Phased Array Probe Virtual Segmentation for Turbine Blade Inspection
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Solution Overview
Problem
Conventional ultrasonic inspections of turbine constructional elements, such as turbine blades, are limited and error-prone, especially for fastening holes of finger pin roots, requiring blade removal and lacking precision in defect detection due to complex geometries.
Innovation Solution
The phased array technique is enhanced by dividing the probe into multiple virtual probes, allowing directed transmission and reception of ultrasonic signals from various angles, enabling accurate defect detection and orientation analysis without manipulating the probe, using the impulse echo method and producing a two-dimensional color-coded display of measurement results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic inspection methods are used on turbine blades, then the inspection can be performed, but the inspection is limited and error-prone, requiring blade removal and lacking precision in defect detection
Solution Approach 1:
The phased array probe is divided into multiple virtual probes (e.g., three virtual probes with about 24 elements each), allowing the inspection to be performed from multiple viewing directions simultaneously. This segmentation enables precise defect detection without requiring blade removal, as each virtual probe captures defect information from its specific angle, collectively providing comprehensive and accurate defect characterization.
2Measurement precision
If blade removal is performed for inspection, then accurate inspection of fastening holes can be achieved, but the process becomes time-intensive and costly
Solution Approach 1:
The mechanical process of removing and reinstalling turbine blades for inspection is replaced by a non-contact or minimal-contact ultrasonic phased array inspection system. The phased array probe, divided into multiple virtual probes, transmits and receives ultrasonic signals to detect defects in fastening holes and other critical areas without requiring blade removal, thereby eliminating time-intensive manual operations while maintaining high inspection accuracy.
3Measurement precision
If a single probe is used for ultrasonic inspection, then the device is simple, but the inspection is error-prone and lacks accuracy for complex geometries
Solution Approach 1:
The single probe is segmented into multiple virtual probes, each independently controlled to transmit and receive ultrasonic signals from different angles. This virtual segmentation allows the system to inspect complex geometries like turbine blade fastening holes with high accuracy, as defects are detected from multiple viewing directions. The physical probe remains simple, but the virtual segmentation achieves the precision of multiple physical probes.
Solution Approach 2:
The inspection approach transitions from a single-viewpoint inspection to a multi-dimensional inspection by dividing the probe into virtual probes positioned at different angular positions. This dimensional expansion in the angular domain enables comprehensive defect detection around complex geometries, improving accuracy without increasing physical probe complexity.
4Measurement precision
If conventional inspection methods are used, then the process is simple, but defects cannot be accurately characterized in terms of position, magnitude, and orientation
Solution Approach 1:
The phased array probe is divided into multiple virtual probes that capture defect information from different angular positions. By analyzing the combined data from all virtual probes, the system can precisely determine defect position, magnitude, and orientation. The segmentation provides multi-angle views that enable comprehensive defect characterization, transforming the complex measurement task into manageable angular components that can be processed and integrated.
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 allows for safe, quick, and accurate detection of defects like cracks on turbine blades, reducing errors and eliminating the need for blade removal, providing precise determination of defect magnitude, position, and orientation through multiple viewing directions and improved imaging displays.
Implementation Method 1
sending and receiving of at least one ultrasonic signal by means of a phased array probe on a surface region, which is to be inspected, of the constructional element
Implementation Method 2
By means of the phased array technique, in particular the direction of the radiated ultrasound, or the direction from which the ultrasound can be received, as the case may be, can be altered
Implementation Method 3
In this case, the impulse echo method is advantageously applied, since by this technique defects can be basically especially accurately determined
Data Source
AI summary
The invention relates to a method which is used to detect defects on a component of a turbine. Said method comprises the following steps; at least one ultrasonic signal is emitted and captured by means of a group beam examination head on a flat region of the component which is to be examined. The invention is characterized according to the following steps: the group of the beam examination heads are distributed into several virtual examination heads and at least one ultrasonic signal is emitted and captured by at least two of the virtual examination heads which is directed to an individual flat region which is to be examined.