Rotating Camera In-Situ Monitoring for Turbine Blade Distortion
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Solution Overview
Problem
Current methods for monitoring turbine blades in gas turbine engines are limited by the use of high brightness lasers, which are unreliable and hazardous, and require a window for visualization, leading to image distortion and limitations in data extraction, especially in rotating components and varying engine configurations.
Innovation Solution
An in situ component monitoring arrangement that uses a camera and light source to rotate with the component, allowing for continuous image capture of a target portion, with wireless data transmission to a controller for comparison, eliminating the need for high brightness lasers and windows, and enabling accurate distortion measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a high brightness laser is used to illuminate the component, then sufficient reflectivity for observation is achieved, but the system becomes unreliable and hazardous
Solution Approach 1:
The patent replaces the expensive, hazardous high brightness laser with a conventional light source combined with a pulsed synchronous camera. The light source can be a simple LED or lamp that is safe and reliable, while the camera captures images during specific time windows to achieve the necessary measurement precision without requiring dangerous laser illumination.
2Ease of operation
If a window is provided for visual access to the component, then monitoring is enabled, but image distortion occurs and data extraction is limited
Solution Approach 1:
The patent removes the window from the system entirely. Instead of viewing the component through a window, the camera is positioned to capture images directly from the component's surface. This eliminates the image distortion caused by the window while still enabling visual access and monitoring of the rotating component.
3Length of stationary object
If the laser beam is projected over a large distance, then the component can be monitored, but the beam can be deviated
Solution Approach 1:
The patent replaces the mechanical laser beam projection system with an optical imaging system. Instead of projecting a laser beam across a large distance and measuring its position, the system uses a camera to capture images of the component illuminated by a safe light source. This substitution eliminates beam deviation issues while maintaining the ability to monitor the component at the required distance.
4Ease of operation
If viewing through a casing window is used, then component monitoring is achieved, but valuable component shape data is lost due to distortion
Solution Approach 1:
The patent removes the casing window that causes image distortion. The camera is positioned to obtain direct images of the component surface without passing through the window. This extraction of the problematic window element eliminates the distortion that causes loss of shape data while preserving the ability to view and monitor the component.
5Measurement precision
If an upstream laser is used for monitoring, then component shape can be determined, but the accuracy of air flow loading on the blade is compromised
Solution Approach 1:
The patent replaces the upstream laser with a conventional light source that does not interfere with air flow. The safe light source illuminates the blade surface without creating the harmful upstream flow disturbances that a laser would cause, while the pulsed camera captures the necessary shape information during rotation.
6Adaptability or versatility
If blade heights and configurations are reconfigured for monitoring, then data extraction at different heights is possible, but considerable time and effort is required
Solution Approach 1:
The patent makes the camera system dynamic by mounting it on the rotating component itself. As the component rotates, the camera rotates with it, automatically tracking the surface being monitored. This dynamic positioning eliminates the need for time-consuming reconfiguration of blade heights and configurations, as the system adapts automatically to the rotating component's position.
7Measurement precision
If current monitoring methods are used, then blade shape can be determined for one particular engine configuration, but versatility across various configurations is limited
Solution Approach 1:
The patent creates a universal monitoring system that can accommodate various engine configurations. The camera mounted on the rotating component captures images of the blade surface as it rotates, and the data processing system can analyze blade shapes for different configurations without requiring system reconfiguration. This multi-functional approach enables the same system to monitor various engine types and blade designs.
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 solution provides accurate, real-time monitoring of turbine blade distortion without the hazards and limitations of previous methods, allowing for simultaneous data extraction and improved blade shape determination across various engine configurations.
Implementation Method 1
the camera is arranged to rotate with the component in use and obtain images of at least a target portion of the component
Implementation Method 2
the light source providing in use illumination of the component as it rotates and the camera arranged to receive, in use an image from the component
Data Source
AI summary
By mounting a camera to rotate with a rotating component to be viewed it is possible to review the whole component illuminated by a light source. Generally the component will be specifically marked with target markings to highlight its profile to allow images produced by the camera to be compared for distortion and displacement. Such in situ monitoring arrangements also allow profiling of the surface, and by projection of a grid or matrix onto a component surface any distortion in that matrix is indicative of variations in the surface or through use of astigmatic techniques variations in the incident image pattern can be utilized in order to determine distance variations.