Resistor Strip Wear Sensor for Gas Turbine Axial Shift
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas turbine engines face challenges in accurately detecting blade tip clearance and axial shift, which affect efficiency and performance, as existing methods lack precision in monitoring wear and radial/axial movements.
Innovation Solution
A wear indication sensor system comprising resistor strips attached to the inner surface of a gas turbine engine, connected by lead wires to a measurement device, which measures resistance changes to determine material removal and calculate blade clearance and axial shift.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conductor strips are embedded in a component at varying depths to monitor wear, then wear detection capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The sensor is divided into multiple conductor strips positioned at different depths within the component wall. Each strip independently monitors wear at its specific depth level, allowing precise detection of wear progression through the wall thickness without requiring a single complex embedded sensor system.
Solution Approach 2:
The conductor strips serve as intermediary elements that translate physical wear (material removal) into measurable electrical resistance changes. This intermediary mechanism enables indirect but precise measurement of wear depth and progression without direct contact with the wearing surfaces.
2Measurement precision
If multiple conductor strips are positioned at different depths to monitor radial and axial creep, then measurement accuracy is improved, but ease of manufacture deteriorates
Solution Approach 1:
The monitoring system is segmented into multiple conductor strips located at different depths (e.g., first strip at intermediate depth, second strip at greater depth) within the component wall. This segmentation enables independent measurement of wear at each depth level, providing accurate radial and axial creep data while using simple, manufacturable strip structures.
Solution Approach 2:
The position parameter (depth) of the conductor strips is varied to create multiple measurement levels within the component wall. By changing the spatial parameter of the sensor strips, the system achieves comprehensive wear monitoring at different depths without complicating the manufacturing process, as each strip can be manufactured and positioned independently.
3Measurement precision
If a resistor strip is configured to abrade when impacted by a blade, then wear indication sensitivity is improved, but reliability of continuous monitoring deteriorates
Solution Approach 1:
The conductor strips are pre-positioned at specific depths within the component wall before operation begins. This preliminary placement ensures that as wear progresses and material is removed, the strips will be exposed in a predetermined sequence, providing reliable and sensitive detection of wear milestones without requiring the strips to migrate or change position during operation.
Solution Approach 2:
The system provides feedback through resistance measurements that indicate the exposure status of each conductor strip. As strips are exposed due to wear, the resistance values change, providing continuous feedback on wear progression. This feedback mechanism maintains reliability by allowing ongoing monitoring of wear status at multiple depth levels.
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
The system effectively measures blade tip clearance and axial shift by detecting resistance changes, enabling precise monitoring of wear and improving engine performance by determining the depth of blade penetration and axial movement.
Implementation Method 1
the measurement device is configured to measure a resistance of the resistor strip between each of the plurality of lead wires
Implementation Method 2
the resistor strip is configured to abrade when impacted by a blade of the gas turbine engine
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A wear indication sensor (100) comprising: a resistor strip (140) configured to be operably attached to the surface (72) of an engine component, the resistor strip including a first end (142) and second end (144); a plurality of lead wires (120) comprising: a first lead wire (120a) electrically connected to the first end (142) proximate an aft end (20b) of the engine component; a second lead wire (120b) electrically connected to the first end (142) proximate a forward end (20a) of the engine component; a third lead wire (120c) electrically connected to the second end (144) proximate the aft end (20b) of the engine component; and a fourth lead wire (120d) electrically connected to the second end (144) proximate the forward end (20a) of the engine component; and a measurement device (300) electrically connected to each of the plurality of lead wires (120), wherein the measurement device (300) is configured to measure a resistance of the resistor strip (140) between each of the plurality of lead wires (120).