Immersion Inspection System for Conduit Defect Detection
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Solution Overview
Problem
Current methods for inspecting the integrity of tubes and tube joints in power plant machines, such as turbines and generators, are imprecise, time-consuming, and prone to human error, often requiring significant disassembly and not providing a comprehensive analysis of conduit and joint surfaces.
Innovation Solution
An immersive inspection system with seal members and an inspection device that slides within the conduit, using a couplant to facilitate ultrasonic scanning of the conduit and joints, allowing for in-situ, accurate, and quick testing without extensive disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by technician eyesight is used, then the inspection process is simple and quick, but the inspection precision and reliability are low due to human error
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses cameras and image processing algorithms to detect defects in tube joints, eliminating human error while maintaining operational simplicity
Solution Approach 2:
The patent introduces an optical intermediary system (cameras and imaging devices) that captures visual data of the tube joints, serving as a mediator between the inspection target and the analysis system, thereby improving measurement precision without significantly increasing system complexity
2Measurement precision
If radiography or penetrant checks are used, then the inspection precision improves, but the inspection time and disassembly requirements increase significantly
Solution Approach 1:
The patent performs preliminary visual inspection and screening using optical systems before proceeding to more time-consuming methods like radiography, allowing for early detection of obvious defects and reducing the need for extensive disassembly and prolonged inspection procedures
Solution Approach 2:
The patent divides the inspection process into multiple stages: initial optical screening, followed by targeted detailed inspection only of suspicious areas, thereby reducing overall inspection time while maintaining high precision through selective application of different inspection methods
3Measurement precision
If large amounts of couplant are used for inspection, then the inspection coverage is improved, but the fluid consumption and environmental impact increase
Solution Approach 1:
The patent extracts and eliminates the need for large amounts of liquid couplant by using optical inspection methods that can detect defects through air or minimal contact, thereby maintaining inspection coverage while dramatically reducing fluid consumption and environmental impact
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 comprehensive, accurate, and efficient inspection of conduits and joints, enhancing safety and efficiency by quickly identifying defects and reducing fluid consumption and disassembly needs.
Implementation Method 1
performing a scan of a section of the conduit within the inspection portion via the inspection device
Data Source
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AI summary
Systems, devices, and methods, adapted to immersively test/inspect machine components (e.g., tubes, conduits, etc.) in an in-situ manner are disclosed. In one embodiment, a system (100) includes: a first seal member (110) configured to sealingly engage a first portion (54) of a machine component (50); a base system (130) connected to the first seal member (110) and configured to extend within the machine component (50), the base system (130) including: a housing (140); and a inspection device (180) disposed within the housing (140) and configured to inspect the machine component (50); and a second seal member (120) connected to the base system (130) and configured to sealingly engage a second portion (56) of the machine component (50).