Ultrasonic Engine Component Inspection Through Shaft Cavity Coupling
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Solution Overview
Problem
Existing non-destructive inspection methods for internal defects in aircraft engine components are inefficient and require significant downtime and expense.
Innovation Solution
An ultrasonic inspection method using an ultrasonic transducer and acoustic coupling media is employed to inspect engine components by directing ultrasonic signals through the components, allowing for detection of internal defects without disassembly, and utilizing relative positional changes to enhance inspection coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional non-destructive inspection methods are used for internal defects in aircraft engine components, then inspection coverage is achieved, but inspection efficiency is low and downtime is significant
Solution Approach 1:
The inspection device is inserted into a bore of the shaft, nesting the inspection apparatus within the existing engine structure. This allows inspection to be performed from within the engine assembly without requiring complete disassembly, thereby reducing downtime while maintaining inspection coverage
Solution Approach 2:
Acoustic coupling media is introduced as an intermediary substance between the ultrasonic transducer and the engine components being inspected. This media enables effective ultrasonic signal transmission through the components, improving inspection efficiency by allowing thorough examination without increasing disassembly requirements
2Measurement precision
If engine components are disassembled for inspection, then internal defects can be detected, but inspection complexity and cost increase
Solution Approach 1:
The ultrasonic inspection device is nested within the shaft bore, allowing it to access and inspect the rotor disk and other components from an internal position. This nesting approach maintains high defect detection capability while avoiding the need to disassemble the engine into separate components, thereby reducing inspection complexity
Solution Approach 2:
The inspection system utilizes the existing structural features of the engine (the shaft bore) to position itself for inspection. The shaft itself serves as the mounting structure for the inspection device, eliminating the need for external complex positioning equipment and reducing overall inspection system complexity
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
Facilitates efficient and minimally disruptive inspection of aircraft engine components, reducing downtime and costs while effectively identifying internal defects such as cracks and corrosion.
Implementation Method 1
generating an ultrasonic signal using the ultrasonic transducer; and directing the ultrasonic signal from the inspection device, sequentially through the shaft and the acoustic coupling media, into the rotor disk
Implementation Method 2
directing the ultrasonic signal from the inspection device, sequentially through the shaft and the acoustic coupling media, into the rotor disk
Implementation Method 3
A reflection of the ultrasonic signal may be directed out of the second engine component, sequentially through the acoustic coupling media and the first engine component, to the inspection device. The determining of the first characteristic further may include detecting a parameter of the reflection of the ultrasonic signal using the ultrasonic transducer
Data Source
AI summary
An inspection method is provided during which an acoustic coupling media is directed into a cavity of an engine assembly. The engine assembly includes a first engine component and a second engine component. The cavity is formed by and extends between the first engine component and the second engine component. An inspection device is arranged with the engine assembly. The inspection device includes an ultrasonic transducer. A first characteristic of the second engine component is determined using the inspection device. The determining of the first characteristic includes: generating an ultrasonic signal using the ultrasonic transducer; and directing the ultrasonic signal from the inspection device, sequentially through the first engine component and the acoustic coupling media, into the second engine component.