Piezoelectric Inspection Stack for In-Situ Powerplant Defect Detection
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Solution Overview
Problem
Existing inspection methods for internal defects in powerplant components are inefficient and often require disassembly, leading to high downtime and costs.
Innovation Solution
A non-destructive inspection method using a piezoelectric actuator and sensor stack, which induces vibrations in the component and measures vibratory responses to detect defects, allowing in-situ inspection while the powerplant remains assembled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection methods are used to detect internal defects, then inspection capability is provided, but component disassembly is required leading to high downtime and costs
Solution Approach 1:
The inspection system is divided into modular components: piezoelectric actuators for vibration generation, piezoelectric sensors for response measurement, and signal processing units. This segmentation allows the inspection device to be compact and suitable for in-situ application without requiring component disassembly, thereby maintaining defect detection capability while eliminating aircraft downtime.
Solution Approach 2:
The patent employs piezoelectric actuators to generate mechanical vibrations in the component and piezoelectric sensors to measure the vibratory response. By analyzing the resonance characteristics and frequency shifts caused by defects, the system can detect internal flaws without disassembly, thus resolving the contradiction between detection capability and time loss.
2Productivity
If piezoelectric actuator and sensor stack are used, then in-situ inspection is enabled with minimal downtime, but electrical isolation between actuator and sensor must be maintained
Solution Approach 1:
A ceramic isolator is introduced as an intermediary component between the piezoelectric actuator and sensor stack. This isolator provides electrical isolation while allowing mechanical vibration transmission, thus enabling the actuator and sensor to function independently without electrical interference. This resolves the contradiction by adding a simple isolating element rather than complex isolation systems.
Solution Approach 2:
The ceramic isolator is placed specifically at the interface between actuator and sensor where electrical isolation is needed, while maintaining mechanical coupling for vibration transmission. This localized application of isolation property allows the rest of the system to remain simple and direct, preserving inspection speed while addressing the isolation requirement.
3Measurement precision
If preloading is applied to ensure contact between inspection device and component, then measurement accuracy is improved, but additional force application complexity increases
Solution Approach 1:
The piezoelectric actuator serves dual functions: generating vibration signals for defect detection and applying preload force to ensure contact between the inspection device and component surface. By merging these two functions into a single component, the system achieves improved measurement precision without adding separate preload application mechanisms, thus avoiding increased complexity.
Solution Approach 2:
The piezoelectric actuator automatically provides the necessary preload force through its own structure and operation, eliminating the need for external preload application systems. This self-service capability ensures consistent contact and measurement accuracy while keeping the device design simple 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
Enables rapid and cost-effective detection of internal defects with minimal aircraft downtime, identifying anomalies such as cracks and corrosion with high sensitivity.
Implementation Method 1
The piezoelectric actuator includes a piezoelectric device configured to induce vibrations in the specimen component
Implementation Method 2
The sensor includes a piezoelectric device configured to measure a vibratory response in the specimen component
Data Source
AI summary
An inspection method is provided during which an inspection device is arranged with a specimen component. The inspection device includes a piezoelectric actuator, an isolator and a piezoelectric sensor. The piezoelectric actuator engages and is preloaded against a surface of the specimen component sequentially through the isolator and the piezoelectric sensor. The isolator electrically isolates the piezoelectric actuator from the piezoelectric sensor. Vibrations are induced in the specimen component using the piezoelectric actuator. A vibratory response in the specimen component excited by the vibrations is measured using the piezoelectric sensor. Response data indicative of the vibratory response measured is provided using the piezoelectric sensor.