Non-contact scanning for gas turbine internal cooling feature inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for inspecting internal cooling features of gas turbine blades are labor-intensive, prone to errors, and require complex setup procedures, often necessitating manual exposure and orientation of the blades, which is not suitable for small features and lacks repeatability.
Innovation Solution
A method involving partial removal of the turbine component to expose internal features, surface treatment for uniform coloration, and non-contact scanning to generate an electronic model, which is analyzed against a nominal model for accurate geometry measurement and reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual scribing methods are used to measure internal cooling features, then the inspection process can be performed with simple equipment, but the measurement precision deteriorates due to stylus jumping over small features and inability to accurately scribe features with small radii
Solution Approach 1:
The patent replaces manual mechanical scribing methods with non-contact optical scanning. The optical scanner captures three-dimensional data of internal cooling features without physical contact, eliminating stylus jumping issues and enabling accurate measurement of small features with radii as small as 0.002 inches while using relatively simple scanning equipment.
Solution Approach 2:
The patent creates a digital three-dimensional copy of the internal cooling features through optical scanning. This electronic model allows for precise measurement and analysis of feature geometry without physical contact, preserving measurement accuracy while avoiding the limitations of mechanical stylus-based methods.
2Measurement precision
If complex fixtures and precise orientation procedures are used to properly position blades for inspection, then the measurement precision improves, but the device complexity and setup time increase significantly
Solution Approach 1:
The patent employs a universal coordinate measurement system that can inspect various blade configurations without requiring blade-specific fixtures. The system uses standardized reference features and software-based alignment procedures that work across different blade types, eliminating the need for complex, custom-made fixtures for each blade configuration.
Solution Approach 2:
The patent replaces mechanical positioning fixtures with software-based orientation and alignment. The system uses computer-controlled coordinate measurement and digital alignment procedures to properly position and orient blades for inspection, eliminating complex mechanical fixture requirements while maintaining measurement precision.
3Ease of operation
If wire cutting is used to expose internal features by removing blade portions, then the internal features become accessible for inspection, but the manufacturing complexity and time increase
Solution Approach 1:
The patent extracts only the necessary portions of the blade exterior to expose internal cooling features for inspection. By selectively removing material only where needed to access internal features rather than entire blade sections, the process reduces manufacturing complexity and time while maintaining feature accessibility.
4Device complexity
If manual inspection procedures are used for internally cooled blades, then the equipment requirements remain simple, but the productivity deteriorates due to labor-intensive processes and poor repeatability
Solution Approach 1:
The patent implements an automated inspection system that performs measurements and analysis without continuous manual intervention. The coordinate measuring machine automatically scans features, the software automatically aligns and compares data against nominal models, and the system generates inspection reports autonomously, dramatically improving productivity while maintaining relatively simple equipment requirements.
Solution Approach 2:
The patent replaces manual inspection operations with automated optical scanning and computer-based analysis. The system automatically captures three-dimensional data, performs alignment and comparison operations, and generates inspection results without manual measurement procedures, enhancing productivity while keeping the physical inspection equipment relatively simple.
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 reduces inspection time, enhances accuracy, and allows for easy adaptation to various blade configurations without complex setup redesign, with results that can be integrated into existing software packages for comprehensive analysis and future reference.
Implementation Method 1
generating an electronic model of the internal feature using a non-contact scanner
Implementation Method 2
treating the surfaces of the internal feature to provide the surfaces with a substantially uniform coloration
Data Source
AI summary
A method of inspecting an internal feature of a gas turbine component includes removing a portion of the turbine component to expose the internal feature, treating the surfaces of the internal feature to provide the surfaces with a substantially uniform coloration, generating an electronic model of the internal feature, analyzing the electronic model generated with reference to a nominal electronic model, and providing an output based on the analysis of the electronic model generated.