JP7451092B2 - A system and method for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine using a robotic system. - Google Patents

Description

The present disclosure relates generally to gas turbine engines, and more particularly, for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine using a robotic system. SYSTEMS AND METHODS.

Gas turbine engine blades, such as compressor or turbine blades, may be manually inspected, cleaned, and repaired periodically. This process can be time consuming, labor intensive, and potentially dangerous. For example, due to the blade profile and sharp edge, workers may wear steel mesh gloves up to their elbows, which can make inspection, cleaning, and repair processes more difficult and time-consuming. . Furthermore, the inspection, surface finish, and repair of each blade can be inconsistent due to human inaccuracies.

Some or all of the above needs and/or challenges may be addressed by some embodiments of the present disclosure. According to one embodiment, a system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine is disclosed. This system consists of a track located adjacent to the rotor, a mechanical arm movable along this track, several tools that can be attached to this mechanical arm, and a tool that can be attached to the mechanical arm. a controller configured to control the position of at least one of the blades about the one or more blades.

According to another embodiment, a method for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine is disclosed. The method includes positioning a track adjacent to a rotor, moving a mechanical arm along the track, attaching at least one of several tools to the mechanical arm, and controlling the position around one or more blades.

Additionally, according to another embodiment, a system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine is disclosed. The system consists of a track located adjacent to the rotor, a robot arm movable along the track, and several The controller may include a tool and a controller configured to control the position of at least one of the tools mounted on the robot arm about the one or more blades.

Other embodiments, aspects, and features of the invention will be apparent to those skilled in the art from the following detailed description, accompanying drawings, and appended claims.

Reference is now made to the accompanying drawings, which are not necessarily drawn to scale.

1 illustrates an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG. 1 illustrates a portion of an example system for inspecting, cleaning, and/or repairing one or more blades mounted on a rotor of a gas turbine engine, according to one embodiment. FIG.

Example embodiments will now be described in more detail below with reference to the accompanying drawings, in which some, but not all, embodiments are shown. This disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout.

The systems and methods described herein may be used to inspect, clean, and/or repair one or more blades mounted on a rotor of a turbomachine. In some examples, the blades may be disposed on a compressor or turbine. Any device having a blade may utilize the systems and methods disclosed herein to inspect, clean, and/or repair the blade. Rotors may also be inspected, cleaned, and/or repaired by this system. In some examples, the turbo engine may be a gas turbine engine. Any industrial turbo engine may be used.

In certain embodiments, automated robotic system 100 may be used to inspect, clean, and/or repair one or more blades 102 mounted on rotor 104. Various components of system 100 may communicate with at least one controller 106 to control their movement. The components may be hardwired to or in wireless communication with the controller 106. Controller 106 may be any suitable computing device having a memory and a processor. Controller 106 may be separate from the components of system 100, or controller 106 may be incorporated within one or more of the components of system 100. In some examples, several controllers 106 may communicate with each other over a network to control various components of the robotic systems disclosed herein.

System 100 may include a mechanical arm (eg, robotic arm 108) disposed on track 110. In some examples, robotic arm 108 may be a six-axis robotic arm. Robotic arm 108 may be any suitable size, shape, or configuration. Track 110 may be disposed adjacent rotor 104. In some examples, track 110 may be parallel to the axial extension of rotor 104 and may extend along all or a portion of the axial extension of rotor 104. Track 110 may be of any suitable size, shape, or configuration. As shown in FIGS. 1 and 2, the robot arm 108 is moved end-to-end along a track 110 to different axial locations along the rotor 104 via one or more actuators. good. In this manner, trajectory 110 may function as a seventh axis for robot arm 108.

Rotary actuator 112 may be mechanically coupled to rotor 104 . In some examples, rotary actuator 112 may include a power roller 114 that is mechanically interlocked with rotor 104. Rotary actuator 112 may be configured to rotate rotor 104 to move blades 102 attached to rotor 104. In this manner, rotary actuator 112 may communicate with controller 106. Controller 106 causes one or more of blades 102 mounted on rotor 104 to rotate rotor 104 via rotary actuator 112 and to move robot arm 108 along trajectory 110 . Robotic arm 108 may be allowed to approach. Once the rotor 104 is rotated into position and the robot arm 108 is moved into position along the track 110, the robot arm 108 moves about its various axes and moves along one or more axes. The tool may be used to inspect, clean, and/or repair blade 102.

To determine the position of blade 102, a rotation sensor 116 may be disposed adjacent rotor 104, as shown in FIGS. 1-3. Rotation sensor 116 may be configured to provide annular position data associated with rotor 104 . In this manner, rotation sensor 116 may communicate with controller 106. In some examples, rotation sensor 116 may include an encoder wheel 118 that is mechanically coupled to rotor 104. Rotation sensor 116 may be of any suitable size, shape, or configuration. Rotor 104 may be disposed on one or more roller stands 126.

As shown in FIGS. 4 and 5, an axial displacement sensor 120 may be disposed adjacent rotor 104. As shown in FIGS. Axial travel sensor 120 may be configured to provide axial position data associated with rotor 104 . In this manner, axial travel sensor 120 may communicate with controller 106 . In some examples, axial movement sensor 120 may be an axial laser sensor 122. Axial laser sensor 122 may use laser 124 to track the amount of movement of rotor 104 that is parallel to the axis of rotation of rotor 104. For example, misalignment of the roller stand 126 may cause the rotor 104 to "displace" in either axial direction. Tracking axial movement is desirable to supplement robot programs.

As shown in FIGS. 1, 2, and 6, system 100 may include a number of tools 128 that can be mounted on robotic arm 108. In some examples, tools 128 may include a vision tool 130, a cleaning tool 132, and a scanning tool 134, as described in more detail below. Any number or type of tools 128 may be used. In some examples, tool 128 may be stored at docking station 136. A docking station 136 may be positioned adjacent track 110 so that tools can be approached by robotic arm 108. In some examples, docking station 136 may include a T-shaped stand 138 with several docks 140 for storing tools 128 when not in use.

End 142 of robot arm 108 may include a coupling configured to attach to at least one of tools 128. For example, each of tools 128 may include a base that can be attached to end 142 of robot arm 108. The base of each of the tools 128 may be identical to facilitate rapid tool replacement. In this manner, the robotic arm 108 may be moved along the track 110 and attached to one of the tools 128 at the docking station 136 to remove the tool 128 from the docking station 136. Controller 106 may communicate with tool 128 at end 142 of robot arm 108 such that tool 128 may be used to inspect, clean, and/or repair blade 102. In other examples, tool 128 may be re-docked to docking station 136 after tool 128 is used. For example, the robot arm 108 may be moved along the track 110 and positioned adjacent the docking station 136 at which point the tool 128 may be re-docked to one of the docks 140 of the docking station 136.

As shown in FIG. 7, vision tool 130 may include a bracket 144 extending outwardly from base 146. As shown in FIG. A base 146 (ie, a tool changer) may be configured to be attached to the end 142 of the robot arm 108. In some examples, optical devices 148 such as 3D cameras and lasers may be attached to the ends of bracket 144. In certain embodiments, the optical device 148 can take a picture and use the contrast with the sharp blade to find and locate shapes/objects, while the laser determines the shape, orientation, and angle of the blade 102. can be identified. Robotic arm 108 may use vision tool 130 to locate vision devices (markers) positioned on rotor 104 to find the clock position of the blades on all legs. Once the blade position is found, the robot arm 108 can then complement its previously taught position and begin the cleaning/scanning process.

Cleaning tool 132 may include a mechanical end effector that can be operated by robotic arm 108 to clean blade 102. Cleaning tool 132 is similar to the cleaning tool disclosed in U.S. patent application Ser. It's good to be there. In some examples, cleaning tool 132 may include two elongate arms 150 with pads 152 attached to the ends. Arm 150 may be attached to mounting block 154 via pivot 156 . Arm 150 can be opened and closed by actuator 158, which is connected to I/O block 160, which can be controlled by controller 106. Plate 162 is attached to base 164. Base 164 (ie, tool changer) is configured to be attached to end 142 of robot arm 108 . An I/O block 160 and air vibration tool 166 may be attached to plate 162. Vibratory tool 166 may be turned on or off by robot arm 108 (ie, controller 106) via I/O block 160. Once the robotic arm 108 positions the pad 152 on the blade 102, the arm 150 may be closed and activate the vibrating tool 166 via the controller 106. The robot arm 108 may then move up and down the blade 102, covering all surfaces until cleaning the blade 102 of debris. This process may be completed for all blades 102 after system 100 uses vision tool 130 to find the position of the blade.

Scanning tool 134 may be used by robotic arm 108 to identify and locate defects in the blade. Scanning tool 134 may include an elongate plate 168 attached to base 170. Base 170 (ie, tool changer) is configured to be attached to end 142 of robot arm 108 . In some examples, a scanner 172 (eg, a line scanner) may be attached to the end of plate 168. Robotic arm 108 may be configured to move scanner 172 along blade 102 . Scanner 172 may be configured to map the surface of the blade using laser 174. Any anomalies found during the scan may output the center location and size of the defect, as well as the blade number and interval to identify the blade location on the rotor 104. Defects detected may include divots, edge defects, and cracks in the surface of blade 102. This process may be completed after cleaning the rotor 104 and/or blades 102 and may be performed on all blades 102. Defects can be modeled, such as in a software program, to provide recommendations and/or visualizations for repairing the blade and/or for use with repair tools to repair the blade 102. In some examples, defects may be compared to a model of the blade's veil line. A post-assembly inspection may be performed using the scanner 172 to determine the as-assembled condition of the blades and/or rotor.

In some examples, as shown in FIG. 8, scanning tool 134 may include a mirror 176 to direct laser 178 into a confined space. That is, the mirror 176 may be configured to fit into the narrow space between the blades 102, thereby directing the sensor package to locations it cannot reach on its own, yet transmitting data with appropriate accuracy. It may become possible.

FIG. 9 shows a repair tool 180 that can be mounted on and used by the robotic arm 108 to repair defects in one or more blades. In certain embodiments, repair tool 180 may be a hybrid tool or the like. In some examples, repair tool 180 may be docked to docking station 136. Repair tool 180 may include an elongated plate 182 attached to a base 184. Base 184 (ie, tool changer) is configured to be attached to end 142 of robot arm 108 . In some examples, a rotary tool 186 (eg, an air rotary tool with a stone bit or bar bit) may be attached to the end of the elongated plate 182. Any suitable repair tool may be used herein. Rotating tool 186 may be in line with elongate plate 182 or may be at a 90° angle. Rotating tool 186 may be disposed at any suitable angle relative to elongate plate 182. Robotic arm 108 may be configured to move rotary tool 186 along blade 102. Rotary tool 186 may be configured for use in repairing (eg, adjusting) one or more defects in the surface of the blade.

In use, controller 106 (or several controllers communicating with each other via a network) may control the amount of movement of various components of system 100. For example, rotary actuator 112 moves rotor 104 to position blade 102 at a desired location and orientation. Robotic arm 108 may move along track 110 and load one of the tools 128 stored at docking station 136. In some examples, robotic arm 108 may be attached to vision tool 130. A vision tool 130 may be moved around each blade 102 by the robotic arm 108 to identify the location of the blades 102. Robotic arm 108 may then re-dock vision tool 130 to docking station 136 and attach cleaning tool 132. Robotic arm 108 may manipulate cleaning tool 132 around each blade 102 to clean blade 102. Robotic arm 108 may then re-dock cleaning tool 132 to docking station 136 and attach scanning tool 134. Robotic arm 108 may operate scanning tool 134 around each blade 102 to digitally map blade 102 to detect defects in blade 102. Another tool 128 (eg, repair tool 180) may be stored at docking station 136 and used by robotic arm 108 to correct/repair defects.

Although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that this disclosure is not necessarily limited to the particular features or acts described. Rather, the specific features and acts are disclosed as example forms of implementing an embodiment.

Finally, representative embodiments are shown below.
[Embodiment 1]
a track (110) disposed adjacent to a rotor (104) having one or more blades (102) mounted thereon;
a mechanical arm (108) movable along a track (110);
a plurality of tools (128) attachable to the mechanical arm (108);
a controller (106) configured to control the position of at least one of the plurality of tools (128) mounted on the mechanical arm (108) about the one or more blades (102); A system (100) comprising:
[Embodiment 2]
The embodiment further comprises a rotation sensor (116) disposed adjacent to the rotor (104), the rotation sensor (116) configured to provide annular position data associated with the rotor (104). 1. The system (100) according to 1.
[Embodiment 3]
3. The system (100) of embodiment 2, wherein the rotation sensor (116) comprises an encoder wheel mechanically interlocked with the rotor (104).
[Embodiment 4]
It further includes an axial displacement sensor (120) disposed adjacent to the rotor (104), the axial displacement sensor (120) detecting axial position data associated with the rotor (104). The system (100) of embodiment 1, configured to provide.
[Embodiment 5]
5. The system (100) of embodiment 4, wherein the axial displacement sensor (120) comprises a laser distance sensor (122).
[Embodiment 6]
The system (100) of embodiment 1, further comprising a rotary actuator (112) mechanically coupled to the rotor (104).
[Embodiment 7]
The system (100) of embodiment 1, further comprising a tool docking station (136) disposed adjacent the track (110).
[Embodiment 8]
The system (100) of embodiment 1, wherein the mechanical arm (108) comprises a robotic arm (108).
[Embodiment 9]
The system (100) of embodiment 1, wherein the mechanical arm (108) comprises at an end thereof a connection configured to be attached to at least one of the plurality of tools (128).
[Embodiment 10]
10. The system (100) of embodiment 9, wherein each of the plurality of tools (128) comprises a base (146) that is attachable to a coupling at an end of the mechanical arm (108).
[Embodiment 11]
The system (100) of embodiment 1, wherein the plurality of tools (128) include a vision tool (130), a cleaning tool (132), and a scanning tool (134).
[Embodiment 12]
positioning a track adjacent a rotor (104) having one or more blades (102) mounted;
moving the mechanical arm (108) along the track (110);
mounting at least one of the plurality of tools (128) on the mechanical arm (108);
controlling the position of at least one of a plurality of tools (128) about one or more blades (102).
[Embodiment 13]
13. The method of embodiment 12, further comprising determining annular position data associated with the rotor (104).
[Embodiment 14]
13. The method of embodiment 12, further comprising determining axial position data associated with the rotor (104).
[Embodiment 15]
13. The method of embodiment 12, further comprising rotating the rotor (104) using a rotary actuator (112) mechanically coupled to the rotor (104).
[Embodiment 16]
13. The method of embodiment 12, further comprising positioning one or more of the plurality of tools (128) in a tool docking station (136) disposed adjacent the track (110).
[Embodiment 17]
a track (110) disposed adjacent to a rotor (104) having one or more blades (102) mounted thereon;
a robotic arm (108) movable along a trajectory (110);
a plurality of tools (128) configured to be stored in a tool docking station (136) and attachable to an end of the robot arm (108);
a controller (106) configured to control the position of at least one of the plurality of tools (128) mounted on the robot arm (108) about the one or more blades (102); comprising a system (100);
[Embodiment 18]
The embodiment further comprises a rotation sensor (116) disposed adjacent to the rotor (104), the rotation sensor (116) configured to provide annular position data associated with the rotor (104). The system (100) according to 17.
[Embodiment 19]
It further includes an axial displacement sensor (120) disposed adjacent to the rotor (104), the axial displacement sensor (120) detecting axial position data associated with the rotor (104). The system (100) of embodiment 1, configured to provide.
[Embodiment 20]
The system (100) of embodiment 1, further comprising a rotary actuator (112) mechanically coupled to the rotor (104).

100 System 102 Blade 104 Rotor 106 Controller 108 Robot arm, mechanical arm 110 Trajectory 112 Rotary actuator 114 Power roller 116 Rotation sensor 118 Encoder wheel 120 Axial movement sensor 122 Axial laser sensor, laser distance sensor 124 Laser 126 Laura Stand 128 tools 130 Visual tool 132 Washing tool 132 Rash Tools 134 Running Tools 136 Docking Station, Tool Docking Station 138 T type stand 140 dock 142 End 146 Base 146 Base 148 Kogaku Device 152 Pad 154 Padd Installation Block 156 Axis 1 60 I / O block 162 plate 164 base 166 vibration tool 168 plate 170 base 172 scanner 174 laser 176 mirror 178 laser 180 repair tool 182 plate 184 base 186 rotary tool

Claims (9)

A robotic system (100) for inspecting and/or repairing one or more blades (102) attached to a rotor (104) of a gas turbine engine, the robotic system (100) comprising:
a track (110) disposed adjacent to a rotor (104) on which the one or more blades (102) are mounted;
a mechanical arm (108) movable along said track (110);
a plurality of tools (128) attachable to the mechanical arm (108);
a controller (106) configured to control the position of at least one of the plurality of tools (128) mounted on the mechanical arm (108) about the one or more blades (102); ,
one or more roller stands (126) on which the rotor (104) is disposed;
a rotary actuator (112) mechanically interlocked with the rotor (104);
a rotation sensor (116) disposed adjacent the rotor (104), the rotation sensor (116) configured to provide annular position data associated with the rotor (104); is,
the plurality of tools (128) include a vision tool (130), a scanning tool (134) and/or a repair tool (180);
the mechanical arm (108) having a coupling at an end thereof configured to be attached to at least one of the plurality of tools (128);
Each of the plurality of tools (128) includes a base (146) attachable to the coupling at the end of the mechanical arm (108), the base (146) of each of the plurality of tools (128) ) are identical to facilitate rapid tool exchange . The robotic system (100) of claim 1, wherein the rotation sensor (116) comprises an encoder wheel (118) mechanically interlocked with the rotor (104). The axial movement sensor (120) further includes an axial movement sensor (120) disposed adjacent to the rotor (104), the axial movement sensor (120) detecting an axial movement sensor (120) associated with the rotor (104). The robotic system (100) of claim 1, configured to provide position data. The robotic system (100) of claim 3, wherein the axial displacement sensor (120) comprises a laser distance sensor (122). The robotic system (100) of claim 1, further comprising a tool docking station (136) disposed adjacent the track (110). The robotic system (100) of claim 1, wherein the mechanical arm (108) comprises a robotic arm (108). A method for inspecting and/or repairing one or more blades (102) mounted on a rotor (104) of a gas turbine engine using a robotic system (100), the method comprising:
disposing the rotor (104) with the one or more blades (102) mounted on one or more roller stands (126);
positioning a track (110) adjacent the rotor (104);
rotating the rotor (104) using a rotary actuator (112) mechanically interlocked with the rotor (104);
determining annular position data associated with the rotor (104);
moving a mechanical arm (108) along said track (110);
attaching at least one of a plurality of tools (128) to the mechanical arm (108);
controlling the position of at least one of the plurality of tools (128) about the one or more blades (102), the plurality of tools (128) being a visual tool (130). , a scanning tool (134) and/or a repair tool (180) ;
the mechanical arm (108) having a coupling at an end thereof configured to be attached to at least one of the plurality of tools (128);
Each of the plurality of tools (128) includes a base (146) attachable to the coupling at the end of the mechanical arm (108), the base (146) of each of the plurality of tools (128) ) are identical to facilitate quick tool replacement . 8. The method of claim 7 , further comprising determining axial position data associated with the rotor (104). 8. The method of claim 7 , further comprising positioning one or more of the plurality of tools (128) on a tool docking station (136) disposed adjacent the track (110).