Patent Description:
At least some known rotary machines, such as turbines for aircraft engines and gas and steam powered turbines for industrial applications, include an outer case and at least one rotor that carries multiple stages of rotating airfoils, i.e., blades, which rotate with respect to the outer case. In addition, the outer case carries multiple stages of stationary airfoils, i.e., guide vanes. The blades and guide vanes are arranged in alternating stages. In at least some known rotary machines, shrouds are disposed on the radially inner surfaces of a stator to form a ring seal around tips of the blades. Together, the blades, guide vanes, and shrouds define a primary flowpath inside the compressor and turbine sections of the rotary machine. This flowpath, combined with a flowpath through the combustor, defines a primary cavity within the rotary machine.

During operation, the components of the rotary machine experience degradation. Accordingly, for at least some known rotary machines, periodic inspections, such as borescope inspections, are performed to assess the condition of the rotary machine in-between service intervals. Examples of conditions observed during inspections include wear (e.g., from incursion of blade tips into the shrouds, particle-induced erosion, water droplet induced erosion, wear due to sliding contact between stationary components), impact (e.g., spallation of thermal barrier coating (TBC) or environmental barrier coating (EBC) from turbine-section components, leading edge burring/bending of compressor blades), cracking (e.g., thermal fatigue, low-cycle fatigue, high-cycle fatigue, creep rupture), edge-of-contact damage between stationary parts, oxidation or hot corrosion of high-temperature metallic sections, static seal degradation, and creep deformation (e.g., of guide vane sidewalls/airfoils, blade platforms, and blade tip shrouds).

During service intervals, the rotary machines are at least partially disassembled to allow repair and/or replacement of damaged components. For example, damaged components of at least some known rotary machines are primarily repaired at overhaul or component repair facilities, with only limited intervention conducted in the field. Processes used to repair compressor and turbine flowpath components include surface cleaning to remove accumulated dirt and oxidation products, stripping and restoration of coated surfaces, crack repair, section replacement, and aero contouring and smoothing. Repairing the components during service intervals reduces the cost to maintain the rotary machine because the cost to repair components is sometimes less than the cost to replace the components. However, sometimes, the components run past their repair limits between planned service intervals. In addition, sometimes, heavily distressed components fail and cause an unplanned outage.

For at least some known rotary machines, an articulating tethered device, such as a borescope, is inserted through an opening of the rotary machine and manipulated within a cavity of the rotary machine for inspection. However, at least some known tethered devices cannot access all locations of the rotary machine. In particular, some non-rotating components in at least some known rotary machines are difficult to access with conventional tethered devices. Furthermore, damage detected during inspection typically goes unmitigated until the machine is at least partially disassembled for scheduled service.

<CIT> describes a positioning assembly for a transducer in a boresonic inspection system. <CIT> describes a method of robotically inspecting in situ an impingement sleeve of a gas turbine cannular combustion component. <CIT> describes an automatic blast device. <CIT> describes an endoscope for inspecting turbines. <CIT> describes an inspection device for an annular combustion chamber of a gas turbine and a method for inspecting an annular combustion chamber of a gas turbine. <CIT> describes apparatus and method for in situ inspection of pressurized vessels. <CIT> describes tooling for retouching of turbine rotor blades and a process making use of that tooling. <CIT> describes methods and apparatus for rotary machinery inspection. <CIT> describes a visual inspection and foreign object retrieval system for the gap of a top upper-bundle of the tube sheet of steam generator secondary side. Reference is also made to <CIT>.

In one aspect, a service apparatus for use in maintaining a turbine assembly is provided. The service apparatus includes a carriage configured to move through a cavity of the turbine assembly, a maintenance device coupled to the carriage, and a motor system coupled to the motorized device. The motor system is configured to move the maintenance device relative to the carriage. The motor system includes a first motor configured to move the maintenance device in a first direction and a second motor configured to move the maintenance device in a second direction.

In another aspect, a system for maintaining a turbine assembly is provided. The system includes the service apparatus of the above aspect. The system also includes a controller for the service apparatus.

As used herein, the terms "processor" and "computer," and related terms, e.g., "processing device," "computing device," and "controller" are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), and application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, "memory" may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a touchscreen, a mouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the exemplary embodiment, additional output channels may include, but not be limited to, an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signal processing (DSP) device, and/or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. As used herein, the term "motor" is not limited to electrically driven rotary motors, but broadly refers to any device that creates motion, including, for example and without limitation, electric motors, internal combustion engines, sterling cycle engines, pneumatic actuators, hydraulic actuators, shape memory alloys, and electroactive polymers. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term processor and processing device.

Embodiments described herein provide service apparatus for use in maintaining a turbine assembly. The service apparatus is configured to fit within and move through a cavity of the rotary machines. The service apparatus includes at least one maintenance device that facilitates repairing and/or inspecting the rotary machine. The maintenance device is coupled to a carriage and includes a motorized system configured to move the maintenance device relative to the carriage. For example, in some embodiments, the motorized system moves the maintenance device in at least three directions relative to the carriage. As a result, the service apparatus provides increased access to locations within the cavity of the rotary machine and reduces the amount of time the turbine assembly is out of service for maintenance.

<FIG> is a cross-sectional schematic view of an exemplary rotary machine and a service apparatus <NUM>. The rotary machine includes a turbine assembly <NUM>. In some embodiments, the rotary machine may include, without limitation, any of the following: a compressor, a blower, a pump, a turbine, a motor, and a generator.

In the exemplary embodiment, turbine assembly <NUM> includes an outer case <NUM>, a turbine <NUM>, an inlet <NUM>, a combustor <NUM>, a compressor <NUM>, and an exhaust <NUM>. Fluid flows from inlet <NUM>, through compressor <NUM>, through combustor <NUM>, through turbine <NUM> and is discharged through exhaust <NUM>. Together, outer case <NUM>, blades <NUM>, guide vanes <NUM>, and shrouds <NUM> define a primary flowpath inside compressor <NUM> and turbine <NUM> of turbine assembly <NUM>. This flowpath, combined with a flowpath through combustor <NUM>, defines a primary cavity within turbine assembly <NUM>.

Also, in the exemplary embodiment, compressor <NUM> and turbine <NUM> include airfoils configured to direct fluid through turbine assembly <NUM>. In particular, compressor <NUM> and turbine <NUM> include blades <NUM> and guide vanes <NUM>. Blades <NUM> are operably coupled with rotating shaft <NUM> such that blades <NUM> rotate when rotating shaft <NUM> rotates. Guide vanes <NUM> and shrouds <NUM> are stationary components and are coupled to an inner surface <NUM> of outer case <NUM>. Blades <NUM> and guide vanes <NUM> generally are positioned alternatingly along the rotor axis within turbine assembly <NUM>. In alternative embodiments, compressor <NUM> and/or turbine <NUM> includes any airfoils that enable turbine assembly <NUM> to operate as described herein.

In addition, in the exemplary embodiment, service apparatus <NUM> is configured to move through turbine assembly <NUM>. Accordingly, service apparatus <NUM> facilitates maintenance of turbine assembly <NUM>. For example, service apparatus <NUM> facilitates inspection and repair of turbine assembly <NUM> at locations within the primary cavity that are difficult to access from an exterior of turbine assembly <NUM>, such as using a borescope. Moreover, service apparatus <NUM> includes a maintenance device <NUM> that is positionable to facilitate service apparatus <NUM> inspecting and/or repairing surfaces of turbine assembly <NUM>.

During operation, service apparatus <NUM> enters turbine assembly <NUM> through any suitable access port or opening of turbine assembly <NUM>. For example, in some embodiments, service apparatus <NUM> enters and/or exits turbine assembly <NUM> through any of inlet <NUM>, exhaust <NUM>, and/or an access port, such as an igniter, borescope, or fuel nozzle port. In the exemplary embodiment, service apparatus <NUM> is sized and shaped to fit within turbine assembly <NUM> (shown in <FIG>) and to travel through said turbine assembly <NUM>, such as through the primary cavity of said turbine assembly (shown in <FIG>). For example, service apparatus <NUM> has a height, length, and width that are less than a clearance required to fit within the primary cavity. In alternative embodiments, service apparatus <NUM> is any size and shape that enables service apparatus <NUM> to operate as described herein.

During operation, service apparatus <NUM> is used to inspect and/or repair interior components of turbine assembly <NUM>. For example, in some embodiments, service apparatus <NUM> is positioned adjacent a portion of interior surface <NUM> of turbine assembly <NUM>. Interior surface <NUM> is any surface within the primary cavity of turbine assembly <NUM>. For example, in some embodiments, interior surface <NUM> includes, without limitation, surfaces of blades <NUM>, guide vanes <NUM>, shrouds <NUM>, and combustor <NUM>. In some embodiments, service apparatus <NUM> detects a characteristic of interior surface <NUM>. For example, in some embodiments, service apparatus <NUM> is used to generate an image of interior surface <NUM> and the image data is examined to determine whether repairs are necessary. If repairs are necessary, service apparatus <NUM> can be used to repair interior surface <NUM>. For example, in some embodiments, service apparatus <NUM> patches a damaged portion of interior surface <NUM>. After inspection and/or repair of interior surface <NUM>, service apparatus <NUM> exits turbine assembly <NUM> through any suitable access port or opening of turbine assembly <NUM>.

Service apparatus <NUM> is positioned and moved within the primary cavity in any manner that enables service apparatus <NUM> to operate as described herein. For example, in some embodiments, a component (not shown), such as a tether, extends from service apparatus <NUM> to the exterior of turbine assembly <NUM> for an operator to control service apparatus <NUM> and move service apparatus <NUM> within the primary cavity. In some embodiments, service apparatus <NUM> includes its own propulsion system to move service apparatus <NUM> within the primary cavity.

<FIG> is a schematic view of an exemplary system <NUM> for use in maintaining turbine assembly <NUM> (shown in <FIG>). System <NUM> includes service apparatus <NUM>, a controller <NUM>, a user interface <NUM>, and a localization system <NUM>. Service apparatus <NUM> includes maintenance device <NUM> and motorized system <NUM>. In alternative embodiments, system <NUM> includes any component that enables system <NUM> to operate as described herein. For example, in some embodiments, maintenance device <NUM> is omitted. In further embodiments, user interface <NUM> is omitted.

In the exemplary embodiment, motorized system <NUM> is coupled to maintenance device <NUM> and is configured to position maintenance device <NUM>. In particular, motorized system <NUM> moves maintenance device <NUM> relative to at least one axis of service apparatus <NUM>. For example, in some embodiments, motorized system <NUM> pivots maintenance device <NUM> about an axis. In further embodiments, motorized system <NUM> moves maintenance device <NUM> in a direction parallel to or perpendicular to the axis. As a result, motorized system <NUM> facilitates positioning maintenance device <NUM> during operation of service apparatus <NUM>. In some embodiments, motorized system <NUM> exchanges signals with and is controlled by controller <NUM>. In alternative embodiments, service apparatus <NUM> includes any motorized system <NUM> that enables service apparatus <NUM> to operate as described herein.

In addition, in the exemplary embodiment, controller <NUM> includes a transceiver <NUM>, a processor <NUM>, and memory <NUM>. Transceiver <NUM> is communicatively coupled with service apparatus <NUM> and is configured to send information to and receive information from a transceiver <NUM> of service apparatus <NUM>. In the exemplary embodiment, transceiver <NUM> and transceiver <NUM> communicate wirelessly. In alternative embodiments, service apparatus <NUM> and controller <NUM> communicate in any manner that enables system <NUM> to operate as described herein. For example, in some embodiments, controller <NUM> and service apparatus <NUM> exchange information through a wired link extending between service apparatus <NUM> and controller <NUM>.

Also, in the exemplary embodiment, controller <NUM> is positioned remotely from service apparatus <NUM>. In particular, controller <NUM> is positioned on the exterior of turbine assembly <NUM> (shown in <FIG>). In alternative embodiments, controller <NUM> is positioned anywhere that enables system <NUM> to operate as described herein. For example, in some embodiments, controller <NUM> is positioned at least partially within the primary cavity, such as within the exhaust <NUM> or inlet <NUM>.

In some embodiments, maintenance device <NUM> includes one or more sensors and/or repair tools. For example, in the exemplary embodiment, maintenance device <NUM> is configured to detect a characteristic of turbine assembly <NUM> (shown in <FIG>) and/or service apparatus <NUM> and generate a signal relating to the characteristic. Transceiver <NUM> is in communication with maintenance device <NUM> and is configured to receive signals relating to the characteristic detected by maintenance device <NUM>. In alternative embodiments, system <NUM> includes any maintenance device <NUM> that enables system <NUM> to operate as described herein, including but not limited to executing nondestructive evaluation, repair, and cleaning. For example, in some embodiments, maintenance device <NUM> of service apparatus <NUM> includes, without limitation, any of the following: an applicator, a drill, a grinder, a heater, a welding electrode, a sprayer, an optical sensor (e.g., visible, infrared, and/or multi-spectral sensor), a mechanical sensor (e.g., stylus profilometer, coordinate measurement probe, load transducer, linear variable differential transformer), a thermal sensor (e.g., pyrometer, thermocouple, resistance temperature detector), a magnetic sensor, an acoustic sensor (e.g., piezoelectric, microphone, ultrasound), and an electromagnetic sensor (e.g., eddy current, potential drop, x-ray).

In addition, in the exemplary embodiment, service apparatus <NUM> includes a processor <NUM> and a memory <NUM>. Processor <NUM> is configured to execute instructions for controlling components of service apparatus <NUM>, such as maintenance device <NUM> and motorized system <NUM>. In alternative embodiments, service apparatus <NUM> includes any processor <NUM> that enables system <NUM> to operate as described herein. In some embodiments, processor <NUM> is omitted.

Also, in the exemplary embodiment, user interface <NUM> is configured to display information relating to the characteristics detected by maintenance device <NUM> for interpretation by the user. For example, in some embodiments, user interface <NUM> displays images of interior surface <NUM> of turbine assembly <NUM> based on received signals. In some embodiments, user interface <NUM> allows a user to input and/or view information relating to control of service apparatus <NUM>. In an exemplary embodiment, user interface <NUM> is configured to display information relating to the state of one or more of maintenance device <NUM> and a power source <NUM> for interpretation by the user. For example, state information may include the position of maintenance device <NUM> relative to carriage <NUM> of the service apparatus. State information may also include charge status of power source <NUM> and/or current draw on the various drive and positioning motors. Processor <NUM> translates user inputs into steering, tool motion, camera control, sensor control, sensor motion, and/or any other commands and sends information via transceiver <NUM> to service apparatus <NUM> via transceiver <NUM>. In some embodiments, user control of service apparatus <NUM> is in real time, such as through a joystick, keyboard, touchscreen or other interface having similar function. In other embodiments, service apparatus <NUM> is controlled partially or wholly according to a pre-programmed routine. In some embodiments, a user inputs information, such as operation goals or conditional directions and service apparatus <NUM> is at least partially automated. In further embodiments, information, such as information received by controller <NUM> from service apparatus <NUM>, control data sent to service apparatus <NUM>, and additional user inputs or state information (e.g., location, time, orientation, datalink quality, battery levels, repair material levels, failure mode indicators), is logged into memory <NUM> and/or memory <NUM>.

In addition, in the exemplary embodiment, localization system <NUM> determines a position of service apparatus <NUM> relative to turbine assembly <NUM> based on information received from service apparatus <NUM>. In further embodiments, localization system <NUM> determines a position of maintenance device <NUM> and/or carriage <NUM> of the service apparatus relative to interior surface <NUM> of turbine assembly <NUM>. In some embodiments, localization system <NUM> indirectly detects a position of service apparatus <NUM> based on characteristics detected by maintenance device <NUM> and/or additional sensors, such as proximity sensors, located on service apparatus <NUM>. For example, in some embodiments, maintenance device <NUM> includes a camera and localization system <NUM> determines a position of service apparatus <NUM> based on an image of a portion of turbine assembly <NUM> visible to service apparatus <NUM>, such as by comparing the image data to a model of the turbine assembly <NUM>. In alternative embodiments, localization system <NUM> determines a position of service apparatus <NUM> in any manner that enables service apparatus <NUM> to operate as described herein. For example, in some embodiments, localization system <NUM> utilizes pre-existing or purposefully placed landmarks within turbine assembly <NUM> to determine a position of service apparatus <NUM>. In further embodiments, devices such as borescopes and/or illuminators are positioned through access ports (not shown) in outer case <NUM> to facilitate localization system <NUM> determining a position of service apparatus <NUM>. In some embodiments, localization system <NUM> utilizes radiography to facilitate determining a position of service apparatus <NUM>.

<FIG> is a perspective view of an alternative embodiment of a service apparatus <NUM> for use with turbine assembly <NUM> (shown in <FIG>). Service apparatus <NUM> includes maintenance device <NUM>, a carriage <NUM>, a motorized trolley system <NUM>, and a mount <NUM>. In alternative embodiments, service apparatus <NUM> includes any component that enables service apparatus <NUM> to operate as described herein.

In reference to <FIG> and <FIG>, in the exemplary embodiment, service apparatus <NUM> is configured to move through the primary cavity of turbine assembly <NUM>. In some embodiments, service apparatus <NUM> enters turbine assembly <NUM> through inlet <NUM>. In further embodiments, service apparatus <NUM> enters turbine assembly <NUM> through combustor <NUM> or exhaust <NUM>. In the exemplary embodiment, service apparatus <NUM> is positioned within the primary cavity by an insertion device (not shown), releasably coupled to mount <NUM> and including, without limitation, any of the following: a rod, a cable, and a tube. Service apparatus <NUM> is configured for positioning between adjacent airfoils. In some embodiments, the insertion device (not shown) and carriage <NUM> are flexible to allow the insertion device to bring service apparatus <NUM> into proximity of a target location between adjacent airfoils. In some embodiments, rotation of rotating shaft <NUM> is used to bring service apparatus <NUM> into proximity of the target turbine components of turbine assembly <NUM> to inspect and/or repair. In alternative embodiments, service apparatus <NUM> is positioned within the primary cavity in any manner that enables service apparatus <NUM> to operate as described herein.

In reference to <FIG>, in the exemplary embodiment, carriage <NUM> extends between a front end <NUM> and a rear end <NUM> of service apparatus <NUM>. Carriage <NUM> is elongated along a longitudinal axis <NUM> of service apparatus <NUM>. In addition, carriage <NUM> is generally rectangular in shape and includes a thin strip of flexible material. In alternative embodiments, service apparatus <NUM> includes any carriage <NUM> that enables service apparatus <NUM> to operate as described herein. For example, in some embodiments, carriage <NUM> is made of multiple pieces of flexible and/or non-flexible material operably coupled together with hinges, elastic spring elements, magnets or any other coupling component.

Also, in the exemplary embodiment, carriage <NUM> is coupled to and supports maintenance device <NUM>. Maintenance device <NUM> is configured to inspect and/or repair one or more surfaces of turbine assembly <NUM> (shown in <FIG>). In addition, motorized trolley system <NUM> is operably coupled to maintenance device <NUM> and carriage <NUM>. Motorized trolley system <NUM> is configured to move maintenance device <NUM> relative to carriage <NUM>. Motorized trolley system <NUM> includes an axial traverse motor <NUM> (broadly a first motor), a pivot motor <NUM> (broadly a second motor), and an extension-dispense motor <NUM> (broadly a third motor). Motorized trolley system <NUM> is configured to couple to and receive signals from controller <NUM> (shown in <FIG>). For example, in some embodiments, controller <NUM> (shown in <FIG>) controls operations of one or more of axial traverse motor <NUM>, pivot motor <NUM>, and extension-dispense motor <NUM> of motorized trolley system <NUM>. In alternative embodiments, motorized trolley system <NUM> is controlled in any manner that enables service apparatus <NUM> to operate as described herein.

In addition, in the exemplary embodiment, axial traverse motor <NUM>, pivot motor <NUM>, and extension-dispense motor <NUM> are configured to position maintenance device <NUM> and facilitate maintenance device <NUM> accessing a <NUM>-dimensional space within turbine assembly <NUM> (shown in <FIG>). Specifically, in the exemplary embodiment, axial traverse motor <NUM>, pivot motor <NUM>, and extension-dispense motor <NUM> allow maintenance device <NUM> to axially move, pivot, and extend relative to carriage <NUM>. For example, axial traverse motor <NUM> of motorized trolley system <NUM> moves maintenance device <NUM> generally along longitudinal axis <NUM> of service apparatus <NUM> in a direction indicated by arrow <NUM>. In some embodiments, carriage <NUM> may be curved and axial traverse motor <NUM> may move maintenance device <NUM> along a curve of carriage <NUM>. Pivot motor <NUM> pivots maintenance device <NUM> about longitudinal axis <NUM> in a direction indicated by arrow <NUM>. Extension-dispense motor <NUM> extends maintenance device <NUM> in a direction away from carriage <NUM> indicated by arrow <NUM>.

During operation, in the exemplary embodiment, axial traverse motor <NUM> moves maintenance device <NUM> to a position along carriage <NUM> between front end <NUM> and rear end <NUM> of service apparatus <NUM>. Pivot motor <NUM> pivots maintenance device at an angle relative to carriage <NUM>. Extension-dispense motor <NUM> extends or retracts maintenance device <NUM> in direction <NUM> perpendicular to longitudinal axis <NUM> to a desired radial position. Accordingly, motorized trolley system <NUM> positions maintenance device <NUM> at a desired position in a <NUM>-dimensional space within turbine assembly <NUM> (shown in <FIG>). As a result, motorized trolley system <NUM> facilitates maintenance device <NUM> reaching a surface of turbine assembly <NUM> (shown in <FIG>). In addition, motorized trolley system <NUM> is compact in size to facilitate service apparatus <NUM> operating within the primary cavity (shown in <FIG>). In alternative embodiments, service apparatus <NUM> includes any motorized trolley system <NUM> that enables service apparatus <NUM> to operate as described herein.

In reference to <FIG> and <FIG>, in the exemplary embodiment, maintenance device <NUM> is configured to repair a surface of turbine assembly <NUM>. For example, service apparatus <NUM> is positioned in general proximity of the region of turbine assembly <NUM> requiring repair. Axial traverse motor <NUM>, pivot motor <NUM>, and/or extension-dispense motor <NUM> position maintenance device <NUM> adjacent the interior surface of turbine assembly <NUM> that needs repair. In some embodiments, the region within turbine assembly <NUM> requiring repair includes, without limitation, any of the following: cracks, coating loss, surface foulant accumulation, worn surfaces, and/or any other deterioration. For example, in some embodiments, repair material is applied onto the interior surface of turbine assembly <NUM> in order to repair such region.

In reference to <FIG>, in the exemplary embodiment, axial traverse motor <NUM> is coupled to carriage <NUM> such that axial traverse motor <NUM> operably engages track <NUM> of carriage <NUM>. Track <NUM> includes a linear array of rectangular holes. During operation, axial traverse motor <NUM> induces motorized trolley system <NUM>, carrying maintenance device <NUM>, to travel along carriage <NUM> generally in the direction indicated by longitudinal axis <NUM>. For example, in some embodiments, axial traverse motor <NUM> drives a sprocket that engages with track <NUM> in carriage <NUM>. In alternative embodiments, service apparatus <NUM> includes any axial traverse motor <NUM> and/or traction system, such as a pinch roller, belt or gear, that enables service apparatus <NUM> to operate as described herein.

Also, in the exemplary embodiment, maintenance device <NUM> is rotatably coupled to pivot motor <NUM>. During operation, pivot motor <NUM> induces maintenance device <NUM> to pivot or rotate relative to longitudinal axis <NUM> of carriage <NUM>. For example, in some embodiments, pivot motor <NUM> includes a rotatory actuator and a rotor coupled to maintenance device <NUM>. Maintenance device <NUM> pivots when the rotor is rotated. In alternative embodiments, service apparatus <NUM> includes any pivot motor <NUM> that enables service apparatus <NUM> to operate as described herein.

In addition, in the exemplary embodiments, maintenance device <NUM> is coupled to an end of extension-dispense motor <NUM> and is moved by extension-dispense motor <NUM>. For example, in some embodiments, extension-dispense motor <NUM> includes a linear actuator that induces maintenance device <NUM> to move linearly. In alternative embodiments, service apparatus <NUM> includes any extension-dispense motor <NUM> that enables service apparatus <NUM> to operate as described herein.

Moreover, in the exemplary embodiment, axial traverse motor <NUM>, pivot motor <NUM>, and extension-dispense motor <NUM> are operably coupled to each other and to maintenance device <NUM>. Thus, operation of axial traverse motor <NUM> axially translates pivot motor <NUM>, extension-dispense motor <NUM> and maintenance device <NUM>. In addition, operation of pivot motor <NUM> pivots extension-dispense motor <NUM> and maintenance device <NUM>. In alternative embodiments, axial traverse motor <NUM>, pivot motor <NUM>, and extension-dispense motor <NUM> of motorized trolley system <NUM> are coupled to maintenance device <NUM> in any manner that enables service apparatus <NUM> to operate as described herein.

<FIG> is a perspective view of maintenance device <NUM>. Maintenance device <NUM> includes a nozzle <NUM>, a screw extruder <NUM>, and a reservoir <NUM>. Nozzle <NUM> extends in a direction generally away from carriage <NUM> and normal to longitudinal axis <NUM> (shown in <FIG>). Moreover, pivot motor <NUM> is configured to pivot maintenance device <NUM> such that nozzle <NUM> pivots about longitudinal axis <NUM>. Nozzle <NUM> is coupled to reservoir <NUM> contained within maintenance device <NUM>. Reservoir <NUM> contains repair material. For example, in some embodiments, reservoir <NUM> contains repair slurry, braze paste, and/or any other repair material. Reservoir <NUM> is operably coupled to nozzle <NUM> such that repair material moves from reservoir <NUM> through nozzle <NUM> and is dispensed via nozzle orifice <NUM> onto an interior surface of turbine assembly <NUM> (shown in <FIG>). In alternative embodiments, maintenance device <NUM> includes any nozzle <NUM> and reservoir <NUM> that enables maintenance device <NUM> to operate as described herein.

In the exemplary embodiment, screw extruder <NUM> is rotated using extension-dispense motor <NUM>. The housing base of nozzle <NUM> includes helical splines <NUM> that engage with threads on the mating section of reservoir <NUM>. These splines <NUM> are configured to engage extruder <NUM> and are oriented counter to a screw pitch of extruder <NUM>. Repair material acts against nozzle <NUM> and functions as a clutching medium when extruder <NUM> is rotated by the extension-dispense motor <NUM>, causing the screw extruder and nozzle <NUM> to extend. Further extension and rotation of nozzle <NUM> is prevented when the tip of nozzle <NUM> makes contact with the surface to be repaired. When rotation of nozzle <NUM> is prevented, the rotation of extruder <NUM> induces repair material to move through orifice <NUM> of nozzle <NUM> and onto the surface to be repaired. In some embodiments, a wiper <NUM> (shown in <FIG>) is operated in coordination with nozzle <NUM> to level repair material on the surface using, for example, the motion of rotating shaft <NUM>, pivot motor <NUM>, and/or axial traverse motor <NUM>. In combination, axial traverse motor <NUM> (shown in <FIG>), rotating shaft <NUM>, and pivot motor <NUM> move maintenance device <NUM> in three-dimensional space. In alternative embodiments, maintenance device <NUM> operates in any manner that enables service apparatus <NUM> (shown in <FIG>) to operate as described herein.

In the exemplary embodiment, extruder <NUM> is rotated by extension-dispense motor <NUM>. In alternative embodiments, maintenance device <NUM> includes any motor that enables service apparatus <NUM> to operate as described herein. For example, in some embodiments, service apparatus <NUM> includes separate motors for extension and operation of maintenance device <NUM>.

<FIG> is a perspective view of an alternative maintenance device <NUM> for use with service apparatus <NUM> (shown in <FIG>). Maintenance device <NUM> includes a nozzle <NUM>, a reservoir housing <NUM>, and a plunger <NUM>. Reservoir housing <NUM> defines an interior space <NUM>. Plunger <NUM> is movably disposed within interior space <NUM>. In particular, plunger <NUM> moves longitudinally relative to reservoir housing <NUM>, transporting repair material <NUM> along interior space <NUM> and through the dispense nozzle <NUM>. In alternative embodiments, maintenance device <NUM> operates in any manner that enables service apparatus <NUM> (shown in <FIG>) to operate as described herein. For example, reservoir housing <NUM> may include an integral nozzle opening and may be of arbitrary length or flexibility. Additionally, plunger <NUM> may be absent and repair material <NUM> may be transported by squeezing deformable reservoir housing <NUM>, such as using pinch rollers. In some embodiments, plunger <NUM> or pinch rollers may be driven by a motorized actuator (not shown).

<FIG> is a schematic view of an alternative motorized system <NUM> for use with service apparatus <NUM> (shown in <FIG>) that includes rotary actuators <NUM>. Rotary actuators <NUM> consist of drive motors <NUM> and driven linkages <NUM>. Motorized system <NUM> is configured to couple to service apparatus <NUM> (shown in <FIG>). Rotary actuators <NUM> are configured to move maintenance device <NUM> (shown in <FIG>) or alternative maintenance device <NUM> (shown in <FIG>) in three-dimensional space. For example, motorized system <NUM> is positionable between a stowed position <NUM>, an extended position <NUM>, a first reaching position <NUM>, and a second reaching position <NUM>. In combination with axial traverse motor <NUM> (shown in <FIG>), rotary actuators <NUM> are controlled in unison to induce motorized system <NUM> to move maintenance device <NUM> or alternative maintenance device <NUM> in at least three directions. In alternative embodiments, motorized system <NUM> is positionable in any manner that enables motorized system <NUM> to operate as described herein.

<FIG> is a schematic view of an alternative motorized system <NUM> for use with service apparatus <NUM> (shown in <FIG>) including linear actuators. Motorized system <NUM> is configured to couple to service apparatus <NUM> (shown in <FIG>) and position maintenance device <NUM> or alternative maintenance device <NUM> (shown in <FIG>). Linear actuators <NUM> consist of motors <NUM> that turn a captive threaded gear around threaded rods <NUM> to regulate the length of the threaded rods <NUM>. In combination with axial traverse motor <NUM> (shown in <FIG>), linear actuators <NUM> include drive components configured to move linearly to induce motorized system <NUM> to move maintenance device <NUM> (shown in <FIG>) or alternative maintenance device <NUM> (shown in <FIG>) in three-dimensional space. For example, motorized system <NUM> is positionable between a stowed position <NUM>, an extended position <NUM>, a first reaching position <NUM>, and a second reaching position <NUM>. Linear actuators <NUM> and axial traverse motor <NUM> (shown in <FIG>) are controlled in unison to enable motorized system <NUM> to move in at least three directions. In alternative embodiments, motorized system <NUM> is positionable in any manner that enables motorized system <NUM> to operate as described herein.

<FIG> is a schematic view of an alternative motorized system <NUM> for use with service apparatus <NUM> (shown in <FIG>) including rotary actuators. Motorized system <NUM> is configured to couple to service apparatus <NUM> (shown in <FIG>) and position maintenance device <NUM>. For example, motorized system <NUM> is positionable between a stowed position <NUM> and extended positions <NUM>, <NUM>. In the exemplary embodiment, motorized system <NUM> includes three rotary actuators, each including a motor and a linkage. Independently controlled extension motors <NUM> and <NUM>, and pivot motor <NUM>, are coupled to linkages <NUM>, <NUM> and <NUM>, respectively. Rotation motor <NUM> drives a rotation between the translation stage <NUM> and linkage <NUM>. Linkage <NUM> houses motors <NUM> and <NUM>. Rotation motor <NUM> drives a rotation between linkage <NUM> and linkage <NUM>. Linkage <NUM> houses motor <NUM>. Motor <NUM> drives a rotation between linkage <NUM> and linkage <NUM>. Linkage <NUM> houses the maintenance device <NUM>. In combination with axial traverse motor <NUM>, extension motors <NUM>, <NUM> and pivot motor <NUM> enable motorized system <NUM> to move maintenance device <NUM> in three-dimensional space. In some embodiments, a wiper <NUM> is operated in coordination with maintenance device <NUM> to apply and level repair material on the repair surface. Motor <NUM> drives maintenance device <NUM> to dispense repair material to the repair location. In alternative embodiments, motorized system <NUM> is positionable in any manner that enables motorized system <NUM> to operate as described herein.

<FIG> is a schematic view of an alternative motorized system <NUM> for use with service apparatus <NUM> (shown in <FIG>) including tendon actuators. In combination with axial traverse motor <NUM>, motorized system <NUM> includes motors <NUM> that regulate the length of tendons <NUM> configured to position maintenance device <NUM> in three-dimensional space. For example, motorized system <NUM> is positionable between a stowed position <NUM> and an extended position <NUM>. In alternative embodiments, motorized system <NUM> is positionable in any manner that enables motorized system <NUM> to operate as described herein.

In the exemplary embodiment, motorized system <NUM> includes motors <NUM> and a maintenance device <NUM> that includes a flexible hollow tube <NUM> and links <NUM>. The links <NUM> are arranged so as to include a plurality of flexible segments (e.g., S1, S2). Links <NUM> circumscribe hollow tube <NUM> and are connected by tensioned tendons <NUM>, such as cables, to allow positioning of end effector <NUM> of maintenance device <NUM> by regulating tendon lengths. For example, during operation, motors <NUM> of motorized system <NUM> manipulate ends of the tensioned tendons <NUM> to cause end effector <NUM> to move. When end effector <NUM> is in a desired position, maintenance device <NUM> dispenses repair material to the desired location. Each motor <NUM> controls the radius of one flexible segment (e.g., S1, S2) of maintenance device <NUM> in a single plane. At least two motors <NUM> are combined with axial traverse motor <NUM> to allow the maintenance device <NUM> to access three-dimensional space. In alternative embodiments, motorized system <NUM> positions any end effector <NUM> that enables service apparatus <NUM> (shown in <FIG>) to operate as described herein. For example, in some embodiments, any number of flexible segments may be arranged to form maintenance device <NUM>. In further embodiments, flexible segments S1, S2 may be configured to bend relative to each other in any plane and each motor may simultaneously drive the curvature of one or more segments.

In reference to <FIG>, a method of assembling service apparatus <NUM> includes providing carriage <NUM> configured to move within the primary cavity of turbine assembly <NUM>. The method also includes coupling motorized trolley system <NUM> to carriage <NUM>. The method further includes coupling maintenance device <NUM> to motorized trolley system <NUM> to facilitate maintenance device <NUM> moving relative to carriage <NUM>. In further embodiments, the method includes coupling maintenance device <NUM> to axial traverse motor <NUM>, pivot motor <NUM>, and/or extension-dispense motor <NUM>.

The above described embodiments provide service apparatus for use in maintaining rotary machines. The service apparatus is configured to fit within and move through a cavity of the rotary machines. The service apparatus includes at least one maintenance device that facilitates repairing and/or inspecting the rotary machine. The maintenance device is coupled to a carriage and includes a motorized system configured to move the maintenance device relative to the carriage. For example, in some embodiments, the motorized system moves the maintenance device in at least three directions relative to the carriage. As a result, the service apparatus provides increased access to locations within the cavity of the rotary machine and reduces the amount of time the rotary machine is out of service for maintenance.

An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) reducing the time to inspect and/or repair rotary machines; (b) increasing the accessibility of difficult-to-reach locations within a turbine assembly for inspection and/or in situ repair; (c) reducing the time that rotary machines are out of service for maintenance; (d) enabling complete in-situ inspection and repair of rotary machines; (e) increasing the precision and/or reliability of inspection and repair of rotary machines; (f) reducing unplanned service outages for a rotary machine; (g) enabling the extension of planned service outages of a rotary machine for inspection and/or repair; and (h) enhancing data capture for use in quantifying and/or modeling the service condition of at least some components of the rotary machine.

Exemplary embodiments of methods, systems, and apparatus for use in maintaining rotary machines are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods, systems, and apparatus may also be used in combination with other systems requiring inspection and/or repair of components, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from using a service apparatus for inspection and/or repair.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

Claim 1:
A service apparatus (<NUM>) for use in maintaining a turbine assembly (<NUM>), said turbine assembly comprising a primary cavity defined by a fluid flowpath through the turbine assembly, the fluid flowpath being defined at least in part by a plurality of rotatable airfoils within the turbine assembly, and the service apparatus configured for removable insertion into said primary cavity, and for positioning between adjacent airfoils, the service apparatus comprising:
a carriage (<NUM>) configured to move through the primary cavity of the turbine assembly;
a maintenance device (<NUM>) coupled to said carriage (<NUM>); and
a motor system (<NUM>) coupled to said maintenance device, wherein said motor system is configured to move said maintenance device relative to said carriage (<NUM>), said motor system comprising:
a first motor (<NUM>);
a second motor (<NUM>); and
a third motor (<NUM>),
wherein said first motor (<NUM>) is configured to move said maintenance device (<NUM>) along a longitudinal axis (<NUM>) of said carriage (<NUM>), said second motor (<NUM>) is configured to pivot said maintenance device (<NUM>) about the longitudinal axis (<NUM>), and said third motor is configured to move said maintenance device radially towards and away from the longitudinal axis (<NUM>).