Optical Scanning for Turbine Vane Flow Area Precision
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Solution Overview
Problem
Existing methods for determining effective flow areas in gas turbine engines are limited in accuracy due to manufacturing tolerances and operational stress, leading to inefficiencies and potential turbine issues like vibration and reduced fuel efficiency.
Innovation Solution
The method involves optical scanning using blue light to create virtual vanes and vane rings, allowing for precise determination of effective flow areas by scanning both sides of vanes, identifying chokepoints, and comparing them to reference specifications, with alerts generated for deviations outside preset tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement methods are used to determine effective flow areas, then the measurement process is simpler, but the measurement precision is insufficient due to manufacturing tolerances and operational stress
Solution Approach 1:
The patent creates virtual copies of physical vanes through optical scanning. Blue light scans capture the precise geometry of each vane, including wear and deformation from operational stress, generating digital models that can be measured without physically disturbing the components. This copying approach enables high-precision measurement while avoiding the complexity of direct physical measurement of worn components.
Solution Approach 2:
The patent replaces traditional mechanical measurement methods with optical scanning technology. Instead of using physical contact tools to measure vane dimensions, the system uses blue light to non-contactly capture vane geometry, eliminating mechanical measurement errors and enabling precise detection of effective flow areas even when vanes are subjected to operational stress and deformation.
2Measurement precision
If individual vane segments are measured separately to account for manufacturing tolerances and operational stress, then the measurement accuracy improves, but the time required for measurement increases
Solution Approach 1:
The patent divides the vane ring into individual vane segments for separate measurement and analysis. Each vane is optically scanned independently, allowing the system to account for variations in manufacturing tolerances and differential wear from operational stress. This segmentation enables precise measurement of each segment's effective flow area while maintaining efficiency through automated processing of multiple segments.
Solution Approach 2:
The patent performs optical scanning and creates virtual models of all vane segments before final assembly or operation. By capturing the geometry of each vane in advance, the system can calculate effective flow areas and identify issues before they affect turbine performance, reducing the need for time-consuming remeasurements and adjustments during maintenance cycles.
3Manufacturing precision
If optical scanning with blue light is used to create virtual vanes, then the measurement precision and detail assessment improve, but the device complexity and initial setup time increase
Solution Approach 1:
The patent uses blue light optical scanning to create accurate virtual copies of physical vane segments. This copying process captures detailed geometry including subtle wear patterns and manufacturing variations, enabling precise assessment of effective flow areas. The virtual models can be repeatedly analyzed without requiring the physical vane to be present, reducing the need for complex repeated measurements.
Solution Approach 2:
The patent utilizes blue light specifically for optical scanning, leveraging its short wavelength to achieve high-resolution measurements of vane geometry. By changing the optical parameter (wavelength) to blue light, the system achieves superior measurement precision for detecting small variations in vane dimensions and wear patterns that would be invisible with longer wavelengths.
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 provides accurate and detailed assessments of individual and total effective flow areas, enabling timely monitoring, repair, or replacement of components to improve turbine performance and efficiency.
Implementation Method 1
The optical scanning may comprise a blue light scan.
Data Source
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Figure 3A~3B
AI summary
A computing device for determining effective flow areas of a turbine or turbine engine includes optically scanning and digital modeling of turbine components to produce virtual vanes, virtual vane segments, and virtual ring assemblies. The computing device determines both individual effective flow areas between vanes and the total effective flow area of a vane ring assembly. Based on the virtual vanes and determined effective flow areas, the computing device may compare one or more turbine components to a reference turbine to determine whether the turbine is out of specification and aid in repair, modification, or reassembly of the turbine or turbine engine.