Automated Optical Crack Detection for Turbine Components
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Solution Overview
Problem
Current crack detection methods in aircraft and gas turbine components, particularly the dye penetrant test, are manual, time-consuming, and environmentally harmful, with limited reproducibility and high energy requirements, making them inefficient for maintenance and repair processes.
Innovation Solution
An automated method using optical interferometry, such as white light interferometry, to detect cracks and damage in aircraft and gas turbine components, which eliminates the need for manual inspection and chemical processes, allowing for precise geometry data collection and comparison to predefined tolerances for accurate damage assessment and repair planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dye penetrant testing is used for crack detection, then crack detection capability is achieved, but maintenance time increases significantly
Solution Approach 1:
The patent replaces the manual mechanical process of dye penetrant testing with an automated optical measurement system. The system uses optical sensors and image processing to automatically detect cracks, eliminating the need for manual application of penetrants, developers, and visual inspection by trained personnel. This substitution dramatically reduces maintenance time while maintaining crack detection capability.
Solution Approach 2:
The measurement system automatically evaluates the captured images to detect cracks without requiring trained personnel for manual assessment. The system self-calibrates and self-evaluates the component geometry and crack indications, reducing dependency on human expertise and significantly accelerating the inspection process.
2Reliability
If manual evaluation of crack indications is performed, then crack detection is achieved, but reproducibility is limited or nonexistent
Solution Approach 1:
The patent replaces manual visual evaluation with automated optical image analysis. The system captures high-resolution images of crack indications and uses computer algorithms to objectively assess their presence and characteristics. This eliminates human variability and subjectivity, ensuring consistent and reproducible evaluation results across different inspections and operators.
Solution Approach 2:
The system incorporates automated feedback mechanisms where measurement results are immediately processed and evaluated against predefined criteria. The optical measurement system provides real-time feedback on crack detection status, enabling consistent decision-making without human intervention and ensuring reproducible results.
3Reliability
If dye penetrant testing is used, then crack detection is achieved, but energy consumption increases due to chemical processes
Solution Approach 1:
The patent replaces the chemical-based dye penetrant process with a non-contact optical measurement system. This eliminates the need for chemical penetrants, cleaners, and developers, thereby removing the energy-intensive heating and drying steps required in traditional chemical testing methods. The optical system achieves crack detection without chemical processes, significantly reducing energy consumption.
4Reliability
If dye penetrant testing is used, then crack detection is achieved, but environmental damage occurs due to chemical substances
Solution Approach 1:
The patent replaces the chemical-intensive dye penetrant method with a non-contact optical inspection system. This eliminates the use of chemical penetrants, solvents, and developers that cause environmental pollution and require special disposal procedures. The optical system provides crack detection capability without any harmful chemical substances, making the process environmentally friendly.
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
This approach significantly reduces maintenance time, improves process reliability and reproducibility, minimizes environmental impact, and enables fully automated repair processes by accurately identifying and classifying damage for swift component restoration.
Implementation Method 1
an optical measurement method, in particular an interferometry method
Data Source
Figure 1~2
AI summary
A method for detecting cracks in an aircraft or gas turbine component includes ascertaining geometric data about the component using an optical measurement method, analyzing the geometric data, using an electronic evaluation device, so as to automatically recognize and/or classify at least one of cracks and other damage and storing a position of the at least one of cracks and other damage.