U.S. patent application number 13/181803 was filed with the patent office on 2013-01-17 for apparatus for inspecting turbomachine components in-situ.
This patent application is currently assigned to General Electric Company. The applicant listed for this patent is Daniel Lawrence Banowetz, Gareth William David Lewis, Thomas Earnest Moldenhauer, Diego Quinones. Invention is credited to Daniel Lawrence Banowetz, Gareth William David Lewis, Thomas Earnest Moldenhauer, Diego Quinones.
Application Number | 20130014571 13/181803 |
Document ID | / |
Family ID | 46969968 |
Filed Date | 2013-01-17 |
United States Patent
Application |
20130014571 |
Kind Code |
A1 |
Quinones; Diego ; et
al. |
January 17, 2013 |
APPARATUS FOR INSPECTING TURBOMACHINE COMPONENTS IN-SITU
Abstract
An apparatus is provided for inspecting a component of a
turbomachine in-situ. The apparatus includes an end effector having
a frame defining a stable platform with a curved surface of the
component, a spring loaded suspension attached to the frame, and a
probe connected to a wedge member, where the probe and wedge member
are connected to the spring loaded suspension. The probe is
configured to inspect the component by passing signals through the
wedge.
Inventors: |
Quinones; Diego; (Rexford,
NY) ; Banowetz; Daniel Lawrence; (Glenville, NY)
; Lewis; Gareth William David; (Lexington, MA) ;
Moldenhauer; Thomas Earnest; (Burnt Hills, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Quinones; Diego
Banowetz; Daniel Lawrence
Lewis; Gareth William David
Moldenhauer; Thomas Earnest |
Rexford
Glenville
Lexington
Burnt Hills |
NY
NY
MA
NY |
US
US
US
US |
|
|
Assignee: |
General Electric Company
|
Family ID: |
46969968 |
Appl. No.: |
13/181803 |
Filed: |
July 13, 2011 |
Current U.S.
Class: |
73/112.05 ;
73/112.01 |
Current CPC
Class: |
G01N 29/265 20130101;
G01N 29/28 20130101; F01D 5/005 20130101; G01N 29/225 20130101;
G01N 2291/2693 20130101 |
Class at
Publication: |
73/112.05 ;
73/112.01 |
International
Class: |
G01M 15/14 20060101
G01M015/14 |
Claims
1. An apparatus adapted for inspecting a component of a
turbomachine, the apparatus comprising: an end effector comprising:
a frame defining a stable platform with a curved surface of the
component; a spring loaded suspension attached to the frame; a
probe connected to a wedge member, the probe and wedge member
connected to the spring loaded suspension; wherein the probe is
configured to inspect the component in-situ by passing signals
through the wedge.
2. The apparatus of claim 1, wherein the probe is an ultrasonic
transducer capable of sending and receiving ultrasonic signals.
3. The apparatus of claim 2, the frame further comprising a
substantially triangular frame having three substantially
cylindrical shells, the substantially cylindrical shells each
having a substantially hemispherical contact point for contacting
the curved surface of the component.
4. The apparatus of claim 3, each of the three substantially
cylindrical shells further comprising: a magnetic element; and a
low friction material located either in or on the substantially
hemispherical contact point; wherein the magnetic element provides
an attractive force to help an operator maintain contact between
the end effector and the component, and the low friction material
facilitates movement of the end effector along the curved surface
of the component.
5. The apparatus of claim 4, wherein the low friction material is
polytetrafluoroethylene (PTFE).
6. The apparatus of claim 2, further comprising: a bendable rod
connected to the end effector; a handle attached to the bendable
rod; and wherein the frame is connected to the bendable rod via a
pivoting connection and a rod coupler.
7. The apparatus of claim 2, the end effector further comprising: a
yoke connected to the spring loaded suspension and the probe and
wedge member, the yoke connected to the wedge member by a pivoting
connection.
8. The apparatus of claim 2, the wedge member further comprising: a
rounded bottom configured to fit the curvature of the component and
to provide an offset so the signals enter the component at a
predetermined angle and distance to an area of interest.
9. The apparatus of claim 2, the end effector further comprising:
an ultrasonic coupling medium supply conduit connected to the wedge
member; wherein the ultrasonic coupling medium supply conduit
supplies an ultrasonic coupling medium, and the wedge member
comprises an ultrasonic coupling medium input connected to the
ultrasonic coupling medium supply conduit and an ultrasonic
coupling medium output to facilitate ultrasonic coupling between
the wedge member and the component.
10. The apparatus of claim 9, wherein the ultrasonic coupling
medium is a gel comprising at least one of, propylene glycol,
glycerin and water.
11. The apparatus of claim 2, wherein the turbomachine is at least
one of a compressor and a gas turbine.
12. The apparatus of claim 11, wherein the turbomachine is the
compressor and the component is at least one of a blade and a
vane.
13. An apparatus adapted for inspecting a component of a
turbomachine, the apparatus comprising: an end effector comprising:
a frame defining a stable platform with a curved surface of the
component; a spring loaded suspension attached to the frame; an
ultrasonic transducer connected to a wedge member, the ultrasonic
transducer capable of sending and receiving ultrasonic signals, the
ultrasonic transducer and wedge member connected to the spring
loaded suspension, the wedge member having a rounded bottom
configured to fit the curvature of the component and to provide an
offset so the signals enter the component at a predetermined angle
and distance to an area of interest; an ultrasonic coupling medium
supply conduit connected to the wedge member, the ultrasonic
coupling medium supply conduit configured to supply an ultrasonic
coupling medium to the wedge member; and wherein the ultrasonic
transducer is configured to inspect the component by passing
signals through the wedge, while the component is inspected
in-situ.
14. The apparatus of claim 13, wherein the wedge member comprises
an ultrasonic coupling medium input connected to the ultrasonic
coupling medium supply conduit and an ultrasonic coupling medium
output to direct the ultrasonic coupling medium to a location
between the wedge member and the component.
15. The apparatus of claim 13, the frame further comprising a
substantially triangular frame having three substantially
cylindrical shells, the substantially cylindrical shells each
having a substantially hemispherical contact point for contacting
the curved surface of the component.
16. The apparatus of claim 15, each of the three substantially
cylindrical shells further comprising: a magnetic element; and a
low friction material located either in or on the substantially
hemispherical contact point; wherein the magnetic element provides
an attractive force to help an operator maintain contact between
the end effector and the component, and the low friction material
facilitates movement of the end effector along the curved surface
of the component.
17. The apparatus of claim 13, further comprising: a bendable rod
connected to the end effector; a handle attached to the bendable
rod; and wherein the frame is connected to the bendable rod via a
pivoting connection and a rod coupler.
18. The apparatus of claim 13, the end effector further comprising:
a yoke connected to the spring loaded suspension and the probe and
wedge member, the yoke connected to the wedge member by a pivoting
connection.
19. The apparatus of claim 13, wherein the turbomachine is at least
one of a compressor and a gas turbine.
20. The apparatus of claim 19, wherein the turbomachine is the
compressor and the component is at least one of a blade and a vane.
Description
BACKGROUND OF THE INVENTION
[0001] The apparatus described herein relates generally to
turbomachines. More specifically, the apparatus relates to
inspecting turbomachine components in-situ.
[0002] Gas turbine compressor blades can get damaged due to
operation. In the event of such damage, timely detection and
replacement of these blades are desirable to prevent airfoil
liberation and subsequent compressor failure. The current practice
for blade inspection requires compressor case removal, which is
inevitably time consuming and expensive. The removal of the
compressor case for inspection of compressor blades also creates
undesirable outage time, thereby resulting in lost income for the
machine owner/operator.
BRIEF DESCRIPTION OF THE INVENTION
[0003] In an aspect of the present invention, an apparatus is
provided for inspecting a component of a turbomachine. The
apparatus includes an end effector having a frame defining a stable
platform with a curved surface of the component, a spring loaded
suspension attached to the frame, and a probe connected to a wedge
member, where the probe and wedge member are connected to the
spring loaded suspension. The probe is configured to inspect the
component in-situ by passing signals through the wedge.
[0004] In another aspect of the present invention, an apparatus is
provided for inspecting a component of a turbomachine. The
apparatus includes an end effector having a frame defining a stable
platform with a curved surface of the component, a spring loaded
suspension attached to the frame, and an ultrasonic transducer
connected to a wedge member. The ultrasonic transducer is capable
of sending and receiving ultrasonic signals. The ultrasonic
transducer and wedge member are connected to the spring loaded
suspension. The wedge member has a rounded bottom configured to fit
the curvature of the component and to provide an offset so the
signals enter the component at a predetermined angle and distance
to an area of interest. An ultrasonic coupling medium supply
conduit is connected to the wedge member, and is configured to
supply an ultrasonic coupling medium to the wedge member. The
ultrasonic transducer is configured to inspect the component by
passing signals through the wedge, while the turbomachine component
is inspected in-situ.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates a partial, cut-away view of a
turbomachine;
[0006] FIG. 2 illustrates a partial perspective view of a
compressor showing the airfoils and vanes;
[0007] FIG. 3 illustrates a schematic diagram of nondestructively
inspecting a component for defects using phased array
ultrasound;
[0008] FIG. 4 illustrates a perspective view of an apparatus that
can be used to inspect turbomachines in-situ, according to an
aspect of the present invention;
[0009] FIG. 5 illustrates a perspective view of the end effector,
according to an aspect of the present invention;
[0010] FIG. 6 illustrates a top view of the end effector, according
to an aspect of the present invention;
[0011] FIG. 7 illustrates a cross-sectional view of the end
effector, according to an aspect of the present invention; and
[0012] FIG. 8 illustrates a partial perspective view of the
compressor airfoils and vanes, with the casing omitted for clarity,
and the apparatus inserted to perform an inspection on an R1 rotor
blade, according to an aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The major challenge in the development of an in-situ blade
inspection method and apparatus is to design a mechanism that can
deliver the inspection tool to the target blade inside the
compressor, due to the stringent spatial constraints imposed by the
tight workspace within the compressor flow path. The delivery
mechanism should be capable of reaching the desired portions of the
target airfoil, blade or vane.
[0014] FIG. 1 illustrates a partial, cut-away view of a
turbomachine 100, which may be a gas turbine compressor. However,
it is to be understood that the present invention can be applied to
any turbomachine, including but not limited to, gas turbines, steam
turbines, compressors, or any machine that transfers energy between
a rotor and a fluid. In compressor 100, half of the compressor bell
mouth 110 is omitted to show the internal vanes and blades. The
bell mouth 110 includes an outer surface 112 and an inner surface
114, and incoming flow passes between these two surfaces.
Typically, a plurality of support members 116 are fastened or
welded to the outer surface 112 and the inner surface 114 for
support. The first stage of stator vanes is called the inlet guide
vanes (IGVs) 120.
[0015] FIG. 2 illustrates a partial perspective view of the
compressor airfoils and vanes, with the casing omitted for clarity.
The stator vanes are generally fixed, while the rotor
airfoils/blades are connected to rotatable rotor 204. The inlet
guide vanes 120 are generally fixed as well, but may pitch around a
radial axis to vary the direction or amount of incoming flow. The
inlet guide vanes 120 are followed by a first row of rotor airfoils
230. The airfoils can also be referred to as the RO airfoils or RO
blades, as they are part of the R0 stage. The stator vanes 240 are
next, and can also be referred to as the S0 vanes, as they are part
of the S0 stage. The next row of rotor airfoils/blades 250 can be
referred to as the R1 airfoils or R1 blades, as they are part of
the R1 stage. The R1 airfoils are followed by the S1 stator vanes
260, as they are part of the S1 stage, and so on.
[0016] It would be desirable if a delivery mechanism could go
through the bell mouth 110 and reach the target blade or vane, as
well as deliver an inspection tool to perform the desired
inspection operation. As one example only, an R1 blade can
experience various types of damage and this blade could be reached
without requiring case removal, according to an aspect of the
present invention.
[0017] Referring to FIG. 3, an aspect of the present invention
solves the problem of gaining access to preform nondestructive
in-situ testing of machine components, such as an airfoil/blade 250
or vane by scanning, rastering or sweeping an ultrasonic beam 312
(phased array ultrasound) to inspect airfoil 250 for defects using
different orientations with one scan. As can be seen in FIG. 3, the
horizontal line 314 of beam 312 represents a sound path normal to
or directly below a transducer probe 316. The vertical line 318 of
beam 312 represents 90 degrees of beam scanning. The cracked
line/defect 320 shown in airfoil 250 indicates a defect in the
airfoil. As can be seen from FIG. 3, defect 320 can only be seen if
the operator using probe 316 is using about a 50.degree. beam angle
relative to the normal beam 314. As the surface 322 where
transducer 316 is in contact with airfoil 250 changes its
orientation, the angle at which beam 312 enters airfoil 250
changes, so that the angle of beam 312 to scan the area of interest
324 in airfoil 250 will change accordingly.
[0018] The phased array transducer probe 316 used with the
apparatus and method of the present invention may be a linear array
probe which is comprised of a series of transducers. Each of these
transducers is triggered at predetermined time intervals and
receives an ultrasound signal back at predetermined time intervals.
This predetermined triggering and receiving is the phasing which
allows the steering of beam 312. The ultrasound signals acquired by
each transducer are then processed by a computer programmed to give
a composite view of the area of interest 324 that is being
examined.
[0019] To inspect a blade 250 from its blade surface 322, the range
of angles which are needed to keep the area of interest 324 in view
must first be determined. A sector scan or sweep is then set up
which is comprised of the angles required for inspection of the
area of interest. During inspection, the entire area of interest
324 can be monitored without interruption of the test. Also, by
using an ultrasonic phased array sector scan, parts in a machine
with limited access, such as airfoils, can be readily inspected
without disassembling the machine containing the airfoil. This is
because the inspection method of the present invention does not
require complete disassembly of the machine to access all areas of
interest by physical means. By using a phased array beam, an
operator can see all beam angles of interest in one scan. This
allows for a more comprehensive view of the inspection area 324 and
reduces the test variation.
[0020] FIG. 4 illustrates a perspective view of an apparatus 400
that can be used to inspect turbomachines (e.g., compressors)
in-situ, according to an aspect of the present invention. The
apparatus 400 includes a handle 410 that is connected to a tube or
rod 420. Preferably, the rod (or tube) 420 is at least partially
bendable or malleable, so that it may be bent into a suitable or
desired shape to fit around (and avoid contact with) the blades and
vanes in the compressor stages. The tube 420 is connected to an end
effector 430 that contains a transducer probe. The handle 410 may
include a rounded bottom 412 into which one end of the tube 420 may
be inserted and secured. For example, a set screw (not shown) may
pass through the rounded bottom and/or the tube 420 to secure the
handle 410 to the tube. The handle 410 is manipulated by an
operator to maneuver the apparatus through the various stages of
vanes and blades of the compressor.
[0021] FIG. 5 illustrates a perspective view of the end effector
430, according to an aspect of the present invention. The end
effector includes a frame 510 that has a substantially triangular
shape, and this frame 510 defines a stable platform with a curved
surface of the compressor blade or vane. The frame 510 also
includes three cylindrical shells 512 that hold magnets 514, and
low friction contact points 516 made of a low friction material or
including a low friction coating. The magnets 514 (or magnetic
elements) provide an attractive force between the end effector 430
and the compressor blade, and this attractive force helps an
operator maintain contact between the end effector and blade during
an inspection procedure. The low friction coating or low friction
material may be formed of polytetrafluoroethylene (PTFE) or any
other suitable low friction material that reduces friction and
facilitates movement of the end effector 430 along the curved
surface of the compressor blade or vane.
[0022] The end effector 430 is connected to the rod 420 via a rod
coupler 520. One end of the rod 420 may be held in the rod coupler
by a compression fitting, a set screw or any other suitable
retaining means. The end effector 430 also includes a spring loaded
suspension attached to the frame 510. The spring loaded suspension
includes the yoke 540, springs 542 and screws 544. The spring
loaded suspension provides pitch and roll motion to the probe 530
and wedge member 535 so that it can keep constant and uniform
contact with the compressor blade during the scanning of areas or
interest for inspection and provides a force to press a yoke 540
toward the blade. The wedge member 535 may be mounted to the yoke
540 via two screws 541 that act as a pivot joint for the wedge
member 535. This pivot joint is positioned such that the load from
the spring loaded suspension system is directed in line with a
region of the wedge member 535 that must be in intimate contact
with the blade. This suspension system forces the wedge to be
firmly and squarely pressed against the blade even as the frame is
slid along the width of the blade and the curvature changes below
the wedge member.
[0023] The wedge member 535, may be formed of a material that
permits transmission of ultrasonic signals, such as poly(methyl
methacrylate) (PMMA) or cross-linked polystyrene, and has a rounded
bottom 536 to fit the curvature of the blade against the platform
and provide a suitable offset to have non-destructive test (NDT)
signals (e.g., ultrasonic signals) enter the component or blade at
a suitable angle and distance to the areas to be inspected. The
wedge member 535 may also be connected to an ultrasonic coupling
medium conduit 550 that may be routed back along rod 420 to a
source of ultrasonic coupling medium (not shown). The wedge member
535 may have an ultrasonic coupling medium input (not shown)
connected to the ultrasonic coupling medium supply conduit 550 and
one or more ultrasonic coupling medium outputs 538. The ultrasonic
coupling medium is used to couple ultrasonically the airfoil 250
and the wedge 535. Any suitable ultrasonic coupling medium or gel
may be used, and as only one non-limiting example, the ultrasonic
coupling medium may be a gel comprised of one or more of propylene
glycol, glycerin and water.
[0024] FIG. 6 illustrates a top view of the end effector 430,
according to an aspect of the present invention. The end effector
430 is connected to the rod coupler via a pivot joint 610. The
pivot joint 610 allows the end effector to pivot up or down in the
plane of the drawing (as illustrated by the curved arrow). The
spring loaded suspension allows the yoke to move as well. For
example, the top of the yoke 540 may move left while the bottom of
the yoke 540 may move to the right, in the plane of the
drawing.
[0025] FIG. 7 illustrates a cross-sectional view of the end
effector 430, according to an aspect of the present invention. The
substantially cylindrical shells 512 may have magnets 514 secured
by set screws 710. The set screws may 710 also be used to hold the
low friction contact points 516 in place as well. The set screws
may be externally threaded, and these external threads can mate
with internal threads on the interior walls of cylindrical shells
512. The offset distance 720 causes the spring loaded suspension to
provide a downward force against the base of the blade and forces
the wedge to rotate downward. The pivot joint 610 may be comprised
of a shoulder screw 730 that passes through a portion of frame 510
and a tang of rod coupler 520.
[0026] FIG. 8 illustrates a partial perspective view of the
compressor airfoils and vanes, with the casing omitted for clarity,
and the apparatus 400 inserted to perform an inspection on an R1
rotor blade, according to an aspect of the present invention. The
end effector 430 is attached to the bendable rod 420 via the pivot
joint 610 and this pivot allows the single degree of freedom
necessary to keep the three points (defined by the end of the
cylindrical shells/low friction points) in contact with the blade
as an operator slides the apparatus 400 back and forth along the
base of the blade as the inspection is taking place. The bendable
rod 420 allows the operator to maneuver the mechanism into the
compressor and place it on the blade with the aid of the magnetic
attraction (via magnets 514). The pre-formed shape of rod 420 may
be specifically designed so the operator can provide control
motions to the end effector 430 to cover all the areas of interest
without contacting the various blades/vanes between the operator
and the blade being inspected. The bendable rod 420 is maneuvered
with the aid of handle 410 with rounded bottom 412 to allow free
rotation of the apparatus 400 and end effector 430 as the geometry
of the area to be inspected changes along the platform of the
blade.
[0027] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *