Continuous-Flow Engine Component Wear Detection via Oxidation Layers
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Solution Overview
Problem
Existing methods for determining the wear state of components in continuous flow engines, such as gas turbines and steam turbines, are inefficient and often require destructive testing, lacking precision and reliability in predicting component life and maintenance needs.
Innovation Solution
A method and system for non-destructive evaluation of oxidation layers on engine components, utilizing properties like distance and thickness, combined with digital models and historical data, to predict wear state and optimize maintenance schedules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional wear evaluation methods are used, then component inspection can be performed, but the methods require destructive testing and lack precision
Solution Approach 1:
The patent replaces traditional mechanical/destructive testing methods with electromagnetic measurement techniques. Specifically, it uses eddy current measurement or ultrasound measurement to detect oxidation layer properties non-destructively, substituting physical destruction with field-based detection to achieve precise wear state evaluation without damaging the component
Solution Approach 2:
The patent introduces oxidation layer properties (thickness, distance to surface) as intermediary parameters that correlate with wear state. Instead of directly measuring wear through destruction, the method measures these intermediary oxidation characteristics that indicate the component's wear condition, enabling indirect but precise assessment
2Reliability
If component replacement is performed based on conservative estimates, then safety is ensured, but operational flexibility and productivity are reduced
Solution Approach 1:
The patent implements a feedback mechanism where actual oxidation layer measurements from operating components are continuously monitored and compared against reference values. This real-time feedback enables dynamic adjustment of maintenance schedules based on actual wear conditions rather than fixed conservative intervals, optimizing both safety and productivity
Solution Approach 2:
The patent changes the maintenance decision parameter from fixed time-based replacement to condition-based replacement using oxidation layer thickness and distance measurements. By monitoring these specific parameters and comparing them to reference values from digital twins or historical data, the system determines optimal replacement timing that ensures safety while maximizing operational flexibility
3Reliability
If extensive safety margins are applied, then reliability is guaranteed, but device complexity and cost increase
Solution Approach 1:
The patent creates digital copies (digital twins) of components that simulate oxidation layer development over time. These digital models replicate the physical component's behavior under various operating conditions, allowing virtual testing and prediction of wear patterns without requiring complex physical safety systems or extensive safety margins in the actual hardware
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 precise prediction of component wear and improved maintenance planning, reducing unnecessary replacements and increasing operational reliability and flexibility.
Implementation Method 1
determining multiple types of oxidation layers and their properties like the distance to the surface and their thickness, wherein the oxidation layers originate from the same material of the component
Data Source
AI summary
A method, system and tool for determining the wear state of a component of a continuous flow engine. The method includes determining multiple types of oxidation layers and their properties, wherein the oxidation layers originate from the same material of the component, and diagnosing the wear state of the component by utilizing the properties of the oxidation layers.