Ultrasonic Transducer Array Inspection for Turbine Component Defects
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Solution Overview
Problem
Conventional inspection methods for turbine components are time-consuming and costly, leading to extended downtime and potential catastrophic failures due to the inability to efficiently identify defects before they cause significant issues.
Innovation Solution
The implementation of an ultrasonic inspection system using arrays of transducer elements mounted on turbine components, which transmit and capture signals to generate images of the interior volume, allowing for early detection of defects and failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used to evaluate turbine components, then inspectors can obtain various information about component condition, but the evaluation process becomes time-consuming and adds to turbine downtime
Solution Approach 1:
The inspection system segments the turbine component into a three-dimensional grid of volumetric elements, allowing parallel processing of different regions. Each element can be independently evaluated, enabling simultaneous analysis of multiple component areas which significantly reduces total inspection time while maintaining comprehensive coverage.
Solution Approach 2:
The system transitions from conventional two-dimensional surface inspection to three-dimensional volumetric inspection by dividing the component into volumetric elements. This dimensional expansion allows inspectors to evaluate internal structures and defects throughout the entire component volume, providing more comprehensive information without proportionally increasing inspection time.
2Loss of information
If conventional inspection methods are used, then component information can be gathered, but the large amount of information from relatively large components is time-consuming to process
Solution Approach 1:
By segmenting the component into discrete volumetric elements, the system organizes large amounts of inspection data into manageable, structured units. This segmentation enables efficient data processing through parallel computation of individual elements while maintaining complete component information, thereby improving processing productivity without sacrificing information completeness.
Solution Approach 2:
The system changes the parameter of data representation from continuous analog signals to discrete digital volumetric element data. This parameter transformation enables more efficient computer processing and storage of inspection information, allowing rapid analysis of complete component data without the time-consuming processing associated with conventional methods.
3Reliability
If periodic testing is performed to assess turbine component failures, then defects can be identified before catastrophic failure, but the inspection process extends turbine downtime
Solution Approach 1:
The system performs preliminary action by conducting comprehensive three-dimensional inspection during scheduled maintenance periods, creating a complete baseline data set of the component's internal structure. This preliminary inspection identifies potential defects early, allowing operators to monitor changes over time and plan repairs during optimal maintenance windows, thereby reducing unplanned downtime while maintaining high reliability.
Solution Approach 2:
By implementing three-dimensional volumetric inspection instead of conventional two-dimensional methods, the system provides more comprehensive defect detection capability that can identify internal flaws not visible on surfaces. This enhanced detection accuracy improves reliability by catching defects earlier, while the efficient parallel processing of volumetric data minimizes the time penalty associated with more thorough inspection.
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 downtime and costly replacements by enabling the early identification of defects, thereby preventing major failures and associated costs.
Implementation Method 1
Each element in each array of transducer elements can be pulsed separately to transmit a signal to the turbine component. The signals can be reflected from the turbine component and captured at each transducer element.
Data Source
AI summary
Embodiments of the disclosure relate to ultrasonic inspection of turbine components. In one embodiment, a method for ultrasonic inspection of a turbine component can include mounting at least one array of transducer elements to the turbine component, (a) separately pulsing a transducer element of the at least one array of transducer elements to transmit a signal to the turbine component, (b) capturing reflected signals from the turbine component at each transducer element in the at least one array of transducer elements, repeating (a) and (b) for each of the other transducer elements in the at least one array of transducer elements, maintaining a constant relative position of the array of transducer elements with respect to the turbine component, analyzing the captured reflected signals using a computer, generating an image of the interior volume of the turbine component by reconstruction of the captured reflected signals and based at least in part on detecting an anomaly in the image of the interior volume of the turbine component, identifying at least one defect or failure in the turbine component.