Borescope Inspection System with Sensor Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional blade inspection methods using borescopes face challenges in accurately aligning the distal end portion with the observed flaw, especially due to the elongated insertion section and remote position from the access port, making it difficult to maintain the same position and viewing direction for detailed inspections.
Innovation Solution
A blade inspection system with a borescope and personal computer setup that includes distance sensors and an acceleration sensor, allowing for real-time calculation of insertion length and attitude, and displaying match indicators to assist in aligning the borescope's position and direction with the previous inspection's parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the insertion section of the borescope is made elongated to reach remote positions in the engine, then the inspection coverage is improved, but it becomes difficult to accurately align and maintain the position and direction of the distal end portion for detailed inspection
Solution Approach 1:
The system incorporates sensors (acceleration sensor, distance sensors) that continuously detect the insertion length and attitude of the borescope, providing real-time feedback to the control unit. This feedback enables automatic adjustment and maintains precise alignment of the distal end portion with the target inspection location, resolving the alignment difficulty caused by the elongated insertion section.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated control system that uses sensors to detect position and attitude, calculates required adjustments, and automatically controls the distal end portion positioning. This substitution eliminates the reliance on inspector skill and physical manipulation, achieving precise alignment despite the elongated insertion section.
2Adaptability or versatility
If manual operation of the borescope is used by an inspector, then flexibility in inspection is maintained, but automation and labor saving are reduced
Solution Approach 1:
The system combines automatic control for precise positioning with the ability to adapt to different inspection scenarios. The control unit automatically manages the elongated insertion section alignment, while the system can accommodate various blade types and inspection requirements, achieving both automation and flexibility simultaneously.
Solution Approach 2:
The control unit acts as an intermediary between the automatic sensing system and the inspection objectives. It processes sensor data, calculates positioning parameters, and executes control commands, enabling automated inspection while maintaining the flexibility to handle different inspection scenarios through software programming.
3Measurement precision
If the distal end portion position is changed for detailed inspection of defects, then inspection detail is improved, but it becomes difficult to maintain the same position and viewing direction as the initial inspection
Solution Approach 1:
The system performs preliminary detection of the target position and attitude during the initial inspection phase. This preliminary information is stored and used as a reference for subsequent detailed inspections, enabling the system to automatically return to and maintain the exact same position and viewing direction while allowing for controlled adjustments to examine defects in detail.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate observation and recording of blade inspections at the same position and viewing direction as the initial image pickup, improving the precision and efficiency of the inspection process.
Implementation Method 1
an acceleration sensor 27 for detecting an attitude of the insertion section 11a
Implementation Method 2
two distance sensors 31a and 31b disposed in the distal end portion 11d of the insertion section 11a
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A blade inspection apparatus 1 has a borescope 11B and a PC 12. The borescope 11B has a distance sensor 32 for detecting an insertion length L when an insertion section 11a of the borescope 11B is inserted through a hole AP provided in a casing C in which a rotor R of an engine is housed, an acceleration sensor 27 for detecting an attitude of the insertion section 11a, and distance sensors 31a and 31b for detecting two distances from the insertion section 11a to two stator vanes on a stator S. The PC 12 compares the insertion length, attitude and two distances detected in the borescope 11B with the insertion length, attitude and two distances relating to an inspection image stored in a HDD 54. When a match occurs therebetween, the PC 12 outputs match information.