Magnetic Camera Probe for Stator Vane Inspection
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Solution Overview
Problem
Current methods for inspecting internal components of gas turbine engines are time-consuming, labor-intensive, and provide limited view and resolution, often requiring disassembly of the compressor housing.
Innovation Solution
An image recording assembly with a camera-based probe, data processing, and storage components, secured to a compressor blade using magnetic coupling mechanisms, allows for remote recording of stator vane images without disassembly, offering 360-degree coverage and improved resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a borescope is used to manually inspect internal components, then inspection can be performed without disassembly, but inspection time and labor intensity increase significantly
Solution Approach 1:
The inspection system performs automated image capture and analysis without requiring continuous manual operation. The camera assembly autonomously captures images of stator vanes as the rotor rotates, and the processor automatically analyzes the images for defects, reducing labor intensity and inspection time while maintaining comprehensive coverage
Solution Approach 2:
The manual borescope inspection process is replaced with an automated optical system. Instead of a human operator manually manipulating a borescope, the system uses a camera assembly mounted on the rotor that automatically captures images, with processing done by a computer system, thereby increasing inspection efficiency and productivity
2Ease of manufacture
If a borescope is used for inspection, then disassembly is avoided, but the field of view and inspection coverage are limited
Solution Approach 1:
The camera assembly mounted on the rotor blade serves multiple functions: it captures images of stator vanes during rotation, provides 360-degree coverage around the compressor, and can inspect multiple stator vanes in sequence. This multi-functional approach eliminates the limited field of view constraint of traditional borescopes while maintaining the advantage of not requiring disassembly
3Ease of manufacture
If a borescope is used for inspection, then the compressor remains assembled, but image resolution and depth of field are insufficient
Solution Approach 1:
Instead of using a single borescope with limited capabilities, the system employs a dedicated camera assembly positioned locally on the rotor blade that can be optimally configured for high-resolution imaging. The camera is positioned to capture images at the optimal distance and angle, providing superior resolution and depth of field while the compressor remains fully assembled
4Measurement precision
If compressor disassembly is performed for inspection, then complete access is achieved, but inspection time and complexity increase
Solution Approach 1:
The system performs complete inspection coverage while the compressor remains assembled. The camera assembly automatically captures images of all stator vanes during rotor rotation, and the processor automatically analyzes the images, eliminating the time-consuming disassembly and reassembly process while maintaining complete inspection coverage
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 comprehensive inspection of internal components with enhanced resolution and coverage, reducing inspection time and labor while maintaining the compressor's integrity.
Implementation Method 1
a mechanism configured to magnetically couple the image recording assembly to a blade of the compressor
Data Source
AI summary
A system is disclosed that includes an image recording assembly for recording images of a stator vane of a compressor and a mechanism configured to magnetically couple the image recording assembly to a rotor blade of a compressor. Additional systems are provided that include image recording assemblies. Methods implementing the disclosed systems are also provided.