The present subject matter relates generally to visual inspections of gas turbine engines, and more particularly, to a digital inspection assistant that aids an operator during visual inspection of a gas turbine engine.
A gas turbine engine typically includes a turbomachinery core having a high pressure compressor, combustor, and high pressure turbine arranged in a serial flow relationship. The core is operable to generate a primary gas flow. The high pressure compressor includes annular arrays (“rows”) of stationary vanes that direct incoming air into downstream, rotating blades of the compressor. Collectively one row of compressor vanes and one row of compressor blades make up a “stage” of the compressor. Similarly, the high pressure turbine includes annular rows of stationary nozzle vanes that direct the gases exiting the combustor into downstream, rotating blades of the turbine. Collectively one row of nozzle vanes and one row of turbine blades make up a “stage” of the turbine. The compressor and/or turbine can include a plurality of successive stages.
In order to allow for periodic inspection of the components of the core engine, borescope ports are typically provided in the engine casings and/or frames. Optical borescope instruments can be inserted through such ports into the core to enable a visual inspection of the engine without requiring disassembly of the engine components. Data obtained during an inspection is typically processed offline, e.g., to identify if any defects are present in the inspected components. The inventors of the present disclosure have invented a digital inspection assistant to aid operators during visual inspections of such components and gas turbine engines generally.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect, a system is provided. The system includes an optical system having an optical probe and a monitor communicatively coupled with the optical probe. The optical probe is insertable through an access port of a gas turbine engine and configured to capture images of an interior of the gas turbine engine at a location associated with the access port. The system also includes an inspection assistant communicatively coupled with the optical system. The inspection assistant has a human-machine interface, one or more processors, and one or more memory devices. The one or more processors of the inspection assistant are configured to: (a) receive data including images captured by the optical probe, the images captured by the optical probe providing internal views of the gas turbine engine; (b) cause the images to be displayed on the human-machine interface; (c) detect one or more defects associated with one or more components of the gas turbine engine; and (d) generate an alert indicating that a defect associated with a component of the gas turbine engine is detected, and wherein the one or more processors of the inspection assistant (a) receive, (b) cause, (c) detect, and (d) generate the alert in real time.
In another aspect, an inspection assistant for aiding an operator during a visual inspection of a gas turbine engine is provided. The inspection assistant includes a human-machine interface having a display, one or more memory devices, and one or more processors. The one or more processors of the inspection assistant are configured to: (a) receive data including images captured of an interior of a core engine of the gas turbine engine; (b) cause the images to be displayed on the display of the human-machine interface; (c) detect one or more defects associated with one or more components of the core engine; and (d) generate an alert indicating that a defect associated with a component of the gas turbine engine is detected, and wherein the one or more processors of the inspection assistant (a) receive, (b) cause, (c) detect, and (d) generate in real time.
In yet another aspect, a method of visually inspecting a gas turbine engine is provided. The method includes capturing images of an interior of a core engine of the gas turbine engine with an optical probe installed through an access port of the gas turbine engine. The method also includes receiving, by an inspection assistant, data that includes the images of the interior of the core engine. Further, the method includes displaying, by the inspection assistant, the images on a display of the inspection assistant. The method also includes detecting, by the inspection assistant, one or more defects associated with one or more components of the core engine. Moreover, the method includes generating, by the inspection assistant, an alert indicating that a defect associated with a component of the core engine is detected. The capturing, the receiving, the displaying, the detecting, and the generating occur in real time.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of any claims and their equivalents.
The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention, and identical numerals indicate the same elements throughout the drawings. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or relative importance of the individual components. Furthermore, as used herein, the term “real time” refers to collection of predetermined data, the time to process the data, and the time of a system response to the events and the environment. In the embodiments described herein, these activities and events occur effectively instantaneously.
Aspects of the present disclosure are directed to a digital inspection assistant for aiding an operator during a visual inspection of a gas turbine engine. In one example aspect, an optical probe of an optical system is installed through an access port of a gas turbine engine. The optical probe can capture images, such as still images or video, of the interior of a core of the gas turbine engine. The optical system can be a borescope or borescope system, for example. An Artificial Intelligence (AI) adaptor is communicatively coupled with the optical system. The AI adaptor includes a gateway and an inspection assistant communicatively coupled thereto. The gateway accesses or otherwise obtains data from the optical system, including images captured by the optical probe. The gateway provides the data to the inspection assistant for real-time analysis. The gateway can include an integrated video converter and video encoder that operate using a streaming protocol to enable low stream latency of the images and other data provided to the inspection assistant. The inspection assistant can be a handheld portable device, such as a tablet.
The inspection assistant can provide interactive inspection guidance to an operator and can detect defects in components of the core of the engine. The inspection assistant can provide real time guidance and defect analysis to an operator. Particularly, the inspection assistant can guide an operator in performing the inspection and can identify defects as the operator performs the visual inspection. Identified defects can be highlighted on a display of the inspection assistant to alert the operator as to their presence, location, and/or size, for example. In this manner, operator productivity and the overall accuracy of such visual inspections can be increased or improved. The analysis results can assist an operator with making asset decisions.
The engine 10 includes a core engine 14 and a fan section 16 positioned upstream of the core engine 14. The core engine 14 includes a substantially tubular outer casing 18 that defines an annular core inlet 20. In addition, the outer casing 18 encloses and supports a low pressure or booster compressor 22 for increasing the pressure of the air that enters the core engine 14 to a first pressure level. A high pressure, multi-stage, axial-flow compressor 24 receives the pressurized air from the booster compressor 22 and further increases the pressure of the air. The pressurized air exiting the high-pressure compressor 24 flows to a combustor 26 where fuel is injected into the flow of pressurized air. The resulting mixture is combusted within the combustor 26. The high energy combustion products are directed from the combustor 26 along the hot gas path of the core engine 14 to a first (high pressure) turbine 28 for driving the high pressure compressor 24 via a first (high pressure) shaft 30, and then to a second (low pressure) turbine 32 for driving the booster compressor 22 and fan section 16 via a second (low pressure) shaft 34 that is generally coaxial with the first shaft 30. After driving each of turbines 28 and 32, the combustion products are expelled from the core engine 14 via an exhaust nozzle 36 to provide propulsive thrust.
It should be appreciated that each compressor 22, 24 may include a plurality of compressor stages, with each stage including both an annular array of stationary compressor vanes and an annular array of rotating compressor blades positioned immediately downstream of the compressor vanes. Similarly, each turbine 28, 32 may include a plurality of turbine stages, with each stage including both an annular array of stationary nozzle vanes and an annular array of rotating turbine blades positioned immediately downstream of the nozzle vanes.
Additionally, as shown in
It should be appreciated that, in several embodiments, the second (low pressure) drive shaft 34 may be directly coupled to the fan rotor assembly 38 to provide a direct-drive configuration. Alternatively, the second drive shaft 34 may be coupled to the fan rotor assembly 38 via a speed reduction device 37 (e.g., a reduction gear or gearbox) to provide an indirect-drive or geared drive configuration. Such a speed reduction device(s) may also be provided between any other suitable shafts and/or spools within the engine 10 as desired or required.
During operation of the engine 10, an initial air flow (indicated by arrow 50) enters the engine 10 through an associated inlet 52 of the fan casing 40. The air flow 50 then passes through or across the fan blades 44 and splits into a first compressed air flow (indicated by arrow 54) that moves through bypass conduit 48 and a second compressed air flow (indicated by arrow 56) that enters the annular core inlet 20 and flows downstream to the booster compressor 22. The pressure of the second compressed air flow 56 is then increased and enters the high pressure compressor 24 (as indicated by arrow 58). After mixing with fuel and being combusted within the combustor 26, the combustion products 60 exit the combustor 26 and flow through the first turbine 28. Thereafter, the combustion products 60 flow through the second turbine 32 and exit the exhaust nozzle 36 to provide thrust for the engine 10. The first compressed airflow that moves through and exits the bypass conduit 48 also provides thrust for the engine 10.
As further shown in
As indicated above, the turbine 28 may generally include any number of turbine stages, with each stage including an annular array of nozzle vanes and follow-up turbine blades 68. For example, as shown in
Moreover, as shown in
As indicated above, the compressor 24 may include a plurality of access ports 62 defined through the compressor casing/frame, with each access port 62 being configured to provide access to the interior of the compressor 24 at a different axial location. Specifically, in several embodiments, the access ports 62 may be spaced apart axially such that each access port 62 is aligned with or otherwise provides interior access to a different stage of the compressor 24. For instance, as shown in
It should be appreciated that similar access ports may also be provided for any of the other stages of the compressor 24 and/or for any of the stages of the low pressure compressor 22. It should also be appreciated that, in addition to the axially spaced access ports 62 shown in
In general, the optical probe 112 may correspond to any suitable optical device that may be inserted through an access port 62, 64 of the gas turbine engine 10 to allow images (e.g., still images and/or video) of the interior of the engine 10 to be captured or otherwise obtained. For instance, in some embodiments, the optical probe 112 may correspond to a borescope, videoscope, fiberscope or any other similar optical device known in the art that allows for the interior of a gas turbine engine 10 to be viewed through an access port 62, 64. In such embodiments, the optical probe 112 may include one or more optical elements 114, such as one or more optical lenses, optical fibers, image capture devices, cables, and/or the like, for obtaining views or images of the interior of the engine 10 at a probe tip 116 of the probe 112 and for transmitting or relaying such images from the probe tip 116 along the length of the probe 112 to the exterior of the engine 10. For instance, as shown in
In some embodiments, a light source 118, such as an LED, may be provided at or adjacent to the probe tip 116 to provide lighting within the interior of the engine 10. The optical probe 112 may also include an articulation assembly 120 that allows the orientation of the probe tip 116 to be adjusted within the interior of the gas turbine engine 10. For example, the articulation assembly 120 may allow for the probe tip 116 to be rotated or pivoted about a single axis or multiples axes to adjust the orientation of the probe tip 116 relative to the remainder of the probe 112. It should be appreciated that the articulation assembly 120 may generally have any suitable configuration and/or may include any suitable components that allow for adjustment of the orientation of the probe tip 116 relative to the remainder of the probe 112. For example, in some embodiments, a plurality of articulation cables 122 may be coupled between the probe tip 116 and one or more articulation motors 124. In such an embodiment, by adjusting the tension of the cables 122 via the motor(s) 124, the probe tip 116 may be reoriented within the gas turbine engine 10. In some embodiments, the articulation assembly 120 may be electronically controlled.
Further, in some embodiments, the optical probe 112 can also include a location signal receiver 126 positioned at or adjacent to its probe tip 116. In such embodiments, the location signal receiver 126 can receive location-related signals from a plurality of location transmitters mounted on or within the engine 10 that provide an indication of the position of the location signal receiver 126 (and, thus, the probe tip 116) relative to the location transmitters. For instance, the location signal receiver 126 can receive signals from the location transmitters that provide an indication of the distance defined between the receiver 126 and each transmitter (e.g., based on the signal strength, the time of flight of the signals, and/or time of arrival of the signals) and/or that provide an indication of the angle defined between the receiver 126 and each transmitter (e.g., based on the angle of incidence or angle of arrival of the signals). The signals received by the location signal receiver 126 may then be transmitted to the scope monitor 130. The scope monitor 130 can include one or more processors and one or more memory devices. The one or more processors of the scope monitor 130 can be used to determine the current location of the probe tip 116 within the gas turbine engine 10 using any suitable signal-based positioning technique, such as a trilateration technique or a triangulation technique. Additionally or alternatively, the signals received by the location signal receiver 126 can be transmitted to the scope monitor 130 and stored on the one or more memory devices. The signals or data containing such signals can be transmitted otherwise provided to a computing device for processing the current location of the probe tip 116. For instance, data containing such signals can be routed to an inspection assistant that can process the signals, and among other things, provide instructions to an operator based on current location of the probe tip 116.
For this embodiment, the AI adaptor 150 includes a gateway 160. The gateway 160 acts as the gateway node between the optical system 110 and the AI adaptor 150. As depicted, the gateway 160 is communicatively coupled with the optical system 110. More particularly, the gateway 160 is communicatively coupled with the scope monitor 130 of the optical system 110. For instance, the scope monitor 130 can include a video output port and a wired cable or link can communicatively couple the scope monitor 130 with the gateway 160. Additionally or alternatively, the optical system 110 and the gateway 160 can be communicatively coupled via a wireless connection, e.g., over a wireless network.
As shown in
The AI adaptor 150 also includes a server 170. The server 170 is communicatively coupled with the gateway 160, e.g., via a suitable wired and/or wireless connection. The server 170 can include one or more processors and one or more memory devices, for example. In some embodiments, the server 170 functions as a data lake. The server 170 can receive data from the gateway 160. The data received by the server 170 can include images (e.g., still images and/or video) captured by the optical probe 112 (
As further shown in
Generally, the inspection assistant 180 is a smart digital assistant to an operator during an inspection of a gas turbine engine. In some embodiments, the inspection assistant 180 is a handheld portable device, such as an iPad, laptop, etc. Advantageously, the portable and handheld aspect of the inspection assistant 180 can facilitate effective and efficient inspection assistance to an operator. For instance, the portable and handheld aspect of the inspection assistant 180 can allow an operator to hold the inspection assistant 180 and move around during the inspection process as desired. In other embodiments, the inspection assistant 180 is neither portable nor handholdable.
The inspection assistant 180 has one or more processors, and one or more memory devices. The one or more memory devices can store information accessible by the one or more processors, including computer-readable instructions that can be executed by the one or more processors. The instructions can be any set of instructions that, when executed by the one or more processors, cause the one or more processors to perform operations, such as any of the operations described herein. For instance, as one example, the instructions can include computer vision system instructions that, when executed, cause the one or more processors to detect defects on one or more components of the engine being inspected. As another example, the instructions can include inspection guide instructions that, when executed, cause the one or more processors to generate an alert or set of instructions or steps for an operator to follow based on various inputs, such as a location of the probe tip 116 (
The inspection assistant 180 also includes a human-machine interface 182. The human-machine interface 182 can include one or more displays, speakers, microphones, user controls (e.g., buttons, dials, levers, touchscreen, etc.), among other possible other machine-human interactive components. The one or more processors can cause particular images to be displayed on a display of the human-machine interface 182 and can cause one or more audible instructions to be generated by the one or more speakers, for example. In addition, the one or more processors can perform operations based on inputs received from the user controls and/or the one or more microphones of the human-machine interface 182.
With reference to
The images captured by the optical probe 112, which can be still images or video, are transmitted to the scope monitor 130 of the optical system 110. The images can be presented on the monitor or display of the scope monitor 130. An operator can view the interior of the engine 10 by viewing the images displayed on the scope monitor 130. As will be appreciated, however, conventional scope monitors have not provided interactive real time inspection assistance and/or analysis to an operator. Thus, in accordance with the inventive aspects of the present disclosure, the AI adaptor 150 is communicatively coupled with the optical system 110 to ultimately provide real-time inspection assistance to an operator performing an inspection of the gas turbine engine 10.
Particularly, data 140 captured, gathered, or associated with the optical system 110 is provided to the AI adaptor 150. More specifically, the data 140 is transmitted to the gateway 160 of the AI adaptor 150. The data 140 can include inspection data and operation data as noted above. The gateway 160 translates the protocol of the data 140 into a preselected protocol as needed and then routes the data 140 to both the server 170 and the inspection assistant 180. The data 140 can be stored on one or more memory devices of the server 170, and as noted above, the data 140 stored on the server 170 can be provided to downstream entities, such as engine customers, engine service personnel, and/or engine manufacturers, among others.
The gateway 160 is configured to route the images captured by the optical probe 112 to the inspection assistant 180. Accordingly, the one or more processors of the inspection assistant 180 are configured to receive at least a portion of the data 140, and more particularly, images captured by the optical probe 112. The images captured by the optical probe 112 can provide internal views of the gas turbine engine 10. Upon receiving the images, the one or more processors of the inspection assistant 180 are further configured to cause the images to be displayed on the human-machine interface 182, e.g., on a display thereof. In this manner, the images captured by the optical probe 112 are simultaneously displayed on the display or monitor of the scope monitor 130 and the human-machine interface 182 of the inspection assistant 180. In some embodiments, only the human-machine interface 182 displays the images.
Notably, the inspection assistant 180 can host or include an inspection analyzer module 184. The inspection analyzer module 184 is a set of instructions executable by the one or more processors of the inspection assistant 180. The inspection analyzer module 184 uploaded to and hosted by the inspection assistant 180 can be specific to the engine or engine model being inspected. As noted above, in some embodiments, the inspection assistant 180 can be a handheld portable device. Accordingly, in such embodiments, the inspection assistant 180 may have relatively limited memory storage available. Loading an analyzer module specific to an engine or engine model can provide an efficient manner of using the relatively limited memory storage of the inspection assistant 180.
In some embodiments, when the inspection analyzer module 184 is executed, the one or more processors of the inspection assistant 180 can detect one or more defects associated with one or more components of the gas turbine engine 10. In this way, the inspection assistant 180 can execute one or more computer vision techniques. Any suitable computer vision system technique or techniques can be implemented, such as e.g., one or more deep learning object recognition techniques. For instance, one or more Convolutional Neural Networks (CNNs) can be utilized to detect defects in components of the engine 10. The CNNs can determine the physical bounds of a given detected defect and can also be used to classify a given defect. In some embodiments, the inspection analyzer module 184 can include CNNs for each associated section of the engine 10, e.g., a CNN for the compressor section, a CNN for the combustor section, a CNN for the turbine section, etc. Further, in some embodiments, the inspection analyzer module 184 can include CNNs for multiple components within a section of the engine 10. For instance, for the compressor section, the inspection analyzer module 184 can include a CNN for detecting defects on the stator vanes, a CNN for detecting defects on the compressor blades, etc.
Example defects that can be detected or identified by the inspection assistant 180 upon execution of the inspection analyzer module 184 can include, without limitation, cracks, welding failures, delamination of a composite component, among others. The detection techniques embodied in the inspection analyzer module 184 hosted on the inspection assistant 180 can be specific to the engine or the engine model being inspected. Furthermore, the detection techniques embodied in the inspection analyzer module 184 hosted on the inspection assistant 180 can be specific to various components, stations, or sections of the engine. For instance, the inspection analyzer module 184 can include instructions for detecting defects associated with components of a compressor of the gas turbine engine 10, instructions for detecting defects associated with components of a turbine of the gas turbine engine 10, instructions for detecting defects associated with components of a combustion section of the gas turbine engine 10, etc.
Further, in some embodiments, once a defect has been detected by the inspection assistant 180, the one or more processors of the inspection assistant 180 are further configured to generate an alert indicating that a defect associated with a component of the gas turbine engine is detected. As one example, in generating the alert indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant 180 can cause the inspection assistant 180 to audibly alert an operator that a defect associated with a component of the gas turbine engine is detected. For instance, the one or more processors of the inspection assistant 180 can cause one or more speakers of the human-machine interface 182 to generate an alarm, audible text (e.g., defect detected), or some other human-audible noise to alert an operator that a defect has been detected.
In some embodiments, operation data received as part of the data 140 can be used to generate contextual audible alerts. For instance, the operation data received as part of the data 140 can include data indicating a location of the probe tip 116 and/or the access port in which the optical probe 112 is installed. The location of the probe tip 116 and/or the access port in which the optical probe 112 is installed can be used to determine the component and/or stage of the component having the detected defect. Accordingly, using this information, the generated audible alert can include context associated with the component having the defect. For instance, the audible generated alert can be “defect detected; high pressure turbine stage one nozzle.” Additionally or alternatively, in other embodiments, upon execution of the inspection analyzer module 184, the one or more processors can use object recognition techniques to identify the component or components presented or displayed on the human-machine interface 182 of the inspection assistant 180. Upon a determination of the objects presented on the human-machine interface 182, the one or more processors can generate an audible alert indicating the component having the defect.
In yet other embodiments, to provide further context to the audible alert indicating the detected defect, the one or more processors can, upon execution of the inspection analyzer module 184, classify the detected defect into a defect class. The defect class can be one of a plurality of possible defect classes. Accordingly, in some embodiments, the inspection analyzer module 184 can include instructions for defect classification. Defects can be classified by size, location, type, severity, etc. With the defect classified, the one or more processors can generate an audible alert indicating the component having the defect and the type of class of the defect. For instance, an example generated alert can be “delamination defect detected at a leading edge of a stage one high pressure turbine blade.”
As another example, in addition to or alternatively to generating audible alerts indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant 180 can cause the inspection assistant 180 to augment the images displayed on the human-machine interface 182. The images displayed on the human-machine interface 182 can be augmented with a defect graphic, for example. For instance, the images can be augmented by overlaying a defect graphic over the defect detected. The defect graphic can be an outline of the bounds of the defect, for example. In some embodiments, the defect graphic overlaying the defect detected in the images displayed on the human-machine interface 182 is represented in a color different from the component having the defect detected. In other embodiments, the defect graphic is presented on the display but not overlaying the detected defect. For instance, the defect graphic can be a text block presented in any suitable location on the display.
By way of example,
In some embodiments, with reference again to
For instance, with reference again to
Notably, the one or more processors of the inspection assistant 180 can, in real time, 1) receive data 140 that includes images of the interior of the gas turbine engine 10 captured by the optical probe 112; 2) cause the images to be displayed on the human-machine interface 182 of the inspection assistant 180; and 3) detect or scan for defects associated with one or more components of the gas turbine engine. The one or more processors can iterate this process as new, refreshed, or otherwise updated data 140 is provided to the inspection assistant 180. Further, upon detection of one or more defects, the one or more processors of the inspection assistant 180 can, in real time, generate an alert indicating that a defect associated with a component of the gas turbine engine is detected. In this manner, the AI adaptor 150, or more particularly the inspection assistant 180, can analyze inspection and operation data 140 and can provide real-time analysis results (e.g., online defect diagnosis) based on the data 140 to an operator. This may, among other things, increase the reliability of defect detection and reduce the tedious work of result management; thus, inspection productivity can be increased, and better asset decisions can be made.
In addition to providing online real time defect analysis, in some embodiments, the inspection assistant 180 can also provide real time interactive assistance or instructions to an operator. In this manner, an operator can be guided through an on-wing visual inspection process.
As one example, the one or more processors of the inspection assistant 180 can provide instructions to an operator based at least in part on a selected work scope of an inspection to be performed on a gas turbine engine. For instance, a work scope of an inspection to be performed on a gas turbine engine can be selected, e.g., by an operator. The selected work scope of the inspection can have an associated set of interactive instructions. The set of interactive instructions can provide step-by-step instructions or a task list for how the inspection associated with the selected work scope is to be performed. In this way, an operator can perform an inspection on an engine with no or minimal experience with a particular engine whilst still being able to successfully perform the inspection. The interactive instructions can be presented or provided to an operator audibly, visually, in a haptic manner (e.g., by vibration of the inspection assistant 180 when an instruction is not followed), as well as other suitable manners. The human-machine interface 182 of the inspection assistant 180 can provide or present the interactive instructions to the operator 200.
In some embodiments, the one or more processors of the inspection assistant 180 can provide instructions to an operator based at least in part on the defect or defects detected. For example, upon detection of a defect of a component of the gas turbine engine 10, the one or more processors of the inspection assistant 180 can provide instructions to an operator to manipulate at least one of the optical probe 112, the engine 10, e.g., by rotating a stage of rotor blades, or some other inspection device. For instance, the provided instructions can indicate that the operator 200 is to change the speed, direction, adjust the lighting, etc. of the optical probe 112 so that the defected defect can be inspected or reexamined once again. In this way, the detection of the defect can be confirmed or validated. Alternatively, a component or components of the engine 10 can be manipulated so that the optical probe 112 can provide images of the detected defect once again, e.g., so that the inspection assistant 180 can perform a second identification and/or classification analysis on the detected defect.
At (302), the method (300) includes capturing images of an interior of a core engine of the gas turbine engine with an optical probe installed through an access port of the gas turbine engine. For instance, with reference to
At (304), the method (300) includes receiving, by an inspection assistant, data that includes the images of the interior of the core engine. For instance, with reference again to
At (306), the method (300) includes displaying, by the inspection assistant, the images on a display of the inspection assistant. For instance, with reference again to
At (308), the method (300) includes detecting, by the inspection assistant, one or more defects associated with one or more components of the core engine. For instance, with reference again to
At (310), the method (300) includes generating, by the inspection assistant, an alert indicating that a defect associated with a component of the core engine is detected. For instance, in some implementations, generating the alert indicating that a defect associated with a component of the gas turbine engine is detected includes causing the inspection assistant to generate an audible alert indicating that a defect associated with a component of the gas turbine engine is detected. In other implementations, generating the alert indicating that a defect associated with a component of the gas turbine engine is detected includes augmenting the images displayed on the display of the inspection assistant with a defect graphic. As one example, the defect graphic can be overlaid over the detected defect, e.g., as shown in
Notably, in performing method (300), the capturing at (310), the receiving at (304), the displaying at (306), the detecting at (308), and the generating at (310) occur in real time. In this way, real-time inspection assistance can be provided to an operator performing an inspection of the core engine of the gas turbine engine 10.
In some further implementations, the method (300) further includes providing, by the inspection assistant, instructions to an operator based at least in part on a selected work scope of an inspection on the gas turbine engine. For instance, a work scope of an inspection to be performed on a gas turbine engine can be selected, e.g., by an operator. The selected work scope of the inspection can have an associated set of interactive instructions. The set of interactive instructions can provide step-by-step instructions or a task list for how the inspection associated with the selected work scope is to be performed. The interactive instructions can be presented or provided to an operator audibly, visually, in a haptic manner (e.g., by vibration of the inspection assistant 180 when an instruction is not followed), as well as other suitable manners. The human-machine interface 182 of the inspection assistant 180 can provide or present the interactive instructions to the operator.
In other implementations, the method (300) further includes providing, by the inspection assistant, instructions to an operator based at least in part on the defect detected. For example, upon detection of a defect of a component of the gas turbine engine 10 at (308), the one or more processors of the inspection assistant 180 can provide instructions to an operator to manipulate at least one of the optical probe 112, the engine 10, e.g., by rotating a stage of rotor blades, or some other inspection device. For instance, the provided instructions can indicate that the operator is to change the speed, direction, adjust the lighting, etc. of the optical probe 112 so that the defected defect can be inspected or reexamined once again. In this way, the detection of the defect can be confirmed or validated. Alternatively, a component or components of the engine 10 can be manipulated so that the optical probe 112 can provide images of the detected defect once again, e.g., so that the inspection assistant 180 can perform a second identification and/or classification analysis on the detected defect.
The one or more memory device(s) 186 can store information accessible by the one or more processor(s) 185, including computer-readable instructions 188 that can be executed by the one or more processor(s) 185. The instructions 188 can be any set of instructions that, when executed by the one or more processor(s) 185, cause the one or more processor(s) 185 to perform operations. The instructions 188 can be software written in any suitable programming language or can be implemented in hardware. The instructions 188 can be any of the computer-readable instructions noted herein. For instance, the instructions 188 can include the inspection analyzer module 184. The memory device(s) 186 can further store data 183 that can be accessed by the processor(s) 185. For example, the data 183 can include received data 140. Further, the data 183 can include one or more table(s), function(s), algorithm(s), model(s), equation(s), etc. according to example embodiments of the present disclosure.
The inspection assistant 180 can also include a communication interface 189 used to communicate, for example, with other components of the visual inspection system 100 or other systems or devices. The communication interface 189 can include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Further aspects of the invention are provided by the subject matter of the following clauses:
1. A system, comprising: an optical system having an optical probe and a monitor communicatively coupled with the optical probe, the optical probe being insertable through an access port of a gas turbine engine and configured to capture images of an interior of the gas turbine engine at a location associated with the access port; an inspection assistant communicatively coupled with the optical system, the inspection assistant having a human-machine interface, one or more processors, and one or more memory devices, the one or more processors of the inspection assistant being configured to: (a) receive data including images captured by the optical probe, the images captured by the optical probe providing internal views of the gas turbine engine; (b) cause the images to be displayed on the human-machine interface; (c) detect one or more defects associated with one or more components of the gas turbine engine; and (d) generate an alert indicating that a defect associated with a component of the gas turbine engine is detected, and wherein the one or more processors of the inspection assistant (a) receive, (b) cause, (c) detect, and (d) generate the alert in real time.
2. The system of any preceding clause, wherein the inspection assistant is a handheld portable device.
3. The system of any preceding clause, wherein the optical system has a display communicatively coupled with the optical probe, and wherein the images captured by the optical probe are simultaneously displayed on the display and the human-machine interface of the inspection assistant.
4. The system of any preceding clause, wherein the one or more processors of the inspection assistant detect the one or more defects associated with one or more components of the gas turbine engine by executing an inspection analyzer module hosted on the inspection assistant.
5. The system of any preceding clause, further comprising: a gateway communicatively coupled with the optical system and the inspection assistant, the gateway being configured to route the images captured by the optical probe to the inspection assistant.
6. The system of any preceding clause, wherein the one or more processors of the inspection assistant are further configured to: provide instructions to an operator based at least in part on a selected work scope of an inspection on the gas turbine engine.
7. The system of any preceding clause, wherein the one or more processors of the inspection assistant are further configured to: provide instructions to an operator based at least in part on the defect detected.
8. The system of any preceding clause, wherein in generating the alert indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant are configured to: cause the inspection assistant to generate an audible alert that indicates a defect associated with a component of the gas turbine engine is detected.
9. The system of any preceding clause, wherein in generating the alert indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant are configured to: augment the images displayed on the human-machine interface by overlaying a defect graphic over the defect detected.
10. The system of any preceding clause, wherein the defect graphic overlaying the defect detected in the images displayed on the human-machine interface is represented in a color different from the component having the defect detected.
11. The system of any preceding clause, wherein the one or more processors of the inspection assistant are configured to: classify the defect detected into a defect class of among a plurality of defect classes; and wherein the defect graphic overlaying the defect detected in the images displayed on the human-machine interface is represented in a color associated with the defect class in which the defect detected has been classified.
12. An inspection assistant for aiding an operator during a visual inspection of a gas turbine engine, the inspection assistant comprising: a human-machine interface having a display; one or more memory devices; one or more processors, the one or more processors of the inspection assistant being configured to: (a) receive data including images captured of an interior of a core engine of the gas turbine engine; (b) cause the images to be displayed on the display of the human-machine interface; (c) detect one or more defects associated with one or more components of the core engine; and (d) generate an alert indicating that a defect associated with a component of the gas turbine engine is detected, and wherein the one or more processors of the inspection assistant (a) receive, (b) cause, (c) detect, and (d) generate in real time.
13. The inspection assistant of any preceding clause, wherein the inspection assistant is a handheld portable device.
14. The inspection assistant of any preceding clause, wherein in generating the alert indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant are configured to: cause the inspection assistant to generate an audible alert that indicates a defect associated with a component of the gas turbine engine is detected.
15. The inspection assistant of any preceding clause, wherein in generating the alert indicating that a defect associated with a component of the gas turbine engine is detected, the one or more processors of the inspection assistant are configured to: augment the images displayed on the human-machine interface with a defect graphic.
16. The inspection assistant of any preceding clause, wherein the defect graphic is overlaid over the defect detected.
17. A method of visually inspecting a gas turbine engine, the method comprising: capturing images of an interior of a core engine of the gas turbine engine with an optical probe installed through an access port of the gas turbine engine; receiving, by an inspection assistant, data that includes the images of the interior of the core engine; displaying, by the inspection assistant, the images on a display of the inspection assistant; detecting, by the inspection assistant, one or more defects associated with one or more components of the core engine; and generating, by the inspection assistant, an alert indicating that a defect associated with a component of the core engine is detected, and wherein the capturing, the receiving, the displaying, the detecting, and the generating occur in real time.
18. The method of any preceding clause, further comprising: displaying, by a scope monitor communicatively coupled with the optical probe, the images of the interior of the core engine, and wherein the images captured by the optical probe are simultaneously displayed on the scope monitor and the display of the inspection assistant.
19. The method of any preceding clause, wherein generating the alert indicating that a defect associated with a component of the gas turbine engine is detected comprises causing the inspection assistant to generate an audible alert indicating that a defect associated with a component of the gas turbine engine is detected.
20. The method of any preceding clause, wherein generating the alert indicating that a defect associated with a component of the gas turbine engine is detected comprises augmenting the images displayed on the display of the inspection assistant by overlaying a defect graphic over the defect detected.