System and method for engine inspection

Patent metadata

Field	Value
Publication number	US-2016178532-A1
Application number	US-201414577255-A
Country	US
Kind code	A1
Filing date	Dec 19, 2014
Priority date	Dec 19, 2014
Publication date	Jun 23, 2016
Grant date	—

Abstract

An optical imaging and processing system includes an optical connection and an optical element disposed at a first end of the optical connection. The first end of the optical connection is configured to extend into a turbine component interior such that the optical element is disposed within the turbine component interior. The system also includes a photodiode array disposed at a second end of the optical connection, where the optical element is configured to transmit a video stream of the turbine component interior to the photodiode array as the optical element is moved within the turbine component interior between multiple vantage points. The system also includes a processor coupled to the photodiode array, wherein the processor is configured to process the video stream to generate a three-dimensional model of at least a portion of the turbine component interior without utilizing a previously defined three-dimensional model input of the turbine component interior.

First claim

1 . An optical imaging and processing system, comprising:
an optical connection and an optical element disposed at a first end of the optical connection, wherein the first end of the optical connection is configured to extend into a turbine component interior such that the optical element is disposed within the turbine component interior; a photodiode array disposed at a second end of the optical connection, wherein the optical element is configured to transmit a video stream of the turbine component interior to the photodiode array as the optical element is moved within the turbine component interior between multiple vantage points; a processor coupled to the photodiode array, wherein the processor is configured to process the video stream to generate a three-dimensional model of at least a portion of the turbine component interior without utilizing a previously defined three-dimensional model input of the turbine component interior.

2 . The system of claim 1 , wherein the processor is configured to:
determine identifying features within image frames of the video stream from the multiple vantage points; determine corresponding identifying features between the image frames; correlate the corresponding identifying features between the image frames to determine relative localization data of the image frames and/or the corresponding identifying features between the image frames; and locate the corresponding identifying features, based on the relative localization data of the image frames and/or the corresponding identifying features between the image frames, in a point cloud such that the point cloud forms the three-dimensional model.

3 . The system of claim 2 , wherein the image frames comprise at least a first image frame, a second image frame, and a third image frame, wherein the first and second image frames are processed by the processor first to locate corresponding identifying features between the first and second image frames in the point cloud, and wherein the second and third image frames are processed second to locate corresponding identifying features between the second and third image frames in the point cloud.

4 . The system of claim 2 , wherein relative localization data comprises relative position and/or relative orientation.

5 . The system of claim 1 , comprising a repositioning device configured to reposition the optical element within the turbine component interior between the multiple vantage points as the video stream is transmitted from the optical element to the photodiode array.

6 . The system of claim 1 , comprising a display coupled to the processor, wherein the display is configured to display the three-dimensional model.

7 . The system of claim 1 , wherein the processor is configured to automatically navigate the three-dimensional model for determining defects within the turbine component interior.

8 . The system of claim 1 , wherein the turbine component is a turbine blade or a compressor blade.

9 . The system of claim 1 , wherein the photodiode array is part of the processor.

10 . The system of claim 1 , wherein the processor compares a three-dimensional model input of the turbine component interior with the three-dimensional model generated by the processor to refine the three-dimensional model into a refined three-dimensional model.

11 . A method for generating a three-dimensional model of a turbine component interior utilizing an optical imaging and processing system, comprising:
capturing a video stream having a plurality of image frames of the turbine component interior via an optical element and an array coupled to the optical element via an optical connection, wherein the optical element is configured to be disposed in the turbine component interior and to transmit the video stream through the optical connection to the array; storing, in a processor of the optical imaging and processing system, the video stream having the plurality of image frames; identifying one or more identifying features in at least a first image frame and a second image frame of the plurality of image frames; determining corresponding identifying features between the first image frame and the second image frame; processing the corresponding identifying features between the first image frame and the second image frame to determine relative localization data between the first image frame and the second image frame and/or the corresponding identifying features in the first and second image frames; placing the corresponding identifying features, based on the relative localization data, into a point cloud for generating the three-dimensional model of the turbine component interior.

12 . The method of claim 11 , wherein processing the corresponding identifying features between the first image frame and the second image to determine relative localization data between the first image frame and the second image frame and/or the corresponding identifying features in the first and second image frames comprises:
setting the first image frame as the initial reference frame and translating, rotating, and/or scaling the corresponding identifying features from the second image frame to correlate with the corresponding identifying features in the first image frame; storing translation, rotation, and/or scaling factors related to the translating, rotating, and/or scaling of the corresponding identifying features from the second image frame; and utilizing the translation, rotation, and/or scaling factors to determine the relative localization data between the first image frame and the second image frame and/or the corresponding identifying features in the first and second image frames.

13 . The method of claim 12 , wherein the plurality of image frames further comprises a third image frame and a fourth image frame, wherein processing the corresponding identifying features between the first image frame and the second image frame is iteratively repeated for the second image frame and the third image frame utilizing the second image frame as the initial reference frame, and the third image frame and the fourth image frame utilizing the third image frame as the initial reference frame.

14 . The method of claim 11 , comprising repositioning the optical element, disposed within the turbine component interior through a single viewing port, via a repositioning device of the optical imaging and processing system, such that the optical element and the array may capture the plurality of image frames from multiple vantage points within the turbine component interior.

15 . The method of claim 11 , comprising displaying the three-dimensional model on a display coupled to the processor.

16 . The method of claim 11 , comprising automatically navigating the three-dimensional model to determine defects within the turbine component interior.

17 . A method for determining defects in a turbine component interior utilizing an optical imaging and processing system, comprising:
generating a three-dimensional (3D) model of the turbine component interior, comprising:
capturing a video stream, via an optical element, having a plurality of image frames of the turbine component interior;
transmitting the video stream having the plurality of image frames of to a processor of the optical imaging and processing system;
determining identifying features in the plurality of image frames;
determining corresponding identifying features between a first image frame and a second image frame of the plurality of image frames;
correlating the corresponding identifying features between the first imag

Assignees

• Gen Electric

Inventors

• Lim Ser Nam
• Pawlowski Joseph Vincent
• Guan Li
• Agarwal Yogesh
• Pandey Binod
• Dhanvantri Srivatsa

Classifications

• G01N21/954

  Inspecting the inner surface of hollow bodies, e.g. bores · CPC title

• G01N21/8851 Primary

  Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges (G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002) · CPC title

• G01B2210/52

  Combining or merging partially overlapping images to an overall image · CPC title

• G01N21/9515

  Objects of complex shape, e.g. examined with use of a surface follower device (measuring contours and curvatures G01B11/24) · CPC title

• G01B11/24

  for measuring contours or curvatures · CPC title