U.S. patent application number 15/030236 was filed with the patent office on 2016-09-01 for method and assembly for inspecting engine component.
The applicant listed for this patent is UNITED TECHNOLOGIES CORPORATION. Invention is credited to James M. Koonankeil.
Application Number | 20160252420 15/030236 |
Document ID | / |
Family ID | 52828723 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160252420 |
Kind Code |
A1 |
Koonankeil; James M. |
September 1, 2016 |
METHOD AND ASSEMBLY FOR INSPECTING ENGINE COMPONENT
Abstract
One exemplary embodiment of this disclosure relates to a method
of inspecting a component of a gas turbine engine. The method
includes performing a through-hole inspection, and determining a
location of the plurality of holes from results of the through-hole
inspection.
Inventors: |
Koonankeil; James M.;
(Malborough, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED TECHNOLOGIES CORPORATION |
Farmington |
CT |
US |
|
|
Family ID: |
52828723 |
Appl. No.: |
15/030236 |
Filed: |
October 17, 2014 |
PCT Filed: |
October 17, 2014 |
PCT NO: |
PCT/US2014/061064 |
371 Date: |
April 18, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61892541 |
Oct 18, 2013 |
|
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|
Current U.S.
Class: |
73/37 |
Current CPC
Class: |
F05D 2270/8041 20130101;
G01M 3/025 20130101; G01K 13/02 20130101; G01N 21/95692 20130101;
F01D 5/186 20130101; G01N 21/954 20130101; F01D 21/003 20130101;
F05D 2260/80 20130101; G01M 15/14 20130101; G01N 21/8806
20130101 |
International
Class: |
G01M 3/02 20060101
G01M003/02; G01K 13/02 20060101 G01K013/02; G01M 15/14 20060101
G01M015/14 |
Claims
1. A method of inspecting a component of a gas turbine engine,
comprising: performing a through-hole inspection; and determining a
location of the plurality of holes from results of the through-hole
inspection.
2. The method as recited in claim 1, wherein the through-hole
inspection includes a flow thermography process.
3. The method as recited in claim 2, wherein the flow thermography
process includes providing a flow of fluid within the component and
taking a thermal image of the plurality of holes as the fluid exits
the plurality of holes.
4. The method as recited in claim 3, wherein taking the thermal
image includes taking a thermal video of the fluid exiting the
plurality of holes.
5. The method as recited in claim 1, wherein the results of the
through-hole inspection include a plurality pixels, and wherein a
blockage is identified when a number of pixels within an acceptable
hole location is below a minimum threshold.
6. The method as recited in claim 5, wherein a hole is determined
to not be blocked if a number of pixels is greater than or equal to
a minimum threshold within the acceptable hole location.
7. The method as recited in claim 1, wherein a misaligned hole is
identified if the determined hole location is outside an acceptable
hole location.
8. The method as recited in claim 7, wherein the results of the
through-hole inspection include a plurality of sets of pixels, each
of the sets of pixels corresponding to one of the plurality of
holes.
9. The method as recited in claim 8, wherein the determined
location of each of the plurality of holes is a centroid of a
corresponding one of the plurality of sets of pixels.
10. The method as recited in claim 8, wherein the determined
location of each of the plurality of holes is a pixel on a
perimeter of a corresponding one of the plurality of sets of
pixels.
11. The method as recited in claim 7, wherein the determined
location of the plurality of holes is expressed relative to
secondary datums.
12. The method as recited in claim 11, wherein the determined
location of the plurality of holes is translated from being
expressed in terms of secondary datums to being expressed in terms
of primary datums.
13. The method as recited in claim 12, wherein the component is an
airfoil including an airfoil section and a root, the secondary
datums located on the root, and the primary datums located on the
airfoil section.
14. An inspection assembly, comprising: a thermal imaging camera; a
fixture for supporting an engine component; a fluid source in
communication with a passageway of the engine component; and a
controller configured to perform a through-hole inspection on the
component, and configured to determine a location of the plurality
of holes from results of the through-hole inspection.
15. The assembly as recited in claim 14, including a conduit
connecting the fluid source to the passageway.
16. The assembly as recited in claim 14, wherein the controller is
configured to identify blocked and partially blocked holes by
comparing a number of pixels within an acceptable hole location
with a minimum threshold.
17. The assembly as recited in claim 14, wherein the controller
compares the determined hole locations for each of the plurality of
holes with acceptable hole locations to identify misaligned
holes.
18. The assembly as recited in claim 14, wherein the controller is
in communication with a model, the model including a minimum pixel
threshold and acceptable hole locations.
19. The assembly as recited in claim 14, wherein the fixture
supports the engine component at a root of the engine component.
Description
BACKGROUND
[0001] Gas turbine engine components, such as rotor blades and
stator vanes, include core cooling passageways configured to
communicate fluid within the component. These core passageways are
in communication with cooling holes, which direct fluid toward an
outer surface of the component. Components are often inspected to
determine whether the cooling holes have been properly
machined.
[0002] In one known inspection method, a component is placed in a
first assembly where the component is visually inspected (e.g.,
using a camera) to determine the location of the cooling holes
relative to an acceptable location for those holes. In a separate
assembly, the component undergoes a through-hole (or thru-hole)
inspection to determine whether the cooling holes are blocked.
SUMMARY
[0003] One exemplary embodiment of this disclosure relates to a
method of inspecting a component of a gas turbine engine. The
method includes performing a through-hole inspection, and
determining a location of the plurality of holes from results of
the through-hole inspection.
[0004] In a further embodiment of any of the above, the
through-hole inspection includes a flow thermography process.
[0005] In a further embodiment of any of the above, the flow
thermography process includes providing a flow of fluid within the
component and taking a thermal image of the plurality of holes as
the fluid exits the plurality of holes.
[0006] In a further embodiment of any of the above, the step of
taking the thermal image includes taking a thermal video of the
fluid exiting the plurality of holes.
[0007] In a further embodiment of any of the above, the results of
the through-hole inspection include a plurality pixels, and wherein
a blockage is identified when a number of pixels within an
acceptable hole location is below a minimum threshold.
[0008] In a further embodiment of any of the above, a hole is
determined to not be blocked if a number of pixels is greater than
or equal to a minimum threshold within the acceptable hole
location.
[0009] In a further embodiment of any of the above, a misaligned
hole is identified if the determined hole location is outside an
acceptable hole location.
[0010] In a further embodiment of any of the above, the results of
the through-hole inspection include a plurality of sets of pixels,
each of the sets of pixels corresponding to one of the plurality of
holes.
[0011] In a further embodiment of any of the above, the determined
location of each of the plurality of holes is a centroid of a
corresponding one of the plurality of sets of pixels.
[0012] In a further embodiment of any of the above, the determined
location of each of the plurality of holes is a pixel on a
perimeter of a corresponding one of the plurality of sets of
pixels.
[0013] In a further embodiment of any of the above, the determined
location of the plurality of holes is expressed relative to
secondary datums.
[0014] In a further embodiment of any of the above, the determined
location of the plurality of holes is translated from being
expressed in terms of secondary datums to being expressed in terms
of primary datums.
[0015] In a further embodiment of any of the above, the component
is an airfoil including an airfoil section and a root, the
secondary datums located on the root, and the primary datums
located on the airfoil section.
[0016] Another exemplary embodiment of this disclosure relates to
an inspection assembly. The assembly includes a thermal imaging
camera, a fixture for supporting an engine component a fluid source
in communication with a passageway of the engine component, and a
controller. The controller is configured to perform a through-hole
inspection on the component, and is further configured to determine
a location of the plurality of holes from results of the
through-hole inspection.
[0017] In a further embodiment of any of the above, the assembly
includes a conduit connecting the fluid source to the
passageway.
[0018] In a further embodiment of any of the above, the controller
is configured to identify blocked and partially blocked holes by
comparing a number of pixels within an acceptable hole location
with a minimum threshold.
[0019] In a further embodiment of any of the above, the controller
compares the determined hole locations for each of the plurality of
holes with acceptable hole locations to identify misaligned
holes.
[0020] In a further embodiment of any of the above, the controller
is in communication with a model, the model including a minimum
pixel threshold and acceptable hole locations.
[0021] In a further embodiment of any of the above, the fixture
supports the engine component at a root of the engine
component.
[0022] The embodiments, examples and alternatives of the preceding
paragraphs, the claims, or the following description and drawings,
including any of their various aspects or respective individual
features, may be taken independently or in any combination.
Features described in connection with one embodiment are applicable
to all embodiments, unless such features are incompatible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings can be briefly described as follows:
[0024] FIG. 1 schematically illustrates an example inspection
assembly according to this disclosure.
[0025] FIG. 2 is a flow chart illustrating an example method
according to this disclosure.
[0026] FIG. 3 illustrates a portion of the component of FIG. 1.
[0027] FIG. 4 illustrates an example inspection result, relative to
the portion of the component illustrated in FIG. 3.
DETAILED DESCRIPTION
[0028] FIG. 1 schematically illustrates an example inspection
assembly 10 for inspecting an engine component 12. It should be
understood that this disclosure is not limited to the details of
the illustrated inspection assembly 10, and otherwise extends to
other inspection assemblies. Further, while the engine component 12
illustrated herein as a turbine blade, it should be understood that
this disclosure extends to other engine components, such as stator
vanes, blade outer air seals (BOAS), combustor liners, and
augmentor liners, as examples.
[0029] The inspection assembly 10 includes a computer 14 in
communication with a controller 16 capable of receiving inputs,
such as from the keyboard 18, and displaying an output in one
example via a display, or monitor, 20. In one example, the
controller 16 includes a microprocessor capable of executing
instructions in accordance with the functionality described
herein.
[0030] In this example, the controller 16 is in communication with
a fluid source 22, which is in fluid communication with the engine
component 12, as will be discussed below. The controller 16 is
further in communication with a camera 24. In one example, the
camera 24 is a thermal infrared (IR) camera used to determine the
temperature of an object by detecting radiation and producing a
still image, or alternatively a video, of that radiation. In this
sense, the assembly 10 provides a flow thermography system. The
controller 16 is further in communication with a model 26, which
may include information such as an acceptable cooling hole
location, a minimum pixel threshold for determining an acceptable
hole size, etc., as will be appreciated from the below.
[0031] In the example where the engine component 12 is a rotor
blade, the engine component 12 includes a root 28, a platform 30,
and an airfoil section 32. The airfoil section 32 extends radially
(e.g., in the radial direction Z) from the platform 30 to a blade
tip 34. The airfoil section 32 includes a pressure side wall 36 and
a suction side wall 38, each of which extend between a leading edge
40, and a trailing edge 42 of the airfoil section 32.
[0032] A plurality of core cooling passageways 44, 46 extend
radially from the root 28 to the blade tip 34. Here, two core
cooling passageways 44, 46 are illustrated. As is known in the art,
these core cooling passageways 44, 46 may be in communication with
a plurality of cooling holes leading from the core cooling
passageways 44, 46 to an outer surface of the airfoil section 32. A
plurality of cooling holes are illustrated in FIG. 3, which will be
discussed in detail below. While core cooling passageways 44, 46
are illustrated, this disclosure extends to platform cooling holes
that may not be in communication with a core cooling
passageway.
[0033] The fluid source 22 is in communication with each of the
core passageways 44, 46 by way of a conduit 48. Upon instruction
from the controller 16, fluid F from the fluid source 22 is
configured to be directed along the core passageways 44, 46. As the
fluid F flows along the core passageways 44, 46, a portion of that
fluid F is directed out the plurality of cooling holes and flows
adjacent the outer surface of the airfoil section 32.
[0034] The camera 24 is configured to generate an image of the
fluid F as it exits these cooling passageways. This image may then
be used to conduct a through-hole inspection, which in turn may be
used to determine the location of the cooling holes.
[0035] A flow chart illustrating an example method according to
this disclosure is provided in FIG. 2. The method according to this
disclosure includes performing a through-hole inspection 50,
determining a location of the plurality of holes machined in the
component 12 based on the results from the through-hole inspection,
at 52, and identifying blocked, partially blocked, and misaligned
cooling holes, at 53.
[0036] In one example of this disclosure, a through-hole
inspection, at 50, is performed using a flow thermography process.
In this process, a flow of fluid F is introduced into the component
12, at 54. FIG. 3 illustrates a portion of the airfoil section 32
of the component 12. The airfoil section 32, as mentioned above,
has been machined to include a plurality of cooling holes 56.
[0037] The cooling holes 56 are intended to communicate fluid F
from one of the core passageways 44, 46 to an outer surface of the
airfoil section 32. Acceptable cooling hole locations 58 are
illustrated herein for purposes of explanation. The acceptable
locations 58 may be provided from engineering specifications and
stored in the model 26.
[0038] In some instances, the cooling holes 56 are not machined
within the acceptable location 58, resulting in a misaligned hole,
illustrated at 56M, wherein the misaligned hole 56M falls outside
the acceptable hole location 58.
[0039] In other instances, the hole may be blocked, or not drilled
at all, as illustrated at 56B. Blocked holes 56B do not communicate
any fluid F from the core passageways 44, 46 to the outer surface
of the airfoil section 32. Further, a hole may be partially
blocked, as illustrated at 56P, in which case the flow of fluid F
communicated between the core passageways 44, 46 and the outer
surface of the airfoil section 32 is insufficient.
[0040] As fluid F flows through the holes 56, the camera 24
provides a thermal image of the cooling holes 56, at 60. FIG. 4
illustrates an example thermal image of the cooling holes of FIG.
3. The image, which may be displayed on the screen 20, is a
plurality of sets 62 of pixels P. In one example, the pixels P are
of a particular color that corresponds to the known temperature of
the fluid F.
[0041] In the bottom left-hand corner of FIG. 4, a first set of
pixels P indicates that the cooling hole 64 is acceptable. In this
example, the pixel count within the acceptable hole location 58 is
greater than or equal to a minimum threshold. The minimum threshold
is a predetermined value known to correspond to a cooling hole that
provides adequate cooling. The minimum threshold may be stored in
the model 26. When the pixel count is below the minimum threshold,
a partially blocked hole, such as the partially blocked hole 66,
will be identified, at 53. Where no pixels are shown within an
expected location 58, a blocked hole, such as the blocked hole 68,
will be identified (again, at 53).
[0042] From the results of the through-hole inspection (e.g., the
image illustrated in FIG. 4), the location of the cooling holes 56
can be determined, at 52. In one example, the location of the
cooling holes 56 is determined first by analyzing the sets of
pixels 62 from the results of the through-hole inspection, at 72.
In a first example, the centroid 62C of the set of pixels 62 is
reported as the determined cooling hole location. In another
instance, a location on the perimeter, 62P of the set of pixels 62
is reported as the identified cooling hole location. While the
centroid 62C may sufficiently indicate the cooling hole location, a
point at the perimeter of the set of pixels 62 may be more
representative of the center of the cooling hole 56, due to the
possibility that the flow of the fluid F may immediately move away
from the cooling holes 56 upon exiting the cooling holes 56.
[0043] At any rate, at 74, the cooling hole location is initially
expressed, at 74, relative to secondary datums 76 located on the
root section 28 of the component 12. For instance, during the
through-hole inspection discussed above, the component 12 may be
supported by its root section, by way a fixture 78. The locations
where the fixture 78 interfaces with the root 28 are referred to as
secondary datums 76. In examples where this disclosure is used
relative to a stator vane, the secondary datums 76 would be
adjacent an inner and/or outer platform.
[0044] These locations are then translated, at 80, to be expressed
in terms of primary datums. As is known in this art, primary datums
are points where a component is typically supported during
machining. Engineering specifications, which include the acceptable
cooling hole locations, are typically provided with reference to
these primary datums. Example primary datums 82A-82D are
illustrated at the leading edge 40 of the airfoil section 32
adjacent the platform (82A), at the leading edge of the airfoil
section adjacent the blade tip 34 (82B), at the upper surface of
the platform 30 (82C), and at the trailing edge 42 (82D).
[0045] At 53, the location of the cooling holes is compared with
the engineering specifications to identify misaligned holes, such
as the misaligned hole 56M, which is identified as a misaligned
hole, at 70 in FIG. 4, because the centroid 70C is located outside
the acceptable hole location 58. Alternatively, if a perimeter is
used to report the cooling hole locations, a misaligned hole may
still be identified because at least some perimeter pixels 70P lie
outside the acceptable hole location 58.
[0046] As known in the art, depending on the defects identified at
53, corrective measures, such as further manufacturing, can be
undertaken to correct the defective cooling holes (such as the 56P,
56 M, and 56B).
[0047] It is possible to mount the component 12 relative to the
primary datums 84A-84D during the initial inspection, however, this
mounting may interfere with the flow of fluid F exiting the cooling
holes 56, which may negatively impact the results of the
through-hole inspection. Alternatively, it may be possible to probe
the component 12 relative to the primary datums 84A-84D, such that
the through-hole inspection would be reported relative to the
primary datums in the first instance. However, probing adds time to
the inspection process.
[0048] Accordingly, this disclosure provides a method and assembly
for inspecting a component without multiple inspection steps, and
therefore increases the overall efficiency of the inspection
process.
[0049] Although the different examples have the specific components
shown in the illustrations, embodiments of this disclosure are not
limited to those particular combinations. It is possible to use
some of the components or features from one of the examples in
combination with features or components from another one of the
examples.
[0050] One of ordinary skill in this art would understand that the
above-described embodiments are exemplary and non-limiting. That
is, modifications of this disclosure would come within the scope of
the claims. Accordingly, the following claims should be studied to
determine their true scope and content.
* * * * *