Laser Profilometer Inspection of Gas Turbine Blades
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Solution Overview
Problem
Current optical camera inspection systems for industrial turbines are time-consuming, require manual repositioning, and are prone to human error, making them inefficient and potentially damaging, especially when inspecting complex internal components like gas turbines during maintenance.
Innovation Solution
A laser profilometer inspection system with an extendable and remotely actuated inspection scope that allows for non-contact, real-time surface profile scanning and dimensional measurement, capable of automatically positioning itself within the turbine for precise data capture, including blade tip gap measurements, without physical contact or human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual optical camera inspection systems are used, then inspection can be performed on turbine components, but the process is time-consuming and requires frequent manual repositioning
Solution Approach 1:
The inspection system performs self-positioning and self-inspection functions through automated control. The system can autonomously navigate to predetermined inspection locations and execute scanning sequences without continuous manual intervention, enabling the system to serve itself in completing the inspection task efficiently
Solution Approach 2:
The system pre-stores inspection path data and component location information in its control memory. Before actual inspection begins, the system has already prepared the optimal scanning routes and positioning sequences, allowing it to execute inspections without real-time manual guidance and significantly reducing inspection time
2Reliability
If manual inspection methods are used, then inspection can be conducted, but human error increases and consistency across teams decreases
Solution Approach 1:
The system incorporates feedback mechanisms where inspection data is automatically captured, processed, and stored in a standardized format. The control system compares actual measurements against predetermined criteria and provides feedback for quality assurance, ensuring consistent evaluation standards across all inspections regardless of operator
Solution Approach 2:
The patent replaces manual mechanical inspection operations with an automated optical inspection system. The mechanical actions of positioning, focusing, and measuring are substituted by computer-controlled mechanisms, eliminating human variability and ensuring repeatable, consistent results across different operators and inspection sessions
3Loss of information
If inspection is performed during cool-down phase, then early data collection is possible, but the process remains time-consuming
Solution Approach 1:
The inspection system is designed to operate continuously during the turbine cool-down phase without interruption. The automated system can begin inspecting components as soon as temperature conditions permit, maintaining continuous scanning operations throughout the cool-down period to maximize data collection while minimizing impact on maintenance schedule
4Measurement precision
If close inspection of internal components is required, then detailed data can be obtained, but physical contact may cause damage
Solution Approach 1:
The system replaces mechanical contact-based measurement methods with non-contact optical profilometry. Laser light is used to scan and measure surface profiles of turbine components without any physical contact, eliminating the risk of mechanical damage while achieving high-precision measurements of critical surfaces and geometries
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 efficient and accurate inspection of turbine components during the cool-down phase, reducing maintenance time, minimizing damage risks, and allowing for early data collection to prioritize repairs, thereby streamlining the maintenance process and improving inspection consistency across teams.
Implementation Method 1
a laser profilometer head (466) coupled to the inspection scope distal end, and including a laser profilometer (410)
Implementation Method 2
Component surface profile scans are performed to determine relative profile heights along a two-dimensional scan line generated by the profilometer
Data Source
AI summary
Internal components of power generation machines, such as gas or steam turbines, are inspected with a laser profilometer inspection system that is inserted and positioned within the turbine, for example through an inspection port that is in communication with an open inter-row spacing volume between an opposing turbine vane and turbine blade row. Component surface profile scans are performed to determine relative profile heights along a two-dimensional scan line generated by the profilometer. Three-dimensional profile information is obtained by translating the scan line across the surface. Real time profile information is gathered without physical contact, which is helpful for extracting off-line engineering information about component surface conditions, including surface spallation, perforation, and gaps between components. The system is capable of determining blade tip gap between a turbine blade tip and its opposing abradable surface in the turbine casing.