Tethered Optical Inspection Rover for Operating Engine Checks
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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, low FPS capability, and limited operational conditions.
Innovation Solution
An optical inspection system deployed via a remotely controlled rover with a stabilization tether, allowing inspections to be conducted while the engine is operating, using a detachable rover with multiple sensors and autonomous or manual control, and a tether providing power, data transmission, cooling, and stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection by technicians is used, then inspection can be performed on fan blades, but the process is time-intensive, costly, and carries risk of FOD/DOD from inspection objects
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system using cameras and image processing. The system captures images of fan blades during engine operation or shutdown and uses automated algorithms to detect damage, eliminating the need for manual inspection and associated FOD/DOD risks while significantly reducing inspection time
Solution Approach 2:
The inspection system performs self-inspection by automatically capturing images and processing them through algorithms that detect FOD, DOD, erosion, and fatigue damage. The system independently identifies and categorizes damage without human intervention in the inspection process, enabling continuous operation and reducing time loss
2Adaptability or versatility
If integrated optical inspection system is embedded in engine housing, then inspection capability is provided, but integration complexity increases and operational flexibility is reduced
Solution Approach 1:
The inspection system is segmented into separate modular components including camera modules, lighting systems, and image processing units that can be independently deployed. The system can be configured as a removable cart-based unit or integrated platform, allowing flexible deployment without permanent engine modifications and enabling operation under various conditions including engine rotation and different temperature states
Solution Approach 2:
The optical inspection system is designed with universal applicability to inspect multiple engine types and configurations. The system can perform various inspection functions including FOD detection, DOD detection, erosion assessment, and fatigue damage identification using the same core technology platform, eliminating the need for engine-specific integrated systems
Data Source
AI summary
An engine inspection apparatus includes a remotely controlled inspection rover, a rover deployment cart, and a stabilization tether having a first end attached to the inspection rover and a second end attached to the rover deployment cart. The stabilization tether is configured to prevent at least one of ingestion of the inspection rover by an engine while the engine is operating and expulsion of the inspection rover by the engine while the engine is operating.