Assembled Aircraft Engine Ultrasonic Inspection Through Shaft Cavities
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Solution Overview
Problem
Existing inspection methods for internal defects in engine components are inefficient and require disassembly, leading to high downtime and costs.
Innovation Solution
An ultrasonic inspection method using an ultrasonic transducer and acoustic coupling media to inspect engine components while they remain assembled, allowing for non-destructive evaluation of internal characteristics and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used to detect internal defects in engine components, then measurement precision can be achieved, but the engine requires disassembly leading to high downtime and loss of time
Solution Approach 1:
The inspection device is nested within the engine structure by positioning the ultrasonic transducer inside a bore of the shaft, allowing the inspection tool to be contained within the engine assembly itself. This eliminates the need for disassembly while enabling direct access to the rotor disk for ultrasonic inspection, thereby resolving the contradiction between maintaining measurement precision and reducing engine downtime
Solution Approach 2:
Acoustic coupling media is introduced as an intermediary substance to facilitate ultrasonic wave transmission through the shaft and into the rotor disk. This mediator enables the ultrasonic signals to pass through the intermediate shaft component effectively, allowing defect detection in the rotor disk without requiring disassembly of the engine assembly
2Ease of operation
If engine components are disassembled for inspection, then access to internal characteristics is improved, but device complexity and inspection cost increase
Solution Approach 1:
The engine assembly is segmented into accessible components with the inspection device positioned within a bore of the shaft. This segmentation allows the ultrasonic transducer to access the rotor disk through the shaft's internal structure without requiring complete disassembly of the engine, thereby maintaining ease of operation while reducing procedural complexity
Solution Approach 2:
The acoustic coupling media serves as an intermediary that simplifies the inspection procedure by enabling direct ultrasonic transmission through the shaft to the rotor disk. This eliminates the need for complex disassembly procedures while maintaining effective access to internal characteristics
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
Facilitates rapid, cost-effective inspection with minimal engine downtime by using ultrasonic signals to detect internal defects in engine components, such as rotor disks, without disassembly.
Implementation Method 1
generating an ultrasonic signal using the ultrasonic transducer; and directing the ultrasonic signal from the inspection device, sequentially through the shaft and the acoustic coupling media, into the rotor disk
Implementation Method 2
an acoustic coupling media is directed into a cavity of an engine rotating assembly... directing the ultrasonic signal from the inspection device, sequentially through the shaft and the acoustic coupling media, into the rotor disk
Implementation Method 3
A reflection of the ultrasonic signal may be directed out of the second engine component, sequentially through the acoustic coupling media and the first engine component, to the inspection device. The determining of the first characteristic further may include detecting a parameter of the reflection of the ultrasonic signal using the ultrasonic transducer
Data Source
Figure 1
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Figure 5
AI summary
An inspection method is provided during which an acoustic coupling media (64) is directed into a cavity (60) of an engine assembly (58). The engine assembly (58) includes a first engine component (44) and a second engine component (22). The cavity (60) is formed by and extends between the first engine component (44) and the second engine component (22). An inspection device (28) is arranged with the engine assembly (58). The inspection device (28) includes an ultrasonic transducer (38). A first characteristic of the second engine component (22) is determined using the inspection device (28). The determining of the first characteristic includes: generating an ultrasonic signal (34) using the ultrasonic transducer (38); and directing the ultrasonic signal (34) from the inspection device (28), sequentially through the first engine component (44) and the acoustic coupling media (64), into the second engine component (22).