Phased Array Ultrasonic Detection for Turbine Rotor Inspection
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Solution Overview
Problem
Current ultrasonic inspection methods for large and complex objects, such as solid steam turbine rotors, are limited by their inability to efficiently detect features like asperities, voids, and cracks in a non-destructive manner, leading to extended repair cycles and high costs due to the need for complex probe positioning and integration.
Innovation Solution
The use of a phased array ultrasonic detection system with transmitting and receiving phased array devices positioned on the periphery of the rotor, transmitting and receiving phased array waves to detect reflecting features within the rotor, allowing for non-destructive analysis without integrating probes into the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single probe ultrasonic techniques are used, then device complexity is reduced, but inspection coverage and detection capability are limited
Solution Approach 1:
The ultrasonic inspection system divides the inspection task into multiple segments by using multiple probes positioned around the rotor periphery. Each probe inspects a specific sector, and the combined data provides complete coverage of the entire rotor cross-section, resolving the contradiction between simple device configuration and comprehensive inspection coverage.
Solution Approach 2:
The system transitions from single-point inspection to multi-point circumferential inspection by positioning probes around the rotor periphery. This spatial arrangement in multiple dimensions enables complete coverage of the rotor cross-section without increasing the complexity of individual probe configurations.
2Measurement precision
If probes are integrated into the object, then inspection accuracy is improved, but manufacturing cost and system complexity increase substantially
Solution Approach 1:
The inspection system extracts the ultrasonic probes from the rotor structure, positioning them externally on the periphery rather than integrating them into the rotor. This external positioning maintains inspection accuracy through multiple measurement points while avoiding the substantial cost and complexity of integration.
Solution Approach 2:
The system uses an intermediary data processing framework that collects ultrasonic signals from multiple externally positioned probes and reconstructs the internal rotor structure. This intermediary approach achieves integration-level accuracy without physical integration, reducing manufacturing cost and system complexity.
3Measurement precision
If complex probe positioning control is used, then detection precision is improved, but inspection time and operational complexity increase
Solution Approach 1:
The probe positions and orientations are pre-configured in a fixed geometric pattern around the rotor periphery before inspection begins. This preliminary arrangement eliminates the need for complex real-time positioning control during inspection, reducing operational complexity and inspection time while maintaining detection precision through the optimized spatial configuration.
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 method enables efficient non-destructive analysis of large objects, reducing repair cycles and costs by using multiple probes in a pitch-catch manner, providing detailed ultrasonic information about reflecting features without the need for probe integration, thus improving detection accuracy and reducing inspection time.
Implementation Method 1
A phased array wave or beam is transmitted through a turbine rotor from the transmitting phased array device to the receiving phased array device
Implementation Method 2
the phased array wave or beam reflecting off of a reflecting feature
Data Source
AI summary
Ultrasonic detection methods are disclosed. The method includes providing an ultrasonic detection system having a transmitting phased array device and a receiving phased array device. A phased array wave is transmitted through a revolutionary body from the transmitting phased array device to the receiving phased array device, thereby obtaining ultrasonic detection information about the revolutionary body. In another embodiment, the method includes positioning the transmitting phased array device and the receiving phased array device on a periphery of a turbine rotor, transmitting a phased array wave into the turbine rotor, the phased array wave not reflecting off of a reflecting feature, adjusting the positioning of the transmitting phased array devices on the periphery of the turbine rotor, and transmitting the phased array wave into the turbine rotor, the phased array wave reflecting off of a reflecting feature. The reflected phased array wave is received by the receiving phased array device.