Claims:1. A device (102) comprising:
an articulation assembly (128) comprising:
a tubular structure (150) comprising an aperture at a distal end (132) and a first connector (134, 504) on an outer surface;
a focus unit (136) disposed within the tubular structure (150) at the distal end (132); and
a fixture (130) comprising a channel (602) and a second connector (614) disposed on an inner surface of the channel (602) , wherein the channel (602) is configured to receive the articulation assembly (128) and guide at least a portion of the articulation assembly (128) comprising the focus unit (136) to pass through the fixture (130), and wherein the second connector (614) is configured to inter-lock with the first connector (134, 504) of the tubular structure (150) so as to position the focus unit (136) at a predetermined location.

2. The device (102) of claim 1, wherein the tubular structure (150) further comprises a guide tube (216) and a pivot tube (218) operatively coupled to each other, wherein the pivot tube (218) comprises one or more parts operatively coupled to each other and movable at a predefined angle with respect to the guide tube (216).

3. The device (102) of claim 2, wherein the focus unit (136) is disposed within the pivot tube (218), wherein the focus unit (136) comprises a data capture sub-unit (404) configured to acquire inspection data comprising at least one of consistent images, ultrasound signals, eddy current signals, and microwave signals of at least a portion of a component under inspection positioned within a casing, and transmit the acquired inspection data to a processing unit (138).

4. The device (102) of claim 3, wherein the guide tube (216) comprises a guide path (502) having the first connector (134, 504).

5. The device (102) of claim 4, wherein the fixture (130) further comprises:
a locating unit (802, 1008) configured to couple to a port of the casing, wherein the locating unit (802, 1008) comprises a third connector (1300) on an inner surface of the locating unit (802, 1008); and
a guiding unit (804, 1010) operatively coupled to the locating unit (802, 1008) and configured to position the focus unit (136) at a predetermined height and a predetermined angle within the casing.

6. The device (102) of claim 5, wherein the guiding unit (804, 1010) comprises:
a clamping element (1602) comprising a first sub-channel (1610) and configured to secure the locating unit (802, 1008) to the port of the casing; and
an orientation knob (1604) coupled to the locating unit (802, 1008), wherein the orientation knob (1604) comprises a second sub-channel (1612) aligned with the first sub-channel (1610) to form the channel of the fixture (130), wherein the first sub-channel (1610) and the second sub-channel (1612) are configured to allow the guide tube (216) and the pivot tube (218) to slide through the guiding unit (804, 1010).

7. The device (102) of claim 6, wherein the orientation knob (1604) comprises the second connector (614) coupled to the second sub-channel (1612) and configured to secure to the first connector (134, 504) of the guide tube (216) when the guide tube (216) slides through the second sub-channel (1612).

8. The device (102) of claim 7, wherein the second connector (614) is configured to secure to the first connector (134, 504) of the guide tube (216) to position the focus unit (136) at the predetermined height from the casing.

9. The device (102) of claim 8, wherein the orientation knob (1604) comprises a fourth connector (1706) on an outer surface, wherein the orientation knob (1604) is configured to secure to the third connector (1300) of the locating unit (802, 1008) when the orientation knob (1604) is rotated.

10. The device (102) of claim 9, wherein the fourth connector (1706) is configured to secure to the third connector (1300) of the locating unit (802, 1008) to position the focus unit (136) at the predetermined angle within the casing.

11. The device (102) of claim 5, wherein the guiding unit (804, 1010) comprises an offset knob coupled to the locating unit (802, 1008) and configured to allow the articulation assembly (128) to pass through the port offset with another port of the casing.

12. A method comprising:
coupling a fixture (130) to a port of a casing;
receiving, by a channel (602) in the fixture (130), an articulation assembly (128), wherein the articulation assembly (128) comprises a tubular structure (150) comprising an aperture at a distal end and a first connector (134, 504) on an outer surface, and a focus unit (136) positioned within the tubular structure (150) at the distal end;
guiding, by the channel (602) of the fixture (130), the articulation assembly (128) to pass through the port of the casing; and
securing a second connector (614) disposed on an inner surface of the channel of the fixture (130) to the first connector (134, 504) to position the focus unit (136) at a predetermined location within the casing.

13. The method of claim 12, wherein coupling the fixture (130) to the port of the casing comprises:
coupling a locating unit (802, 1008) of the fixture (130) to the port of the casing, wherein the locating unit (802, 1008) comprises a third connector (1300) on an inner surface of the locating unit (802, 1008); and
operatively coupling a guiding unit (804, 1010) of the fixture (130) to the locating unit (802, 1008) to position the focus unit (136) at a predetermined height and a predetermined angle within the casing.

14. The method of claim 13, wherein operatively coupling the guiding unit (804, 1010) of the fixture (130) to the locating unit (802, 1008) comprises:
securing, by a clamping element (1602) of the guiding unit (804, 1010), the locating unit (802, 1008) to the port of the casing, wherein the clamping element (1602) comprises a first sub-channel (1610); and
coupling an orientation knob (1604) of the guiding unit (804, 1010) to the locating unit (802, 1008), wherein the orientation knob (1604) comprises a second sub-channel (1612) aligned with the first sub-channel (1610) to form the channel of the fixture (130).

15. The method of claim 14, wherein coupling the orientation knob (1604) of the guiding unit (804, 1010) to the locating unit (802, 1008) comprises securing the second connector (614) to the first connector (134, 504) of a guide tube (216) when the guide tube (216) slides through the second sub-channel (1612) to position the focus unit (136) at the predetermined height within the casing, wherein the second connector (614) is coupled to the second sub-channel (1612).

16. The method of claim 15, wherein coupling the orientation knob (1604) of the guiding unit (804, 1010) to the locating unit (802, 1008) comprises securing a fourth connector (1706) of the orientation knob (1604) to a third connector (1300) on the locating unit (802, 1008) when the orientation knob (1604) is rotated to position the focus unit (136) at the predetermined angle within the casing.

17. The method of claim 15, further comprising moving a pivot tube (218) of the articulation assembly (128) at a predefined angle with respect to the guide tube (216) of the articulation assembly (128).

18. The method of claim 12, wherein the focus unit (136) is positioned at the predetermined location within the casing to acquire inspection data of a component disposed in a confined space within the casing, wherein the inspection data comprises at least one of consistent images, ultrasound signals, eddy current signals, microwave signals of at least a portion of the component.

19. A system comprising:
a first positioning device (2102) configured to couple to a first port of a plurality of ports of a casing having at least one component disposed in a confined space, wherein the first positioning device (2102) comprises:
a first articulation assembly (2110) comprising a first focus unit (2112); and
a first fixture (2114) configured to guide the first articulation assembly (2110) to pass through the first port of the casing and position the first focus unit (2112) at a first location within the casing; and
a second positioning device (2104) configured to couple to a second port of the plurality of ports, wherein the second positioning device (2104) comprises:
a second articulation assembly (2120) comprising a second focus unit (2122); and
a second fixture (2124) configured to guide the second articulation assembly (2120) to pass through the second port of the casing and position the second focus unit (2122) at a second location within the casing.

20. The system of claim 19, wherein the first fixture (2114) is configured to position the first focus unit (2112) at the first location during each of a plurality of focus cycles, and wherein the first focus unit (2112) is configured to acquire first inspection data comprising at least one of consistent images, ultrasound signals, eddy current signals, microwave signals associated with a first side of the at least one component during each of the plurality of focus cycles.

21. The system of claim 19, wherein the second fixture (2124) is configured to position the second focus unit (2122) at the second location during each of the plurality of focus cycles, and wherein the second focus unit (2122) is configured to acquire second inspection data comprising at least one of consistent images, ultrasound signals, eddy current signals, microwave signals associated with a second side of the at least one component during each of the plurality of focus cycles.
, Description:[0001] Embodiments of the present invention relate generally to a positioning device and more particularly to positioning a focus unit in a gas turbine engine for inspecting a component in the gas turbine engine.
[0002] Typically, a gas turbine engine includes components, such as turbine blades that are disposed in a confined space within a casing. Such components are inspected periodically to assess distress and structural integrity of the components. In one example, the turbine blade may be coated with thermal barrier coatings (TBCs) for protecting the blade from elevated operating temperatures within the gas turbine engine. However, the TBCs are subjected to degradation during service life. As a consequence, the blades may be affected/distressed. Hence, the blades need to be inspected periodically to assess the integrity of the coating and distress level of the blades.
[0003] In a conventional system, the blades may be partially disassembled from the gas turbine engine and each of the blades is visually inspected. However, such a technique is labor intensive and time consuming. Also, since the defects of the blades are measured manually, uncorroborated results may be produced.
[0004] In another conventional system, a borescope inspection (BSI) kit is used for inspecting the blades. In particular, the BSI kit includes a cable coupled to a joy stick. The cable is inserted through a port of the casing. Further, an operator uses the joy stick to maneuver the cable to a particular location in the casing to capture images of the blades. However, a skilled operator is required to maneuver the cable to the same location during each of the inspection cycles to capture consistent images of the blades. Otherwise, inconsistent images of the blades may be acquired. Consequently, faults or distress in the blades may have to be determined manually which requires significant time and efforts. Moreover, in some instances, it will be difficult to get consistent images of the blades even with the skilled operator.
[0005] Therefore, there is a need for an improved system and method for inspecting a component.
BRIEF DESCRIPTION
[0006] In accordance with one embodiment of the present invention a positioning device is presented. The positioning device includes an articulation assembly including a tubular structure including an aperture at a distal end and a first connector on an outer surface. Also, the articulation assembly includes a focus unit disposed within the tubular structure at the distal end. Further, the positioning device includes a fixture including a channel and a second connector disposed on an inner surface of the channel, wherein the channel is configured to receive the articulation assembly and guide at least a portion of the articulation assembly including the focus unit to pass through the fixture, and wherein the second connector is configured to inter-lock with the first connector of the tubular structure so as to position the focus unit at a predetermined location.
[0007] In accordance with another embodiment of the present invention a method for positioning a focus unit is presented. The method includes coupling a fixture to a port of a casing. Also, the method includes receiving, by a channel in the fixture, an articulation assembly, wherein the articulation assembly comprises a tubular structure comprising an aperture at a distal end and a first connector on an outer surface, and a focus unit positioned within the tubular structure at the distal end. Further, the method includes guiding, by the channel of the fixture, the articulation assembly to pass through the port of the casing. In addition, the method includes securing a second connector disposed on an inner surface of a channel of the fixture to the first connector to position the focus unit at a predetermined location within the casing.
[0008] In accordance with yet another embodiment of the present invention a system is presented. The system includes a first positioning device configured to couple to a first port of a plurality of ports of a casing having at least one component disposed in a confined space, wherein the first positioning device includes a first articulation assembly including a first focus unit, and a first fixture configured to guide the first articulation assembly to pass through the first port of the casing and position the first focus unit at a first location within the casing. Further, the system includes a second positioning device configured to couple to a second port of the plurality of ports, wherein the second positioning device includes a second articulation assembly including a second focus unit, and a second fixture configured to guide the second articulation assembly to pass through the second port of the casing and position the second focus unit at a second location within the casing.
DRAWINGS
[0009] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0010] FIG. 1 is a block diagram of a turbine system including a positioning device in accordance with an embodiment of the present invention;
[0011] FIGs. 2 and 3 are diagrammatical representation of a portion of a turbine having a positioning device in accordance with an embodiment of the present invention;
[0012] FIG. 4 is a diagrammatical representation of a pivot tube used in a positioning device in accordance with an embodiment of the present invention;
[0013] FIG. 5 is a diagrammatical representation of a guide tube used in a positioning device in accordance with an embodiment of the present invention;
[0014] FIGs. 6 and 7 depict different perspective views of a fixture used in a positioning device in accordance with an embodiment of the present invention;
[0015] FIG. 8 is a perspective view of a locating unit of a fixture in accordance with an embodiment of the present invention;
[0016] FIG. 9 is a perspective view of a guiding unit of a fixture in accordance with an embodiment of the present invention;
[0017] FIGs. 10-12 are different perspective views of a portion of a turbine having a positioning device in accordance with another embodiment of the present invention;
[0018] FIGs. 13-15 depict different perspective views of a locating unit of a fixture, in accordance with an embodiment of the present invention;
[0019] FIG. 16 is a perspective view of a portion of a fixture in accordance with an embodiment of the present invention;
[0020] FIGs. 17-18 depict different perspective views of an orientation knob of a fixture in accordance with an embodiment of the present invention;
[0021] FIG. 19 is a side view of an orientation knob of a fixture in accordance with an embodiment of the present invention; and
[0022] FIG. 20 is a flow chart illustrating a method for positioning a focus unit in a turbine in accordance with aspects of the present invention.
DETAILED DESCRIPTION
[0023] As will be described in detail hereinafter, various embodiments of a system and a method for positioning a focus unit in a gas turbine engine are disclosed. The focus unit aids in inspecting one of more components of the gas turbine engine. In particular, embodiments of the system and the method discloses a positioning device that is used to position the focus unit, such as a data capture sub-unit at a desired location within the gas turbine engine. As a result, the data capture sub-unit may acquire consistent images of the component. Also, distress in the component may be automatically determined using these consistent images. Further, the data capture sub-unit may acquire consistent images of the component during each inspection cycle, which in turn aids in evaluating a progression of the distress in the component.
[0024] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this specification belongs. The terms “first”, “second”, and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The use of terms “including,” “comprising” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. When introducing elements of various embodiments disclosed herein, the articles “a,” “an,” “the,” and “said” are intended to mean that there can be one or more elements.
[0025] Turning now to the drawings, FIG. 1 is a block diagram of a turbine system 100 having a positioning device 102 in accordance with an embodiment of the present invention. The positioning device 102 is configured to acquire consistent data of a component in the turbine system 100. The consistent data is referred to as the data that is associated with the same portion of the component in each of a plurality of inspection cycles. The consistent data may be further used to inspect the component. It may be noted that the positioning device 102 may be used in other systems and is not limited to the turbine system 100.
[0026] In the illustrated embodiment, the turbine system 100 includes an inlet unit 104, a compressor 106, a fuel injector 108, a combustor 110, a turbine 112, a shaft 114, and an exhaust unit 116. It may be noted that the turbine system 100 may include other components and is not limited to the components shown in FIG. 1. The inlet unit 104 is coupled to the compressor 106 which is coupled to the combustor 110. Further, the combustor 110 is coupled to the turbine 112. Also, the exhaust unit 116 is coupled to the turbine 112. Furthermore, the turbine 112 is coupled to the compressor 106 via the shaft 114.
[0027] The turbine system 100 may be used for providing mechanical energy to a load 118. More specifically, when the turbine system 100 is operated, air 120 enters the inlet unit 104 as a “working fluid” and is then compressed by the compressor 106. Further, compressed air is fed to the combustor 110. Also, the fuel 122 is injected from the fuel injector 108 to the combustor 110. Thereafter, a mixture of the compressed air and the fuel are combusted in a combustion chamber of the combustor 110. After a combustion reaction in the combustion chamber, energy is then extracted from a combusted mixture of the air and the fuel to rotate a plurality of turbine blades 124 of the turbine 112. The rotation of the plurality of turbine blades 124 causes rotation of the shaft 114. As a result, the mechanical energy is delivered to the load 118 that is coupled to the shaft 114. Expanded exhaust gas is fed from the turbine 112 to the exhaust unit 116 where the exhaust gas is processed to reduce harmful emissions. In one embodiment, a processed exhaust gas may be released to the environment.
[0028] Typically, the turbine blades 124 of the turbine 112 are coated with thermal barrier coatings (TBCs) for protecting the turbine blades 124 from higher operating temperatures within the turbine system 100. However, during operation of the turbine system 100, the TBCs are subjected to degradation over a period of service life. As a consequence, the turbine blades 124 may be distressed and damaged. Hence, the turbine blades 124 need to be inspected periodically to assess the integrity of the TBCs and a distress level in the turbine blades 124.
[0029] To overcome the above shortcomings/problems, the exemplary turbine system 100 uses the positioning device 102 that aids in inspecting the turbine blades 124 during each of a plurality of inspection cycles. It may be noted that the positioning device 102 may be used for inspecting any component and is not limited to the turbine blades 124 of the turbine 112. It may be noted that the terms “blade” and “component” or “blades” and “components” may be used interchangeably in the below description. Further, it may be noted that the terms “inspection cycles” and “focus cycles” may be used interchangeably in the below description.
[0030] As depicted in FIG. 1, the positioning device 102 is coupled to a port 126 of the turbine 112. Further, the positioning device 102 includes an articulation assembly 128 and a fixture 130. The articulation assembly 128 includes a tubular structure 150 having an aperture at a distal end 132 and a first connector 134 on an outer surface 152 of the tubular structure 150. In one embodiment, the first connector 134 may include one or more countersink holes on the outer surface of the tubular structure 150. Further, the articulation assembly 128 includes a focus unit 136 that is disposed within the tubular structure 150 at the distal end 132. In one embodiment, the focus unit 136 may include a data capture sub-unit that is used for acquiring inspection data such as videos or images of the turbine blades 124.
[0031] Further, the fixture 130 is coupled to the turbine 112 and configured to guide the tubular structure 150 to pass through the port 126 of the turbine 112. In particular, the fixture 130 includes a channel and a second connector (shown) that is disposed on an inner surface of the channel. In one embodiment, the second connector includes a spring-loaded plunger. Further, the channel is used to receive the tubular structure 150 and guide at least a portion of the of the tubular structure 150 and the focus unit 136 to pass through the fixture 130. When the portion of the tubular structure 150 passes through the fixture 130, the second connector such as the spring-loaded plunger is configured to inter-lock with the first connector 134 such as the countersink hole on the tubular structure 150 so as to position the focus unit 136 at a predetermined location within the turbine 112.
[0032] By positioning the focus unit 136 at a predetermined location, the data capture sub-unit of the focus unit 136 may acquire the inspection data of the turbine blades 124. Moreover, since the focus unit 136 is positioned at the predetermined location during each of the inspection cycles, the acquired inspection data is consistent for each of the inspection cycles.
[0033] Furthermore, a processing unit 138 is coupled to the positioning device 102. Also, the processing unit 138 receives and processes the acquired inspection data to determine the distress in the turbine blades 124 and rank a level of distress in the turbine blades 124. Moreover, since the inspection data is consistent during each of the inspection cycles, the processing unit 138 automatically processes the inspection data to determine the distress and progression of the distress in each of the turbine blades 124. Additionally, the processing unit 138 may be used to transmit and display the distress level of the turbine blades 124 on a display unit 140. In one embodiment, a 3D model corresponding to each turbine blade 124 may be used for displaying the distress level. In one example, the inspected data that is superimposed on the 3D model may be viewed in a virtual immersive world by an operator in a remote location. Optionally, the processing unit 138 may transmit the inspection data to an external device 142 for further processing the inspection data. In one embodiment, the processing unit 138 may convert the inspection data to data frames and may wirelessly communicate the data frames to the external device 142. The aspect of acquiring the inspection data will be explained in greater detail with reference to FIG. 2.
[0034] FIG. 2 depicts a perspective view of a portion of the turbine 112 having the positioning device 102 in accordance with an embodiment of the present invention. The turbine 112 includes an inner casing 202 and an outer casing 204 that encloses the inner casing 202. The outer and inner casings 204, 202 include ports 206, 208 that are used for inspecting the turbine 112. In the illustrated embodiment, the port 208 of the inner casing 202 is offset from the port 206 of the outer casing. 204. In one embodiment, the port 206 of the outer casing 204 includes an embossed feature 210 having a C-shaped profile 212 provided on a top surface 214.
[0035] Further, the turbine 112 includes the radially arranged turbine blades 124 that are positioned within the inner casing 202 and spaced apart along a longitudinal axis of the turbine system. Further, the turbine blades 124 are attached to the shaft 114 and configured to rotate the shaft 114 when the turbine system 100 is operated. It may be noted that the turbine 112 may include other components and is not limited to components shown in FIG. 2.
[0036] In the illustrated embodiment, the positioning device 102 includes the articulation assembly 128 and the fixture 130. The articulation assembly 128 includes the tubular structure 150 having a guide tube 216 and a pivot tube 218 that are operatively coupled to each other. Further, the pivot tube 218 is positioned at a distal end of the tubular structure 150. Also, the pivot tube 218 is movable at a predefined angle with respect to the guide tube 216. In one example, the predefined angle may be in a range from about 90 degrees to about 180 degrees. In one embodiment, a spring-loaded locking knuckle is used to couple the pivot tube 218 to the guide tube 216. When the tubular structure 150 is inserted into the turbine 112, the spring-loaded locking knuckle aids in positioning the pivot tube 218 at the predefined angle. In one embodiment, the pivot tube 218 is held at a predefined position due to tension of the spring-loaded locking knuckle to form a L-shaped tubular structure. In another embodiment, the pivot tube 218 is coupled to the guide tube 216 using a connector that aids in positioning the pivot tube 218 at the predefined angle. In one example, the connector includes a mechanical link, torsional springs, smart material actuators, pneumatic and the like. In one embodiment, the pivot tube 218 may include one or more parts that are coupled to each other. Also, these parts may be movable to the predefined angle with respect to the guide tube 216. Further, these parts may be extended to position the focus unit 136 in both in-plane and out of plane of the guide tube 216. Moreover, by extending these parts of the pivot tube 218, the focus unit 136 may get complete coverage of the blade 124.
[0037] FIG. 3 is a perspective view of a portion of the positioning device 102 disposed within the turbine 112 in accordance with an embodiment of the present invention. As discussed above, the turbine 112 includes the radially arranged turbine blades 124 that are positioned within a casing and spaced apart along a longitudinal axis of the turbine system. The articulation assembly 128 includes the tubular structure 150 having the guide tube 216 and the pivot tube 218 that are operatively coupled to each other. The pivot tube 218 is movable at a predefined angle with respect to the guide tube 216. More specifically, when the tubular structure 150 is passing through the casing, the pivot tube 216 will be in-line with the guide tube 216. As the tubular structure 150 enters a space within the casing, the spring-loaded locking knuckle coupled between the pivot tube 216 and the guide tube 216 aids in moving the pivot tube 218 to the predefined angle. In the embodiment of FIG. 4, the pivot tube 216 is moved to an angle of 90 degrees with respect to the guide tube 216.
[0038] FIG. 4 is a perspective view of the pivot tube 218 in accordance with an exemplary embodiment of the present invention. The pivot tube 218 includes a focus unit 136 positioned at a distal end. The focus unit 136 includes a data capture sub-unit 404. The data capture sub-unit 404 is configured to acquire inspection data of the turbine blades 124. In one embodiment, the inspection data includes video, consistent images, ultrasound signals, eddy current signals, and/or microwave signals of at least a portion of each turbine blade 124. It may be noted that the inspection data may include other related data, and is not limited to the data mentioned hereinabove. In one embodiment, the video or consistent images of each turbine blade 124 may be used for estimating distress level in each of the turbine blades. Similarly, the ultrasound signals may be used for determining thickness of the coating, such as the TBC on each of the turbine blades 124. Further, the eddy current signals may be used for detecting coating cracks in one or more turbine blades 124. The microwave signals may be used for determining coating integrity of each of the turbine blades 124.
[0039] Furthermore, the data capture sub-unit 404 may include a camera coupled with a light source, an ultrasound transducer, a current source, a microwave generator, or a combination thereof. The camera is used for acquiring videos or images. The ultrasound transducer is used for acquiring the ultrasound signals. Similarly, the current source may be used for acquiring the eddy current signals. Further, the microwave generator is used for sending and receiving the microwave signals. In one embodiment, the data capturing sub-unit 404 may include multiple cameras along with a light source to get coverage and dimensional measurements of the blade. It may be noted that the light source may be a structured or unstructured light source. Also, the light source may be a monochromatic or polychromatic light source. It may be noted that the data capturing sub-unit 404 may use one or more technologies, such as ultrasound, eddy-current, infrared, microwave, terahertz, lidar, hyper spectral cameras, optical coherence tomography etc. for acquiring the inspection data.
[0040] The data capture sub-unit 404 is positioned proximate to an aperture 408 at the distal end of the pivot tube 218. Additionally/alternatively, the pivot tube 218 may have an aperture formed in the side wall 410. The data capture sub-unit 404 may be positioned towards the aperture in the side wall 410 to enable acquisition of the inspection data at a different angle.
[0041] For ease of understating, in the illustrated embodiment, the data capture sub-unit 404 is considered to be having the camera for acquiring video or images of at least a portion of each of the turbine blades 124. In one embodiment, the data capture sub-unit 404 includes one or more lenses 412 and a mirror to enhance a field of view (FOV) of the camera for acquiring video or images of each of the turbine blades 124.
[0042] FIG. 5 is a perspective view of the guide tube 216 in accordance with an exemplary embodiment of the present invention. The guide tube 216 is an elongated structure that is coupled to the pivot tube. The guide tube 216 is used to enable insertion of the pivot tube 218 into the turbine. In one embodiment, the guide tube 216 includes a guide path 502 having a first connector 504. The guide path 502 may be a groove formed on an outer surface 152 of the guide tube 216. In the illustrated embodiment, the first connector 504 may include countersink holes formed in the guide path 502. The countersink holes are separated from each other by a predetermined distance along the guide path 502.
[0043] FIG. 6 is a perspective view of the fixture 130 in accordance with one embodiment of the present invention. The fixture 130 is molded as a single structure having a channel 602 along a longitudinal direction 606. The channel 602 is offset from a central axis 604 of the fixture 130 so that the channel 602 can be inserted into the ports of the outer and inner casings that are offset from each other. Further, the channel 602 is configured to receive the articulation assembly and guide the articulation assembly to pass through the fixture 130 and the casings of the turbine. Furthermore, the fixture 130 includes a clip structure 608 and teeth 610 that are used for coupling the fixture 130 to the port of the outer casing. More specifically, when the fixture 130 is positioned on the port such that a portion 612 of the channel 602 is located inside the port, the clip structure 608 expands and locks with the embossed feature on the port of the outer casing. Further, the teeth 610 extending along a circumferential direction of the fixture 130, enable to hold the fixture 130 against the embossed feature on the port. When the clip structure 608 locks with the embossed feature on the port, the fixture 130 is restricted from rotating relative to the port.
[0044] Additionally, the fixture 130 includes a second connector 614 that is disposed on an inner surface 624 of the channel 602. In one embodiment, the second connector 614 may include a spring-loaded plunger. The second connector 614 is configured to inter-lock with the first connector of the guide tube.
[0045] FIG. 7 is a perspective view of the fixture 130 in accordance with one embodiment of FIG. 6. As discussed previously, the fixture 130 includes the channel 602 along the longitudinal direction. The channel 602 is offset from the central axis 604 of the fixture 130. When the pivot tube and the guide tube are inserted through the channel 602, the second connector 614 (see FIG. 6) on the inner surface 624 of the channel 602 inter-locks with the first connector of the guide tube so that the focus unit in the pivot tube is positioned at a predetermined location within the inner casing of the turbine. More specifically, the second connector 614 such as the spring-loaded plunger inter-locks with the first connector such as the countersink holes in the guide path of the guide tube to position the focus unit at a predetermined height within the inner casing of the turbine. The predetermined height may be referred to as a height/position of the focus unit with reference to the outer casing of the turbine. It may be noted that the guide tube may be pushed downwards or upwards so that the second connector 614 inter-locks with a desired countersink hole in the guide path to locate the focus unit at the predetermined height. Further, the focus unit may be positioned at different heights by moving the spring-loaded plunger 614 in the channel 602 to inter-lock with different countersink holes in the guide path.
[0046] FIG. 8 is a perspective view of a locating unit 802 of the fixture in accordance with an exemplary embodiment. The locating unit 802 is configured to couple the fixture to the port of the outer casing. In one embodiment, the locating unit 802 includes a clip structure 808 and teeth 810 formed on a bottom surface. When the locating unit 802 is positioned on the embossed feature of the port, the clip structure 808 expands and locks with the embossed feature on the port. The teeth 810 enables to secure the locating unit 802 to the embossed feature on the port. Moreover, when the clip structure 808 locks with the embossed feature on the port, the locating unit 802 is restricted from rotation relative to the port.
[0047] FIG. 9 is a perspective view of a guiding unit 804 of the fixture in accordance with an exemplary embodiment. The guiding unit 804 is operatively coupled to the locating unit and configured to position the focus unit at the predetermined location within the inner casing of the turbine. In particular, the guiding unit 804 includes an offset knob 812 that is coupled to the locating unit. Also, the offset knob 812 has a channel 814 that is offset from a central axis of the guiding unit 804. In addition, the guiding unit 804 has a grip 806 at a top portion for allowing a user or an operator to hold the fixture while coupling the fixture to the outer casing of the turbine. During the mounting process, the channel 814 passes through the ports of the outer and inner casings that are offset from each other. Also, the channel 814 in the guiding unit 804 aids in guiding the articulation assembly to pass through the inner and outer casings of the turbine.
[0048] Further, the offset knob 812 includes a second connector (not shown) that is disposed on an inner surface of the channel 814. In one embodiment, the second connector may include a spring-loaded plunger. When the pivot tube and the guide tube are inserted into the channel 814, the second connector on the inner surface of the channel 814 inter-locks with the first connector of the guide tube so that the focus unit in the pivot tube is positioned at the predetermined location within the inner casing of the turbine. Specifically, the second connector such as the spring-loaded plunger inter-locks with the first connector such as one of the countersink holes formed in the guide path of the guide tube.
[0049] Referring again to FIGS. 1-7, during operation, the operator or user may position a reference blade among the plurality of blades 124 at a desired location or a reference location. Further, the fixture 130 is coupled to the port 206 on the outer casing 204 of the turbine 112. Thereafter, the articulation assembly 128 is inserted into the channel 602 of the fixture 130. More specifically, the pivot tube 218 and the guide tube 216 slide through the channel 602 of the fixture 130. Further, when the pivot tube 218 having the focus unit 136 passes through the inner casing 202, the guide tube 216 interlocks with the fixture 130 to position the focus unit 136 at the predetermined location within the inner casing 202 of the turbine 112. More specifically, the focus unit 136 is positioned at a predetermined height within the inner casing 202. The focus unit 136 may be positioned proximate to a first side of the turbine blades 124. In one embodiment, the first side may be a pressure side of the turbine blades 124.
[0050] Furthermore, the data capture sub-unit 404 is activated to acquire the inspection data of the turbine blades 124. The operator rotates the blades 124 to complete at least one revolution. Concurrently, the data capture sub-unit 404 acquires video or images of the rotating turbine blades 124. In one embodiment, the data capture sub-unit 404 may be positioned proximate a first half such as an upper portion of the turbine blades 124 to acquire video or images of the first half of each turbine blade 124. Further, the data capture sub-unit 404 may transmit the acquired images or video of the first half of the turbine blades124 to the processing unit 138. The processing unit 138 may store the images or video of the first half of the turbine blades 124. Optionally, the processing unit 138 may transmit the images or video to an external device 142 for further processing the acquired images or video.
[0051] After acquiring images or video of the first half of the turbine blades 124, the articulation assembly 128 may be further inserted into the fixture 130 to position the focus unit 136 proximate to the second half such as a lower portion of the turbine blades 124. In one embodiment, the guide tube 216 may be pushed downwards so that the second connector 614 such as the spring-loaded plunger of the fixture 130 secures with another countersink hole 504 of the guide tube 216 of the articulation assembly 128. Further, the data capture sub-unit 404 in the focus unit 136 acquires video or images of the second half of each turbine blade 124. Also, the data capture sub-unit 404 transmits the acquired video or images of the second half of the turbine blades 124 to the processing unit 138. The processing unit 138 may store the images or video of the second half of the turbine blades 124 for further processing the acquired images or video. It may be noted that the above-mentioned procedure may be repeated for different predetermined heights to acquire images or video of different portions of the turbine blades 124. It should be noted herein the above-mentioned procedure may be performed individually for each of the turbine blades 124.
[0052] After acquiring video or images of the turbine blades 124, the processing unit 138 may use one or more distress ranking algorithms to process the images or video to determined distress level in each of the turbine blades 124. Further, the processing unit 138 may compare the determined distress level with a pre-stored data or distress level determined during previous inspection cycles to estimate progression of distress in each of the turbine blades 124.
[0053] FIG. 10 is a perspective view of a portion of the turbine provided with the positioning device 102 in accordance with another embodiment of the present invention. In the illustrated embodiment, the positioning device 102 is used to position the focus unit 136 at a predetermined angle in addition to positioning at a predetermined height within the inner casing 202 of the turbine. Additionally, the positioning device 102 is used to position the focus unit 136 proximate to a second side of the turbine blades 124. In one embodiment, the second side may be a suction side of the turbine blades 124. In the embodiment of FIG. 10, a port 1002 on an outer casing 1004 is concentric with a port 1006 on an inner casing 1007 of the turbine 112.
[0054] In accordance with the exemplary embodiment, the fixture 130 includes a locating unit 1008 and a guiding unit 1010. The locating unit 1008 is coupled to the port 1002 of the outer casing 1004. Further, the guiding unit 1010 is coupled to the locating unit 1008. Also, the guiding unit 1010 may be rotated over the locating unit 1008 to position the focus unit 136 at the predetermined angle.
[0055] FIG. 11 is another perspective view of the portion of the turbine 112 provided with the positioning device 102 in accordance with the embodiment of FIG. 10. As discussed earlier, the pivot tube (see FIG. 4) may be movable with respect to the guide vane (see FIG. 5). In one example, the spring-loaded locking knuckle coupled between the pivot tube and the guide tube aids in moving the pivot tube to a predefined angle. As a result, the focus unit 136 in the pivot tube is also positioned at the predefined angle. In FIG. 11, the focus unit 136 is positioned at an angle of 90 degrees with respect to the guide tube.
[0056] FIG. 12 is another perspective view of the portion of the turbine provided with the positioning device 102 in accordance with the embodiment of FIG. 10. As discussed previously, the fixture 130 includes the locating unit 1008 and the guiding unit 1010. In FIG. 12, the focus unit 136 is positioned at an angle of 120 degrees with respect to the guide tube.
[0057] FIGS. 13-15 are different perspective views of the locating unit 1008 in accordance with an exemplary embodiment of the present invention. The locating unit 1008 includes a third connector 1300 on an inner surface. More specifically, the third connector 1300 includes a first set of countersink holes 1302 and a second set of countersink holes 1304 on the inner surface. The first set of countersink holes 1302 are aligned at a first predetermined angle with reference to the focus unit. Similarly, the second set of countersink holes 1304 are aligned at a second predetermined angle with reference to the focus unit. The alignment of the first and second sets of countersink holes 1302, 1304 facilitates to acquire the inspection data along a lateral direction of the turbine blades. In addition, the locating unit 1008 includes a clip structure 1306 at a bottom surface. This clip structure 1306 is used for coupling the locating unit 1008 to an embossed feature on the port 1002. The clip structure 1306 locks with the embossed feature on the port 1002 so that the locating unit 1008 is prevented from rotating relative to the port 1002.
[0058] FIG. 16 is a perspective view of a portion of the fixture 130 in accordance with an exemplary embodiment. The fixture 130 includes the guiding unit 1010 having a clamping element 1602 and an orientation knob 1604. The clamping element 1602 is used to secure the locating unit 1008 to the port 1002 of the outer casing 1004. In one embodiment, the clamping element 1602 includes a threaded structure 1606 on an outer surface that is used to secure or couple with a corresponding threaded structure on an inner surface of the port 1002 of the outer casing 1004. The clamping element 1602 includes a head portion 1608 used for holding the locating unit 1008 against the port 1002 of the outer casing 1004. The clamping element 1602 also includes a first sub-channel 1610 extending along a longitudinal direction.
[0059] The orientation knob 1604 is coupled to the locating unit 1008. The orientation knob 1604 includes a second sub-channel 1612 extending along a longitudinal direction. Also, the second sub-channel 1612 is aligned with the first sub-channel 1610 of the clamping element 1602 to form a channel of the fixture 130. The first sub-channel 1610 and the second sub-channel 1612 are configured to allow the guide tube and the pivot tube to slide through the guiding unit 1010. Further, the orientation knob 1604 includes a connector 1614 such as a spring-loaded plunger that is coupled to the second sub-channel 1612. The connector 1614 is configured to secure to the first connector such a countersink hole of the guide tube when the guide tube slides through the second sub-channel 1612. The connector 1614 is configured to secure to the first connector of the guide tube to position the focus unit at a predetermined height with reference to the outer casing.
[0060] FIGS. 17-18 are perspective views of the orientation knob 1604 in accordance with an exemplary embodiment of the present invention. The orientation knob 1604 includes a first portion 1702 and a second portion 1704. The first portion 1702 is disposed within the locating unit and the second portion 1704 is positioned on top of the locating unit. The first portion 1702 includes a fourth connector 1706 formed on an outer surface and configured to secure to the third connector (see FIG. 15) of the locating unit. In one embodiment, the fourth connector 1706 includes a set of spring-loaded plungers that inter-locks with the first set of countersink holes of the locating unit to position the focus unit at the first predetermined angle. After acquiring the inspection data at the first predetermined angle of the focus unit, the orientation knob 1604 is rotated so that the fourth connector 1706 inter-locks with the second set of countersink holes of the locating unit. Further, the inspection data is acquired at the second predetermined angle of the focus unit. The orientation knob 1604 is rotated and the focus unit 136 is used to acquire the inspection data of the turbine blades at different angles.
[0061] FIG. 19 is a side view of the orientation knob 1604 in accordance with an exemplary embodiment of FIGS. 17-18. As discussed earlier, the orientation knob 1604 includes the first portion 1702 and the second portion 1704. The first portion 1702 includes the fourth connector 1706 formed on the outer surface and configured to secure to the third connector of the locating unit.
[0062] With reference to FIGS. 1-19, during operation, the operator or user may position a reference blade among the plurality of turbine blades 124 at a desired location or a reference location. Further, the fixture 130 is coupled to the port 1002 on the outer casing 1004 of the turbine. In particular, the clamping element 1602 is inserted through the locating unit 1008 and fitted to the port 1002 of the outer casing 1004. Further, the orientation knob 1604 is coupled to the locating unit 1008. The orientation knob 1604 inter-locks with the locating unit 1008 to position the focus unit 136 at a first predetermined angle in the turbine 112. In one embodiment, the fourth connector 1706 such as the spring-loaded plungers of the orientation knob 1604 secures to the third connector 1300, such as the countersink holes of the locating unit 1008.
[0063] Thereafter, the articulation assembly 128 is inserted into the channel of the fixture 130. More specifically, the pivot tube 218 and the guide tube 216 slide through the channel of the fixture 130. Further, when the pivot tube 218 having the focus unit 136 passes through the inner casing 1007 via the ports 1002, 1006, the guide tube 216 interlocks with the orientation knob 1604 to position the focus unit 136 at the predetermined height relative to the outer casing 1004 of the turbine 112. In one embodiment, the second connector 1614 such as the spring-loaded plunger of the orientation knob 1604 secures with the first connector 504 such as the countersink hole in the guide path 502 of the articulation assembly 128. Additionally, the focus unit 136 may be positioned proximate to the second side or the suction side of the turbine blades 124.
[0064] Furthermore, the data capture sub-unit 404 is activated to acquire the inspection data of the turbine blades 124 at the predetermined height and a first predetermined angle. More specifically, the operator rotates the turbine blades 124 to complete at least one revolution. Concurrently, the data capture sub-unit 404 acquires the video or images of the rotating turbine blades 124 at the predetermined height and the first predetermined angle. In one embodiment, the focus unit 136 may be positioned proximate to a left half of an upper portion of the turbine blades 124 to acquire the video or images of the left half of the upper portion of each turbine blade 124. Further, the data capture sub-unit 404 may transmit the acquired images or videos of the left half of the upper portion of each turbine blade to the processing unit. The processing unit may store the images or videos of the left half of the upper portion of the turbine blades 124. Optionally, the processing unit may transmit these images or video to the external device for further processing the images or video.
[0065] After acquiring the images or video of the left half of the upper portion of the turbine blades 124, the orientation knob 1604 is rotated to rotate the articulation assembly 128 and position the focus unit 136 at a second predetermined angle to acquire the images or videos of the right half of the upper portion the turbine blades 124. In one embodiment, the orientation knob 1604 is rotated so that the fourth connector 1706 such as the spring-loaded plungers on the outer surface secures with the third connector 1300 such the second set of countersink holes 1304 of the locating unit 1008. Further, the data capture sub-unit 404 transmits the acquired images of the right half of the upper portion of the turbine blades 124 to the processing unit. The processing unit 138 may store the images or videos of the right half of the upper portion of the turbine blades 124. Optionally, the processing unit may transmit the images or video to the external device 142 for further processing the images or video.
[0066] After acquiring the images or video of the upper portion of the turbine blades 124, the articulation assembly 128 may be inserted further into the fixture 130 to position the focus unit 136 proximate to the lower portion of the turbine blades 124. In one embodiment, the guide tube 216 may be pushed downwards so that the second connector 1614 such as the spring-loaded plunger of the guiding unit 1010 secures with another countersink hole 504 in the guide tube 216 of the articulation assembly 128. Furthermore, the articulation assembly 128 may be rotated to position the focus unit 136 at the first predetermined angle to acquire the images or video of the left half of the lower portion of the turbine blades 124. Further, the data capture sub-unit 404 may transmit the acquired images or video of the left half of the lower portion of the turbine blades 124 to the processing unit. The processing unit may store the images or video for further processing.
[0067] Further, the orientation knob 1604 is rotated to rotate the articulation assembly 128 and position the focus unit 136 at the second predetermined angle to acquire images or video of the right half of the lower portion of the turbine blades 124. Further, the data capture sub-unit 404 transmits the acquired images or video of the right half of the lower portion of the turbine blades124 to the processing unit. The processing unit may store the images or video for further processing. It may be noted that the above-mentioned procedure may be repeated for different pre-determined heights and different pre-determined angles to acquire images of different portions of the turbine blades 124. It may be noted that the focus unit having a camera with a better field of view (FOV) may be used to acquire the images or video of the turbine blades 124 at a predetermined height and a predetermined angle.
[0068] After acquiring the video or images of the turbine blades 124, the processing unit may use one or more distress ranking algorithms to process the images or video to determine distress level in each of the turbine blades 124. Further, the processing unit may compare the determined distress level with a pre-stored data or distress level determined during previous inspection cycles to estimate progression of distress in each of the turbine blades 124.
[0069] Turning now to FIG. 20, a flow chart illustrating a method 2000 for positioning a focus unit in a turbine in accordance with an embodiment of the present invention is depicted. At step 2002, a fixture is coupled to a port of a casing. In one embodiment, the fixture includes a clip structure and teeth that are used for coupling the fixture to the port of the outer casing of the turbine. More specifically, when the fixture is pressed against the port, the clip structure expands and locks with the embossed feature on the port. The teeth on the circumference of the fixture are configured to hold the fixture against the embossed feature on the port.
[0070] Subsequently, at step 2004, an articulation assembly is received by a channel in the fixture. The articulation assembly includes a tubular structure having an aperture at a distal end and a first connector on an outer surface. Further, the articulation assembly includes a focus unit positioned within the tubular structure at the distal end.
[0071] At step 2006, the channel of the fixture guides the articulation assembly to pass through the port of the casing. In one embodiment, the fixture is molded as a single structure having the channel along a longitudinal direction of the fixture. Further, the channel is configured to receive the articulation assembly and guide the articulation assembly to pass through the fixture and the casing of the turbine.
[0072] Further, at step 2008, a second connector disposed on an inner surface of the channel of the fixture is secured to the first connector to position the focus unit at a predetermined location within the casing. In particular, when the portion of the articulation assembly passes through the fixture, the second connector such as the spring-loaded plunger inter-locks with the first connector such as the countersink hole in the tubular structure so as to position the focus unit at the predetermined location within the turbine. After positioning the focus unit at the predetermined location, the data capture sub-unit is used to acquire the inspection data of the turbine blades. Further, a processing unit receives and processes the inspection data to determine the distress in the turbine blades and rank a level of distress in each of the turbine blades.
[0073] Referring to FIG. 21, a perspective view 2100 of a portion of the turbine 112 having two positioning devices in accordance with an embodiment of the present invention, is depicted. The turbine includes a casing 2105 having a first port 2106 and a second port 2108. Also, the turbine 112 includes the radially arranged turbine blades 124 that are positioned within a confined space of the casing 2105 and spaced apart along a longitudinal axis of the turbine system. The two positioning devices includes a first positioning device 2102 that is coupled to the first port 2106 and a second positioning device 2104 that is coupled to the second port 2108. Further, the first positioning device 2102 includes a first articulation assembly 2110 having a first focus unit 2112. Also, the first positioning device 2102 includes a first fixture 2114 that is configured to guide the first articulation assembly 2110 to pass through the first port 2106 of the casing 2105. Further, the first fixture 2114 is configured to position the first focus unit 2112 at a first location within the casing 2105. In one example, the first location may be towards a first side of the blades 124. In one embodiment, the first fixture 2114 is configured to position the first focus unit 2112 at the first location during each of a plurality of focus cycles. Further, the first focus unit 2112 is configured to acquire first inspection data. The first inspection data include consistent images, ultrasound signals, eddy current signals, or microwave signals associated with a first side of the blades during each of the plurality of focus cycles. The firs side may be the pressure side of the blades. In another embodiment, the first fixture 2114 is configured to position the first focus unit 2112 at the first location during each of the plurality of focus cycles.
[0074] Similarly, the second positioning device 2104 includes a second articulation assembly 2120 having a second focus unit 2122. Also, the second positioning device 2104 includes a second fixture 2124 that is configured to guide the second articulation assembly 2120 to pass through the second port 2108 of the casing 2105. Also, the second fixture 2124 is configured to position the second focus unit 2122 at a second location within the casing 2105. In one example, the second location may be towards a second side of the blades 124. In one example, the second side may be the suction side of the blades 124. In one embodiment, the second fixture 2124 is configured to position the second focus unit 2122 at the second location during each of a plurality of focus cycles. Further, the second focus unit 2122 is configured to acquire second inspection data. The second inspection data include consistent images, ultrasound signals, eddy current signals, or microwave signals associated with a second side of the blades 124 during each of the plurality of focus cycles.
[0075] In accordance with the exemplary embodiments discussed herein, the exemplary system and method discloses positioning the focus unit at a predetermined location. As a result, the data capture sub-unit acquires consistent images or videos of the component to be inspected. Further, distress in the component may be automatically determined based on the consistent images or videos. Further, the data capture sub-unit is used to acquire the consistent images or videos of the component during each of the inspection cycles, which in turn facilitates to evaluate a progression of distress in the component. Moreover, the exemplary positioning device is a non-motorized device. In particular, the positioning device does not use any motor or actuator for guiding the articulation assembly and/or locking the articulation assembly with the fixture. Also, the focus unit is positioned at the predetermined location by mechanical interlocking of the components in the positioning device. As a result, cost for manufacturing and maintaining the positioning device may be substantially reduced. This in-turn reduces the cost that is associated with inspection of components in the turbine.
[0076] While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure.