阅读说明：本技术 检查和维修工具 (Inspection and repair tool ) 是由 托德·威廉·丹科 安巴利什·贾扬特·库尔卡尼 马格奥克斯·华莱士 赫里希凯什·凯沙万 伯纳德 于 2021-06-09 设计创作，主要内容包括：一种用于检查和维修燃气涡轮发动机的部件的表面的方法,该方法包括：将检查和维修工具插入到燃气涡轮发动机的内部；利用检查和维修工具检查部件的表面；利用检查和维修工具从燃气涡轮发动机的内部进行部件的表面的维修,在检查部件和进行部件的表面的维修之间检查和维修工具保留在燃气涡轮发动机的内部。(A method for inspecting and repairing a surface of a component of a gas turbine engine, the method comprising: inserting inspection and maintenance tools into an interior of a gas turbine engine; inspecting a surface of the component with an inspection and repair tool; the method includes performing a repair of a surface of the component from an interior of the gas turbine engine with an inspection and repair tool remaining in the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.)

1. A method for inspecting and repairing a surface of a component of a gas turbine engine, comprising:

inserting an inspection and service tool into an interior of the gas turbine engine;

inspecting the surface of the component with the inspection and repair tool;

performing a repair of the surface of the component from the interior of the gas turbine engine with the inspection and repair tool remaining in the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

2. The method of claim 1, further comprising:

determining that the surface of the component includes a defect based on the inspection of the surface of the component with the inspection and repair tool.

3. The method of claim 1, wherein inspecting the surface of the component with the inspection and repair tool comprises inspecting the surface of the component with a plurality of cameras of the inspection and repair tool.

4. The method of claim 3, wherein the plurality of cameras comprises two cameras defining overlapping fields of view.

5. The method of claim 3, wherein inspecting the surface of the component with the inspection and repair tool further comprises measuring a distance between the surface of the component and the inspection and repair tool.

6. The method of claim 1, wherein inspecting the surface of the component with the inspection and repair tool comprises overlaying an exemplary image relative to one or more captured images.

7. The method of claim 1, wherein the surface of the component is a thermal barrier coating of the component.

8. The method of claim 7, further comprising:

determining that the surface of the component includes a defect based on the inspection of the surface of the component with the inspection and repair tool, and wherein determining that the surface of the component includes the defect comprises receiving data indicative of spallation of the thermal barrier coating.

9. The method of claim 8, wherein performing the repair of the surface of the component comprises spraying a thermal barrier coating restorative onto spallation of the thermal barrier coating.

10. The method of claim 1, wherein performing the repair of the surface of the component comprises positioning a spray head of the inspection and repair tool based at least in part on a vision system of the inspection and repair tool to spray material on the component.

Technical Field

The present subject matter relates generally to inspection and maintenance tools used within gas turbine engines and methods of using the same.

Background

The use of Thermal Barrier Coatings (TBC) on components such as combustors, High Pressure Turbine (HPT) blades, vanes and shrouds helps such components survive higher operating temperatures, increases component durability and improves engine reliability. TBC's are typically formed from ceramic materials and deposited over environmentally friendly bond coats to form so-called TBC systems.

Under conditions of use, hot section engine components protected by TBC systems are susceptible to various modes of damage, including erosion, oxidation and corrosion due to exposure to the gaseous products of combustion, Foreign Object Damage (FOD), and attack from environmental pollutants. The source of environmental pollutants is ambient air, which the engine draws in for cooling and combustion. The type of environmental contaminants in the ambient air will vary from location to location, but may be of concern to aircraft as their purpose is to move from one location to another. These environmental pollutants are in addition to the corrosive and oxidative pollutants produced by the combustion of fuels.

Some of these contaminants may result in loss of TBC throughout the life of the component, leaving a small portion of TBC behind or completely removing a portion of TBC, exposing the underlying component to operating conditions and possibly damaging the component.

Accordingly, methods and systems for servicing TBCs would be useful.

Disclosure of Invention

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.

Aspects of the present disclosure relate to a method for inspecting and repairing a surface of a component of a gas turbine engine. The method comprises the following steps: inserting inspection and maintenance tools into an interior of a gas turbine engine; inspecting a surface of the component with an inspection and repair tool; the method includes performing a repair of a surface of the component from an interior of the gas turbine engine with an inspection and repair tool remaining in the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

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.

Drawings

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:

FIG. 1 is a schematic cross-sectional view of an exemplary gas turbine engine, according to various embodiments of the present subject matter;

FIG. 2 is a perspective cross-sectional view of a combustor assembly having a damaged TBC in accordance with an exemplary embodiment of the present disclosure;

FIG. 3 is a schematic view of a system for in situ inspection and repair of a portion of a thermal barrier coating of a component according to an exemplary embodiment of the present disclosure;

FIG. 4 is another schematic view of a system for in situ inspection and repair of a portion of a thermal barrier coating of a component according to an exemplary embodiment of the present disclosure;

FIG. 5 is a close-up perspective view of a distal end of an inspection and service tool having a spray head in a first position according to an exemplary embodiment of the present disclosure;

FIG. 6 is a photograph of a thermal barrier coating in need of repair;

FIG. 7 is a close-up perspective view of the distal end of the inspection and service tool of FIG. 5 with the spray head in a second position;

FIG. 8 is a flow chart of a method for inspecting and repairing a thermal barrier coating of a component of a gas turbine engine according to an exemplary aspect of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

Detailed Description

Reference will now be made in detail to the present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar reference numbers have been used in the drawings and the description to refer to the same or similar parts of the invention.

The word "exemplary" is used herein to mean "serving as an example, instance, or illustration. Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one element from another, and are not intended to denote the position or importance of the various elements.

The terms "forward" and "aft" refer to relative positions within the gas turbine engine or vehicle and to normal operating attitudes of the gas turbine engine or vehicle. For example, for a gas turbine engine, forward refers to a position closer to the engine inlet, and aft refers to a position closer to the engine nozzle or exhaust outlet.

The terms "upstream" and "downstream" refer to relative directions with respect to fluid flow in a fluid path. For example, "upstream" refers to the direction from which the fluid flows, while "downstream" refers to the direction to which the fluid flows.

Unless otherwise indicated herein, the terms "coupled," "secured," "attached," and the like, refer to a direct coupling, securing, or attachment, as well as an indirect coupling, securing, or attachment through one or more intermediate components or features.

The term "repair" in relation to a component generally refers to any repair or maintenance activity on such a component, including any activity of adding material to the component, removing material from the component, or changing material properties of all or part of the component. In at least certain embodiments, the term "repair" in relation to a component refers to performing tasks related to rejuvenating damaged portions of the component and maintaining or protecting damaged and undamaged portions of the component.

The singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about", "about" and "substantially", are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of a method or machine for constructing or manufacturing the component and/or system. For example, approximate language may refer to being in the range of 10%.

Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

It should be appreciated that in order to repair a damaged area of a thermal barrier coating ("TBC"), one or more inspection operations are typically performed manually using, for example, a borescope inspection tool. During the inspection operation, any areas that need to be repaired may be recorded. Subsequently, the engine may be "removed" from the wing (i.e., unloaded from the aircraft), the component may be removed (or the engine may be disassembled to the extent that the component is exposed), the area in need of repair may be cleaned, a thermal barrier coating repair may be applied and cured, and the component may be reinstalled and the engine reinstalled on the aircraft.

This is a rather time consuming and expensive process. In view of the above, it will be appreciated that it would be desirable if systems and methods were available for servicing and inspecting thermal barrier coatings without requiring a variety of different tools and without requiring the engine to be removed from the wing and at least partially disassembled.

Accordingly, aspects of the present disclosure provide systems and methods for repairing a surface of a component of a gas turbine engine, such as a TBC of a component of a gas turbine engine. The systems and methods described herein may facilitate in situ inspection and repair of TBCs or other aspects of components.

In at least one exemplary aspect, the method may include inserting an inspection and service tool into an interior of a gas turbine engine; inspecting a surface of the component with an inspection and repair tool; and performing repair of the component surface from within the gas turbine engine using inspection and repair tools. In this manner, it will be appreciated that the inspection and repair tools remain inside the gas turbine engine between inspecting the component and performing the repair of the component surface. This may effectively result in a more compact inspection and repair process using inspection and repair tools, saving time and cost compared to conventional inspection and repair processes. More specifically, by using tools capable of both inspection and repair processes, the overall time to perform these operations, as well as the amount of time an engine is out of service, may be reduced.

Referring now to the drawings, FIG. 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure. More particularly, for the embodiment of fig. 1, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as "turbofan engine 10". As shown in FIG. 1, turbofan engine 10 defines an axial direction A (extending parallel to longitudinal centerline 12 for reference) and a radial direction R. Generally, turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream from fan section 14.

The exemplary core turbine engine 16 shown generally includes a substantially tubular casing 18 defining an annular inlet 20. The housing 18 encloses in serial flow relationship: a compressor section including a booster or Low Pressure (LP) compressor 22 and a High Pressure (HP) compressor 24; a combustion section 26; a turbine section including a High Pressure (HP) turbine 28 and a Low Pressure (LP) turbine 30; and an injection exhaust nozzle section 32. A High Pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A Low Pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

For the illustrated embodiment, the fan section 14 includes a variable pitch fan 38, the variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced apart manner. As shown, fan blades 40 extend generally outward in a radial direction R from a disk 42. Each fan blade 40 is rotatable relative to the disk 42 about a pitch axis P by virtue of the fan blades 40 being operatively coupled to a suitable actuating member 44, the actuating members 44 being configured to collectively vary the pitch of the fan blades 40 in unison. Fan blades 40, discs 42, and actuating members 44 together may be rotated about longitudinal axis 12 by LP shaft 36 across optional power gearbox 46. Power gearbox 46 includes a plurality of gears for reducing the rotational speed of LP shaft 36 to a more efficient rotational fan speed.

Still referring to the exemplary embodiment of FIG. 1, disk 42 is covered by a rotatable forward nacelle 48, the rotatable forward nacelle 48 being aerodynamically shaped to promote airflow over the plurality of fan blades 40. Additionally, exemplary fan section 14 includes an annular fan case or outer nacelle 50 that circumferentially surrounds at least a portion of fan 38 and/or core turbine engine 16. It should be appreciated that the nacelle 50 may be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Moreover, a downstream section 54 of nacelle 50 extends over an exterior portion of core turbine engine 16 to define a bypass airflow passage 56 therebetween.

During operation of turbofan engine 10, an amount of air 58 enters turbofan engine 10 through nacelle 50 and/or an associated inlet 60 of fan section 14. As the quantity of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is channeled or directed into the bypass airflow channel 56, and a second portion of the air 58, as indicated by arrow 64, is channeled or directed into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is commonly referred to as the bypass ratio. Then, as the second portion of air 64 is channeled through High Pressure (HP) compressor 24 and into combustion section 26, a pressure of second portion of air 64 is increased, and second portion of air 64 is mixed with fuel and combusted within combustion section 26 to provide combustion gases 66.

The combustion gases 66 are channeled through HP turbine 28, wherein a portion of thermal and/or kinetic energy from combustion gases 66 is extracted via sequential stages of HP turbine stator vanes 68 coupled to casing 18 and HP turbine rotor blades 70 coupled to HP shaft or spool 34, thereby rotating HP shaft or spool 34, supporting operation of HP compressor 24. The combustion gases 66 are then channeled through LP turbine 30, wherein a second portion of thermal and kinetic energy is extracted from the combustion gases 66 via sequential stages of LP turbine stator vanes 72 coupled to outer casing 18 and LP turbine rotor blades 74 coupled to LP shaft or spool 36, thereby rotating LP shaft or spool 36, thereby supporting operation of LP compressor 22 and/or rotation of fan 38.

Subsequently, the combustion gases 66 are directed through the injection exhaust nozzle section 32 of the core turbine engine 16 to provide propulsion. At the same time, as first portion of air 62 is channeled through bypass airflow passage 56 prior to being discharged from fan nozzle exhaust section 76 of turbofan engine 10, the pressure of first portion of air 62 is substantially increased, which also provides propulsion. HP turbine 28, LP turbine 30, and jet exhaust nozzle section 32 at least partially define a hot gas path 78 for channeling combustion gases 66 through core turbine engine 16.

Referring now to FIG. 2, a close-up cross-sectional view of the combustion section 26 of the exemplary turbofan engine 10 of FIG. 1 is provided. More specifically, FIG. 2 provides a perspective cross-sectional view of a combustor assembly 100 that may be positioned in the combustion section 26 of the exemplary turbofan engine 10 of FIG. 1, according to an exemplary embodiment of the present disclosure.

As shown, combustor assembly 100 generally includes an inner liner 102 extending generally along an axial direction A between an aft end 104 and a forward end 106, and an outer liner 108 also extending generally along an axial direction A between an aft end 110 and a forward end 112. Together, the inner liner 102 and the outer liner 108 at least partially define a combustion chamber 114 therebetween. The inner liner 102 and the outer liner 108 are each attached to an annular dome. More specifically, the combustor assembly 100 includes an inner annular dome 116 attached to the forward end 106 of the inner liner 102 and an outer annular dome 118 attached to the forward end 112 of the outer liner 108. Although inner and outer annular domes 116, 118 are shown to each include a closed surface defining a slot 122 for receiving the forward ends 106, 112 of the respective inner and outer liners 102, 108, any suitable attachment scheme may be utilized to attach the liners to the respective domes. Moreover, although the exemplary combustor assembly 100 shown includes an inner annular dome and an outer annular dome, it should be appreciated that in other embodiments, the domes may be formed in a single dome configuration or any other suitable multi-dome configuration (e.g., 3 domes, etc.).

The combustor assembly 100 also includes a plurality of fuel-air mixers 124 spaced apart along the circumferential direction within the outer dome 118. More specifically, the plurality of fuel-air mixers 124 are disposed between the outer dome 118 and the inner dome 116 along the radial direction R. Compressed air from the compressor section of turbofan engine 10 flows into or through a fuel-air mixer 124 where the compressed air is mixed with fuel and ignited to generate combustion gases 66 within combustion chamber 114. Inner dome 116 and outer dome 118 are configured to facilitate providing such a flow of compressed air from the compressor section into or through fuel-air mixer 126. For example, outer dome 118 includes an outer shroud 126 at a forward end 128, and inner dome 116 similarly includes an inner shroud 130 at a forward end 132. The outer shroud 126 and the inner shroud 130 may facilitate channeling a flow of compressed air from the compressor section 26 into or through one or more fuel-air mixers.

Further, inner dome 116 and outer dome 118 each include attachment portions configured to facilitate mounting combustor assembly 100 within turbofan engine 10. For example, outer dome 118 includes an attachment extension 134 configured to be mounted to an outer combustor casing (not shown), while inner dome 116 includes a similar attachment extension 138 configured to be attached to an annular support member (not shown) within turbofan engine 10. In certain exemplary embodiments, inner dome 116 may be integrally formed as a single annular component, and similarly, outer dome 118 may also be integrally formed as a single annular component. However, it should be appreciated that in other exemplary embodiments, the inner dome 116 and/or the outer dome 118 may alternatively be formed from one or more components joined in any suitable manner. For example, referring to the outer dome 118, in certain exemplary embodiments, the outer shroud 126 may be formed separately from the outer dome 118 and attached to the front end 128 of the outer dome 118 using, for example, a welding process. Similarly, the attachment extension 134 may also be formed separately from the outer dome 118 and attached to the front end 128 of the outer dome 118 using, for example, a welding process. Additionally or alternatively, inner dome 116 may have a similar configuration.

Still referring to FIG. 2, the exemplary combustor assembly 100 also includes a plurality of circumferentially arranged heat shields 142 positioned about each fuel-air mixer 124. For the depicted embodiment, the heat shield 142 is attached to the outer and inner domes 118, 116 and extends between the outer and inner domes 118, 116. The heat shield 142 is configured to protect certain components of the turbofan engine 10 from the relatively extreme temperatures of the combustion chamber 114.

It should be appreciated that each of the heat shield 142, the inner liner 102, and the outer liner 104 are exposed to relatively harsh conditions of relatively high temperature during operation of the gas turbine engine. In this way, a thermal barrier coating 146 is provided on at least the exposed surfaces of one or more of these components.

Particularly for the embodiment of FIG. 2, the heat shield 142 includes a thermal barrier coating 146 for protecting the underlying structure of the heat shield 142. The thermal barrier coating 146 may be a ceramic coating or any other suitable coating.

Further, it will also be appreciated that, through operation of gas turbine engine 10, one or more portions of thermal barrier coating 146 may wear or degrade faster than other portions of thermal barrier coating 146. For example, as schematically shown in FIG. 2, the thermal barrier coating 146 includes a wear portion 148 between adjacent fuel-air mixers 124. The wear portion 148 shown schematically in FIG. 2 may represent spallation of the thermal barrier coating.

Referring now to FIG. 3, an inspection and service tool 200 is provided according to an exemplary embodiment of the present disclosure, and the inspection and service tool 200 may be used with the exemplary gas turbine engine 10 and its components described above with reference to FIGS. 1 and 2.

For the exemplary embodiment of fig. 3, inspection and service tool 200 generally includes an elongated insertion member 202 and an implement body 204 attached to elongated insertion member 202 at a distal end 206 of elongated insertion member 202. As will be described in greater detail below, appliance body 204 may be configured to perform one or more inspection and/or maintenance operations.

More specifically, for the embodiment of FIG. 3, the inspection and service tool 200 utilizes a robotic arm assembly 208 (also sometimes referred to as a "serpentine arm" assembly), and the elongated insertion member 202 is configured as a robotic arm of the robotic arm assembly 208. The robot arm assembly 208 generally defines a vertical direction V, a longitudinal direction L, and a lateral direction (perpendicular to the longitudinal direction L and the vertical direction V; not shown). In addition to the elongated insertion member 202 or robotic arm, the robotic arm assembly 208 also includes a base 210. Although not shown, the robotic arm defines a fluid passageway therethrough. The fluid channel may be in direct fluid communication with the supply line and/or the fluid heater, or alternatively may be in fluid communication with a fluid source through the base 210.

For the illustrated embodiment, the base 210 generally includes one or more motors 212 operable with the robotic arm to actuate the robotic arm. Accordingly, the depicted robotic arm assembly 208 may be referred to as a motorized robotic arm assembly. Additionally, for the illustrated embodiment, the robotic arm includes a plurality of segments 214 (also referred to as "links") that are sequentially arranged between the root end 216 and the distal end 206 and extend from the base 210, e.g., generally along the longitudinal direction L of the robotic arm assembly 208 for the illustrated embodiment. Notably, for the illustrated embodiment, the robotic arm is coupled to the base 210 at a root end 216 thereof.

Further, with particular reference to the robotic arm, as shown, each segment 214 may be moved relative to a leading adjacent segment 214 (i.e., segment 214 immediately in front of/toward distal end 206 of segment 214) and a trailing adjacent segment (i.e., segment 214 immediately behind/toward root end 216 of segment 214) along at least two degrees of manipulation to form the two-dimensional shape of the robotic arm in fig. 3. For example, each segment 214 may move up or down along the vertical direction V of the robotic arm assembly 208 relative to the front and rear adjacent segments 214, 214. However, it will be further understood that for the depicted exemplary embodiment, each segment 214 may be further moved relative to the respective front and rear adjacent segments 214 along at least four degrees of operation. For example, each segment 214 may also be movable in a lateral direction (perpendicular to the longitudinal direction L and the vertical direction V) relative to the front and rear adjacent segments 214. In this manner, the robotic arm is generally movable to form various three-dimensional shapes. In this manner, the robotic arm may be movable to position the distal end 206 and the appliance body 204 adjacent to a number of different components of the interior of the gas turbine engine.

Briefly, as noted, the depicted robotic arm assembly 208 utilizes a motorized robotic arm assembly. Thus, it will be appreciated that, in at least certain exemplary embodiments, the one or more motors 212 of the base 210 may generally pull various wires (not shown) that extend through the robotic arm and terminate at various segments 214 of the robotic arm. By pulling on these various wires, one or more motors 212 of the base 210 may control the movement of the segments 214 of the robotic arm.

However, in other embodiments, any other suitable configuration may be provided to control the robotic arm. In certain exemplary embodiments, motor 212 may be operably coupled to a controller of inspection and service tool 200 (such as controller 220 of inspection and service tool 200 discussed below).

However, it will be further appreciated that in other exemplary embodiments, other elongated insertion members 202 may also be provided. For example, in other embodiments, the elongated insertion member 202 may be a manual serpentine arm assembly that is manually moved into position. Alternatively, elongated insert member 202 may be a flexible or semi-flexible tube that may be bent into a desired shape to position its distal end 206 at a desired location inside the gas turbine engine. Alternatively, elongated insert member 202 may be a series of links having a predetermined shape that are selectively rigidized such that when moved to a rigid position to position appliance body 204 at a desired location inside the gas turbine engine, they form the desired shape. Other configurations are also contemplated.

Still referring to the exemplary inspection and service tool 200 shown in FIG. 3, the exemplary inspection and service tool 200 also includes a controller 220. The example controller 220 depicted in fig. 3 is configured to receive data from aspects of the example inspection and service tool 200 (e.g., from the fixture body 204 as described below) and make control decisions for the inspection and service tool 200 based on the received data, for example.

With particular reference to the operation of the controller 220, in at least some embodiments, the controller 220 can include one or more computing devices 222. Computing device 222 may include one or more processors 222A and one or more memory devices 222B. The one or more processors 222A may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, and/or other suitable processing device. The one or more memory devices 222B may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, and/or other memory devices.

The one or more memory devices 222B may store information accessible by the one or more processors 222A, including computer-readable instructions 222C that may be executed by the one or more processors 222A. The instructions 222C may be any set of instructions that, when executed by the one or more processors 222A, cause the one or more processors 222A to operate. In some embodiments, instructions 222C may be executable by one or more processors 222A to cause the one or more processors 222A to perform operations, such as any operations and functions for which controller 220 and/or computing device 222 are configured to operate, as described herein, for operation of inspection and service tool 200 (e.g., method 300) and/or any other operations or functions of one or more computing devices 222. The instructions 222C may be software written in any suitable programming language or may be implemented in hardware. Additionally and/or alternatively, the instructions 222C may be executed in logically and/or virtually separate threads on the processor 222A. Memory device 222B may further store data 222D that may be accessed by processor 222A.

Computing device 222 may also include a network interface 222E for communicating, for example, with other components of inspection and service tool 200, gas turbine engines being serviced, aircraft including gas turbine engines, and the like. For example, in the embodiments described above, gas turbine engine and/or inspection and service tool 200 includes one or more sensors for sensing data indicative of one or more parameters of inspection and service tool 200, the gas turbine engine, or both. Controller 220 is operably coupled to one or more sensors, e.g., through network interface 222E, such that controller 220 can receive data indicative of various operating parameters sensed by the one or more sensors during operation. Network interface 222E may include any suitable components for interfacing with one or more wired/wireless communication networks, including, for example, a transmitter, a receiver, a port, a controller, an antenna, and/or other suitable components.

Referring now to FIG. 4, a close-up side cross-sectional view of combustor assembly 154, and a schematic illustration of inspection and service tool 200 according to an exemplary embodiment of the present disclosure, is provided. In certain exemplary embodiments, the inspection and service tool 200 of FIG. 4 may be configured in a similar manner as the inspection and service tool 200 of FIG. 3, and the combustor assembly 154 of FIG. 4 may be positioned in the combustion section 114 of the exemplary turbofan engine 100 of FIG. 2. Accordingly, it should be appreciated that the exemplary combustor assembly 154 generally defines an axial direction A, a radial direction R, and a circumferential direction C.

Referring first to the exemplary combustor assembly 154 depicted, the combustor assembly 154 generally includes an inner liner 156 that extends generally along an axial direction a, and an outer liner 158 that also extends generally along the axial direction a. Together, the inner liner 156 and the outer liner 158 at least partially define a combustion chamber 160 therebetween. An inner liner 156 and an outer liner 158 are both attached to the annular dome. More specifically, the annular dome includes an inner dome section 162 attached to the inner liner 156 and an outer dome section 164 attached to the outer liner 158. Inner and outer dome sections 162, 164 may be integrally formed (or alternatively may be formed from multiple components attached in any suitable manner), and may each extend along circumferential direction C to define an annular shape. Combustor assembly 154 also includes fuel nozzles 166 positioned at least partially within the annular dome and a heat shield 168 positioned about fuel nozzles 166. One or more of inner dome section 162 and outer dome section 164 and heat shield 168 may include a thermal barrier coating thereon.

During operation of a gas turbine engine including the exemplary combustor assembly 154 shown, temperatures within the combustor 160 may be relatively high, and thermal barrier coatings on one or more of the inner and outer dome sections 162, 164 and the heat shield 168 may degrade over time. Accordingly, the present disclosure generally provides an inspection and service tool 200 to inspect one or more of these components for such degradation and service the degradation in situ (i.e., when the combustor assembly 154 is installed in a gas turbine engine), and also without significantly disassembling the gas turbine engine (e.g., removing the components to expose degraded thermal barrier coating components of the gas turbine engine).

Referring now specifically to exemplary inspection and service tool 200, it will be appreciated that combustor assembly 154 is enclosed by a casing 224. For the illustrated embodiment, the shell 224 and the outer liner 158 of the combustor assembly 154 together define an access port 226. The access port 226 may be, for example, an igniter port of the combustor assembly 154 that is currently existing or is to be added in the future, or any other suitable access port 226 (e.g., borescope hole, etc.). As described above, inspection and service tool 200 generally includes an elongated insertion member 202 and an implement body 204 attached to elongated insertion member 202. As with the exemplary embodiment of fig. 3, the elongated insertion member 202 of the inspection and service tool 200 of fig. 4 is configured as a robotic arm. The robotic arms are configured to guide the appliance body 204 through the access port 226 and into the interior of the gas turbine engine, and more specifically, the interior of the combustor assembly 154, or more specifically, the combustion chamber 160 of the depicted exemplary combustor assembly 154.

In this manner, it will be appreciated that inspection and service tool 200 may be used to perform one or more inspection and service operations within the interior of a gas turbine engine, and more specifically, within the interior of a combustor assembly, by guiding fixture body 204 therein. Implement body 204 may include one or more implements to facilitate internal inspection. For example, as will be described in more detail below, the appliance body 204 may include a vision system for providing feedback to help guide the appliance body 204 internally and inspect one or more components of the interior. For example, the vision system may be used to inspect thermal barrier coatings on the inner dome 162, outer dome 164, heat shield 168, and the like. Additionally, implement body 204 may include one or more implements to facilitate internal maintenance. For example, the appliance body 204 may include a spray head for spraying a thermal barrier coating restorative onto a degraded portion of an internal thermal barrier coating (e.g., onto the worn portion 148 of the thermal barrier coating 146 discussed above with reference to FIG. 2).

Referring now to FIG. 5, a close-up perspective view of distal end 206 of inspection and service tool 200 is provided, according to an exemplary embodiment of the present disclosure. Exemplary inspection and service tool 200 may be constructed in substantially the same manner as exemplary inspection and service tool 200 described above with reference to fig. 3 and 4. For example, inspection and service tool 200 generally includes an elongated insertion member 202 and an implement body 204 attached to elongated insertion member 202 at a distal end 206 of elongated insertion member 202.

For the illustrated embodiment, the appliance body 204 includes an appliance for performing inspection and maintenance operations. Specifically, for the illustrated embodiment, appliance body 204 includes a base 230 extending along a longitudinal direction L2 and a vision system. More specifically, for the illustrated embodiment, the vision system is positioned at least partially within the base 230 or coupled to the base 230. More specifically, for the illustrated embodiment, the vision system includes a plurality of cameras 232, and in particular, a first camera 232A and a second camera 232B. The first camera 232A and the second camera 232B are spaced apart along the longitudinal direction L2 of the base 230.

As shown in fig. 5, the first camera 232A defines a first field of view 234A and the second camera 232B defines a second field of view 234B. The first field of view 234A overlaps the second field of view 234B. More specifically, for the illustrated embodiment, the first field of view 234A and the second field of view 234B overlap at a location 236 that is within about 12 inches from the base 230 of the fixture body 204 (e.g., at a location that is within about 8 inches, such as within about 6 inches, such as within about 3 inches, such as within about 1 inch from the base 230 of the fixture body 204).

In this manner, the vision system may provide improved feedback for navigating the inspection and service tool 200 within the gas turbine engine and inspection within the gas turbine engine. For example, the overlapping fields of view 234A, 234B may provide a desired depth perception when the inspection and service tool 200 is operated.

Additionally, it will be appreciated that, in certain exemplary embodiments, implement body 204 may additionally or alternatively include any other suitable means for determining a distance between implement body 204 and the part being inspected. For example, the tool body 204 may include one or more laser depth sensors, or other suitable hardware (not shown).

Further, it will be understood that the one or more cameras 232 of the vision system are operably coupled to the controller 220 (see fig. 3-4) such that the vision system and the controller 220 may be used to inspect the interior of the gas turbine engine. For example, the vision system may be configured to communicate an image of the thermal barrier coating of the interior to the controller 220 along with location information indicating where the thermal barrier coating is inside. The controller 220 may be configured to then compare the image to one or more baseline images to determine whether the thermal barrier coating is damaged. For example, referring briefly to fig. 6, a sample image of thermal barrier coating 146 is depicted on a dome (similar to domes 162, 164 of fig. 3) of combustor assembly 154. Thermal barrier coating 146 includes a damaged portion 148, referred to as spallation, where thermal barrier coating 146 has worn away. Controller 220 may receive the image, compare it to one or more baseline images, and determine that there is damage requiring repair on thermal barrier coating 146 using, for example, a pixel-by-pixel analysis. As discussed below, the extent (e.g., depth, width, area, shape, etc.) of the damaged portion 148 may be determined by analysis by the controller 220 to facilitate customized repair of such damaged portion 148.

However, it will be appreciated that in other exemplary embodiments, the controller 220 may utilize any other suitable analysis technique to determine whether there is any damage to the thermal barrier coating 146, the extent of such damage, and the like. For example, in other exemplary embodiments, the controller 220 may utilize a machine learning tool trained to identify the presence and/or extent of damage to the thermal barrier coating 146 or other components inside the engine.

Referring still to FIG. 5, and now also to FIG. 7, another schematic illustration of the exemplary inspection and service tool 200 of FIG. 5 is provided, it being further appreciated that the fixture body 204 includes a spray head 240. Spray head 240 is movably coupled to base 230 of appliance body 204 and is movable between a retracted position, as shown in FIG. 7, and an extended position, as shown in FIG. 5.

Specifically, for the illustrated embodiment, spray head 240 is rotatably coupled to base 230 about a pin connection 242. For the illustrated embodiment, spray head 240 rotates at least about 30 degrees (e.g., at least about 45 degrees, such as at least about 90 degrees) and less than 360 degrees between the retracted position shown in FIG. 7 and the extended position shown in FIG. 5. It is noted that for the illustrated embodiment, the spray head 240 rotates along reference arrow 244 in fig. 5 in a plane parallel to the longitudinal direction L2. In this manner, when in the extended position, spray head 240 defines a first angle (e.g., about 90 degrees for the illustrated embodiment) with longitudinal direction L2, and when in the retracted position, spray head 240 defines a second angle (e.g., about 0 degrees for the illustrated embodiment) with longitudinal direction L2 that is different from the first angle.

In this manner, when the spray head 240 is in the retracted position, the appliance body 204 defines a smaller cross-sectional profile to facilitate insertion of the appliance body 204 into the interior of the gas turbine engine (e.g., through an access port, such as the access port 226 of FIG. 4). Thereafter, once appliance body 204 is inside, spray head 240 may be moved from the retracted position to the extended position to allow operation of spray head 240, as described below. Spray head 240 may be spring loaded.

Notably, for the illustrated embodiment, spray head 240 is fluidly connected to a fluid source via one or more fluid passages 246 extending along the length of elongate insertion member 202. One or more fluid channels 246, shown in phantom in fig. 5 and 7, may be separate fluid conduits extending through elongate insertion member 202 or may be integrally formed within elongate insertion member 202. The one or more fluid passages 246 may provide a flow of repair material 248 to the spray head 240 to be sprayed on the damaged portion of the thermal barrier coating to repair the damaged portion of the thermal barrier coating. The repair material 248 may be a slurry formed from a powder and a carrier, which may be formed as a complement to the thermal barrier coating. For example, the powder may be a machine-curable ceramic powder mixture configured to bond to the damaged portion of the thermal barrier coating.

Although a single fluid passage 246 is schematically illustrated in fig. 5 and 7, in other exemplary embodiments, inspection and service tool 200 may include multiple passages. For example, the inspection and service tool 200 may include passages for service material 248, passages for cleaning and conditioning fluids, passages for curing fluids, and the like. Each of these passages may be in fixed or selective fluid communication with the spray head 240.

Still referring to FIG. 5, it will be further appreciated that the spray head 240 defines an outlet 250 for spraying the repair material 248 onto the damaged portion of the thermal barrier coating. For the illustrated embodiment, the exit 250 is within the field of view 234 of the vision system. More specifically, for the illustrated embodiment, the exit 250 is within the first field of view 234A and/or the second field of view 234B of the first and second cameras 232 of the vision system. In this manner, the controller 220 can confirm the position of the spray head 240 and the coverage of the sprayed repair material 248 (or other material/fluid).

Further, it should still be understood that the example appliance body 204 is movable to assist in the spraying operation. More specifically, for the illustrated embodiment, implement body 204 includes a stationary portion 252 and a rotating portion 254. Rotating portion 254 includes base 230 and spray head 240, and rotating portion 254 is rotatably coupled to stationary portion 252 such that rotating portion 254 is rotatable in circumferential direction C about longitudinal direction L2. The stationary portion 252 includes one or more motors positioned therein for selectively moving the rotating portion 254 about the circumferential direction C. Accordingly, it will be appreciated that in certain exemplary embodiments, the implement body 204 may move the spray head 240 in the circumferential direction C during a spraying operation to provide a more uniform coverage of the sprayed repair material 248 (or other material/fluid).

It should be understood that the above-described exemplary inspection and service tool 200 is provided by way of example only. In other exemplary embodiments, inspection and service tool 200 may have any other suitable configuration. For example, in other exemplary embodiments, spray head 240 may be movably coupled to base 230 in any other suitable manner (e.g., rotating and sliding, etc.), spray head 240 may have any other configuration of outlets 250 (e.g., a linear array or other pattern of outlets 250), appliance body 204 may have any other suitable vision or inspection system, appliance body 204 may be configured to rotate in any other suitable manner, etc.

Referring now to FIG. 8, a method 300 for inspecting and repairing a surface of a component of a gas turbine engine is provided. The method 300 may utilize inspection and repair tools according to one or more of the exemplary configurations discussed above with respect to fig. 1-7.

The method 300 includes inserting an inspection and service tool into an interior of the gas turbine engine at (302). In certain exemplary aspects, inserting the inspection and service tool into the interior of the gas turbine engine at (302) may include inserting the inspection and service tool into the interior of the gas turbine engine through an inspection port of the engine to position an appliance body of the inspection and service tool within a combustion chamber of a combustor assembly of the engine.

The method 300 further includes inspecting the surface of the component with an inspection and repair tool at (304). For the illustrated embodiment, inspecting the surface of the component with the inspection and repair tool at (304) includes inspecting the surface of the component with a plurality of cameras of the inspection and repair tool at (306). In certain exemplary aspects, the plurality of cameras includes two cameras defining overlapping fields of view. Further to the illustrated embodiment, inspecting the surface of the component with the inspection and repair tool at (304) includes measuring a distance between the surface of the component and the inspection and repair tool at (308).

Notably, for the exemplary aspect of FIG. 8, the inspection and service tool includes a spray head that pivots between a retracted position and an extended position. For such exemplary aspects, inspecting the surface of the component with the inspection and service tool at (304) includes moving the spray head from the retracted position to the extended position after inserting the inspection and service tool into the interior of the gas turbine engine at (307).

Additionally, in certain exemplary aspects, inspecting the surface of the component with the inspection and service tool at (304) includes moving the inspection and service tool inside the cavity using the serpentine arm assembly at (309).

The method 300 further includes determining, at (310), that the surface of the component includes a defect based on inspection of the surface of the component with the inspection and repair tool. In this manner, it will also be appreciated that inspecting the surface of the component with the inspection and repair tool at (304) may include utilizing any suitable inspection and analysis technique. For example, in certain exemplary aspects, inspecting the surface of the component with the inspection and repair tool at (304) includes superimposing the exemplary image relative to the one or more captured images at (312), and determining that the surface of the component includes the defect at (310) includes determining that the surface of the component includes the defect based on a comparison of the superimposed exemplary image relative to the one or more captured images at (311).

Further, it will be understood that, in certain exemplary aspects, the surface of the component is a thermal barrier coating of the component, and determining that the surface of the component includes the defect at (310) includes receiving data indicative of spallation of the thermal barrier coating at (314). The data indicative of spallation of the thermal barrier coating may be the comparison data described above, or may be the result of a machine learning tool trained to identify spallation.

The method 300 further includes performing a repair of the surface of the component from the interior of the gas turbine engine with an inspection and repair tool at (316), the inspection and repair tool remaining in the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component. In this manner, it will be appreciated that both inspection of the surface of the component at (304) and repair of the surface of the component at (316) may be accomplished in situ without having to remove the inspection and repair tools. This may allow for a more time-and cost-effective inspection and repair process.

Still referring to FIG. 8, it will be understood that, in certain exemplary aspects, performing repair of the surface of the component at (316) further includes spraying a thermal barrier coating restorative onto spallation of the thermal barrier coating at (318).

Additionally, in certain exemplary aspects, such as the exemplary aspect shown, performing the repair of the surface of the component at (316) further includes positioning a spray head of the inspection and repair tool to spray material on the component at (320) based at least in part on a vision system of the inspection and repair tool.

Further, in certain exemplary aspects, such as the depicted exemplary aspects, performing repair of the surface of the component at (316) additionally includes spraying a pre-treatment material on the surface of the component at (322), and subsequently spraying a repair material on the surface of the component. With such exemplary aspects, inspection and repair tools may remain inside the gas turbine engine between spraying the pre-treatment material on the surface of the component and spraying the repair material on the surface of the component.

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 languages of the claims.

Further aspects of the invention are provided by the subject matter of the following clauses:

a method for inspecting and repairing a surface of a component of a gas turbine engine, comprising: inserting an inspection and service tool into an interior of the gas turbine engine; inspecting the surface of the component with the inspection and repair tool; performing a repair of the surface of the component from the interior of the gas turbine engine with the inspection and repair tool remaining in the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

The method according to one or more of these clauses, further comprising: determining that the surface of the component includes a defect based on the inspection of the surface of the component with the inspection and repair tool.

The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool comprises inspecting the surface of the component with a plurality of cameras of the inspection and repair tool.

The method of one or more of these clauses, wherein the plurality of cameras comprises two cameras defining overlapping fields of view.

The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool further comprises measuring a distance between the surface of the component and the inspection and repair tool.

The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool includes superimposing an exemplary image relative to one or more captured images.

The method of one or more of these clauses, wherein the surface of the component is a thermal barrier coating of the component.

The method according to one or more of these clauses, further comprising: determining that the surface of the component includes a defect based on the inspection of the surface of the component with the inspection and repair tool, and wherein determining that the surface of the component includes a defect comprises receiving data indicative of spallation of the thermal barrier coating.

The method of one or more of these claims, wherein performing the repair of the surface of the component comprises spraying a thermal barrier coating restorative onto spallation of the thermal barrier coating.

The method of one or more of these clauses, wherein performing the repair of the surface of the component includes positioning a spray head of the inspection and repair tool based at least in part on a vision system of the inspection and repair tool to spray material on the component.

The method according to one or more of these claims, wherein performing the repair of the surface of the component comprises spraying a pre-treatment material on the surface of the component and subsequently spraying a repair material on the surface of the component, and wherein the inspection and repair tool remains in the interior of the gas turbine engine between spraying the pre-treatment material on the surface of the component and spraying the repair material on the surface of the component.

The method of one or more of these clauses, wherein the inspection and service tool comprises a camera and a spray head defining a field of view, wherein the spray head comprises an outlet, and wherein the outlet is within the field of view.

The method according to one or more of these clauses, wherein the camera is a first camera, wherein the field of view is a first field of view, wherein the inspection and service tool additionally comprises a second camera defining a second field of view, wherein the first field of view and the second field of view together define an overlapping field of view, wherein the outlet is within the overlapping field of view

The method of one or more of these clauses, wherein the inspection and service tool includes a spray head, and wherein the spray head pivots between a retracted position and an extended position.

The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool comprises moving the inspection and repair tool inside a cavity using a serpentine-arm robot.

A tool for inspecting, servicing, or both inspecting and servicing components within a gas turbine engine, comprising: an elongated insertion member; and an appliance body attached to the elongated insert member, the elongated insert member configured to guide the appliance body within the interior of the gas turbine engine, the appliance body including a base and a spray head movably coupled to the base and movable between a retracted position and an extended position.

The tool of one or more of these clauses, wherein the fixture body defines a smaller cross-sectional profile when the spray head is in the retracted position to facilitate insertion of the fixture body into the interior of the gas turbine engine.

The tool of one or more of these clauses, wherein the appliance body further comprises a vision system positioned at least partially within or coupled to the base.

The tool of one or more of these clauses, wherein the vision system defines a field of view, wherein the spray head comprises an outlet, and wherein the outlet is within the field of view.

The tool of one or more of these clauses, wherein the elongated insertion member is a robotic arm tool comprising one or more fluid channels extending along its length.