System and method for profiling the edges of an airfoil

Abstract

A tool for profiling an airfoil includes a body including a locator portion and an upper portion. The locator portion includes an engagement surface and the engagement surface is sized and configured to engage the airfoil. The upper portion includes an edge slot that is sized and configured to place an edge of the airfoil into the slot. An abrasive is applied to the side of the edge slot. The upper portion and the locator portion are sized and shaped together such that when the edge of the airfoil is disposed in the edge slot and the engagement surface of the locator portion is simultaneously pressed against the airfoil, the engagement of the abrasive with the edge of the airfoil effectively profiles the edge of the airfoil into a preselected and desired shape.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application 63 / 346,415, filed May 27, 2022, and U.S. Utility Application 18 / 150,588, filed January 5, 2023, which are incorporated herein by reference in their entirety. Technical Field

[0003] These teachings generally concern the outlined portions of the airfoil components of an aircraft engine (e.g., fan blades and / or propellers). Background Technology

[0004] Aircraft engines have different blades or airfoils that guide air through different parts of the engine or perform other functions. The edges of airfoils or blades can deform or degrade due to wear, dirt, or other conditions. If the edges of an airfoil or blade wear and degrade, it may lose its ideal or designed shape, and the overall performance of the engine will be affected. Attached Figure Description

[0005] In the following detailed description, particularly when studied in conjunction with the accompanying drawings, various needs are at least partially met by providing methods and apparatus for contouring airfoil elements, fan blades, or propellers for aircraft engines. A complete and feasible disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, in which:

[0006] Figure 1 This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0007] Figure 2 Including illustrations of tools constructed according to various embodiments of these teachings;

[0008] Figure 3 Including illustrations of tools constructed according to various embodiments of these teachings;

[0009] Figure 4 Including illustrations of tools constructed according to various embodiments of these teachings;

[0010] Figure 5 This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0011] Figure 6A This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0012] Figure 6B This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0013] Figure 7 Illustrations of edge grooves and airfoil edges of tools constructed according to various embodiments of these teachings;

[0014] Figure 8A Including illustrations of the airfoil edges constructed according to various embodiments of these teachings;

[0015] Figure 8B Including illustrations of the airfoil edges constructed according to various embodiments of these teachings;

[0016] Figure 8C Including illustrations of the airfoil edges constructed according to various embodiments of these teachings;

[0017] Figure 8D Including illustrations of the airfoil edges constructed according to various embodiments of these teachings;

[0018] Figure 9 This includes flowcharts constructed based on various embodiments of these teachings;

[0019] Figure 10A This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0020] Figure 10B This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0021] Figure 10C This includes illustrations of tools and airfoils constructed according to various embodiments of these teachings;

[0022] Figure 11 Including illustrations of automated systems for contouring the edges of airfoils according to various embodiments of these teachings; and

[0023] Figure 12 Including various embodiments of these teachings for use Figure 11 The flowchart shows a method for using an automated system to outline the edges of an airfoil.

[0024] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various embodiments of this teaching. Similarly, common but well-understood elements that are useful or necessary in commercially viable embodiments are generally not depicted in order to provide a less obstructive view of these various embodiments of this teaching. Certain actions and / or steps may be described or depicted in a particular sequence of occurrence, and those skilled in the art will understand that such specificity regarding the sequence is not actually necessary. Detailed Implementation

[0025] The methods presented in this paper provide tools and approaches for contouring the leading edges (and other edges) of airfoils, fan blades, and propellers of aircraft engines to improve engine aerodynamic efficiency. This contouring can be performed, for example, when the engine is mounted in an aircraft or on an aircraft. These tools are specifically constructed and customized for a particular airfoil design or shape. That is, different airfoil shapes will require different tools. The “leading edge” refers to the region of the airfoil that extends from the root to the tip, through which relative airflow first passes (the blade chord is the line from the leading edge to the trailing edge of the airfoil before passing through the rest of the blade chord). In axial-flow gas turbine engines mounted on conventional fixed-wing aircraft, the leading edge is typically positioned in front of the blade chord, where the forward direction is the direction of the aircraft's travel. The leading edge region extends a short distance downstream on either side of the relative airflow stagnation point.

[0026] It should be understood that many of the descriptions provided herein relate to airfoil components (used in aircraft engines). It should also be understood that the tools described herein can be used on all types of fan blades and propellers. For example, these methods are also applicable to fan blades and propellers in other systems.

[0027] The tool described herein uses the nominal shape and positioning features of an airfoil to reconstruct the leading edge shape using an abrasive such as sandpaper. The positioning features ensure that the shape of the airfoil is controlled to the nominal line of the airfoil during the contouring operation. In each respect, the tool translates (moves) along the leading edge of the airfoil while applying pressure (e.g., by a person or automated system) to the positioning features. As described above, the method described herein is effective in contouring the leading edge of an airfoil and can be applied to all other edges of the airfoil, including the trailing edge.

[0028] Multiple tools can be used to profile a single airfoil type or design. In each aspect, each individual tool is configured to re-profile different areas of the airfoil. In a specific example, three tools are utilized, each designed to machine or profile different aspects or parts of the airfoil. In each example, the first tool will remove most of the erosion from the leading edge of the airfoil. If necessary, the second and / or third tools will remove high points from the concave and convex sides of the airfoil. The final shape of the airfoil will conform to an ideal shape, approach an ideal shape (as close as possible), or some other desired or specific shape.

[0029] It should be understood that only a portion of the leading edge of the airfoil can be profiled. If one end of the airfoil is considered to be in the 0% position (e.g., the "root" or base of the airfoil when it is attached to a shaft), and the other end is considered to be in the 100% position (opposite end or tip), then in one example, the profiled edge of the airfoil may only occur between the 75% and 100% positions. In this particular example, the tool is specifically designed to be used with each airfoil to profile the outer 25% span of the airfoil (i.e., from the 75% to the 100% position). This region of the airfoil is where most of the thrust is generated.

[0030] In other aspects, chords or airfoil measurements can be added to the airfoil to avoid removing too much material from the blade. This can also be achieved by marking the airfoil with a template to provide a process reference. Another use of the template is to mark the movement limits along the blade edge to prevent the tool from being used in areas where the tooling form is unsuitable.

[0031] In other respects, the tool described herein utilizes the nominal shape of the airfoil, at its thickest point (approximately greater than 75%, i.e., the outer 25%), and positioning features on the convex or concave side, to restore the leading-edge shape using sandpaper or some other abrasive. By using the certified nominal shape and taking into account the thickness of the abrasive (e.g., sandpaper), the tool will restore the leading-edge shape to an approved, certified design. The tool's positioning features, when placed on the convex or concave side of the airfoil, will ensure that the leading-edge shape is controlled to the nominal line or shape of the airfoil during the profiling operation, and this ensures that the leading-edge shape is not biased to either side of the blade.

[0032] As the tool translates (moves) along the leading edge, pressure is applied to the positioning feature. This ensures that the tool's shape is correctly applied to the leading edge as the airfoil twists and turns along its span. To ensure that this movement along the leading edge is smooth and continuous, in addition to the pressure applied to the positioning feature, the tool thickness is selected to account for the airfoil's varying torsional distortion.

[0033] As described above, contouring is achieved by translating (moving) the tool along the leading edge of the airfoil while applying pressure to the tool at the leading edge and the positioning feature. In each respect, 80-90% of the total force applied to the tool (e.g., by a human hand or fingers) is applied to the area of ​​the tool at the leading edge of the engaging airfoil, while 10-20% of the total force applied to that part of the tool is applied to the positioning feature.

[0034] The tool's ease of use and size allow for profiler application even when the engine is still attached to the aircraft. The tool is small enough to fit between adjacent blades or airfoil sections of an engine mounted on or under the wing. In this context, "on the wing" indicates the engine is mounted on the aircraft, while "under the wing" indicates the engine is not. The profiler operation described herein produces more efficient fan blades, resulting in fuel savings for the customer.

[0035] After the contouring is complete, a final coating step or operation can be performed. For example, the edges of the airfoil can be coated, or other anti-corrosion or anti-wear coatings can be applied.

[0036] Before using tools, preparatory steps can be taken. For example, edges or surfaces can be cleaned to remove any existing coatings. These preparatory or preventative steps prevent abrasives (such as sandpaper) from becoming clogged with coatings, which could alter the effectiveness of the abrasive (such as sandpaper).

[0037] Many of the methods described in this paper are described as being performed manually, such as by a person using the tool. However, it is understood that these methods can also be performed automatically or a combination of automatic and manual methods. For example, the tools provided in this paper can be attached to a robotic arm (or an automated system), and the robot can control the movement of the tool.

[0038] In addition to contouring, this tool can perform other functions. For example, it can provide honing or grinding as finishing options for metal surfaces.

[0039] Among other advantages, using the tools described herein allows for the recovery of the leading edge shape without requiring a skilled operator or advanced manufacturing processes. Additionally, this method offers improved repeatability when performing contouring operations. Furthermore, this method provides a specific procedural process, rather than a process requiring skilled operation. The method presented herein has a lower probability of error and is used to reduce the time required for contouring airfoils.

[0040] The terms and expressions used herein have the same general technical meaning as those skilled in the art would assign to them, unless otherwise specified herein. Unless otherwise expressly stated, the word “or” as used herein shall be interpreted as having a disjunctive structure rather than a conjunctive structure. The terms “connection,” “fixation,” “attachment,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment through one or more intermediate components or features, unless otherwise specified herein.

[0041] Unless the context clearly indicates otherwise, the singular forms “one,” “a,” and “this” include plural references.

[0042] The approximate language used in this specification and claims is intended to modify any quantitative expression that may be varied without altering the underlying function. Therefore, values ​​modified by one or more terms, such as “about,” “approximately,” and “basically,” are not limited to specified precise values. In at least some instances, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to a margin of 10%.

[0043] The above and other benefits become clearer after a thorough review and study of the following detailed description.

[0044] Now for reference Figure 1 This describes an example of a method (including a tool) for contouring the edge of an airfoil blade. An airfoil 102 (which may be in or removed from an engine) has a leading edge 104. A contouring tool 106 can move back and forth along the leading edge 104 of the airfoil 102 in the direction indicated by an arrow labeled 108. The airfoil 102 can be any blade, wheel blade, fan blade, or similar structure included in a segment of an aircraft engine, such as a compressor segment or a turbine segment of an aircraft engine. The contouring tool 106 includes a slot 107.

[0045] When the airfoil 102 is placed in the slot 107 of the contouring tool 106, the contouring tool 106 presses against or positions itself on the airfoil 102 using the locator portion 109 applied to it, and as the contouring tool 106 translates along the leading edge 104 of the airfoil 102, the leading edge 104 is contoured according to the desired shape defined by the shape of the slot 107 of the tool 106. In these respects, the size, shape, and / or configuration of the contouring tool 106 are configured such that as the contouring tool 106 translates along the leading edge 104 in the direction indicated by the arrow marked 108, the contouring tool 106 grinds, smooths, polishes, or otherwise impacts the leading edge 104 to conform to the shape of the slot 107 oriented by the locator portion 109. Further details regarding the contouring tool 106 and its use are described elsewhere herein.

[0046] Multiple tools can be used to outline different aspects of the leading edge 104 (or the area associated with the leading edge) of the airfoil 102. Each different tool can be designed to perform different operations on the leading edge 104 and / or different areas, sides, and regions of the airfoil 102.

[0047] For example, now refer to Figure 2 , Figure 3 and Figure 4 Describe three such tools: 200, 300, and 400. Figure 2The tool 200 is configured to profile the airfoil 102 into a predetermined ideal shape, a near-ideal shape, or a desired shape. Figure 3 The tool 300 is configured to contour the high point or point of the airfoil edge 104 on one side (e.g., concave or convex) of the airfoil 102 (the edge of the airfoil protrudes or has some raised area or edge). Figure 4 The tool 400 is configured to be on the opposite side of the contoured airfoil 102 (e.g., with). Figure 3 The high point or point of the airfoil edge 104 (the opposite side, such as the opposite concave side or the opposite convex side).

[0048] As mentioned and in some respects, one end of airfoil 102 is considered to be in the 0% position, and the other end of airfoil 102 is considered to be in the 100% position. Tools 106, 200, 300, and 400 described herein utilize the nominal shape of airfoil 102, at its thickest point (approximately greater than 75%, which may also be considered the outer 25%), and positioning features on the convex or concave side, to restore the shape or profile of leading edge 104 using sandpaper or some other abrasive. Because tools 106, 200, 300, and 400 include the desired nominal shape and take into account the thickness of the abrasive (e.g., sandpaper), tools 106, 200, 300, and 400 restore the shape or profile of leading edge 104 to a desired shape (e.g., an approved, certified design).

[0049] Furthermore, the size, shape, and dimensions of tools 106, 200, 300, and 400 are constructed and customized specifically for the particular design or shape of airfoil 102. In other words, airfoils with different shapes will have different or separate tools. For example, the shape or size of the tools may differ depending on the thickness, length, width, and torsion of a particular airfoil design.

[0050] Now for specific reference Figure 2 The tool 200 includes a body 202 and a locator portion 204. The locator portion 204 has a surface 206. The upper portion of the body 202 includes an opening slot 208, which includes an edge slot 210 (for placing the edge of the airfoil 102). The shape and / or size of the edge slot 210 is determined according to the ideal or desired shape of the edge 104 of the airfoil 102 to which the contouring operation will be performed. The sides 212 of the edge slot 210 are coated with an abrasive (e.g., sandpaper). In all respects, the entire edge slot 210 is coated with sandpaper. The sides of the opening slot 208 may also include an abrasive. The size, shape, and / or dimensions of the opening slot 208 and the edge slot 210 are determined according to the desired shape.

[0051] When tool 200 is positioned on airfoil 102, edge 104 is positioned in opening slot 208 and edge slot 210, surface 206 of locator portion 204 contacts surface 130 of airfoil 102, and as tool 200 translates along leading edge 104 of airfoil 102, leading edge 104 is contoured according to a desired shape. As tool 200 translates, surface 206 of locator portion 204 translates along surface 130 of airfoil 102 (as does the rest of tool 200). As surface 206 of locator portion 204 translates along surface 130 of airfoil 102, surface 206 of locator portion 204 moves with the contour (e.g., twist) of surface 130 of airfoil 102, ensuring that the contour of leading edge 104 of airfoil 102 relative to surface 130 of airfoil 102 is properly contoured. The positioning of the surface 206 of the locator portion 204 on the surface 130 of the airfoil 102 maintains the alignment of the airfoil 102 in the edge groove 210.

[0052] Various types of abrasives can be used in the tools 106, 200, 300, and 400 described herein. Sandpaper is one example of an abrasive, but other abrasives can include natural abrasives such as calcite, diamond, iron oxide, sand, feldspar, or corundum, as well as synthetic abrasives such as CBN, ceramics, alumina, or silicon carbide. The abrasive can be bonded to paper or woven fabric, or it can be directly bonded or coated onto tool 200. As the abrasive rubs against the edge 104 (edge ​​surface) of the airfoil 102, the edge 104 is profiled into an ideal shape, a near-ideal shape, or a desired shape. Instead of abrasives, cutting tools with the desired shape and / or cutting edge (e.g., on a cutter or file) can also be used.

[0053] In one specific example, the abrasive is sandpaper. In one example, the grit count / quantity of the sandpaper can be 150–400 grits. Other grit ranges can be used depending on the application.

[0054] The main body 202 may be made of plastic or other suitable materials.

[0055] During operation, tool 200 is positioned on the edge 104 of airfoil 102 such that edge 104 is received in opening slot 208, more specifically, in edge slot 210. Surface 206 of the locator portion 204 presses against surface 130 of the airfoil. Figure 2(Not shown in the image) to orient the edge groove 210 relative to the edge 104. The body 202 and the locator portion 204 are configured such that when the edge 104 of the airfoil 102 is positioned in the edge groove 210 and the surface 206 of the locator portion 204 presses against the surface 130 of the airfoil 102, the tool 200 is correctly positioned on the edge 104 of the airfoil 102. For example, the tool 200 is positioned such that it can correctly contour the edge 104 of the airfoil 102 to an ideal or near-ideal shape. If the surface 206 of the locator portion 204 does not press against the surface 130 of the airfoil 102 to orient the edge groove 210 of the tool 200 relative to the edge 104 of the airfoil 102, the edge 104 of the airfoil may be contoured in an inappropriate or skewed shape.

[0056] During operation, tool 200 moves along the leading edge 104 of airfoil 102 (e.g., Figure 1 (As shown) it moves manually or automatically. As the tool 200 moves along the edge 104 of the airfoil 102, the edge 104 of the airfoil 102 interacts with and is abraded by the abrasive (e.g., sandpaper) on the side surface 212 of the edge groove 210. With this contact and abrasion, the leading edge 104 of the airfoil 102 is brought into an ideal shape, close to an ideal shape, or a desired shape (e.g., indicated by the shape or size of the edge groove 210 and the orientation of the edge groove 210 relative to the edge 104 of the airfoil 102).

[0057] It should be understood that only a portion of the leading edge 104 of the airfoil 102 can be contoured. If one end 150 of the airfoil 102 is considered to be in the 0% position and the other end 152 of the airfoil 102 is considered to be in the 100% position, then in one example, the contouring of the edge 104 of the airfoil 102 may only occur in the 75% to 100% position. As described above, the surface 206 of the locator portion 204 is also translated (along with the rest of the tool 200). As the surface 206 of the locator portion 204 follows the surface 130 of the airfoil 102, the orientation or relative position between the surface 130 of the airfoil 102 and the edge groove 210 is maintained along the length of the edge 104, ensuring that the leading edge 104 of the airfoil 102 is correctly contoured.

[0058] Now for reference Figure 5 The airfoil 220 is shown as being inserted into the opening slot 208 and the edge slot 210. The dimensions and construction of the body 202 are such that when the edge 104 of the airfoil 102 is in the edge slot 210 and the surface 206 of the locator portion 204 presses against the surface 130 of the airfoil 102 (as shown in the image), Figure 5 As shown), the tool 200 can move along the edge 104 to contour (e.g., by sanding or smoothing) the leading edge 104 of the airfoil 102.

[0059] Now for reference Figure 3 It describes the provision of information about Figure 2 The described tool 200 is another type of tool 300 operating differently. Tool 300 includes a body 302. The body 302 has a locator portion 304 with a surface 306. The upper portion of the body 302 includes an opening slot 308, which includes an edge groove 310. In some examples, an abrasive (e.g., sandpaper) is applied to the side surface 312 of the edge groove 310. As the abrasive rubs against the edge 104 (edge ​​surface) of the airfoil 102, the edge 104 is contoured to an ideal or near-ideal shape. In some other examples, the abrasive is removed from the side surface 312.

[0060] Tool 300 also includes a raised portion 330 having a surface 332. Surface 332 is covered with an abrasive such as sandpaper. Surface 332 is configured to contact the raised portion of edge 104, which will be discussed in further detail below. When the edge 104 of airfoil 102 is profiled by tool 300, surface 332 engages the raised portion (e.g., concave or convex side) on surface 130 of edge 104 of airfoil 102 and polishes it. As mentioned and in some respects, the sandpaper on side 312 is removed, and tool 300 is used only to remove high points from one side or edge of airfoil.

[0061] The body 302 and the protrusion 330 may be made of plastic or other suitable materials. In operation, the tool 300 is positioned above the edge 104 of the airfoil 102 such that the edge 104 is received in the opening slot 308, more specifically, in the edge groove 310. The surface 306 of the locator portion 304 presses against the surface 130 (not shown) of the airfoil 102 to orient the edge groove 210 relative to the edge 104. The body 302 and the locator portion 304 are configured such that when the edge 104 of the airfoil 102 is positioned in the edge groove 310 and the surface 306 of the locator portion 304 presses against the surface 130 of the airfoil 102, the edge 104 of the airfoil 102 is correctly positioned, for example, the edge 104 of the airfoil 102 is positioned to be correctly profiled into an ideal or near-ideal shape. If the surface 306 of the locator portion 304 does not press against the surface 130 of the airfoil 102 so that the edge groove 310 of the tool 300 is oriented relative to the edge 104 of the airfoil 102, then the edge 104 of the airfoil may be profiled in an inappropriate or skewed shape.

[0062] During operation, tool 300 moves along the leading edge 104 of airfoil 102 (e.g., Figure 1(As shown) It moves manually or automatically. As the tool 300 moves along the edge 104 of the airfoil 102, the edge 104 of the airfoil 102 interacts with and is abraded by the abrasive (e.g., sandpaper) on the side surface 312 of the edge groove 310. With this contact and abrasion, the leading edge 104 of the airfoil 102 is brought into an ideal shape, close to an ideal shape, or a desired shape (e.g., indicated by the shape or size of the edge groove 310 and the orientation of the edge groove 310 relative to the edge 104 of the airfoil 102).

[0063] Now for reference Figure 4 This describes another type of tool 400. Tool 400 performs actions related to... Figure 2 and Figure 3 The described tool operates in various ways (e.g., tool 400 is configured to contour or impact different areas of the tool described in these other figures). Tool 400 includes a body 402. Body 402 has a locator portion 404 having a surface 406. The upper portion of body 402 includes an opening slot 408, which includes an edge slot 410. In some embodiments, an abrasive (e.g., sandpaper or grit) is applied to the side surface 412 of the edge slot 410, and in other embodiments, the abrasive is not applied to the side surface 412. If the abrasive is present on the side surface 412, the edge is contoured to a desired shape (e.g., an ideal shape or near-ideal shape) as the edge of the airfoil (edge ​​surface) rubs against the abrasive.

[0064] The tool 400 also includes a raised portion 430 having a surface 432. The surface 432 is covered with an abrasive such as sandpaper. As the airfoil is profiled, the surface 432 engages and sands the raised portion on one side (e.g., the convex side) of the airfoil. As mentioned and in some respects, the sandpaper on the side 412 is removed and the tool is used only to remove the high points from one side (e.g., the concave side) of the airfoil.

[0065] The body 402 and the protrusion 430 may be made of plastic or other suitable materials. In operation, the tool 400 is positioned over the edge 104 of the airfoil 102 such that the edge 104 is received in the opening slot 408, more specifically, in the edge groove 410. The surface 406 of the locator portion 404 presses against the surface 131 (not shown) of the airfoil 102 to orient the edge groove 410 relative to the edge 104. The body 402 and the locator portion 404 are configured such that when the edge 104 of the airfoil 102 is positioned in the edge groove 410 and the surface 406 of the locator portion 404 presses against the surface 131 of the airfoil 102, the edge 104 of the airfoil 102 is correctly positioned, for example, positioned such that the airfoil can be correctly profiled into an ideal or near-ideal shape. If the surface 406 of the locator portion 404 does not press against the surface 131 of the airfoil 102 to orient the edge groove 410 of the tool 400 relative to the edge 104 of the airfoil 102, the edge 104 of the airfoil may be profiled in an inappropriate or skewed shape.

[0066] During operation, the tool 400 moves manually or automatically along the leading edge 104 of the airfoil 102 (e.g., Figure 1 As the tool 400 moves along the edge 104 of the airfoil 102, the edge 104 of the airfoil 102 interacts with and is abraded by the abrasive (e.g., sandpaper) on the side surface 412 of the edge groove 410. With this contact and abrasion, the leading edge 104 of the airfoil 102 is brought into an ideal shape, close to an ideal shape, or a desired shape (e.g., indicated by the shape or size of the edge groove 410 and the orientation of the edge groove 410 relative to the edge 104 of the airfoil 102).

[0067] Now for reference Figure 6A and Figure 6B This describes an example of a contouring tool 200 and its use. An airfoil 102 includes a leading edge 104. The leading edge 104 of the airfoil 602 is inserted into an edge slot 210 of the contouring tool 200. More specifically, the leading edge 104 is inserted into the slot 210 and moved back and forth along the leading edge 104 in the direction of the arrow marked 608.

[0068] A person (hand 610) engages tool 200 onto airfoil 102. The locator portion 204 of the contouring tool 200 presses against one side 130 of airfoil 102. The person's hand or fingers 610 press, hold, and / or fix tool 200 there. Simultaneously, the leading edge 104 of airfoil 102 is positioned in the groove 210 of contouring tool 200. Another person's hand or fingers 620 engage the other side of contouring tool 200. As the locator portion 204 presses against airfoil 102, the hands 610 and 620 together and cooperatively slide the contouring tool 200 back and forth along the leading edge 104 to contour the leading edge 104 of airfoil 102. Because the locator portion 204 follows surface 130, its relative position remains constant, thereby ensuring that the leading edge 104 of airfoil 102 is correctly contoured. In all respects, 80-90% of the total force applied to tool 100 is applied to the area of ​​the leading edge 104 of the engaging airfoil of tool 200, while 10-20% of the total force applied to part of tool 200 is applied to the positioning feature.

[0069] Now for reference Figure 7 An example of an edge groove 210 is described, in which the leading edge of an airfoil is positioned within the edge groove 210. The airfoil 102 has a leading edge 104, and the leading edge 104 is placed within the groove 210 of the tool 200. An abrasive (e.g., sandpaper) 706 adheres to the edge of the groove 210. As the tool 200 moves along the leading edge 104 (moving in and out of the page in this view), the leading edge 104 is re-outlined according to the shape of the groove 210.

[0070] Now for reference Figures 8A-8D The figures show and describe different cross-sections of the leading edge 104 of the airfoil 102 in different physical states. The airfoil 102 includes a convex side 812 and a concave side 813. Initially, the leading edge 810 is rough, worn, and / or incorrectly shaped, and this is gradually profiled into a nominal or desired shape. As also shown in these figures, the leading edge has an ideal edge shape 808, a minimum profile shape 804 (the minimum shape for which profileding is performed), and a maximum profile shape 806 (the maximum shape for which profileding is performed). In this example, the initial leading edge 810 includes two high points 814, 816. The high points 814, 816 are more significantly convex relative to the ideal edge shape 808, while the remainder of the initial leading edge 810 is not significantly convex relative to the ideal edge shape 808.

[0071] Figures 8A-8D The effect of contouring the edge 104 of the airfoil 102 is shown. All these figures show the cross-section of the edge 104 of the airfoil 102. In these examples, a first tool (e.g., tool 200) is applied to produce... Figure 8B The shape in the middle.

[0072] Then, a second tool (e.g., tool 300) is applied to obtain... Figure 8C The shape shown. This action removes the high point 816 on the concave side 813.

[0073] Finally, a third tool (e.g., tool 400) is applied to the leading edge to obtain Figure 8D The shape shown. This will remove the high point 814 on the convex side 812.

[0074] It should be understood that some or all of the tools (e.g., tools 200, 300, and 400) may be used. For example, it may be necessary to use only tool 200 instead of tools 300 and 400. In another example, tools 200 and 300 may be needed instead of tool 400. In yet another example, tools 200 and 400 may be needed instead of tool 300. In yet another example, all of tools 200, 300, and 400 may be needed. In some respects, the number of tools used depends on the specific airfoil being serviced.

[0075] More specifically, Figure 8A The airfoil 102 is shown before any tool is applied to contour the leading edge 104. It can be seen that the leading edge 810 is rough, uneven, and has two high points 814 and 816.

[0076] Figure 8B The figure shows the airfoil 102 after the application of a first tool (e.g., tool 200). The figure shows that the initial grinding of the leading edge 104 has occurred, but the two high points (protrusions) 814 and 816 of the leading edge 104 still exist.

[0077] Figure 8C The figure shows an airfoil 102 after the application of a second tool (e.g., tool 300), which grinds the concave side of the airfoil 102. The figure shows that high points 816 have been ground or outlined by tool 300. In various aspects, the surface 332 of tool 300 is applied against the high points 816 to reduce or remove them.

[0078] Figure 8D The figure shows the airfoil 102 after a third tool (e.g., tool 400) has been applied to the convex side of the airfoil 801. The figure shows that the high points 814 have been tooled or contoured. In various aspects, the surface 432 of tool 400 is applied against the high points 816 to reduce or remove these high points 814.

[0079] Now for reference Figure 9 An example of a method for contouring the leading edge 104 of the airfoil 102 is described.

[0080] In step 902, the leading edge 104 of the airfoil 102 is positioned in the edge groove 210 of the tool 200. The tool includes a body defining a locator portion 204 and an upper portion. The locator portion 204 includes an engagement surface 206. Positioning can be performed manually, but in some cases automatic positioning can be used (e.g., by a machine such as a robot).

[0081] In step 904, the engagement surface 206 of the tool 200 is pressed to engage the surface of the airfoil 102. As shown elsewhere herein, the engagement surface 206 is positioned relative to the locator portion 204 of the tool 200. A user, for example, uses their hands and fingers to manually position and press the tool 200 such that the engagement surface 206 presses against the surface 130 of the airfoil 102. Depending on the tool used, the surface of the airfoil 120 may be the convex or concave side of the airfoil 102. As described above, this step can be performed manually, but in some cases automatic positioning can be used (e.g., by a machine such as a robot).

[0082] In step 906, when the edge 104 of the airfoil 102 is positioned in the edge groove 210 and the surface of the locator portion 204 simultaneously presses against the surface 130 of the airfoil 102, the tool 200 moves back and forth along the leading edge 104 of the airfoil 102, such that the engagement of the tool 200 with the edge 104 of the airfoil 102 effectively profiles the edge 104 of the airfoil 102 into a pre-selected and desired shape. As described elsewhere herein, one or more grooves in the tool 200 are constructed, sized, and / or shaped according to the desired shape of the leading edge of the airfoil. As the forward and backward movements occur, abrasive friction, smoothing, grinding, or otherwise impacts the leading edge on the tool to conform it to the desired shape. This step can be performed manually, but in some cases automatic positioning can be used (e.g., by a machine such as a robot).

[0083] Now for reference Figure 10A , Figure 10B and Figure 10C An example of a contouring tool 1000 with a stop 1020 is described. The stop 1020 is attached to the tool and prevents the tool from further contouring the edge of the airfoil once the stop 1020 strikes the airfoil.

[0084] More specifically, the airfoil 102 includes a leading edge 104. The leading edge 104 of the airfoil 102 is manually or automatically inserted into a slot in a contouring tool 1000 (examples of which include tools 200, 300, and 400). The leading edge 104 of the airfoil 102 is manually or automatically inserted into the slot and moved back and forth along the leading edge 104 in the direction of the arrow marked 1008. A person (or possibly a machine) engages the tool with the airfoil 102. The locator portion 1011 of the contouring tool 1000 (e.g., surfaces 206, 306, and 406 of tools 200, 300, and 400) is manually or automatically pressed against one side of the airfoil 102.

[0085] A stop 1020 is coupled to the contouring tool 1000 and, once the stop 1020 contacts the leading edge 104 of the airfoil 102, limits further material removal from the edge of the airfoil 102 to prevent excessive material removal. The stop 1020 is deployed in any position such that once sufficient material has been removed from the edge 104 of the airfoil 102, the stop 1020 impacts the airfoil 102. In this case, the stop 1020 includes a roller 1022 held by a support 1024. However, other examples of stops (e.g., pads) may also be used. One or more of the roller 1022 and the support 1024 contact the leading edge 104 to prevent excessive material removal.

[0086] In all respects, the contouring tool 1000 is configured to remove high points on the airfoil 102. Initially, a gap exists between the blunted edge of the leading edge 104 of the airfoil 102 and the contouring tool 1000. As these high points are removed, the gap size decreases because the tool 1000 will move relative to the blade cross-section, in this example, in the general direction (downward) of the arrow marked 1026. In other words, as the contouring tool 1000 moves back and forth in the direction indicated by the arrow marked 1008, it also moves slightly downward in the direction indicated by the arrow marked 1026. As the airfoil 1002 is contoured, the stop 1020 eventually contacts the airfoil 1002 to prevent further material removal, as the stop 1020 is not abrasive. Once contact is complete, the movement of the contouring tool 1000 in the direction of the arrow marked 1008 is stopped manually or automatically. In other respects, the stop 1020 can orient the tool 1000 so that the tool 1000 will not rotate.

[0087] Now for reference Figure 11An example of an automated system 1100 for contouring the edge 104 of an airfoil 102 is described. The automated system 1100 includes a processor 1102, a memory 1104, an actuation element 1106, tools (or multiple tools) 200, 300, or 400, and an airfoil 1110. A user interface (not shown) may be coupled to the processor 1102 to allow a human user to interact with the system and / or receive information (e.g., system feedback, messages, images, or other information or data). The aforementioned components may be located in the same area (e.g., the same space), but in other examples they may be distributed at different remote locations (e.g., the processor 1102 may be located in a central location, while the actuation element 1106, tools 200, 300, or 400, and airfoil 1110 may be located at remote locations).

[0088] Processor 1102 is any processing device such as a controller or microprocessor. Memory 1104 is any type of electronic memory device, such as random access memory, read-only memory, or electronically erasable programmable read-only memory (EEPROM), to name a few examples. Memory 1104 stores executable computer instructions that control the actuation element 1106.

[0089] Actuation component 1106 can be assembled into a robot, multiple robots, or multiple other machines. Actuation component 1106 may include arms, pliers, and / or grippers in any configuration arrangement to allow the use of tools 200, 300, or 400 and the application of tools 1108 to the edge of airfoil 102.

[0090] Tool 200, 300, or 400 is any combination of the tools described herein (e.g., tools 200, 300, and / or 400 as described above). Airfoil 102 is an airfoil blade as described herein.

[0091] In operation, the actuating member 1106 is coupled to or attached to the tool 200, 300, or 400. For example, if the actuating member 1106 includes a robotic arm, the tool 1108 is attached (using any suitable attachment procedure or structure) to the end of the robotic arm. In these respects, both the actuating member 1106 and the tool 200, 300, or 400 have structures for supporting attachments. For example, the tool 200, 300, or 400 may be configured such that specific areas of the tool 200, 300, or 400 can be gripped by the actuating member 1106.

[0092] The attachment process can be automated (e.g., controlled by processor 1102) or manual (e.g., performed by a human). Once tools 200, 300, or 400 are attached, processor 1102 sends control signals to move the robotic arm to a position around airfoil 102, locate the edge 104 of airfoil 102 (e.g., by taking an image of airfoil / airfoil edge of airfoil 102 using a camera and processing the image, for example, using machine learning or artificial intelligence methods, to find the edge), move tools 200, 300, or 400 to engage the slots of tools 200, 300, or 400 with the edge 104 of airfoil 102, and then move tools 200, 300, or 400 over the edge of airfoil 102, as described elsewhere herein.

[0093] Periodically, tools 200, 300, or 400 can be removed from the airfoil 102, allowing further images of the edges of the airfoil 102 to be obtained. These further images can be evaluated to see if further contouring is needed or if contouring can be stopped. When a stop is used in conjunction with tools 200, 300, or 400 (as shown), a sensor can detect when the stop contacts the airfoil, thereby stopping the contouring operation.

[0094] When using multiple tools, tools can be attached to and removed from the actuating member 1106 as needed. For example, a first tool (e.g., tool 200) can be used. After contouring with the first tool is complete, the first tool can be removed from the actuating member 1106, and a second tool (e.g., tool 300) can be used. After contouring with the second tool is complete, the second tool is removed from the actuating member 1106, and a third tool (e.g., tool 400) is attached to the actuating member 1106. The edge contouring is then performed using the third tool.

[0095] As described above, the automated operation of the automation system 1100 can utilize the processor 1102, which can employ artificial intelligence or machine learning methods during operation. For example, a neural network configured to recognize the leading edge of an airfoil (in order to correctly position tools 200, 300, or 400 using the actuating member 1106) can be used. These methods can also be used to recognize when the airfoil 102 has been sufficiently contoured into a predetermined shape. In other examples, the neural network can determine when a specific tool needs to be used (e.g., determining which tools 200, 300, and / or 400 should be used). If a neural network is used, it can be trained using training images and / or other data, enabling the aforementioned determinations. The training process alters the layers, weights, or other structure of the neural network.

[0096] Now for reference Figure 12 , described Figure 11 An example of system operation. In step 1202, processor 1102 engages or attaches tool 200, 300, or 400 to or attaches it to a robotic arm (where the robotic arm is an example of actuation member 1106). For example, if the robotic arm includes a gripper, the processor sends a control signal to the robotic arm that effectively causes the gripper to open around tool 200, 300, or 400, and then close to secure tool 200, 300, or 400 in the gripper. Alternatively, a person may attach tool 200, 300, or 400 to the robotic arm.

[0097] In step 1204, one or more cameras acquire images of the tool and / or airfoil 102 (including the edges of the airfoil 102 and the placement of the airfoil 102 relative to the tool 200, 300, or 400 on the robotic arm). In step 1206, these images are processed by processor 1102 to obtain information such as the position of the edge of the airfoil 102, the distance from the tool 200, 300, or 400 to the edge of the airfoil 102, and the path from the current position of the tool 200, 300, or 400 to the edge of the airfoil 102. The determined information may be represented as coordinates in a global coordinate system.

[0098] In step 1208, using the information obtained in step 1206, processor 1102 sends a control signal to move the robot arm to the position of tool 200, 300 or 400 around airfoil 102, then positions the edge of airfoil 102 and moves tool 200, 300 or 400 such that the groove of tool 200, 300 or 400 fits into the edge of airfoil 102.

[0099] In step 1208, processor 1102 sends a control signal to the robotic arm, causing the robotic arm (in the gripper) to move tool 200, 300, or 400 over the edge of airfoil 102, as described elsewhere herein. Step 1208 results in the edge of airfoil 102 being contoured or machined by tool 200, 300, or 400. In various respects, step 1208 can be performed for a predetermined amount of time.

[0100] In step 1210, the processor 1102 determines whether the tools 200, 300, or 400 have profiled or machined the edge of the airfoil 102 into the desired shape. To do this, the tools 200, 300, or 400 can be removed from the edge of the airfoil 102, thereby obtaining further images of the edge of the airfoil 102. These further images can be evaluated by the processor 1102 to see if further profilening is needed or if profilening can be stopped. In some respects, machine learning methods can be used to determine whether the image of the airfoil's edge has been machined into an acceptable shape.

[0101] When the stop is used with tool 200, 300 or 400 (e.g.) Figure 10A , Figure 10B and Figure 10C As shown), the sensor can detect when the stop contacts the airfoil, allowing the processor 1102 to stop the contouring operation. If the answer in step 1210 is affirmative (the desired shape has been achieved), the process ends. If the answer in step 1210 is negative (the desired shape has not yet been achieved), execution returns to step 1208 as described above.

[0102] When using multiple tools, refer to Figure 12 The described method is applicable. When using multiple tools, the robotic arm can be automatically opened and closed as needed. For example, the first tool (e.g., tool 200) can be used first. In use... Figure 12 After the process of contouring with the first tool is completed, the first tool can be detached from the robot arm, and a second tool (e.g., tool 200) is used. After contouring with the second tool is completed, the second tool is detached from the robot arm, and a third tool (e.g., tool 300) is attached to the robot arm. The edge contouring is then performed using the third tool. Other images of the airfoil 1110 can be obtained, and the processor 1102 can determine whether a specific tool needs to be used.

[0103] Advantageously, the tools and methods described herein for using these tools offer various advantages. The provided tools are small and easy to use. Each tool can be customized to a specific desired leading-edge shape. Because these tools are small, they can be used on airfoils while the airfoils remain attached to the engine. In other words, using these methods does not require engine disassembly. For these reasons, the methods provided herein are cost-effective and easy to use and implement.

[0104] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0105] A tool for contouring the edge of an airfoil, the tool comprising: a body including: an edge groove configured to be positioned on the edge of the airfoil; and an engagement surface configured to engage at least one surface of the airfoil when the edge groove receives the edge of the airfoil, such that the edge groove is oriented relative to the edge of the airfoil.

[0106] The tool according to any of the preceding clauses, wherein the edge groove includes an abrasive.

[0107] The tool according to any of the preceding clauses, wherein the abrasive is selected from the group consisting of sandpaper, natural abrasives and synthetic abrasives.

[0108] The tool according to any of the preceding clauses, wherein the abrasive is bonded to paper or woven fabric.

[0109] According to any of the preceding clauses, the tool wherein the engagement surface is configured as the convex side of the engagement airfoil.

[0110] According to any of the preceding clauses, the tool wherein the engagement surface is configured to engage the concave side of the airfoil.

[0111] The tool according to any of the preceding clauses further includes a stop that is configured to eventually contact the edge as the tool is used.

[0112] The tool according to any of the preceding clauses further includes a roller.

[0113] The tool according to any of the preceding clauses, wherein the edge groove has the shape of an airfoil edge.

[0114] According to any of the preceding clauses, the engagement surface is configured to follow the surface of the airfoil as the edge groove moves along the edge of the airfoil.

[0115] The tool according to any of the preceding clauses further includes a wider groove for guiding the edge groove onto the edge of the airfoil.

[0116] The tool described in any of the preceding clauses, wherein the tool is one of a set of tools.

[0117] The tool according to any of the preceding clauses, wherein a robot or actuating component is coupled to and guides the tool.

[0118] A method for contouring the edge of an airfoil, the method comprising: positioning the edge of the airfoil in an edge groove of a tool; and engaging an engagement surface with at least one surface of the airfoil when the edge groove receives the edge of the airfoil, such that the edge groove is oriented relative to the edge of the airfoil.

[0119] According to the method described in any of the preceding clauses, the edge groove includes an abrasive, and the edge is contoured as the edge engages the abrasive.

[0120] The method according to any of the preceding clauses, wherein the abrasive is selected from the group consisting of sandpaper, natural abrasives and synthetic abrasives.

[0121] The method according to any of the foregoing clauses, wherein the abrasive is bonded to paper or woven fabric.

[0122] According to the method described in any of the preceding clauses, the contouring of the tool is stopped by a stop connected to the tool.

[0123] The method according to any of the preceding clauses, wherein the robot or actuating component is coupled to the tool and guides the tool.

[0124] The method according to any of the preceding clauses, wherein the tool is manually engaged with the airfoil.

[0125] Those skilled in the art will recognize that various modifications, alterations, and combinations can be made to the above embodiments without departing from the scope of the invention, and such modifications, alterations, and combinations will be considered to be within the scope of the inventive concept.

Claims

1. A tool for contouring the edge of an airfoil, characterized in that, The tools include: The main body, the main body includes: Edge groove, wherein the edge groove is configured to be positioned on the edge of the airfoil; A mating surface, the mating surface being configured to engage at least one surface of one side of the airfoil when the edge groove receives the edge of the airfoil, such that the edge groove is oriented relative to the edge of the airfoil; and The raised portion has an abrasive surface or a cutting edge surface, the abrasive surface or cutting edge surface being configured such that when the edge groove is located on the edge of the airfoil and the engagement surface engages with at least one surface on one side of the airfoil, the raised portion on the surface of the edge of the airfoil is surface-engaged and polished when the edge of the airfoil is profiled by the tool.

2. The tool according to claim 1, characterized in that, in, The edge groove includes abrasive.

3. The tool according to claim 2, characterized in that, in, The abrasive is selected from the group consisting of sandpaper, natural abrasives and synthetic abrasives.

4. The tool according to claim 2, characterized in that, in, The abrasive is bonded to paper or woven fabric.

5. The tool according to claim 1, characterized in that, in, The mating surface is configured to engage the convex side of the airfoil.

6. The tool according to claim 1, characterized in that, in, The mating surface is configured to engage the concave side of the airfoil.

7. The tool according to claim 1, characterized in that, It further includes a stop that is configured to eventually contact the edge as the tool is used.

8. The tool according to claim 7, characterized in that, This further includes rollers.

9. The tool according to claim 1, characterized in that, in, The edge groove has the shape of the edge of an airfoil.

10. The tool according to claim 1, characterized in that, in, The mating surface is configured to follow the surface of the airfoil as the edge groove moves along the edge of the airfoil.

11. The tool according to claim 1, characterized in that, It further includes a wider groove for guiding the edge groove onto the edge of the airfoil.

12. The tool according to claim 1, characterized in that, in, The tool is one of a set of tools.

13. The tool according to claim 1, characterized in that, in, A robot or actuating component is attached to the tool and guides the tool.

14. A method for contouring the edge of an airfoil, characterized in that, The method includes: Position the edge of the airfoil in the edge groove of the tool; When the edge groove receives the edge of the airfoil, the mating surface engages with at least one surface on one side of the airfoil, so that the edge groove is oriented relative to the edge of the airfoil; and The tool contacts at least one protruding portion of the edge of the airfoil having an abrasive surface or a cutting edge surface configured such that, when the edge groove is located on the edge of the airfoil and the engagement surface engages with at least one surface on one side of the airfoil, the tool contours the edge of the airfoil, and the surface engages the protruding portion on the surface of the edge of the airfoil and polishes it.

15. The method according to claim 14, characterized in that, in, The edge groove includes abrasive, and the edge is contoured as it engages with the abrasive.

16. The method according to claim 15, characterized in that, in, The abrasive is selected from the group consisting of sandpaper, natural abrasives and synthetic abrasives.

17. The method according to claim 15, characterized in that, in, The abrasive is bonded to paper or woven fabric.

18. The method according to claim 15, characterized in that, in, The contouring of the tool is stopped by a stop connected to the tool.

19. The method according to claim 15, characterized in that, in, A robot or actuating component is attached to the tool and guides the tool.

20. The method according to claim 15, characterized in that, in, The tool is manually engaged with the airfoil.

Images