Turbine Blade Erosion Sensor Using Segmented Conductive Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Monitoring erosion and corrosion of turbine blades is challenging due to remote locations and the need for machine downtime during inspections, which can lead to catastrophic failures if undetected.
Innovation Solution
A sensor system with conductive elements made of corrosion-resistant materials, similar to the turbine blades, that provide erosion and corrosion indicators through electrical property monitoring, allowing for online detection of pit depths during operation without downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used to monitor erosion and corrosion of turbine blades, then detection capability is provided, but machine downtime is required and inspection complexity increases due to remote locations
Solution Approach 1:
The sensor system is installed on the turbine blade before operation begins, with conductive elements positioned at strategic locations where erosion and corrosion are most likely to occur. This preliminary placement enables continuous monitoring without requiring subsequent shutdowns for inspection setup
Solution Approach 2:
The sensor system performs self-monitoring during normal turbine operation, detecting erosion and corrosion through electrical property changes in the conductive elements. The system serves itself by continuously assessing its own condition and providing data without external intervention or machine downtime
2Measurement precision
If traditional inspection methods are used to monitor turbine blades, then erosion and corrosion can be detected, but inspection difficulty increases due to remote locations and special equipment requirements
Solution Approach 1:
The patent replaces mechanical inspection methods (physical access, special equipment) with an electrical sensing system. Conductive elements embedded in the blade substrate provide electrical signals that indicate erosion and corrosion conditions, eliminating the need for mechanical inspection equipment and remote access
3Reliability
If corrosion resistant material is used for the first element, then corrosion resistance is improved, but erosion monitoring accuracy may be affected if the material properties differ significantly from the substrate
Solution Approach 1:
The sensor system uses different materials for different functions: the first element uses corrosion-resistant material specifically for corrosion protection, while the second element uses material matching the substrate for erosion monitoring. Each element has optimized local properties appropriate to its specific monitoring function
Solution Approach 2:
The sensor system is divided into separate functional elements: a first element for corrosion monitoring and a second element for erosion monitoring. This segmentation allows each element to be optimized for its specific function without compromising the other, with the corrosion-resistant first element protected from corrosion and the substrate-matched second element accurately tracking erosion
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 continuous monitoring of erosion and corrosion, improving maintenance scheduling and predicting when mitigation measures are needed, thereby reducing the risk of catastrophic failures.
Implementation Method 1
an electrical property monitoring device configured to monitor an electrical property associated with each of the plurality of conductive elements
Data Source
AI summary
An erosion sensor that can separately monitor erosion and corrosion of a substrate, such as a wind turbine blade or a turbine blade used in devices such as gas turbines, aircraft engines, microturbines, steam turbines, and the like is disclosed. The sensor can include a first element or “erosion part” that is made of a corrosion resistant material. The first element of the sensor has similar erosion properties to the substrate being monitored. The sensor can further include a second element or a “corrosion part” that is made of a material having similar erosion and corrosion properties to the substrate. The sensor can provide an erosion indicator based on the erosion of the first element and a corrosion indicator based on the erosion and corrosion of the second element.