Eddy Current Probe Micromanipulator for Turbine Surface Inspection

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Solution Overview

Problem

Inspection of components within gas turbine engines, particularly for detecting small defects like cracks, is challenging due to their inaccessible and complex geometries, leading to costly and time-consuming dismantling and potential damage during manual visual inspections, with existing methods failing to detect sub-surface defects effectively.

Innovation Solution

An inspection system utilizing a macromanipulator with a micromanipulator, featuring a scotch yoke mechanism and eddy current probe, allows for systematic and fine inspection of surfaces within confined spaces, enabling detection of small defects by separating movements and providing precise, non-destructive evaluation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If visual inspection using borescope is performed, then inspection can be conducted without dismantling, but detection of small defects and sub-surface defects is difficult

Engineering Contradiction:

Improveinspection accessibilityVSAvoiddefect detection capability

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces the mechanical visual inspection system with an eddy current-based non-contact detection system. The eddy current probe generates electromagnetic fields that penetrate the component surface and detect subsurface defects through changes in electrical conductivity, eliminating the need for physical contact and visual observation limitations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the inspection parameter from optical (visual) to electromagnetic (eddy current). By using eddy current technology, the inspection can detect defects based on changes in electrical conductivity rather than visual appearance, enabling detection of subsurface cracks and defects that are invisible to the naked eye.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If manual visual inspection is performed, then no special equipment is needed, but inspection precision and reliability are insufficient

Engineering Contradiction:

Improveequipment simplicityVSAvoiddefect detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces manual visual inspection with an automated eddy current inspection system. The eddy current probe provides objective, quantitative measurements of defect depth and size, eliminating the subjectivity and imprecision of manual visual assessment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Difficulty of detecting and measuring

If dismantling is performed to inspect components, then inspection access is improved, but time and cost increase significantly

Engineering Contradiction:

Improveinspection accessVSAvoiddismantling time

Core Design Contradiction:

Difficulty of detecting and measuringVSLoss of time

Solution Approach 1:

The patent uses eddy current technology to perform non-contact inspection through existing access points, eliminating the need for mechanical dismantling. The electromagnetic fields penetrate the component surface through small openings or existing ports, providing full inspection access without physical disassembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Difficulty of detecting and measuring

If dismantling and reassembly is performed, then inspection can be conducted, but risk of component damage increases

Engineering Contradiction:

Improveinspection capabilityVSAvoidcomponent damage risk

Core Design Contradiction:

Difficulty of detecting and measuringVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical inspection methods with non-contact eddy current detection. The electromagnetic probe detects defects without physical contact with the component surface, completely eliminating the risk of mechanical damage during inspection and subsequent reassembly operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The system enables accurate and repeatable detection of small defects, such as cracks, within gas turbine engines without dismantling, reducing costs and minimizing damage, while providing a digital representation for defect localization.

Implementation Method 1

eddy currents (a type of electric current) are commonly used to detect small defects (e.g., cracks) at a surface and a sub-surface level

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

The scotch yoke mechanism is configured to translate the probe support in response to the rotation of the actuating arm such that the probe support slides along the pair of guide rails

Methodology Applied

Scientific EffectMechanical translation mechanism: Mechanical Advantage

Data Source

PatentUS20250377337A1Inspection system and method for inspecting a surface

Publication Date: 2025.12.11 ROLLS ROYCE PLC

AI summary

An inspection system for inspecting a surface includes a macromanipulator including an inspection end configured to be disposed proximal to the surface. The inspection system further includes a micromanipulator coupled to the inspection end. The. micromanipulator includes a housing, a pair of guide rails at least partially disposed within and fixedly coupled to the housing, a probe support slidably coupled to the pair of guide rails, an actuating arm disposed within the housing and coupled to the probe support via a scotch yoke mechanism, and an actuating mechanism configured to rotate the actuating arm relative to the housing. The inspection system further includes a probe coupled to the probe support for inspecting the surface.