Inspection Scope Mounting for In-Situ Powerplant Defect Detection
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Solution Overview
Problem
Existing inspection methods for internal defects in powerplant components are inadequate, particularly when the components are installed and operational, as they lack effective non-destructive techniques for detecting small defects with minimal downtime and expense.
Innovation Solution
An inspection system using an expandable mount and a piezoelectric actuator to induce vibrations in powerplant components, coupled with a sensor to measure vibratory responses, allowing for the detection of internal defects without disassembly, using an inflatable bladder or mechanical expandable mount to maintain contact and position the inspection scope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for internal defects in powerplant components, then inspection can be performed, but the component must be disassembled and the powerplant shut down, resulting in significant downtime and expense
Solution Approach 1:
The patent replaces traditional mechanical disassembly and visual inspection methods with a vibration-based inspection system. An actuator induces vibrations in the component, and sensors detect vibratory responses to identify internal defects, eliminating the need for physical disassembly and powerplant shutdown while maintaining high detection sensitivity.
Solution Approach 2:
The inspection scope serves as an intermediary device that can be inserted through existing access ports in the powerplant. It carries actuators and sensors that interact with the component through contact, enabling defect detection without direct access to the component's interior or disassembly of the powerplant structure.
2Ease of operation
If the inspection scope is inserted into the powerplant interior to inspect components, then non-destructive inspection can be performed with minimal downtime, but the inspection scope must be precisely positioned and maintained in contact with the component
Solution Approach 1:
The inspection scope incorporates an expandable mount that can dynamically change its configuration. The mount expands from a compact state during insertion to an expanded state during inspection, providing stable contact with the component. This dynamic transformation simplifies the positioning process while ensuring reliable contact maintenance during vibration-induced inspection.
Solution Approach 2:
The inspection scope is divided into functional segments: the insertable scope body, the expandable mount mechanism, the actuator, and the sensor array. This segmentation allows each component to perform its specific function independently, with the expandable mount handling positioning and contact maintenance while the actuator and sensor focus on defect detection.
3Measurement precision
If high-frequency vibrations are induced in the component to detect small defects, then detection sensitivity increases, but the risk of damaging the component or inducing false signals increases
Solution Approach 1:
The actuator induces periodic vibrations at specific frequencies that correspond to the natural resonant frequencies of the component. By tuning the vibration frequency to match these natural frequencies, the system amplifies the vibratory response signals from internal defects while keeping the excitation amplitude low, thereby maintaining high detection sensitivity without risking component damage or generating false signals.
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 non-destructive inspection of powerplant components for internal defects, such as cracks and corrosion, with high sensitivity to small defects, while the powerplant remains operational, reducing downtime and maintenance costs.
Implementation Method 1
Vibrations are induced in the component using the actuator
Implementation Method 2
A vibratory response in the component excited by the vibrations is measured using a sensor to provide sensor data
Implementation Method 3
An expandable mount is deployed within the interior of the powerplant to fix a position of the head of the inspection scope and maintain contact between the actuator and the component
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An inspection method is provided during which a head (36) of an inspection scope (28) is inserted into an interior (26) of a powerplant (24). The head (36) of the inspection scope (28) includes an actuator (40). The powerplant (24) includes a component (22) within the interior (26) of the powerplant (24). The head (36) of the inspection scope (28) is arranged within the interior (26) of the powerplant (24) with the actuator (40) contacting the component (22). An expandable mount (44) is deployed within the interior (26) of the powerplant (24) to fix a position of the head (36) of the inspection scope (28) within the interior (26) of the powerplant (24) and maintain contact between the actuator (40) and the component (22). Vibrations are induced in the component (22) using the actuator (40).