of feature points F3 and F3' that indicate both ends of a predetermined portion of the turbine 3 on the image (step S133). The predetermined portion is a structure whose actual dimensions (circumferential length) are known from the design information of the turbine 3. In the example of Fig. 15, a cooling section consisting of multiple cooling holes provided in the rotor blade 33 is used as the predetermined portion. The operator visually confirms the position of the predetermined portion on the image and designates third feature points F3 and F3' that indicate both ends of the predetermined portion.

[0074] In addition, the ratio calculation unit 83 calculates the ratio (distance per pixel) of the size of a specified part on the image to the actual dimensions of the specified part included in the design information of the turbine 3, based on the third feature points F3, F3' specified by the worker (step S134).

[0075] The position setting unit 84 sets a first position F4 indicating the circumferential position of the stator blade 37 and a second position F5 indicating the circumferential position of the rotor blade 33 (step S135). The first position F4 is, for example, as shown in FIG. 15 , an end portion on one circumferential side of the stator blade 37 (inner shroud). The operator visually checks the stator blade 37 on the image and specifies a feature point indicating the circumferential end portion of the stator blade 37. The position setting unit 84 then sets the specified feature point as the first position F4. The second position F5 is, for example, as shown in FIG. 15 , a feature point F3 on one end side of a predetermined portion (cooling portion) provided on the rotor blade 33. The operator visually checks the rotor blade 33 on the image and specifies a feature point indicating one end side of the cooling portion on the rotor blade 33. The position setting unit 84 then sets the specified feature point as the second position F5. In addition, when a feature point (F3 or F3′) at either end of a predetermined portion (cooling portion) is used as a feature point indicating the circumferential position of the rotor blade 33, the position setting unit 84 may omit the designation operation by the operator and automatically set the feature point F3 or F3′ designated in step S133 as the second position F5.

[0076] The distance estimation unit 85 estimates the actual circumferential distance between the first position F4 and the second position F5 in the ground coordinate system based on the circumferential distance between the first position F4 and the second position F5 on the image and the ratio calculated in step S134 (step S136). At this time, as shown in the example of FIG. 15 , the axial positions of the first position F4 and the second position F5 may differ. In such a case, the distance estimation unit 85 virtually matches the axial positions of the first position F4 and the second position F5 to estimate the circumferential distance between these positions F4 and F5. Specifically, the distance estimation unit 85 first sets a first virtual line L4 that is parallel to the second reference line L2 and passes through the first position F4, and a second virtual line L5 that is parallel to the second reference line L2 and passes through the second position F5. Next, the distance estimation unit 85 sets a first intersection F6 where the first reference line L1 and the first virtual line L4 intersect, and a second intersection F7 where the first reference line L1 and the second virtual line L5 intersect. The distance estimation unit 85 then calculates the distance from the first intersection F6 to the second intersection F7 on the first reference line L1 as the circumferential distance between positions F4 and F5. Note that, when the first reference line L1 does not intersect with the first virtual line L4 or the second virtual line L5, as in the example of FIG. 15 , a third virtual line L6 may be set by translating the first reference line L1, and the distance from the first intersection F6 where the third virtual line L6 and the first virtual line L4 intersect to the second intersection F7 where the third virtual line L6 and the second virtual line L5 intersect may be calculated as the circumferential distance between positions F4 and F5. In this case, the length of the third virtual line L6 may be changed (enlarged or reduced) from the length of the first reference line L1 as necessary. Based on the ratio calculated in step S134, the distance estimation unit 85 estimates the actual circumferential distance in the ground coordinate system corresponding to the circumferential distance (number of pixels) on the image between the positions F4 and F5.

[0077] The phase estimation unit 86 estimates the phase shift amount of the rotor blade 33 with respect to the reference phase based on the estimated actual circumferential distance, and outputs the estimated relative phase to the camera image monitor 91 and the drive control device 8 (step S137). For example, the design information of the turbine 3 includes a reference distance indicating the actual circumferential distance between the first position F4 and the second position F5 in the reference phase. The phase estimation unit 86 estimates the phase shift amount (±α degrees) of the rotor blade 33 with respect to the reference phase (0 degrees) from the difference between the actual circumferential distance estimated in step S136 and the reference distance read from the design information.

[0078] The phase shift amount output by the phase estimation unit 86 is displayed on the camera image monitor 91 in a superimposed manner on the image captured by the sensor 612 .

[0079] Next, returning to FIG. 13 , the operator determines whether to continue the entry operation of the inspection tube 6 based on the information on the phase shift amount displayed on the camera image monitor 91 or the like (step S14). For example, if the phase shift amount of the moving surface 33 is relatively small and there is a low possibility of contact when the inspection tube 6 is entered along the current route R, the operator determines that the entry operation can be continued. On the other hand, if the phase shift amount of the moving surface 33 is relatively large and there is a high possibility of contact when the inspection tube 6 is entered along the current route R, the operator determines that the entry operation cannot be continued. The phase estimation unit 86 may output information indicating whether the phase shift amount is equal to or less than a predetermined threshold and display it on the camera image monitor 91. In this case, the operator determines whether to continue the entry operation based on the information indicating whether the phase shift amount is equal to or less than the threshold. If it is determined that the entry operation cannot be continued, the operator operates, for example, the drive control device 8 to change the position or posture of the inspection tube 6. Alternatively, the operator may cause the drive control device 8 to recalculate the route R. The operator operates, for example, the drive control device 8 to change and update the three-dimensional shape data of the interior of the turbine 3 based on the amount of phase shift estimated by the phase estimation unit 86. The drive control device 8 recalculates the route R based on the updated three-dimensional shape data. Alternatively, the drive control device 8 may automatically update the three-dimensional shape data based on information about the amount of phase shift and recalculate the route R.

[0080] (Actions and Effects) As described above, the monitoring device 80 according to the present embodiment includes: an image acquisition unit 81 that acquires an image including the stationary vanes 37 and the rotor blades 33 from the sensor 612; a ratio calculation unit 83 that calculates a ratio of the size of a predetermined portion on the image to the actual dimension based on both end positions of the predetermined portion of the turbine 3 specified on the image and the actual dimension of the predetermined portion included in design information of the turbine 3; a position setting unit 84 that sets a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotor, based on characteristic points of the stationary body and the rotor specified on the image; a distance estimation unit 85 that estimates the actual circumferential distance between the first position F4 and the second position F5 in the ground coordinate system based on the circumferential distance between the first position F4 and the second position F5 on the image and the calculated ratio; and a phase estimation unit 86 that estimates the amount of phase shift of the rotor blades 33 with respect to a reference phase, based on the estimated actual circumferential distance.

[0081] In conventional technology, a route was generated assuming that the rotor blades were shut down at their reference phase. Therefore, when an inspection tube was inserted along the route, if the rotor blades were shut down at a different position (phase) than expected, the inspection tube could interfere with the rotor blades. Furthermore, in conventional inspection systems that perform inspections while checking images of the turbine interior, operators relied solely on image information to estimate the amount of deviation of the rotor blades from their reference phase, but the accuracy of this estimation depended on the operator's level of skill. Therefore, it was difficult for an unskilled operator to perform a non-overhaul inspection with a certain level of quality and within a limited time. In contrast, the monitoring device 80 of this embodiment can automatically estimate, from images, the amount of deviation (phase) of the rotor blades 33 from their reference phase when they were shut down. Therefore, by referring to the estimated phase deviation, an operator can easily determine whether or not to insert the inspection tube 6 along the pre-set route R. This allows an operator to perform a non-overhaul inspection with a certain level of quality and within a limited time, regardless of their level of skill.

[0082] The monitoring device 80 further includes a reference line setting unit 82 that accepts designation of first feature points F1, F1' that indicate both ends of a line segment extending in the circumferential direction of the turbine 3 in the ground coordinate system and second feature points F2, F2' that indicate both ends of a vertical line perpendicular to the circumferential line segment in the ground coordinate system, and sets a first reference line L1 connecting the first feature points F1, F1' and a second reference line L2 connecting the second feature points F2, F2' on the image. The phase estimation unit 86 determines the distance from a first intersection F6 of a line segment (first virtual line L4) that passes through the first position F4 and is parallel to the second reference line L2 and the first reference line L1 to a second intersection F7 of a line segment (second virtual line L5) that passes through the second position F5 and is parallel to the second reference line L2 and the first reference line L1 as the circumferential distance between the first position F4 and the second position F5 on the image.

[0083] In this way, the monitoring device 80 can more accurately estimate how much the rotor blade 33 is shifted in the circumferential direction from the reference phase.

[0084] The predetermined portion is provided on the rotor blade 33, and the position setting unit 84 sets the position on one end side of the predetermined portion (characteristic point F3 or F3') as the second position F5.

[0085] By doing this, the monitoring device 80 can eliminate the need for the operator to specify the second position F5, thereby reducing the operator's workload and shortening the work time required to estimate the phase shift amount.

[0086] Furthermore, the operator or the drive control device 8 may update the three-dimensional shape data based on the amount of phase shift of the rotor blade 33. In this case, it is possible to generate a route R that can more reliably prevent the inspection tube 6 from interfering with narrow portions, based on the three-dimensional shape data that reflects the actual position (phase) of the rotor blade 33.

[0087] Second Embodiment Next, a second embodiment will be described in detail with reference to Figures 16 to 20. Note that, among the configurations of the second embodiment, the same configurations as those of the first embodiment will be described using the same reference numerals as those of the first embodiment.

[0088] (Functional Configuration of Monitoring Apparatus) Fig. 16 is a block diagram showing the functional configuration of a monitoring apparatus according to Embodiment 2. As shown in Fig. 16, a monitoring apparatus 80 according to this embodiment includes an image acquisition unit 81, a feature point setting unit 87, and a position and orientation estimation unit 88.

[0089] The image acquisition unit 81 acquires an image including the stationary blades 37 and the rotor blades 33 from a sensor 612 provided at the tip of the inspection tube 6 .

[0090] The feature point setting unit 87 receives designation of a plurality of feature points on an image.

[0091] The position and orientation estimation unit 88 estimates the position and orientation of the sensor 612 in the ground coordinate system based on the positions of multiple feature points on the image and the position information of the feature points in the ground coordinate system included in the design information of the turbine 3.

[0092] (Example of processing by monitoring device) Fig. 17 is a first flowchart showing an example of the monitoring method of the second embodiment. Fig. 18 is a second flowchart showing an example of the monitoring method of the third embodiment. Fig. 19 is a diagram for explaining processing in the monitoring method of the second embodiment. Fig. 20 is a diagram for explaining the function of the position and orientation estimation unit of the second embodiment. Here, details of the monitoring method S2 using the monitoring device 80 of the second embodiment will be described with reference to Figs. 17 to 20.

[0093] 17, the operator installs the inspection device 5 on the turbine 3, which is the object to be inspected (step S20), and inserts the tip of the inspection tube 6 into a location where a feature point of the object to be inspected is located (step S21). The operator also adjusts the angle of view of the sensor 612 (the orientation of the inspection tube 6) while watching the camera image monitor 91 so that the feature points of the stator blade 37 and the rotor blade 33 are simultaneously captured (step S22). These processes are the same as steps S10 to S12 of the first embodiment ( FIG. 13 ).

[0094] Once the adjustment of the angle of view of the sensor 612 is completed, the monitoring device 80 acquires an image from the sensor 612 that simultaneously includes characteristic points of the stator blades 37 and the rotor blades 33, and performs a process of estimating the position and attitude of the sensor 612 (step S23).

[0095] The flow of the position and attitude estimation process S23 by the monitoring device 80 will be described with reference to Figures 18 and 19. First, the image acquisition unit 81 acquires an image captured by the sensor 612 (step S230). Figure 19 shows an example of an image acquired by the image acquisition unit 81. As a result of the adjustment in step S22, the image simultaneously includes both the stationary blades 37 and the rotating blades 33, as shown in Figure 19.

[0096] Next, the feature point setting unit 87 receives designation of an origin F10 and a feature point F11 on the image from the operator and identifies the positions (XY coordinates) of each point F10 and F11 in the normalized image coordinate system (step S231). The origin F10 is the origin of the normalized image coordinate system. The positions of the surrounding feature points F11 on the image are expressed as two-dimensional positions (XY coordinates) from the origin F10. The origin F10 and the feature point F11 are structures provided on the stator vane 37 and the rotor blade 33, and are structures whose positions (XYZ coordinates) in the ground coordinate system are known from three-dimensional shape data included in the design information of the turbine 3. In the example of FIG. 19 , cooling holes provided on the stator vane 37 and the rotor blade 33 are designated as the origin F10 and the feature point F11. In addition, in the three-dimensional shape data, some of the multiple structures (cooling holes) are predetermined as target structures, and the data includes position information indicating the positions (XYZ coordinates) in the ground coordinate system of the target structure and surrounding structures included in images captured by the sensor 612 at multiple positions within the turbine 3. Therefore, in step S22, the operator adjusts the angle of view of the sensor 612 so that the target structure is included in the image. Then, the operator first designates the target structure on the image as the origin F10, and then designates a predetermined number (six in the example of FIG. 19 ) of structures surrounding the target structure as feature points F11.

[0097] Next, the position and orientation estimation unit 88 calculates a perspective projection matrix P of the sensor 612 based on the positions of the specified origin F10 and feature point F11 on the image (XY coordinates of each point in the normalized image coordinate system) and the three-dimensional shape data (XYZ coordinates of each point in the ground coordinate system) (step S232). The perspective projection matrix P is calculated by solving a known simultaneous linear equation.

[0098] Furthermore, the position and orientation estimation unit 88 decomposes the perspective projection matrix P (= K[R, t]) into a rotation matrix R and a translation vector t to estimate the position and orientation (X, Y, Z, Roll, Pitch, Yaw) of the sensor 612 in the ground coordinate system, and outputs these to the camera image monitor 91, the self-position display monitor 92, and the drive control device 8 (step S233). The camera image monitor 91 then superimposes and displays information about the position and orientation of the sensor 612 estimated by the position and orientation estimation unit 88 on the image captured by the sensor 612. Furthermore, the self-position display monitor 92 displays the current position and orientation of the tube 62 on the route R, based on the information about the position and orientation of the sensor 612 estimated by the position and orientation estimation unit 88.

[0099] Furthermore, the position and attitude estimation unit 88 may calculate an error between the estimated position and attitude of the sensor 612 and the target position and attitude of the sensor 612, and output the error to the camera image monitor 91, the self-position display monitor 92, and the drive control device 8 (step S234). Then, the camera image monitor 91 displays information indicating the error from the target position and target attitude of the sensor 612 superimposed on the image captured by the sensor 612.

[0100] The processing by the position and orientation estimation unit 88 may be performed using an existing general-purpose library including a position estimation solver implemented as a function, as shown in FIG. 20 . The position estimation solver receives inputs of an image captured by the sensor 612, feature point information indicating the positions (XY coordinates) of an origin F10 and surrounding feature points F11 in the image specified by the operator, and three-dimensional shape data including the positions (XYZ coordinates) of each point F10 and F11 in the ground coordinate system. The position estimation solver outputs estimated values ​​of the position and orientation of the sensor 612 in response to these inputs (step S233). The position and orientation estimation unit 88 calculates and outputs the errors between the estimated values ​​of the position and orientation output by the position estimation solver and the target values ​​(step S234).

[0101] 17 , the operator determines whether to continue the insertion operation of the inspection tube 6 based on the information on the estimated values ​​of the position and orientation of the sensor 612 displayed on the camera image monitor 91 or the like and the error from the target values ​​(step S24). For example, if the error between the target position and orientation of the sensor 612 and the target position is relatively small and the possibility of contact is low even if the inspection tube 6 is inserted along the current route R, the operator determines that the insertion operation can be continued. On the other hand, if the error between the target position and orientation of the sensor 612 and the target position is relatively large and the possibility of contact is high if the inspection tube 6 is inserted along the current route R, the operator determines that the insertion operation cannot be continued. Note that the position and orientation estimation unit 88 may output information indicating whether the error between the target position and orientation of the sensor 612 and the target position is equal to or less than a predetermined threshold and display the information on the camera image monitor 91. In this case, the operator determines whether to continue the insertion operation based on the information indicating whether the error between the target position and orientation of the sensor 612 and the target position is equal to or less than a threshold. If it is determined that the entry operation cannot be continued, the operator operates, for example, the drive control device 8 to change the position and posture of the inspection tube 6. After the change, the series of processes in Fig. 18 is executed again, and if the error between the target position and the target posture of the sensor 612 becomes less than the threshold value, it is determined that the entry operation can be continued.

[0102] (Actions and Effects) As described above, the monitoring device 80 according to this embodiment includes an image acquisition unit 81 that acquires an image including the stator blades 37 and the rotor blades 33 from the sensor 612 provided at the tip of the inspection tube 6, a feature point setting unit 87 that accepts designation of a plurality of feature points F10, F11 on the image, and a position and attitude estimation unit 88 that estimates the position and attitude of the sensor 612 in the ground coordinate system based on the positions of the plurality of feature points F10, F11 on the image and the position information in the ground coordinate system of the feature points F10, F11 included in the design information of the turbine 3.

[0103] In conventional technology, workers estimated the sensor position and other information based solely on image information, but the accuracy of this estimation depended on the worker's level of skill. Therefore, it was difficult for workers other than highly skilled to perform non-open inspections with a certain level of quality and within a limited time. Furthermore, with conventional technology, it was difficult to accurately detect the position of an object in an environment with few features, such as inside a turbine. In contrast, the monitoring device 80 of this embodiment, with the above-described configuration, can accurately estimate the position and orientation of the sensor 612 even in a narrow space with few features for position detection, such as inside the turbine 3. Therefore, by referring to the estimated position and orientation of the sensor 612, the worker can perform non-open inspections with a certain level of quality and within a limited time, regardless of their level of skill.

[0104] Furthermore, the position and orientation estimation unit 88 further estimates the error between the estimated position and orientation of the sensor 612 and the target position and target orientation of the sensor 612 .

[0105] In this way, the monitoring device 80 allows the operator to easily grasp the degree to which the sensor 612 has deviated from the target position and target posture, which enables the operator to correctly determine, regardless of their level of skill, whether to continue the insertion operation of the inspection tube 6 or whether to adjust the position and posture of the inspection tube.

[0106] Third Embodiment Next, a third embodiment will be described in detail with reference to Figures 21 and 22. Note that, among the configurations of the third embodiment, the same configurations as those of the above-mentioned embodiments will be described using the same reference numerals as those of the above-mentioned embodiments.

[0107] (Functional Configuration of Monitoring Device) Fig. 21 is a block diagram showing the functional configuration of a monitoring device according to the third embodiment. As shown in Fig. 21, this embodiment is a combination of the first and second embodiments. That is, a monitoring device 80 according to this embodiment includes an image acquisition unit 81, a reference line setting unit 82, a ratio calculation unit 83, a position setting unit 84, a distance estimation unit 85, a phase estimation unit 86, a feature point setting unit 87, and a position and orientation estimation unit 88. The functions of each unit are the same as those described in the first and second embodiments.

[0108] (Example of processing by the monitoring device) Fig. 22 is a flowchart showing an example of a monitoring method according to the third embodiment. Here, details of the monitoring method S3 using the monitoring device 80 according to the third embodiment will be described with reference to Fig. 22.

[0109] 22, the operator installs the inspection device 5 on the turbine 3, which is the object to be inspected (step S30), and inserts the tip of the inspection tube 6 into a location where a feature point of the object to be inspected is located (step S31). The operator also adjusts the angle of view of the sensor 612 (the orientation of the inspection tube 6) while watching the camera image monitor 91 so that the feature points of the stator blade 37 and the rotor blade 33 are simultaneously captured (step S32). These processes are the same as steps S10 to S12 in the first embodiment ( FIG. 13 ).

[0110] When the adjustment of the angle of view of the sensor 612 is completed, the monitoring device 80 acquires an image from the sensor 612 that simultaneously includes characteristic points of the stationary blade 37 and the rotor blade 33, and executes a process of estimating the phase shift amount of the rotor blade 33 with respect to the reference phase (step S33). This process is the same as the process of step S13 in the first embodiment (FIGS. 13 and 14).

[0111] The monitoring device 80 also acquires an image from the sensor 612 that simultaneously includes characteristic points of the stationary blades 37 and the rotor blades 33, and executes a process of estimating the position and attitude of the sensor 612 (step S34). This process is the same as the process of step S23 in the second embodiment (FIGS. 17 and 18).

[0112] Next, the operator determines whether or not to continue the insertion operation of the inspection tube 6 based on the phase shift amount of the rotor blade 33 displayed on the camera image monitor 91 or the like and the error between the estimated value and the target value of the position and attitude of the sensor 612 (step S35). This process is the same as the process of step S14 in the first embodiment (FIG. 13) or step S24 in the second embodiment (FIG. 17).

[0113] (Actions and Effects) As described above, the monitoring device 80 according to this embodiment includes the image acquisition unit 81, ratio calculation unit 83, position setting unit 84, distance estimation unit 85, and phase estimation unit 86 of the first embodiment, as well as the feature point setting unit 87 and position and orientation estimation unit 88 of the second embodiment.

[0114] In this way, the monitoring device 80 can enable the worker to easily grasp the amount of phase shift of the rotor blade 33 and the position and attitude of the sensor 612. This enables the worker to perform non-overhaul inspection with a certain level of quality or higher within a limited time, regardless of their level of skill.

[0115] Other Embodiments Although the embodiments have been described in detail above with reference to the drawings, the specific configuration is not limited to the above, and various design modifications are possible. That is, in other embodiments, the order of the above-described processes may be changed as appropriate. Furthermore, some processes may be executed in parallel.

[0116] <Additional Notes> The monitoring device, inspection device, monitoring method, and program described in each embodiment can be understood, for example, as follows.

[0117] (1) According to the first aspect, the monitoring device 80 includes an image acquisition unit 81 that acquires an image including a stationary body of the rotating machine and a rotating body that rotates relative to the stationary body from a sensor 612 provided at the tip of the inspection tube 6; a ratio calculation unit 83 that calculates a ratio of the size of a predetermined part on the image to the actual dimension based on both end positions of the predetermined part of the rotating machine specified on the image and the actual dimension of the predetermined part included in the design information of the rotating machine; a position setting unit 84 that sets a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotating body based on feature points of the stationary body and the rotating body specified on the image; a distance estimation unit 85 that estimates the actual circumferential distance between the first position and the second position in a ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and a phase estimation unit 86 that estimates the amount of phase shift with respect to the reference phase of the rotating body based on the estimated actual circumferential distance.

[0118] In conventional technology, a route was generated assuming that the rotor blades were shut down at their reference phase. Therefore, when an inspection tube was inserted along the route, if the rotor blades were shut down at a different position (phase) than expected, the inspection tube could interfere with the rotor blades. Furthermore, in conventional inspection systems that perform inspections while checking images of the turbine interior, operators relied solely on image information to estimate the amount of deviation of the rotor blades from their reference phase, but the accuracy of this estimation depended on the operator's level of skill. Therefore, it was difficult for an unskilled operator to perform a non-overhaul inspection with a certain level of quality and within a limited time. In contrast, the monitoring device 80 of this embodiment can automatically estimate, from images, the amount of deviation (phase) of the rotor blades 33 from their reference phase when they were shut down. Therefore, by referring to the estimated phase deviation, an operator can easily determine whether or not to insert the inspection tube 6 along the pre-set route R. This allows an operator to perform a non-overhaul inspection with a certain level of quality and within a limited time, regardless of their level of skill.

[0119] (2) According to the second aspect, the monitoring device 80 according to the first aspect further includes a reference line setting unit 82 that sets a first reference line on the image corresponding to a line segment extending in the circumferential direction of the rotating machine in a ground coordinate system and a second reference line on the image corresponding to the vertical line, based on the positions of both ends of a line segment extending in the circumferential direction of the rotating machine in the ground coordinate system and a vertical line perpendicular to the line segment in the ground coordinate system, and the phase estimation unit 86 determines the circumferential distance between the first position and the second position on the image to be the distance from a first intersection of a first virtual line that passes through the first position and is parallel to the second reference line and the first reference line, to a second intersection of a second virtual line that passes through the second position and is parallel to the second reference line and the first reference line.

[0120] In this way, the monitoring device 80 can more accurately estimate how much the rotor blade 33 is shifted in the circumferential direction from the reference phase.

[0121] (3) According to the third aspect, in the monitoring device 80 relating to the first or second aspect, the predetermined portion is provided on a rotating body, and the position setting unit 84 sets the position of one end side of the predetermined portion as the second position.

[0122] By doing this, the monitoring device 80 can eliminate the need for the operator to specify the second position F5, thereby reducing the operator's workload and shortening the work time required to estimate the phase shift amount.

[0123] (4) According to a fourth aspect, the monitoring device 80 according to any one of the first to third aspects further includes a feature point setting unit 87 that receives designation of multiple feature points on the image, and a position and attitude estimation unit 88 that estimates the position of the sensor 612 in the ground coordinate system based on the positions of the multiple feature points on the image and the position information in the ground coordinate system of the feature points included in the design information of the rotating machine.

[0124] In this way, the monitoring device 80 can enable the worker to easily grasp the amount of phase shift of the rotor blade 33 and the position and attitude of the sensor 612. This enables the worker to perform non-overhaul inspection with a certain level of quality or higher within a limited time, regardless of their level of skill.

[0125] (5) According to the fifth aspect, in the monitoring device 80 according to the fourth aspect, the position and orientation estimation unit further estimates the error between the estimated position and orientation of the sensor 612 and the target position and target orientation of the sensor 612.

[0126] In this way, the monitoring device 80 allows the operator to easily grasp the degree to which the sensor 612 has deviated from the target position and target posture, which enables the operator to correctly determine, regardless of their level of skill, whether to continue the insertion operation of the inspection tube 6 or whether to adjust the position and posture of the inspection tube.

[0127] (6) According to the sixth aspect, the monitoring device 80 includes an image acquisition unit 81 that acquires an image including a stationary body of the rotating machine and a rotating body that rotates relative to the stationary body from a sensor 612 provided at the tip of the inspection tube 6, a feature point setting unit 87 that accepts designation of multiple feature points on the image, and a position and attitude estimation unit 88 that estimates the position and attitude of the sensor 612 in the ground coordinate system based on the positions of the multiple feature points on the image and position information in the ground coordinate system of the feature points included in the design information of the rotating machine.

[0128] In conventional technology, workers estimated the sensor position and other information based solely on image information, but the accuracy of this estimation depended on the worker's level of skill. Therefore, it was difficult for workers other than highly skilled to perform non-open inspections with a certain level of quality and within a limited time. Furthermore, with conventional technology, it was difficult to accurately detect the position of an object in an environment with few features, such as inside a turbine. In contrast, the monitoring device 80 of this embodiment, with the above-described configuration, can accurately estimate the position and orientation of the sensor 612 even in a narrow space with few features for position detection, such as inside the turbine 3. Therefore, by referring to the estimated position and orientation of the sensor 612, the worker can perform non-open inspections with a certain level of quality and within a limited time, regardless of their level of skill.

[0129] (7) According to the seventh aspect, the inspection device 5 comprises an inspection tube 6 having a sensor 612 at the tip thereof, and the monitoring device 80 according to any one of the first to sixth aspects.

[0130] (8) According to the eighth aspect, the monitoring method includes the steps of: acquiring an image including a stationary body of the rotating machine and a rotating body rotating relative to the stationary body from a sensor 612 provided at the tip of the inspection tube 6; calculating a ratio of the size of a predetermined part of the rotating machine on the image to the actual dimension based on both end positions of the predetermined part specified on the image and the actual dimension of the predetermined part included in design information of the rotating machine; setting a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotating body based on feature points of the stationary body and the rotating body specified on the image; estimating an actual circumferential distance in a ground coordinate system between the first position and the second position based on the circumferential distance on the image between the first position and the second position and the calculated ratio; and estimating a phase shift amount relative to a reference phase of the rotating body based on the estimated actual circumferential distance.

[0131] (9) According to the ninth aspect, the monitoring method includes the steps of acquiring an image including a stationary body of the rotating machine and a rotating body that rotates relative to the stationary body from a sensor 612 provided at the tip of the inspection tube 6, accepting designation of multiple feature points on the image, and estimating the position and attitude of the sensor 612 in the ground coordinate system based on the positions of the multiple feature points on the image and position information in the ground coordinate system of the feature points included in the design information of the rotating machine.

[0132] (10) According to the tenth aspect, the program causes the monitoring device 80 to execute the following steps: acquiring an image including a stationary body of the rotating machine and a rotating body that rotates relative to the stationary body from the sensor 612 provided at the tip of the inspection tube 6; calculating a ratio of the size of a specified part of the rotating machine on the image to its actual dimensions based on the positions of both ends of the specified part on the image and the actual dimensions of the specified part included in the design information of the rotating machine; setting a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotating body based on feature points of the stationary body and the rotating body specified on the image; estimating the actual circumferential distance between the first position and the second position in the ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and estimating the amount of phase shift from the reference phase of the rotating body based on the estimated actual circumferential distance.

[0133] (11) According to the eleventh aspect, the program causes the monitoring device 80 to execute the following steps: acquiring an image including a stationary body of the rotating machine and a rotating body rotating relative to the stationary body from the sensor 612 provided at the tip of the inspection tube 6; accepting designation of multiple feature points on the image; and estimating the position and attitude of the sensor 612 in the ground coordinate system based on the positions of the multiple feature points on the image and the position information in the ground coordinate system of the feature points included in the design information of the rotating machine.

[0134] According to the above aspect, it is possible to estimate the amount of phase shift of the rotor with respect to the reference phase during non-open inspection of the rotary machine.

[0135] REFERENCE SIGNS LIST 1 Gas turbine 2 Compressor 3 Turbine 4 Combustor 5 Inspection device 6 Inspection tube 61 Inspection cable 62 Tube 62A Active part 62B Follower part 63 Tube body 65 Attitude actuator 67 Advance / retreat actuator 7 Guide jig 8 Drive control device 31 Turbine rotor 32 Turbine moving blade stage 33 Moving blade (rotating body) 35 Turbine casing (stationary body) 36 Turbine stator blade stage 37 Stator blade (stationary body) 80 Monitoring device 81 Image acquisition unit 82 Reference line setting unit 83 Ratio calculation unit 84 Position setting unit 85 Distance estimation unit 86 Phase estimation unit 87 Feature point setting unit 88 Position and attitude estimation unit 91 Camera image monitor 92 Self-position display monitor

Claims

1. A monitoring device comprising: an image acquisition unit that acquires an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; a ratio calculation unit that calculates a ratio of a size of a specific part of the rotating machine on the image to an actual dimension based on both end positions of the specific part specified on the image and an actual dimension of the specific part included in design information of the rotating machine; a position setting unit that sets a first position indicating a circumferential position of the stationary body and a second position indicating a circumferential position of the rotating body based on respective feature points of the stationary body and the rotating body specified on the image; a distance estimation unit that estimates an actual circumferential distance between the first position and the second position in a ground coordinate system based on the circumferential distance between the first position and the second position on the image and the calculated ratio; and a phase estimation unit that estimates an amount of phase shift of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

2. The monitoring device according to claim 1, further comprising a reference line setting unit that sets a first reference line on the image corresponding to a line segment extending in a circumferential direction of the rotating machine in the ground coordinate system and a second reference line on the image corresponding to the vertical line, based on the positions of both ends of a line segment extending in the circumferential direction of the rotating machine in the ground coordinate system and a vertical line perpendicular to the line segment in the ground coordinate system, and the phase estimation unit determines the circumferential distance between the first position and the second position on the image to be a distance from a first intersection of the first reference line and a first virtual line passing through the first position and parallel to the second reference line, to a second intersection of the first reference line and a second virtual line passing through the second position and parallel to the second reference line.

3. The monitoring device according to claim 1, wherein the predetermined portion is provided on the rotating body, and the position setting unit sets a position on one end side of the predetermined portion as the second position.

4. The monitoring device described in claim 1, further comprising: a feature point setting unit that accepts designation of a plurality of feature points on the image; and a position and orientation estimation unit that estimates a position of the sensor in a ground coordinate system based on positions of the plurality of feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

5. The monitoring device according to claim 4, wherein the position and orientation estimation unit further estimates an error between the estimated position and orientation of the sensor and a target position and target orientation of the sensor.

6. A monitoring device comprising: an image acquisition unit that acquires an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; a feature point setting unit that accepts designation of a plurality of feature points on the image; and a position and attitude estimation unit that estimates the position and attitude of the sensor in a ground coordinate system based on the positions of the plurality of feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

7. An inspection device comprising: an inspection tube having a sensor at its tip; and a monitoring device according to any one of claims 1 to 6.

8. A monitoring method comprising the steps of: acquiring an image including a stationary body of a rotating machine and a rotating body rotating relatively to the stationary body from a sensor provided at the tip of an inspection tube; calculating a ratio of a size of a specified part of the rotating machine on the image to an actual dimension based on both end positions of the specified part specified on the image and an actual dimension of the specified part included in design information of the rotating machine; setting a first position indicating a circumferential position of the stationary body and a second position indicating a circumferential position of the rotating body based on respective feature points of the stationary body and the rotating body specified on the image; estimating an actual circumferential distance in a ground coordinate system between the first position and the second position based on the circumferential distance on the image between the first position and the second position and the calculated ratio; and estimating an amount of phase shift of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

9. A monitoring method comprising the steps of: acquiring an image including a stationary body of a rotating machine and a rotating body rotating relatively to the stationary body from a sensor provided at the tip of an inspection tube; accepting designation of a plurality of feature points on the image; and estimating the position and attitude of the sensor in a ground coordinate system based on the positions of the plurality of feature points on the image and position information in the ground coordinate system of the feature points included in design information of the rotating machine.

10. A program that causes a monitoring device to execute the following steps: acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; calculating a ratio of the size of a specified part of the rotating machine on the image to the actual dimensions based on both end positions of the specified part specified on the image and the actual dimensions of the specified part included in the design information of the rotating machine; setting a first position indicating the circumferential position of the stationary body and a second position indicating the circumferential position of the rotating body based on respective feature points of the stationary body and the rotating body specified on the image; estimating the actual circumferential distance of the first position and the second position in a ground coordinate system based on the circumferential distance of the first position and the second position on the image and the calculated ratio; and estimating the amount of phase shift of the rotating body with respect to a reference phase based on the estimated actual circumferential distance.

11. A program that causes a monitoring device to execute the following steps: acquiring an image including a stationary body of a rotating machine and a rotating body that rotates relative to the stationary body from a sensor provided at the tip of an inspection tube; accepting designation of multiple feature points on the image; and estimating the position and attitude of the sensor in a ground coordinate system based on the positions of the multiple feature points on the image and position information in the ground coordinate system of the feature points included in the design information of the rotating machine.

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