Low profile embedded blade tip clearance sensor

1. A device comprising, in combination, a blade clearance sensor and a radial flow separation wall of a gas turbine engine, wherein the blade clearance sensor is embedded in the radial flow separation wall, the radial flow separation wall comprising:

a splitter hoop located radially outward from blades in a first flow path within the gas turbine engine, the splitter hoop being about concentric to a blade path of the blades; and

one or more guide vane bases attached to a guide vane located radially outward from the splitter hoop in a second flow path within the gas turbine engine, each of the one or more guide vane bases being securely attached to a radially outward surface of the splitter hoop, wherein at least one of the one or more guide vane bases includes a vane orifice, and

wherein the blade clearance sensor is configured to detect a blade clearance between the blades and the splitter hoop.

2. The device of claim 1 , wherein the blade clearance sensor further comprises a housing; and a sensing element at least partially enclosed in the housing.

3. The device of claim 1 , wherein the blade clearance sensor is securely connected to the splitter hoop by one or more welds.

4. The device of claim 2 , wherein the blade clearance sensor further comprises a first section and a second section oriented radially outward from the first section when the blade clearance sensor is installed in the gas turbine engine, wherein the first section is at least partially enclosed in a splitter hoop orifice located in the splitter hoop.

5. The device of claim 4 , wherein the second section is at least partially enclosed in the vane orifice located in the one or more guide vane bases.

6. The device of claim 1 , wherein a radially inward surface of the splitter hoop is at least partially coated with an abradable coating.

7. The device of claim 4 , wherein a radially inward surface of the splitter hoop is at least partially coated with an abradable coating with the exception of the splitter hoop orifice.

8. The device of claim 7 , wherein a radially inward surface of the first section of the blade clearance sensor is coated with a dielectric abradable coating.

9. The device of claim 1 , wherein the one or more guide vane bases further comprises a passageway through which a lead wire electrically connects the blade clearance sensor to a measurement device.

10. The device of claim 5 , wherein a potting material encapsulates the second section of the blade clearance sensor within the vane orifice.

11. The device of claim 5 , wherein the vane orifice stretches across two guide vane bases.

12. The device of claim 9 , wherein a potting material fully encapsulates the lead wire within the passageway.

13. A method of embedding a blade clearance sensor into a radial flow separation wall within a gas turbine engine, wherein the radial flow separation wall comprises a splitter hoop and one or more guide vane bases, the method comprising:

forming a splitter hoop orifice within the splitter hoop, wherein the splitter hoop is located radially outward from blades in a first flow path within the gas turbine engine when the splitter hoop is installed in the gas turbine engine;

forming a vane orifice within the one or more guide vane bases;

aligning the vane orifice with the splitter hoop orifice, the vane orifice being radially outward from the splitter hoop office in a second flow path within the gas turbine engine; and

inserting the blade clearance sensor into the vane orifice and the splitter hoop orifice.

14. The method of claim 13 , further comprising:

securely attaching the one or more guide vane bases to a radially outward surface of the splitter hoop.

15. The method of claim 13 , further comprising:

forming a passageway within the one or more guide vane bases;

electrically connecting a lead wire to the blade clearance sensor; and

inserting the lead wire into the passageway.

16. The method of claim 15 , further comprising:

encapsulating the lead wire within the passageway.

17. The method of claim 13 , further comprising:

encapsulating the blade clearance sensor within the splitter hoop orifice at a radially inward side of the splitter hoop orifice with a dielectric abradable coating.

18. The method of claim 13 , further comprising:

encapsulating the blade clearance sensor within the vane orifice at a radially outward side of the vane orifice.

19. The method of claim 13 , further comprising:

coating a radially inward side of the splitter hoop with an abradable coating with the exception of the splitter hoop orifice.