Turbine Strain Monitoring via Reference Surface Features
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Solution Overview
Problem
Components operating in high-temperature and corrosive environments, such as gas turbine systems, face challenges in monitoring stress and strain due to elevated temperatures and varied force distributions, which existing methods struggle to address effectively.
Innovation Solution
The use of reference surface features, including machined and naturally occurring features, to facilitate strain monitoring without additional sensor components, utilizing imaging techniques and a system with an imaging device and processor to measure distances and analyze strain across the component surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional strain sensors are used to monitor stress and strain in turbine components, then measurement capability is provided, but device complexity and manufacturing difficulty increase due to the need for additional sensor components and their integration into high-temperature environments
Solution Approach 1:
The turbine component itself serves as the sensing element by incorporating reference surface features (such as machined gratings or natural surface patterns) that directly encode strain information. The component's surface features deform with the component, eliminating the need for separate strain sensors and their complex integration into high-temperature turbine environments.
Solution Approach 2:
Instead of using physical strain sensors, the patent creates an optical copy or representation of strain through reference surface features on the component. These features act as a mechanical-optical transducer, where surface deformations are captured as optical patterns that can be analyzed without requiring sensors to physically contact or be embedded in the high-temperature component.
2Measurement precision
If strain sensors are integrated into turbine components operating at elevated temperatures, then strain measurement is enabled, but reliability decreases due to sensor degradation in high-temperature and corrosive environments
Solution Approach 1:
The turbine component's own surface serves as the measurement reference, eliminating vulnerable external sensors. The reference surface features are either machined directly into the component or are natural surface characteristics that inherently survive the component's operational environment, ensuring measurement reliability throughout the component's service life.
Solution Approach 2:
The reference surface features act as an intermediary between the component's mechanical deformation and the optical measurement system. These features transfer the strain information from the high-temperature component to the measurement system without requiring the sensor itself to withstand the harsh thermal and corrosive conditions.
3Measurement precision
If multiple measurement points are used to capture varied force distributions across turbine components, then comprehensive strain monitoring is achieved, but measurement system complexity and time increase
Solution Approach 1:
The patent transitions from point-based strain measurement to area-based measurement by using arrayed reference surface features distributed across the component surface. This allows simultaneous capture of strain information at multiple locations through a single optical field of view, converting a temporal sequence of point measurements into a parallel spatial measurement.
Solution Approach 2:
The measurement system divides the component surface into multiple measurement zones, each containing reference surface features that independently encode local strain information. This segmentation allows comprehensive coverage of the component while maintaining efficient measurement through optical techniques that can capture multiple zones simultaneously.
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 method enables accurate and efficient monitoring of strain, creep, and fatigue in high-temperature components, providing a consistent and non-invasive means to assess component health and determine necessary modifications or maintenance without the need for separate strain sensors.
Implementation Method 1
imaging techniques and a system with an imaging device and processor to measure distances and analyze strain across the component surface
Data Source
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AI summary
Methods (200) for monitoring a component include locating (210) a plurality of machined surface features on the component, locating (220) at least one reference point, and measuring (230) a plurality of first distances between the plurality of machined surface features and the at least one reference point.