Variable Focus Optical Inspection for In-Situ Turbine Component Repair

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Solution Overview

Problem

Existing optical inspection systems for power generation apparatus components have fixed focal planes, making it difficult to accurately inspect features that fall outside of this plane, and require ex-situ repair, increasing downtime and costs.

Innovation Solution

A system with a variable focal length structure and a controller to adjust the focal plane, ensuring that regions of interest on power generation apparatus components are in focus, allowing for both accurate inspection and in-situ repair.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a fixed focal plane optical structure is used, then the device complexity is reduced, but the measurement precision of features outside the focal plane deteriorates

Engineering Contradiction:
Improveoptical structure complexityVSAvoidinspection accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies the dynamics principle by transforming the fixed focal plane optical structure into a variable focal plane structure. The optical system can dynamically adjust its focal plane position to match different component depths, allowing features at various distances from the optical probe to remain in focus. This dynamic adjustment capability resolves the contradiction by maintaining measurement precision across different depths without significantly increasing device complexity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by varying the focal plane position parameter of the optical structure. Instead of maintaining a fixed focal distance, the system adjusts the focal plane parameter to correspond with the depth of different component features being inspected. This parameter adjustment enables accurate optical interrogation of features at multiple depths while keeping the optical structure relatively simple.

Inventive Principle:
Principle #35Parameter changes

2Ease of repair

If ex-situ repair is performed by disassembling the power generation apparatus, then the repair quality can be improved, but the loss of time and productivity deteriorates

Engineering Contradiction:
Improverepair qualityVSAvoiddowntime
Core Design Contradiction:
Ease of repairVSLoss of time

Solution Approach 1:

The patent applies the self-service principle by enabling repair operations to be performed in-situ within the power generation apparatus without requiring disassembly. The optical system and repair tools are introduced through existing access points, allowing the component to be repaired in its original location and operational context, thus eliminating downtime associated with disassembly and reassembly.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent implements preliminary action by performing inspection and repair operations before the power generation apparatus needs to be taken offline for extended periods. By using in-situ repair capabilities, maintenance can be performed during shorter shutdown windows or even during operational transitions, preventing the need for lengthy disassembly and reassembly cycles.

Inventive Principle:
Principle #10Preliminary action

3Measurement precision

If the optical probe is positioned close to the component, then the measurement precision improves, but the adaptability to inspect features at different distances deteriorates

Engineering Contradiction:
Improveoptical interrogation accuracyVSAvoidinspection range
Core Design Contradiction:
Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the focal plane position adjustable rather than fixed. The optical system can dynamically shift its focal plane to match different distances from the probe, allowing high-resolution inspection of features whether they are close to or far from the optical probe. This dynamic focal adjustment maintains measurement precision across a versatile inspection range.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements universality by designing an optical system that can effectively inspect features at multiple distances from the probe. The variable focal plane capability allows the same optical probe to accurately interrogate both near-field and far-field features, making the inspection system universally applicable to diverse component geometries and defect locations without requiring multiple specialized probes.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS12276619B2System for use with component of power generation apparatus
Publication Date: 2025.04.15 ROLLS ROYCE PLC
  • US12276619B2 patent drawing
  • US12276619B2 patent drawing
  • US12276619B2 patent drawing

AI summary

A system for use with a component of a power generation apparatus includes a lens arrangement disposed proximal to the component. The system further includes a variable focal length structure spaced apart from the lens arrangement and optically coupled with the lens arrangement. The variable focal length structure has a focal plane that is adjustable. The system further includes a controller communicably coupled with the variable focal length structure. The controller is configured to control the variable focal length structure to adjust the focal plane of the variable focal length structure, such that at least one region of interest of the component is in focus.