Dual-Camera Tool Assembly for 3D Gas Turbine Blade Inspection
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Solution Overview
Problem
Current methods for inspecting gas turbine engines are labor-intensive, prone to human error, and require significant time and resources, especially when detecting damage such as deformations, cracks, and foreign particle-induced nicks on compressor and turbine blades.
Innovation Solution
A tool assembly comprising a body with a first camera and a second camera, along with a controller that determines the spatial positions of the cameras based on images of reference and target features. This system generates a three-dimensional representation of the target feature, enabling precise inspection and measurement of defects within the gas turbine engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used to detect damaged components in gas turbine engines, then inspection thoroughness can be maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical imaging system comprising multiple cameras, lighting sources, and computer processing. The system automatically captures images of engine components from multiple angles, processes them through algorithms to detect defects, and generates inspection reports without human intervention in the actual inspection process, thereby dramatically improving productivity while reducing inspection time
Solution Approach 2:
The system creates digital copies (images) of the physical engine components using multiple cameras. These digital representations are then processed and analyzed by computers to detect defects such as cracks, deformations, and foreign particle damage. This copying approach allows repeated analysis without additional time cost and enables automated defect detection, resolving the contradiction between thorough inspection and time consumption
2Measurement precision
If manual inspection is performed to detect defects, then flexibility in inspection approach is maintained, but human error increases and measurement precision decreases
Solution Approach 1:
The patent replaces human inspectors with automated optical sensors and computer algorithms for defect detection. The system uses multiple cameras with controlled lighting to capture high-resolution images, then applies image processing algorithms to objectively identify and measure defects such as cracks, deformations, and foreign particle damage. This eliminates human subjectivity and fatigue-related errors, significantly improving both measurement precision and inspection reliability
Solution Approach 2:
The system incorporates feedback mechanisms where the computer analyzes captured images, identifies potential defects, and can adjust imaging parameters or request re-imaging of suspicious areas. The system provides quantitative measurements of defect characteristics and compares them against acceptance criteria, creating a closed-loop inspection process that continuously improves accuracy and reliability through systematic feedback rather than subjective human judgment
3Reliability
If comprehensive inspection of all engine components is conducted, then defect detection capability is improved, but resource consumption and inspection complexity increase
Solution Approach 1:
The inspection system is divided into modular functional components: multiple cameras positioned at different locations, separate lighting sources for different viewing angles, independent image capture systems, and distinct image processing algorithms for different defect types. This segmentation allows the complex inspection task to be broken down into manageable subsystems that can be independently optimized and maintained, reducing overall system complexity while maintaining comprehensive defect detection capability
Solution Approach 2:
The patent designs a multi-functional inspection system where the same camera system can inspect multiple different engine components (blades, vanes, discs) by repositioning or reconfiguring the cameras. The image processing algorithms are designed to detect various defect types (cracks, deformations, foreign particle damage) across different component types using unified methodologies. This universality reduces the need for multiple specialized inspection systems, thereby managing complexity while maintaining comprehensive detection capability
Data Source
AI summary
A system and method of using a tool assembly is provided. The system includes a body, a first camera and a second camera fixed to the body, and a controller. The controller is configured to receive data indicative of images of a reference feature from the first camera, determine data indicative of a first spatial position of the first camera based at least in part on the received data indicative of the images of the reference feature, and determine data indicative of a second spatial position of the second camera based on the first spatial position, a known spatial relationship between the first location and the second location, or both. Further, the controller may be configured to receive data indicative of images of a target feature using the second camera, derive dimensions of the target feature based on the images, and generate a three-dimensional representation of the target feature.