Phased Array Ultrasonic Inspection for Turbine Rotor Bore
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Solution Overview
Problem
Conventional ultrasonic testing systems for inspecting turbine and generator rotor bores are limited by the need for fixed angle wedges, which require frequent transducer repositioning and lack flexibility in focal depth, leading to inefficient inspections and incomplete coverage of near and far field areas.
Innovation Solution
A phased array ultrasonic testing system with a computer-controlled transducer that uses a 2D phased array transducer to steer and focus ultrasonic beams in multiple directions, reducing the need for multiple wedges and allowing for sectorial scanning and dynamic depth focusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ultrasonic testing systems use fixed angle wedges, then the inspection method is simple to implement, but the inspection time is excessive and the coverage is incomplete
Solution Approach 1:
The patent applies dynamic focusing and steering capabilities to the ultrasonic transducer system. The focal depth and beam angle are made variable through electronic control of phased array elements, allowing the inspection system to adapt to different inspection requirements without physical repositioning. This resolves the contradiction by enabling rapid adjustment of inspection parameters electronically rather than mechanically.
Solution Approach 2:
The system changes the focal depth parameter dynamically during inspection using phased array technology. By electronically adjusting the focal point along the beam path and changing beam angles through phase delays, the system can inspect multiple areas without physical repositioning, significantly reducing inspection time while maintaining comprehensive coverage.
2Adaptability or versatility
If multiple wedges are used to achieve multi-angle inspection, then the inspection coverage is improved, but the device complexity and number of components increase
Solution Approach 1:
The phased array transducer serves multiple functions: it can steer beams in multiple directions, focus at varying depths, and inspect both near and far field areas with a single device. This multi-functional capability replaces the need for multiple specialized wedges and transducers, reducing component count while maintaining comprehensive multi-angle inspection capability.
Solution Approach 2:
The patent replaces the mechanical system of multiple physical wedges with an electronic phased array system. Beam steering and focusing are achieved through electronic phase delays and amplitude weighting rather than mechanical repositioning of physical wedges, significantly simplifying the device while maintaining or enhancing inspection versatility.
3Measurement precision
If transducer repositioning is performed frequently to change inspection angles, then the inspection thoroughness is improved, but the inspection efficiency decreases
Solution Approach 1:
The system replaces mechanical repositioning operations with electronic beam steering. Phase delays applied to individual array elements enable rapid change of beam angles and focal positions without physical movement, maintaining thorough flaw detection capability while dramatically increasing inspection speed.
Solution Approach 2:
The phased array system maintains continuous inspection capability by electronically steering beams without interrupting the inspection process. The ability to rapidly switch between different beam angles and focal depths allows uninterrupted scanning, improving both thoroughness and efficiency compared to discrete repositioning operations.
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 inspection time, enhances sensitivity to flaws, and provides more accurate assessments of rotor integrity by enabling simultaneous multi-angle beam inspection without the need for extensive transducer repositioning, potentially cutting inspection duration from three days to one day and reducing the number of required wedges by 50-80%.
Implementation Method 1
The transducers direct sound, i.e., ultrasonic waves or beams, from the rotor bore surface into the rotor material
Implementation Method 2
When the ultrasound waves interact with something (e.g., a void, a crack or other defect) having a significant difference in impedance from that of the propagation medium, a portion of the ultrasound is either reflected or diffracted back to the source
Implementation Method 3
A phased array ultrasonic transducer is coupled to a surface of the rotor bore... A control system adapted to define a plurality of focal laws of the ultrasonic beam, controls the emission of the ultrasonic beam from the phased array ultrasonic transducer and steers and focuses the ultrasonic beam
Implementation Method 4
The transducers typically include piezocrystal elements that are excited by an electrical voltage to induce the ultrasonic waves in the structure
Data Source
AI summary
A phased array ultrasonic testing system for examining discontinuities in turbine or generator rotor bores formed within turbine or generator rotors of a turbine or generator rotor assembly. The system includes a phased array ultrasonic transducer structured to be coupled to a surface of the rotor bore at a first location in order to emit an ultrasonic beam toward a second location of the rotor bore which is to be examined. The system further includes a control system with a computer and a controller for programming, emitting, and steering the ultrasonic beam via at least one, two-dimensional phased array transducer, thereby precisely and accurately inspecting the area of interest. Computer control of the beam permits the number of inspection locations and the number of different transducer wedges to be reduced providing for an efficient, timely inspection.