Sensor Coupon for Gas Turbine Retrofitting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for retrofitting measurement devices into gas turbine components, such as those involving MEMS devices and thermal barrier coatings, are complicated by the need for trenches and routing connections, making it difficult to integrate sensors effectively into existing components.
Innovation Solution
A self-powered, wireless sensor is embedded within a coupon that is welded or fitted onto the turbine component, with a thermal barrier coating covering the sensor, allowing for direct measurement of parameters like temperature, pressure, and strain, and includes a measurement channel for fluid contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If MEMS devices are deposited in trenches with routed connections to distal locations, then sensor measurement capability is achieved, but the difficulty of retrofitting existing components increases
Solution Approach 1:
The sensor system is segmented into a modular coupon that can be independently manufactured and then attached to the turbine component. This segmentation allows the sensor to be fabricated with its connections in a controlled environment and then installed as a complete unit, eliminating the need to route connections through the component body during retrofitting.
Solution Approach 2:
The coupon acts as an intermediary carrier that holds the MEMS sensor and its connections. Instead of directly embedding the sensor into the turbine component with complex internal routing, the coupon serves as a mediator that simplifies the installation process by providing a pre-configured platform for the sensor.
2Measurement precision
If trenches are created and connections routed to distal locations for sensor installation, then direct measurement is enabled, but the complexity of the installation process increases
Solution Approach 1:
The installation process is segmented into simple steps: attach the pre-configured coupon to the component surface. The complex sensor fabrication and connection routing are completed during coupon manufacturing, not during component installation, thereby reducing installation complexity.
Solution Approach 2:
The sensor, its connections, and its mounting structure are all prepared in advance during coupon fabrication. This preliminary action transfers the complexity from the installation phase to the manufacturing phase, where the complexity can be managed more effectively.
3Measurement precision
If sensors are embedded in recesses of the component, then measurement functionality is achieved, but the difficulty of retrofitting existing components increases
Solution Approach 1:
Instead of embedding the sensor into the component (traditional approach), the invention inverts the approach by attaching a sensor-containing coupon to the component's external surface. This reversal eliminates the need to create recesses and route connections through the component body.
Solution Approach 2:
The sensor system is separated from the component body and placed on an independent coupon that attaches to the surface. This segmentation allows the sensor to be installed without modifying the component's internal structure, greatly simplifying retrofitting.
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 simplifies the retrofitting process by using a coupon with an embedded sensor, enabling direct and efficient measurement of working fluid parameters, overcoming the complexity of existing methods and enhancing the integration of sensors into turbine components.
Implementation Method 1
a coating, such as a thermal barrier coating covers an outer layer of the sensor and at least part of an outer surface of the coupon
Implementation Method 2
a coupon that is fitted, such as by welding, in or located on the component
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a component (2) that is configured to be exposed to a working fluid. The component (2) comprises a coupon (8) fitted in or located on the component (2) and a measurement sensor (14) embedded in and/or located on the coupon (8).