Industrial Machine Assessment via Digital Part Grading
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Solution Overview
Problem
Industrial machines, such as gas turbine engines and gas compressors, face challenges in assessing wear, corrosion, and fatigue damage due to their operating conditions, requiring effective methods for component evaluation to determine replacement needs.
Innovation Solution
A system and process for assessing industrial machines, including an assessment device with a user interface that displays a part assessment interface with engineering instructions and grading comparison images, allowing assessors to input measurements and select part grades, and generates an assessment report with recommendations for part replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual assessment methods are used for industrial machine parts, then assessors can evaluate wear, corrosion, and fatigue damage, but the accuracy and consistency of part grading vary due to subjective judgment
Solution Approach 1:
The patent creates digital copies of parts through 3D scanning and imaging technologies. These digital replicas capture precise geometric and surface information, replacing subjective manual measurement with objective digital data that can be consistently analyzed and compared against reference models.
Solution Approach 2:
The patent replaces manual mechanical assessment methods with automated computational analysis systems. Software algorithms process the digital part data to automatically detect wear, corrosion, and fatigue patterns, eliminating human subjectivity and providing consistent, repeatable grading across different assessors.
2Loss of information
If detailed manual inspection of each part is performed, then comprehensive assessment data is collected, but the time required for assessment increases significantly
Solution Approach 1:
The patent performs preliminary 3D scanning and data capture of parts before detailed analysis. This preliminary action creates a complete digital record that can be quickly processed later, allowing comprehensive assessment without time-consuming manual measurements during the actual inspection.
Solution Approach 2:
The patent uses automated image processing and computational algorithms to rapidly analyze part conditions. These computational systems process comprehensive assessment data much faster than manual inspection, maintaining data completeness while dramatically reducing assessment time.
3Adaptability or versatility
If traditional assessment protocols are used for industrial machines, then existing procedures can be followed, but the process lacks standardization across different assessors and facilities
Solution Approach 1:
The patent develops a universal assessment system that can evaluate multiple part types and conditions through standardized 3D scanning and analysis protocols. The same digital capture and analysis methods apply across different assessors and facilities, ensuring consistent standards while adapting to various part geometries and assessment requirements.
Data Source
AI summary
The systems and methods disclosed herein include an assessment system and process for assessing an industrial machine and its various sections, sub-sections, and parts. In embodiments, the assessment system includes an assessment device that includes an assessment overviewer and a part assessor. The assessment overviewer provides an assessor with a selectable industrial machine schematic that illustrates the assessment status of each section of the industrial machine, such as by changing the appearance of each section based its assessment status. The part assessor provides a part assessment interface with engineering instructions and a part grading user interface that provides for a comparison of digital images to complete the part grading.