Abstract:
A method determines the layer thickness of a TBC coating of at least one blade of a non-positive-displacement machine. To this end, at least one electromagnetic wave is emitted to the surface of the at least one blade, the at least one electromagnetic wave is then at least partially reflected by the at least one blade, and the reflected portion of the at least one electromagnetic wave is received and subsequently processed. In addition, the at least one electromagnetic wave is emitted with a frequency matched to the layer thickness of the TBC coating, and the phase of the at least one electromagnetic wave is compared with the phase of the at least one received electromagnetic wave. The at least one emitted electromagnetic wave undergoes a phase change during reflection and the layer thickness of the TBC coating is determined by the phase comparison.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is based on and hereby claims priority to German Application No. 10 2005 038 890.6 filed on Aug. 17, 2005 and PCT Application No. PCT/EP2006/064727 filed on Jul. 27, 2006, the contents of which are hereby incorporated by reference. 
     BACKGROUND OF THE INVENTION 
     The invention relates to a method for determination of the layer thickness of a TBC coating on at least one rotor blade of a continuous flow machine. The invention also relates to a method for determination of the layer thickness of a TBC coating on at least one stator blade of a continuous flow machine. The invention furthermore relates to a corresponding TBC layer thickness measurement apparatus for carrying out the methods, as well as use of the method and of the TBC layer thickness measurement apparatus. 
     Continuous flow machines, such as steam or gas turbines, are used as thermal power machines in engineering, in order to convert energy stored in a gas flow to mechanical energy, in particular to a rotary movement. 
     In order to achieve as high an overall energy utilization efficiency as possible, particularly in gas turbines, the gas inlet temperatures from the combustion chamber into the flow channel of the gas turbine are chosen to be as high as possible. By way of example, according to the related art, such gas inlet temperatures are around 1200° C. 
     In order that the blades which are arranged in the flow channel of the turbine withstand the thermal stress, they are provided with a surface coating, a so-called TBC coating (Thermal Barrier Coating). A blade coating such as this is, however, subject to aging in that it becomes eroded from the blade as a function of the operating life over time, so that the layer thickness decreases continuously. Without the TBC coating, the blade is subject to a very high thermal load, leading to destruction of the blade. This can result in a power reduction or, in the final analysis, damage to the turbine. 
     WO 2004/065918 A2 specifies a method for determination of the quality of a TBC coating on blades in a continuous flow machine, as well as an apparatus for carrying out the method. In this case, electromagnetic waves are transmitted in the area of the blades, and the component of the electromagnetic waves reflected from the blades is received again and is evaluated. During the evaluation, the intensity of the received electromagnetic waves is determined, and the surface quality of the blades is then determined from this. This method allows the existence of a coating to be verified well. It is virtually impossible to obtain detailed information about the layer thickness, particularly at room temperature, since the amplitude attenuation of the electromagnetic wave is virtually lost in the system noise. 
     SUMMARY 
     One possible object is to specify a method, a TBC layer thickness measurement apparatus for carrying out the method, use of the method and use of the TBC layer thickness measurement apparatus, by which the layer thickness of a TBC coating on blades in a continuous flow machine can be determined as accurately as possible, and in particular also during operation. 
     The inventors propose a method for determination of the layer thickness of a TBC coating on at least one rotor blade of a continuous flow machine wherein
         at least one electromagnetic wave is transmitted at the surface of the at least one rotor blade,   the at least one electromagnetic wave is at least partially reflected from the at least one rotor blade, and   the reflected component of the at least one electromagnetic wave is received and processed further.       

     The method is in this case characterized in that
         the at least one electromagnetic wave is transmitted at a frequency which is matched to the layer thickness of the TBC coating,   the phase of the at least one transmitted electromagnetic wave is compared with the phase of the at least one received electromagnetic wave, with the at least one transmitted electromagnetic wave having its phase changed on reflection, and   the layer thickness of the TBC coating is determined by the phase comparison.       

     The inventors also propose a method for determination of the layer thickness of a TBC coating on at least one stator blade of a continuous flow machine, wherein
         at least one electromagnetic wave is transmitted at the surface of the at least one stator blade,   the at least one electromagnetic wave is at least partially reflected from the at least one stator blade, and   the reflected component of the at least one electromagnetic wave is received and processed further,       

     The method is in this case characterized in that
         the at least one electromagnetic wave is transmitted at a frequency which is matched to the layer thickness of the TBC coating,   the phase of the at least one transmitted electromagnetic wave is compared with the phase of the at least one received electromagnetic wave, with the at least one transmitted electromagnetic wave having its phase changed on reflection,   and   the layer thickness of the TBC coating is determined by the phase comparison.       

     This makes use of the fact that the phase difference between the transmitted wave and the reflected wave component contains information about the layer thickness of the TBC coating, which can be determined by evaluation of the reflected wave component. The phase difference is in this case dependent on the layer thickness of the TBC coating, to be precise being 0° when no TBC coating is present, and increasing continuously as the layer thickness increases. 
     It is particularly advantageous to determine not only the layer thickness of the TBC coating on the at least one rotor blade but also the layer thickness of the TBC coating on the at least one stator blade. This allows comprehensive monitoring of those components of the continuous flow machine which are subject to particular loading. 
     It is also advantageous for the layer thickness of the TBC coating on the blades to be determined from the value of the phase change. In this case, at least one electromagnetic wave is transmitted at a predetermined frequency or wavelength. In particular ((2n+1)/4)-times the wavelength, where n=0, 1, 2, . . . is in the order of magnitude of ±50%, preferably ±20%, of the layer thickness in order to create a particularly steep phase gradient, that is to say the ratio of the phase change to the layer thickness change. It is thus possible to determine the layer thickness even with little amplitude attenuation. As the layer thickness of the TBC coating decreases, the phase change, that is to say the phase difference between the transmitted wave and the reflected wave component, decreases. 
     It is also advantageous to determine at least one resonant frequency, with the phase change at the resonant frequency corresponding to a value of (360°·n+1800) where n=0, 1, 2, . . . and to determine the layer thickness of the TBC coating on the blades from the value of the at least one resonant frequency. Since a resonant frequency is in each case associated with a phase change of (360°·n+180°), and the resonant frequency is dependent on the layer thickness, determination of at least one resonant frequency provides the desired layer thickness information, by the phase change of (360°·n+180°). This is because the associated wavelength in the transmitted electromagnetic wave is actually (4/(2n+1))-times as great at the respective resonant frequency than the thickness of the TBC coating. 
     In this case, it is advantageous to use a single device for production of the at least one electromagnetic wave for reception of the reflected at least one electromagnetic wave. The space saving obtained in this way makes it possible to fit a plurality of combined transmitting and receiving units at different points in the continuous flow machine. For example, it is possible to have devices for transmission and reception of electromagnetic waves arranged distributed over the circumference of the continuous flow machine, in which case an arrangement can be provided as required. 
     It is advantageous to provide at least one millimetric wave in the frequency range from 30 GHz to 130 GHz, in particular from 50 GHz to 90 GHz, as at least one electromagnetic wave. The wavelengths of the electromagnetic waves at frequencies from this frequency range are therefore in the typical order of magnitude of the layer thickness of the TBC coating, thus ensuring a particularly pronounced phase change on reflection. 
     The layer thickness of the TBC coating can advantageously be determined during operation of the continuous flow machine. This allows on-line layer thickness measurement thus allowing action at an appropriate time when a risky decrease in the TBC coating is recorded. This makes it possible to avoid the continuous flow machine being shut down for times required to carry out precautionary testing of the TBC coating or else repair measures on damaged blades. 
     According to this plan, the TBC layer thickness measurement apparatus for carrying out the methods is proposed, having
         at least one unit for production of an electrical oscillation,   at least one unit for production of electromagnetic waves from the oscillation,   at least one unit for reception of electromagnetic waves   and   an evaluation unit for evaluation of the electromagnetic waves which can be received, designed such that   the evaluation unit compares the phase of the at least one transmitted electromagnetic wave with the phase of the at least one received electromagnetic wave.       

     The TBC layer thickness measurement apparatus results in the advantages as explained above for the method. 
     The unit(s) for production of the at least one electromagnetic wave and reception of the reflected at least one electromagnetic wave are advantageously arranged in a flow channel in the continuous flow machine. They may each be formed by antennas which are suitable for production and transmission, as well as for reception, of electromagnetic millimetric waves. The unit for production of an electrical oscillation may, for example, be formed by an electronic oscillator which is operatively connected to the antenna for production of the at least one electromagnetic wave. The unit for reception of electromagnetic waves is preferably operatively connected to an evaluation unit which is able to use the signals produced by the unit for reception to determine the layer thickness of the TBC coating on the blades. Furthermore, it is feasible for the at least one unit for production of the at least one electromagnetic wave and the at least one unit for reception of the reflected at least one electromagnetic wave to be arranged outside the flow channel of the continuous flow machine. The at least one electromagnetic wave which is produced is then transmitted into the flow channel via at least one waveguide which is arranged in an appropriate position in the flow channel of the continuous flow machine. The at least one electromagnetic wave which is reflected on the blades is likewise passed via at least one waveguide to the at least one unit for reception. 
     In this case, it is advantageous for the at least one electromagnetic wave to be transmitted directionally and/or such that it can be focused by the at least one antenna. This ensures a specific layer thickness measurement. Furthermore, this also allows position resolution of the layer thickness measurement on the blades if, furthermore, the antenna is designed such that translational and/or rotary movements of the antenna are possible. 
     It is also advantageous for the at least one unit for production of electromagnetic waves to be suitable both for transmission and for reception of electromagnetic waves. This makes it possible to reduce the number of components further. For example this allows the at least one unit for production of electromagnetic waves to be operatively connected via a coupling unit to the unit for production of an oscillation. The signals which result from the received electromagnetic waves are supplied via the coupling unit to the evaluation unit. A plurality of coupling unit and antennas can also be provided and, for example, are connected in parallel to a plurality of associated evaluation units or else, using time-division multiplexing, to one evaluation unit, for example. 
     The continuous flow machine can preferably be a steam or gas turbine. Particularly in the range of large machines, the TBC layer thickness measurement apparatus allows simple, operationally reliable and accurate layer thickness measurement of the TBC coating on the gas turbine blades, thus making it possible to ensure more effective operation and, in particular, to further reduce expensive shut down times resulting from maintenance and repair measures because of TBC coatings and blades having been destroyed. By way of example, this makes it possible to increase the availability of an energy supply equipped with a gas turbine. The apparatus could also be designed such that the effects on the steam or gas turbine in the flow channel of the continuous flow machine are largely kept low. 
     The inventors also propose a use of the method for determination of the layer thickness of a TBC coating in a steam or gas turbine. 
     Furthermore, the inventors propose to use the TBC layer thickness measurement apparatus in the flow channel of the continuous flow machine, with the at least one unit for production of electromagnetic waves being arranged in the flow channel of the continuous flow machine. 
     In this case, it is advantageous for the continuous flow machine to be a steam or gas turbine. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which: 
         FIG. 1  shows a gas turbine according to the prior art, in the form of a partially sectioned, perspective view, 
         FIG. 2  shows an enlarged view of a detail from the drawing in  FIG. 1  with an apparatus according to one potential embodiment of the invention, 
         FIG. 3  shows an outline circuit diagram relating to the embodiment of the method, 
         FIG. 4  shows a rotor blade in the gas turbine shown in  FIG. 1 , 
         FIG. 5  shows a stator blade of the gas turbine shown in  FIG. 1 , 
         FIG. 6  shows a spectral intensity distribution and a phase profile of reflected electromagnetic waves for the same layer thickness of the TBC coating, as a function of the wave frequency, 
         FIG. 7  shows three phase profiles of reflected electromagnetic waves at a different wave frequency as a function of the layer thickness of the TBC coating, 
         FIG. 8  shows the relationship between a reciprocal of the resonant frequency and the layer thickness of the TBC coating, and 
         FIG. 9  shows an antenna arrangement for monitoring stator and/or rotor blades. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. 
       FIG. 1  shows a gas turbine  1  according to the related art, which is designed for a high gas inlet temperature of about 1200° C. The gas turbine  1  has rotor blades  4  which are arranged on a rotor shaft  3 , which is mounted such that it can rotate in a housing  2 . Furthermore, stator blades  11  are provided, and are connected to the housing  2  such that they cannot rotate (see  FIG. 4 ,  FIG. 5 ). The rotor blades  4  and the stator blades  11  are each provided with a TBC coating  12  in order to withstand the physical loads in the flow channel  6  of the gas turbine  1 . By way of example, the TBC (TBC: Thermal Barrier Coating) coating  12  is composed of yttrium-stabilized zirconium oxide (so-called YSZ). 
     As illustrated in  FIG. 2 , the turbine  1  is equipped with a TBC layer thickness management apparatus according to one potential embodiment of the invention, which has an antenna  8 , in particular an antenna designed for millimetric waves, which project into the flow channel  6  of the gas turbine  1 . The antenna  8 , which is intended in particular for electromagnetic waves at frequencies from 30 GHz to 130 GHz, in particular at frequencies from 50 GHz to 90 GHz, is arranged in the area of the blades  4 ,  11  to be investigated, in particular between two blade rows. The antenna  8  is used as a device for transmission of electromagnetic waves, and can also be used as a device for reception of electromagnetic waves. The antenna  8  is connected for communication purposes to a circulator  16 . The apparatus also has a radio-frequency generator  14 , which is operatively connected to the circulator  16  via an amplifier  15 . The circulator  16  is connected to a reception amplifier  17 , which is coupled to the evaluation unit  19 . The evaluation unit  19  is itself in turn connected to the radio-frequency generator  14 . 
     In detail, the method for determination of the layer thickness of the TBC coating  12  on rotor and stator blades  4  and  11  as shown in  FIG. 3  is carried out as follows: 
     The electronic radio-frequency generator  14  produces a radio frequency and a fixed, predeterminable frequency in the range between 30 GHz and 130 GHz, preferably between 50 GHz and 90 GHz. The radio frequency is supplied to the amplifier  15 , which itself supplies the amplified radio frequency via the circulator  16  to the antenna  8 . The antenna  8  uses the radio-frequency energy supplied to it to produce at least one corresponding electromagnetic wave  31 , and transmits this preferably directionally and in particular focussed, on the basis of its polar diagram characteristic. At least one corresponding blade  4 ,  11  reflects a component  32  of the transmitted at least one electromagnetic wave  31  back, in particular, to the same antenna  8 . The reflected electromagnetic waves  32  are converted via the antenna  8  back to an electrical signal, which is supplied to the circulator  16 . The circulator  16  now separates the received signal from the transmitted signal, and supplies this to the reception amplifier  17 . The signal is passed from the reception amplifier  17  to the evaluation unit  19 . 
     A graph G 1  in  FIG. 6  shows a frequency-dependent spectral intensity distribution S and a corresponding frequency-dependent phase profile (p of a reflected electromagnetic wave  32  when the TBC coating  12  has a constant layer thickness. The dashed-line ordinate indicates the intensity I of the reflected electromagnetic wave  32 , while the solid-line ordinate indicates the phase difference Δφ between the transmitted wave  31  and the reflected wave component  32 . The frequency is shown on the abscissa. The illustrated intensity distribution has a minimum and a specific frequency fr, the so-called resonant frequency. 
     At this resonant frequency fr, ¼ of the wavelength of the electromagnetic wave  31 ,  32  in the TBC coating  12  corresponds precisely to the layer thickness of the TBC coating  12 . In this case, the components of the transmitted electromagnetic wave  31  which are reflected on the surface of the TBC coating  12  and the components of the transmitted electromagnetic wave  31  which are reflected on the boundary surface between the TBC coating  12  and the metal located underneath it at least partially cancel one another out. The phase profile φ shows a phase difference Δφ of 0° at low frequencies, increasing continuously towards higher frequencies. The phase profile φ has the highest gradient at the resonant frequency fr shown in  FIG. 6 , with the value of the phase difference Δφ there corresponding to 180°. 
     In addition to the resonant frequency fr indicated in  FIG. 6 , there are also further resonant frequencies fr n , which are not illustrated, where n=0, 1, 2, . . . , and fr=fr 0 . In consequence, ((2n+1)/4)-times the wavelength of the electromagnetic wave  31 ,  32  in the surface coating corresponds at each resonant frequency fr n  precisely to the layer thickness of the TBC coating  12 . The phase difference Δφ at the respective resonant frequency fr n  is then given in a corresponding manner by: Δφ=(360°·n+180°). 
     By way of example, a further graph G 2  in  FIG. 7  shows three phase profiles φ 1 , φ 2  and φ 3  of reflected electromagnetic waves  32  at different frequencies f 1  (90 GHz), f 2  (70 GHz) and f 3  (50 GHz), respectively, with the ordinates indicating the phase difference Δφ between the transmitted wave  31  and the reflected wave component  32 , and with the layer thickness of the TBC coating  12  being plotted on the abscissa. If there is no TBC coating  12 , in precisely the same way as when the layer thicknesses of the TBC coating  12  are low, the phase difference Δφ is 0° for all three frequencies f 1 , f 2 , f 3 . As the layer thickness increases, the phase difference Δφ increases up to a magnitude of 360° in the graph G 2  that is shown; in this case, the greatest gradient in all the phase profiles φ 1 , φ 2 , φ 3  occurs when the phase difference Δφ is 180°. This is where the resonance as described above occurs, to be precise as an example for n=0. When the phase difference Δφ is 180°, the layer thickness of the surface coating  12  corresponds precisely to ¼ of the wavelength of the electromagnetic wave  31 ,  32  in the TBC coating  12 . The frequencies f 1 , f 2 , f 3  of the electromagnetic waves  32  are then equal to resonant frequencies for the corresponding layer thickness. The respective layer thickness is therefore c/(4·fi) where i=1, 2, 3, where c is the speed of propagation of the electromagnetic wave  31 ,  32  in the TBC coating  12 . 
     The evaluation unit  19  is first of all used to determine the phase difference Δφ between the transmitted and the reflected electromagnetic wave  31 ,  32 . The phase difference Δφ is then compared with a previously recorded calibration curve, which, for example, has a phase profile as shown by the graph G 2  in  FIG. 7 , and the layer thickness of the TBC coating  12  is determined from this. 
     As can also be seen in  FIG. 7 , the phase profiles φ 1 , φ 2 , and φ 3  for lower frequencies and therefore also the resonant frequencies are shifted towards greater layer thicknesses. 
     A third graph G 3  in  FIG. 8  shows the relationship between the resonant frequency fr n  and the reciprocal of the resonant frequency fr n   −1  and the layer thickness. The ordinate indicates the layer thickness, while the reciprocal of the resonant frequency fr n   −1  is plotted on the abscissa. As can be seen, the relationship between the layer thickness and the reciprocal of the resonant frequency fr n   −1  is defined by a straight line L. The lower the resonant frequency fr n , or the higher the reciprocal of the resonant frequency fr n   −1 , the greater is the layer thickness of the TBC coating  12 . 
     It is therefore also possible for the antenna  8  to transmit electromagnetic waves  31  with a broad frequency band, which may be in the range between 30 GHz and 130 GHz, preferably between 50 GHz and 90 GHz, and for the antenna  8 , in particular, to receive them again after reflection on the at least one blade  4 ,  11 . After conversion to an electrical signal, these are then supplied via the circulator  16  and the reception amplifier  17  to the evaluation unit  19 . The evaluation unit  19  determines the phase differences Δφ between the transmitted and reflected electromagnetic wave  31 ,  32 , and identifies those frequencies fr n  with a phase difference of Δφ=(360°·n+180°), in particular when n=0. The reciprocal of these frequencies fr n  is then compared with a previously recorded calibration line, which indicates the relationship between the layer thickness and the reciprocal of the resonant frequencies fr n   −1  on the basis of the graph  3  in  FIG. 8 , and the layer thickness of the TBC coating  12  is determined from this. The phase difference Δφ=180° is associated with the “first” resonant frequency fr 0 . However, it is also feasible to identify higher-order resonant frequencies fr n  for which n&gt;0, and which occur at higher phase differences Δφ=(360°·n+180°), and to evaluate these in a corresponding manner. 
     The determined layer thickness of the TBC coating  12  is signaled via display and signaling units, which are not illustrated in any more detail, to a monitoring point, and/or are passed to a control center. The evaluation unit may also be equipped with a comparison function, which can be used to detect that the layer thickness has fallen below a predeterminable threshold value. For example a message can be emitted automatically when the threshold value is undershot in order to initiate an appropriate protective measure, for example shutting down the turbine  1 . 
       FIG. 9  shows examples of embodiments and arrangements of different antennas  81 ,  82  and  83  with the respectively associated polar diagram characteristic  810 ,  820  and  830 . The antennas  81 ,  82  and  83  are arranged in the flow channel  6 , in the area of the rotor blades  4  and/or stator blades  11  to be investigated, between the blade rows. An embodiment as a rod antenna or as a coaxial antenna is appropriate, in particular as a coaxial dipole antenna. Other antenna forms, such as horn antennas, are, however, likewise feasible. The polar diagram characteristic may be symmetrical, as in the case of the antennas  81  and  83 , or else asymmetric, as in the case of the antenna  82 . In addition to antennas with a broad lobe characteristic, it is also possible to use antennas which can direct the electromagnetic waves  31  and, furthermore, can also transmit them in a focusing form. In particular, this may be done by using the horn antennas that have been mentioned. 
     The methods and devices described above should not be regarded as being restricted to the exemplary embodiment. The scope of protection likewise includes the provision of a plurality of antennas  8  for transmission and/or for reception, as well, in order, for example, to achieve measurement redundancy or else greater accuracy. 
     Furthermore, the methods and devices provide the capability for simultaneous layer thickness measurement of the TBC coating  12  on said blades  4 ,  11 . 
     The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004).