Optical Inspection Rover With Stabilization Tether for Running Engines
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Solution Overview
Problem
Current methods for inspecting fan blades in gas turbine engines are time-intensive, costly, and risky, involving manual inspections that can introduce Foreign Object Damage (FOD) and require skilled technicians, while existing integrated optical inspection systems face challenges with integration, cost, and operational limitations.
Innovation Solution
An optical inspection system deployed via a remotely controlled rover with a stabilization tether, which includes a locomotion system, inspection sensors, and a rover deployment cart, allowing inspections to be conducted while the engine is operating, preventing ingestion or expulsion, and providing power, data transmission, and cooling support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection of fan blades is performed by technicians, then inspection can be conducted, but it is time-intensive, costly, and carries risk of FOD from inspection objects
Solution Approach 1:
The patent replaces manual mechanical inspection by technicians with an automated optical inspection system that uses cameras and image processing to capture and analyze fan blade images, eliminating the need for physical contact and reducing FOD risk while enabling faster inspection
Solution Approach 2:
The inspection system is designed to operate autonomously within the engine housing, with the optical sensor rover independently navigating, capturing images, and transmitting data without requiring continuous human intervention or engine shutdown
2Productivity
If optical inspection system is integrated into engine housing, then inspection efficiency is improved, but integration complexity and cost increase
Solution Approach 1:
The inspection system is divided into separate functional modules: a movable rover unit with optical sensors, a stabilization tether system, and an external control station. This segmentation allows the inspection functionality to be added without permanently modifying the engine housing structure
Solution Approach 2:
The stabilization tether acts as an intermediary between the rover and the engine housing, providing mechanical support and positioning without requiring permanent mounting structures, thereby reducing integration complexity
3Loss of time
If inspection is performed while engine is operating, then turnaround time is reduced, but risk of rover ingestion or expulsion increases
Solution Approach 1:
The stabilization tether provides a counteracting force to balance the aerodynamic forces generated by engine operation, preventing the rover from being ingested or expelled while allowing the engine to remain running during inspection
4Ease of manufacture
If single rover is used to inspect multiple engines, then cost is reduced, but rover must be moved between engines
Solution Approach 1:
The stabilization tether uses flexible, extendable connections that allow the rover to be rapidly deployed to and retrieved from different engine positions without requiring complex repositioning mechanisms or disassembly
Solution Approach 2:
The rover system is designed with dynamic deployment capabilities, allowing rapid transition between static inspection positions on different engines, minimizing non-productive movement time through efficient tether-based repositioning
Data Source
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AI summary
An engine inspection apparatus includes a remotely controlled inspection rover (110), a rover deployment cart (130), and a stabilization tether (150) having a first end attached to the inspection rover (110) and a second end attached to the rover deployment cart (130). The stabilization tether (150) is configured to prevent at least one of ingestion of the inspection rover (110) by an engine (402) while the engine (402) is operating and expulsion of the inspection rover (110) by the engine (402) while the engine (402) is operating.