Bladed Rotor Inspection Using 3D Scans and Targeted Probing
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Solution Overview
Problem
Current inspection methods for integrally bladed rotors in gas turbine engines lack efficiency and accuracy, particularly in identifying areas of interest and generating comprehensive three-dimensional models for effective repair and maintenance.
Innovation Solution
An inspection system and method that utilizes a combination of scanners, including coordinate measuring machines and structured light scanners, along with a contact probe and robotic arm, to scan and inspect bladed rotors, generating detailed three-dimensional models and identifying areas of interest for non-destructive testing and repair analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used for integrally bladed rotors, then the inspection process is simpler, but the accuracy and efficiency of defect detection are insufficient
Solution Approach 1:
The inspection process is divided into multiple stages: initial scanning to identify areas of interest, followed by targeted non-destructive inspection of specific regions. This segmentation allows the system to achieve high measurement precision only where needed, rather than uniformly across the entire rotor, thereby improving defect detection accuracy while managing system complexity.
Solution Approach 2:
A preliminary scan is performed to identify areas of interest before conducting detailed non-destructive inspection. This preliminary action filters the inspection scope to only those regions requiring detailed examination, improving overall measurement precision while reducing the complexity and time required for full-surface detailed inspection.
2Reliability
If comprehensive scanning is performed on the entire bladed rotor, then complete coverage is achieved, but the inspection time and resource consumption increase significantly
Solution Approach 1:
The rotor surface is segmented into areas of interest and non-critical areas. Detailed inspection is applied only to areas of interest identified by preliminary scanning, while other areas receive minimal or no detailed inspection. This maintains inspection reliability for critical regions while significantly reducing total inspection time.
Solution Approach 2:
Instead of performing exhaustive inspection uniformly across the entire rotor, the system applies partial action by focusing detailed inspection only on areas of interest. This approach achieves sufficient reliability for defect detection in critical regions without the time penalty of complete comprehensive scanning.
3Productivity
If manual inspection methods are used, then equipment cost is lower, but the productivity and consistency of inspection results decrease
Solution Approach 1:
The inspection system performs self-service by automatically identifying areas of interest through preliminary scanning and then automatically directing non-destructive inspection resources to those areas. This automation improves productivity and consistency of inspection results while the modular architecture manages device complexity through standardized interfaces and processes.
Data Source
AI summary
An article of manufacture may include a tangible, non-transitory computer-readable storage medium having instructions stored thereon that, in response to execution by a processor, cause the processor to perform operations comprising: commanding, via the processor, a first scan of a bladed rotor; generating, via the processor, a three-dimensional model based on a first set of data received from a first scanner; comparing, via the processor, the three-dimensional model to an acceptable three-dimensional model of the bladed rotor; determining, via the processor, areas of interest based on the comparison; and commanding, via the processor, a contact probe to perform a non-destructive inspection on the areas of interest.