Stitched Surface Imaging for Gas Turbine Combustor Inspection
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Solution Overview
Problem
Existing internal inspection systems for gas turbine combustors and transition ducts face challenges in visualizing and analyzing the interior surface topography due to the large number of overlapping images and image distortion caused by the non-cylindrical shape of transition ducts, making it difficult to efficiently assess wear and condition changes.
Innovation Solution
A camera inspection system with a rotatable and articulable scope that captures panoramic images by stitching together sequential photos, using computer algorithms to correct for distortions and create comprehensive 3D models, allowing for interactive analysis and tracking of surface changes over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a scope camera is inserted to capture individual photos of the interior surfaces, then inspection coverage is achieved, but the large number of overlapping images makes visualization and analysis difficult and time-consuming
Solution Approach 1:
The patent merges multiple sequential photos into a single stitched panoramic image that represents the entire interior surface. This combining process transforms hundreds of individual images into one comprehensive view, enabling inspectors to analyze the complete surface area without manually examining each photo separately, thereby dramatically reducing analysis time while maintaining full inspection coverage
2Loss of information
If sequential photos are taken to cover the entire interior surface, then complete inspection data is obtained, but making comparisons among numerous small overlapping images to visualize surface topography and changes is difficult
Solution Approach 1:
The system combines multiple sequential photos into a single stitched panoramic image that preserves all inspection data while presenting it in a unified, easily visualizable format. The stitching process maintains the spatial relationships and surface topography information across the entire interior surface, allowing inspectors to view and compare the complete surface area in one continuous image rather than navigating through numerous separate photos
3Area of stationary object
If images are captured at various angles to cover non-cylindrical transition ducts, then complete surface coverage is achieved, but image distortion occurs from the angles of the inner surface relative to the camera
Solution Approach 1:
The patent addresses image distortion by transitioning from 2D image capture to 3D surface mapping. The system captures images at multiple angles and uses stereo vision algorithms to reconstruct the three-dimensional geometry of the non-cylindrical transition duct interior. This 3D reconstruction eliminates perspective distortion by mathematically correcting the images based on the measured surface geometry, providing accurate representations of the interior surfaces regardless of camera angles
Data Source
AI summary
A method of generating a comprehensive image (87) of interior surfaces (78, 80) of machine components such as a gas turbine combustor basket (59) and transition duct (34) by digitally stitching together multiple photographs (82) thereof, and analyzing the comprehensive image by contouring (91, 95A-B) of colors and shadings thereon, and quantifying and tracking aspects of the contours (A, B, C) over time for indications of degradation (89) of the interior surfaces. A scope (58) may be inserted into a port (56) in the combustor with a camera (72, 74) in a rotatable end (70) of the scope for obtaining a circumferential set (84) of photos at each axial position along a length of the combustor and transition duct. A 3D surface scanning device (76) in the scope may define the geometry of the interior surface for 3D photographic modeling thereof providing a virtual walk-through inspection.