Cooling hole positioning system and method

Abstract

A system and method for locating cooling holes on an exterior surface of a turbine engine component based on three-dimensional measurements along the X-, Y-, and Z-axes and two-dimensional measurements extracted along the X- and Y-axes. The two-dimensional data is analyzed to find common geometric features of the component and determine a scan area based on the common geometric features. The component is measured within the scan area to locate cooling holes on the exterior surface of the component. Surface profiles of the cooling holes are extracted along the X- and Y-axes, and orientations of the cooling holes are extracted along the Z-axis. A set of three-dimensional coordinates of the cooling holes is calculated based on the surface profiles and orientations.

Description

[Technical Field]

[0001] The present disclosure relates generally to cooling hole positioning systems and methods, and more particularly to systems and methods for locating cooling holes on used turbine engine parts and using collected location data to automate the reopening of cooling holes after the used parts have been recoated. [Background technology]

[0002] Turbine engines, such as gas turbine engines or steam turbine engines, are widely used in industry and for power generation. As such, turbine engines are exposed to high temperatures for extended periods of time, which can cause deformation of turbine engine components over time. Accordingly, coatings, such as thermal barrier coatings for gas turbine engines or corrosion-preventive coatings for steam turbine engines, can be applied to turbine engine components to help protect the components from thermal damage. Additionally, turbine engine components can include cooling holes to facilitate improved air circulation around the components to reduce damage from extended exposure to high temperatures.

[0003] Typically, cooling holes need to be "reopened" after a coating is applied to a turbine engine component. Computer modeling (e.g., CAD models) can be used to determine the three-dimensional locations of cooling holes on unused turbine engine components. However, computer models may be unreliable for locating cooling holes on used turbine engine components because turbine engine components that have been exposed to high temperatures for extended periods of time may experience creep in cooling hole locations due to thermal deformation. As a result, cooling holes on used turbine engine components often must be located manually, reducing the efficiency of the repair, recoating, and cooling hole reopening process. Therefore, there is a need for a system and method for locating cooling holes on used turbine engine components and using the collected location data to automate the reopening of cooling holes after the used parts have been recoated. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] US Patent Application Publication No. 2009 / 0220349 Summary of the Invention

[0005] In one aspect, a positioning method for use with a turbine engine component is provided. The method includes measuring an exterior surface of the component along X-, Y-, and Z-axes to obtain three-dimensional data including X-, Y-, and Z-axis data points. The method also includes extracting two-dimensional data along the X- and Y-axes, including X- and Y-axis data points. The method also includes analyzing the two-dimensional data to find common geometric features of the component, analyzing the two-dimensional data to determine a scan area based on the common geometric features of the component, and measuring the component within the scan area along the X-, Y-, and Z-axes to identify locations of cooling holes on the exterior surface of the component. The method also includes extracting at least one surface profile of the cooling hole along the X- and Y-axes and extracting an orientation of the cooling hole along the Z-axis. The method further includes calculating a set of three-dimensional coordinates of the cooling hole along the X-, Y-, and Z-axes based on the at least one surface profile and orientation, the set of three-dimensional coordinates including the X-, Y-, and Z-axis data points.

[0006] In another aspect, a positioning method for use with a turbine engine component is provided. The method includes collecting a plurality of cross sections of a cooling hole along a surface height, the plurality of cross sections being along an X-axis and a Y-axis, each of the plurality of cross sections correlating a cooling hole depth to a surface width. The method also includes analyzing each of the plurality of cross sections and detecting a maximum cross section depth for each of the plurality of cross sections. The method also includes extracting an orientation of the cooling hole along a Z-axis, the orientation including the maximum cross section depth for each of the plurality of cross sections.

[0007] In yet another aspect, a positioning system for use with a turbine engine component is provided. The positioning system includes a data acquisition system configured to inspect cooling holes on an exterior surface of the component, the data acquisition system including an imaging device configured to acquire images of the component. The positioning system also includes a processor in operative communication with the data acquisition system. The processor is configured to measure the exterior surface of the component along the X-axis, Y-axis, and Z-axis to acquire three-dimensional data including X-axis data points, Y-axis data points, and Z-axis data points. The processor is also configured to extract two-dimensional data along the X-axis and Y-axis, including the X-axis data points and the Y-axis data points. The processor is also configured to analyze the two-dimensional data to find common geometric features of the component and to determine a scan region based on the common geometric features of the component. The processor is also configured to measure the component within the scan region along the X-axis, Y-axis, and Z-axis, identify locations of the cooling holes on the exterior surface of the component, extract at least one surface profile of the cooling holes along the X-axis and Y-axis, and extract an orientation of the cooling holes along the Z-axis. The processor is further configured to calculate a three-dimensional coordinate set of the cooling hole along an X-axis, a Y-axis, and a Z-axis based on the at least one surface profile and orientation, the three-dimensional coordinate set including an X-axis data point, a Y-axis data point, and a Z-axis data point. [Brief explanation of the drawings]

[0008] [Figure 1]1 is a schematic diagram of an exemplary turbine engine component; [Figure 2] FIG. 2 is a schematic diagram of a front view of the turbine engine component of FIG. 1. [Figure 3] FIG. 2 is a schematic diagram of a cross-sectional side view of the turbine engine component of FIG. 1. [Figure 4] FIG. 2 is a schematic diagram of an exemplary positioning system for use in analyzing the turbine engine component of FIG. 1. [Figure 5] FIG. 5 is a schematic diagram of a portion of the positioning system of FIG. [Figure 6] FIG. 5 is a schematic diagram of another portion of the positioning system of FIG. [Figure 7] 2 is a flowchart illustrating an exemplary positioning method for use in analyzing the turbine engine component of FIG. 1. [Figure 8] 2 is an exemplary illustration of a three-dimensional image of the turbine engine component of FIG. 1. [Figure 9] 2 is an exemplary illustration of a two-dimensional image of the turbine engine component of FIG. 1. [Figure 10A-B] 2 is an exemplary illustration of a surface profile of a cooling hole of the turbine engine component of FIG. 1. FIG. [Figure 11A-B] 2 is an exemplary illustration of another surface profile of the cooling hole of the turbine engine component of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0009] Embodiments described herein relate to systems and methods for locating cooling holes on used turbine engine parts and using collected location data to automate the reopening of the cooling holes after the used parts have been recoated, such as with a thermal barrier coating or a corrosion inhibitor coating.

[0010] The systems and methods described herein facilitate automated location of cooling holes on used turbine engine parts. Advantages of the systems and methods described herein include at least the following: (i) improved accuracy of automated cooling hole location by using common geometric features of used turbine engine parts as a reference baseline for measurements; (ii) improved accuracy and repeatability of automated cooling hole location on used turbine engine parts by using calibrated scan areas for measurements as opposed to computer models; and (iii) reduced cost of automated cooling hole location by using a laser line projector as opposed to a blue light scanner.

[0011] When introducing elements of various embodiments disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the element. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0012] Unless otherwise indicated, approximation language such as "generally," "substantially," and "about" used herein indicates that the modified term may apply only to an approximate degree, as recognized by one of ordinary skill in the art, rather than to an absolute or complete degree. Thus, values ​​modified by one or more terms such as "about," "approximately," and "substantially" are not limited to the exact value specified. In at least some instances, approximation language may correspond to the precision of the instrument used to measure the value. Additionally, unless otherwise indicated, terms such as "first," "second," and the like are used herein merely as labels and are not intended to impose any order, position, or hierarchical requirements on the items referred to by these terms. Furthermore, for example, a reference to a "second" item does not require or exclude the presence of, for example, a "first" or lower-numbered item, or a "third" or higher-numbered item.

[0013] FIG. 1 is a schematic diagram of an exemplary turbine engine component 100. The component 100 may be any of a variety of component types used in various turbine engine applications, such as components utilized in high-temperature applications. In some embodiments, the component 100 may be a turbine blade, a compressor blade, a vane, a nozzle, a shroud, a rotor, a transition piece, and / or a casing. In other embodiments, the component 100 may be any other component of a turbine engine. In the exemplary embodiment, the component 100 includes a plurality of cooling holes 102 formed therein. The cooling holes 102 may facilitate improved air circulation around the component 100 during operation of the turbine engine and, therefore, may facilitate reducing deformation of the component 100 caused by prolonged exposure to high temperatures. In the exemplary embodiment, the component 100 includes an exterior surface 104 having the cooling holes 102 spaced apart. The cooling holes 102 may be spaced across the exterior surface 104 using any suitable technique, either during or after manufacture of the component 100.

[0014] In the exemplary embodiment, part 100 has a length 106 and a width 108. In the following description, part 100 may be described as extending "vertically," or along a vertical Y direction, or "horizontally," or along a horizontal XZ plane. It should be understood that these phrases are descriptive and should not be construed as overly limiting. In the embodiment illustrated in FIG. 1 , length 106 extends vertically along the vertical Y direction, and width 108 extends horizontally along the horizontal XZ plane. Measurements of length 106 and width 108 of part 100 may vary, and part 100 should not be construed as limited to the illustrated shape formed by length 106 and width 108 (shown in FIG. 1 ).

[0015] 2 and 3 are schematic diagrams of exemplary cooling holes 102 formed in a component 100. More specifically, FIG. 2 illustrates a front view of the component 100, and FIG. 3 illustrates a cross-sectional side view of the component 100. In the exemplary embodiment, as shown in FIG. 2, the cooling holes 102 have an elliptical shape when viewed from the front on the exterior surface 104. Each cooling hole 102 is defined by a pair of side surfaces 109, an upper end 111, and a lower end 113. As shown in FIG. 2, the side surfaces 109 extend along a surface height 110 of the cooling hole 102, the surface height 110 being defined between the vertices of each of the upper end 111 and the lower end 113. Furthermore, as shown in FIG. 2, the upper end 111 and the lower end 113 each extend along a surface width 112 of the cooling hole 102, the surface width 112 being defined between the vertices of each side surface 109. Sides 109, top end 111, and bottom end 113 are all connected to one another with rounded joints to form the elliptical shape of cooling hole 102. In the exemplary embodiment, as shown in Figures 1 and 2, surface height 110 extends vertically along length 106 (e.g., along the vertical Y direction) and surface width 112 extends horizontally along width 108 (e.g., along the horizontal XZ plane).

[0016] 3 , each cooling hole 102 extends from the exterior surface 104 into the part 100 to a depth 114 that varies across the surface height 110. In the exemplary embodiment, the cooling holes 102 are shallowest, and have a minimum depth 114, at an upper end 111 and deepest at or below a lower end 113, with the depth 114 increasing across the surface height 110 from the upper end 111 to the lower end 113. In the exemplary embodiment, the depth 114 is deepest at a submerged point 116 formed below the lower end 113 (e.g., below the lower end 113 in the vertical Y direction), at which point the cooling hole 104 connects to a channel 118 of the cooling air channel system of the part 100.

[0017] 4 is a schematic diagram of an exemplary positioning system 200 used to locate cooling holes 102 across the exterior surface 104 of part 100. In the exemplary embodiment, positioning system 200 includes a data acquisition system 202 that collects three-dimensional data related to part 100 and cooling holes 102. Positioning system 200 also includes a processor 204 that analyzes the three-dimensional data collected by data acquisition system 202.

[0018] In an exemplary embodiment, data collection system 202 includes an imaging device 206 that acquires images of part 100. FIGS. 5 and 6 are schematic diagrams of an exemplary embodiment of imaging device 206 of data collection system 202 in use with part 100. Imaging device 206 may include a lens assembly and / or an image capture device for acquiring images of part 100. In an exemplary embodiment, data collection system 202 communicates with processor 204 (shown in FIG. 4 ). Processor 204 may be coupled to data collection system 202 via any suitable wired and / or wireless connection. Processor 204 may be programmed to analyze and / or store images acquired by imaging device 206. Additionally, processor 204 may be programmed to operate components of data collection system 202, such as imaging device 206, and perform various steps described herein.

[0019] In an exemplary embodiment, imaging device 206 inspects and obtains three-dimensional measurements of part 100. Imaging device 206 may utilize any suitable surface metrology technology to inspect and obtain measurements of part 100 along the X-axis, Y-axis, and Z-axis. In an exemplary embodiment, data acquisition system 202, in communication with processor 204, analyzes the three-dimensional data obtained by imaging device 206 and generates a two-dimensional image of part 100.

[0020] 5 and 6 , the data collection system 202 also includes a laser line projector 209 and a sensor 210. In an exemplary embodiment, the data collection system 202 emits light 208 in the form of a laser beam from the laser line projector 209. In some embodiments, the data collection system 202 may obtain measurements of the part 100 along the X-, Y-, and Z-axes based on the elapsed time for the light 208 to travel from the laser line projector 209 to the exterior surface 104 of the part 100 and back to the sensor 210. In other embodiments, the data collection system 202 may obtain measurements of the part 100 based on the amount of light 208 detected on the exterior surface 104 of the part 100 along the X-, Y-, and Z-axes relative to the field of view of the sensor 210.

[0021] In an exemplary embodiment, light 208 is emitted from laser line projector 209 in a band that covers only a portion of part 100. As shown in FIG. 6 , light 208 may be emitted as a line across part 100, with the line of light 208 being directed toward the line of cooling holes 102 across part 100. As shown in FIG. 5 , data collection system 202 also includes a robotic arm 212 that selectively moves laser line projector 209 as needed to reflect light 208 off the entire exterior surface 104 of part 100. Robotic arm 212 may support and facilitate movement of other components of data collection system 202, such as sensor 210. Additionally, processor 204 may be programmed to operate robotic arm 212, such as via various motors and / or drive components thereof, to selectively move robotic arm 212 and position data collection system 202 relative to part 100 to facilitate measurement of part 100.

[0022] The processor 204 may include a computer, controller, microcontroller, microcomputer, programmable logic controller (PLC), application specific integrated circuit, and / or other programmable circuitry. The processor 204 may also include various input / output channels for receiving inputs from and sending control signals to various other components in communication with the processor, such as, but not limited to, the imager 206. The processor 204 may be a single master processor that communicates with various other components of the positioning system 200 and / or may include multiple individual component processors (such as, but not limited to, an imager processor and / or a three-dimensional data collection subsystem processor). The various individual component processors may communicate with each other and with a master processor, and these components may be collectively referred to as the processor 204.

[0023] FIG. 7 is a flowchart of an exemplary positioning method 300 for locating cooling holes 102 across the exterior surface 104 of part 100. In an exemplary embodiment, processor 204 (shown in FIG. 4) performs various steps of positioning method 300. Accordingly, positioning system 200 (shown in FIG. 4) and positioning method 300 may cooperate as described herein. While positioning method 300 is described herein with reference to positioning system 200, it should be understood that positioning method 300 is not limited to positioning system 200 and that positioning method 300 may be used in other embodiments. Furthermore, positioning system 200 should not be understood as being limited solely to use with positioning method 300. FIG. 8 is an exemplary embodiment of a three-dimensional image 400 of part 100, and FIG. 9 is an exemplary embodiment of a two-dimensional image 500 of part 100, each of which may be acquired using positioning method 300 by imaging device 206 of data acquisition system 202 (shown in FIG. 4).

[0024] When the positioning method 300 is performed, three-dimensional surface data (shown in FIG. 8) of the part 100 is collected 302 along the X-axis 402, the Y-axis 404, and the Z-axis 405, as shown in FIG. 7. The three-dimensional surface data of the part 100 may be collected using any suitable image analysis method and includes X-axis data points 406, Y-axis data points 408, and Z-axis data points 412 (shown in FIG. 8). Two-dimensional surface data of the part 100 along the X-axis 402 and the Y-axis 404 (shown in FIG. 9) is extracted from the three-dimensional surface data collected 302 by the data collection system 202.

[0025] The positioning method 300 (shown in FIG. 7 ) also includes analyzing 304 two-dimensional surface data of the part 100, such as from a two-dimensional image 500 (shown in FIG. 9 ), such as extracted from the collected 302 three-dimensional surface data, to find common geometric features of the part 100 and facilitate placement of a scan region for the laser line projector 209. In an exemplary embodiment, the X-axis data points 406 and the Y-axis data points 408 are referenced to a common geometric feature of a leading edge 414 of the part 100 (shown in FIG. 9 ), with a reference angle 415 of the leading edge 414 serving as the (0,0) XY data point. The placement of the scan region is based on the X-axis and Y-axis data points 406, 408 relative to the reference angle 415 of the leading edge 414. Because the locations of the cooling holes 102 may change due to thermal deformation of the part 100 due to prolonged exposure to high temperatures, placing the scan region based on the leading edge 414 may facilitate improved imaging accuracy for locating the cooling holes 102 in the part 100.

[0026] In some embodiments, the reference angle 415 of the leading edge 414 may have an X-axis and Y-axis data point other than (0,0), and a different feature of the part 100 acts as the (0,0) XY data point for measuring the part 100 (such as a feature of the part 100 that is not subject to dimensional creep or operational damage). In other embodiments, the common geometric feature may be a different reference feature of the part 100, such as a reference feature near a scanned area that is not easily deformed by the operating conditions of the turbine engine. The common geometric feature may include, but is not limited to, a leading edge, a leading edge corner, a trailing edge, a trailing edge corner, an angel wing angle, and / or a platform angle.

[0027] The positioning method 300 (shown in FIG. 7 ) also includes locating 306 the cooling holes 102 of the part 100 and extracting two-dimensional coordinates of each of the cooling holes 102 from the extracted two-dimensional surface data, such as from the two-dimensional image 500 (shown in FIG. 9 ). The cooling holes 102 may be located from the two-dimensional surface data using any suitable image processing and machine learning analysis. For example, pixel analysis may be used to locate the cooling holes 102 spaced apart on the exterior surface 104 of the part 100 based on differences in color depth (e.g., color or grayscale differences) between individual pixels or groups of pixels. In some embodiments, the pixel analysis may include dividing the total number of pixels into groups based on color depth (e.g., darker color depth or lighter color depth) to indicate specific reference points (e.g., the cooling holes 102 or the exterior surface 104 of the part 100). In other embodiments, different pixel analysis methods may be used to distinguish the cooling holes 102 from the exterior surface 104 of the part 100.

[0028] The positioning method 300 (shown in FIG. 7 ) also includes extracting 308 a surface profile 602 (shown in FIGS. 10A-10B ) of each of the cooling holes 102 of the part 100 from collected three-dimensional surface data, such as from the three-dimensional image 400 (shown in FIG. 8 ). The surface profile data may be extracted from the three-dimensional surface data using any suitable surface profile analysis method. FIGS. 10A-10B are exemplary embodiments of plots of the surface profile 602, as may be extracted from the three-dimensional surface data by the processor 204 (shown in FIG. 4 ). FIG. 10A illustrates the surface profile 602 as a first plot 600 along a first axis 606 and a second axis 608 generally perpendicular to the first axis 606. FIG. 10B illustrates the surface profile 602 as a second plot 700 along a first axis 606 and a third axis 610 generally perpendicular to the first axis 606.

[0029] In the exemplary embodiment, surface profile 602 represents a horizontal cross section of cooling hole 102 (e.g., along a horizontal XZ plane), where surface profile 602 is generally parallel to surface width 112 and generally perpendicular to surface height 110 (shown in FIG. 2 ). Surface profile 602 extends between sides 109 of cooling hole 102 (shown in FIG. 2 ). First plot 600 depicts surface profile 602 as surface height 110 (shown in FIG. 2 ) displayed along a first axis 606 and depth 114 (shown in FIG. 3 ) displayed along a second axis 608. Thus, first plot 600 shows how depth 114 of cooling hole 102 varies across surface height 110.

[0030] In the exemplary embodiment, the first example 602a of the first plot 600 exhibits a high variance in the depth 114 across the surface height 110, as indicated by the generally U-shaped curve of the data points. Further, for example, the second example 602b of the first plot 600 exhibits a low variance in the depth 114 across the surface height 110, as indicated by the generally flat curve of the data points. Thus, the variation in the curvature of the first plot 600 (e.g., as shown in the first example 602a through the second example 602b in FIG. 10A ) corresponds to the variation in the measured depth 114, and each example of the first plot 600 includes a maximum depth marker 604 indicating the maximum measured depth 114 for that cross-section of the cooling hole 102 (e.g., the location where the depth 114 is deepest across the surface width 112).

[0031] The positioning method 300 (shown in FIG. 7) also includes extracting 310 the orientation 802 of each of the cooling holes 102 of the part 100 (shown in FIG. 10B). The second plot 700 shows the surface profile 602 as the surface width 112 (shown in FIG. 2) displayed along the first axis 606 and each cross-section of the surface profile 602 (shown in FIG. 10A) displayed along the third axis 610. Thus, the second plot 700 shows the alignment of each cross-section of the surface profile 602 with the maximum depth marker 604 displayed along the surface width 112.

[0032] 11A-11B are further exemplary embodiments of plots of the surface profile 602, as may be extracted from the three-dimensional surface data by the processor 204 (shown in FIG. 4), specifically showing the orientation 802 of the cooling holes 102. FIG. 11A shows the surface profile 602 as a third plot 800 along the first axis 606 and the third axis 610, with a line connecting each maximum depth marker 604 to indicate the orientation 802 along the third axis 610 (shown in FIG. 10B). FIG. 11B shows the surface profile 602 as a fourth plot 900 along the first axis 606 and the second axis 608, with the surface height 110 (shown in FIG. 3) displayed along the first axis 606 and the maximum depth markers 604 displayed along the second axis 608. Thus, the fourth plot 900 shows how the maximum depth markers 604 vary across the surface height 110.

[0033] Positioning method 300 (shown in FIG. 7 ) further includes calculating 312 three-dimensional coordinates of each of cooling holes 102 of part 100 to construct an overall three-dimensional profile along the X-axis, Y-axis, and Z-axis. Calculating the three-dimensional coordinates of each cooling hole 102 includes combining data points obtained by locating 306 the cooling holes 102 from the collected two-dimensional surface data, extracting 308 a surface profile 602 of each of the cooling holes 102 from the collected three-dimensional data, and extracting 310 an orientation 802 of each of the cooling holes 102. In an exemplary embodiment, X-axis data points 406 and Y-axis data points 408 are known from locating 306 the cooling holes 102 from the collected two-dimensional data. Further, in an exemplary embodiment, Z-axis data points 412 are known from extracting 308 the surface profile 602 of each of the cooling holes 102 from the collected three-dimensional data and extracting 310 an orientation 802 of each of the cooling holes 102.

[0034] Described herein are exemplary systems and methods for locating cooling holes on used turbine engine parts and using collected location data to automate the reopening of the cooling holes after the used part has been recoated. The exemplary systems and methods described herein offer several advantages over conventional designs and processes, including improved accuracy and repeatability of locating cooling holes on used turbine engine parts through the use of a scan area calibrated for measurements based on the leading edge of the used turbine engine part.

[0035] The above description is intended to be illustrative only, and those skilled in the art will recognize that modifications may be made to the described embodiments without departing from the scope of the invention as disclosed. Modifications that are within the scope of the invention will be apparent to those skilled in the art upon review of this disclosure, and such modifications are intended to fall within the scope of the appended claims. The systems and methods described herein are not limited to the specific embodiments described herein; rather, portions of the various systems may be utilized independently and separately from other systems and methods described herein.

[0036] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. Moreover, references to "one embodiment" in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. In accordance with the principles of the invention, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0037] Further aspects of the invention are provided by the subject matter of the following clauses.

[0038] 1. A positioning method for use with a turbine engine component, the method comprising: measuring an exterior surface of the component along X-, Y-, and Z-axes to obtain three-dimensional data including X-, Y-, and Z-axis data points; extracting two-dimensional data along the X- and Y-axes including the X- and Y-axis data points; analyzing the two-dimensional data to find a common geometric feature of the component; analyzing the two-dimensional data to determine a scan area based on the common geometric feature of the component; measuring the component within the scan area along the X-, Y-, and Z-axes to identify locations of cooling holes on the exterior surface of the component; extracting at least one surface profile of the cooling hole along the X- and Y-axes; extracting an orientation of the cooling hole along the Z-axis; and calculating a set of three-dimensional coordinates of the cooling hole along the X-, Y-, and Z-axes based on the at least one surface profile and orientation, the set of three-dimensional coordinates including the X-, Y-, and Z-axis data points.

[0039] 10. The method of claim 9, wherein measuring the part to identify the location of the cooling holes includes measuring a surface height and a surface width, wherein the surface height is greater than the surface width.

[0040] 10. The method of claim 1, wherein measuring the part to identify the location of the cooling holes includes measuring a depth extending into the part from an exterior surface, the depth varying along a surface height and a surface width.

[0041] The method of any of the preceding clauses, wherein analyzing the two-dimensional data to find common geometric features of the parts further comprises locating a leading edge of an exterior surface of the parts.

[0042] The method of any of the preceding clauses, wherein analyzing the two-dimensional data to determine a scan area based on a common geometric feature of the part further comprises identifying a location of a reference angle of the leading edge.

[0043] The method of any of the preceding clauses, wherein measuring the part within the scanned area to identify the location of the cooling holes includes calculating the location of the cooling holes relative to a reference angle of the leading edge.

[0044] The method of any of the preceding clauses, wherein measuring the part within the scanned area to identify the locations of the cooling holes includes calculating the locations of the cooling holes relative to a reference feature of the part.

[0045] The method of any of the preceding clauses, wherein measuring the part to identify the location of the cooling holes further comprises measuring a maximum depth, the maximum depth being at one end of a surface elevation.

[0046] 10. The method of claim 1, wherein extracting a surface profile of the cooling hole along the X-axis and the Y-axis includes collecting a plurality of cross sections of the cooling hole along a surface height, each of the plurality of cross sections correlating a depth of the cooling hole to a surface width; analyzing each of the plurality of cross sections; and detecting a maximum cross section depth for each of the plurality of cross sections.

[0047] The method of any preceding clause, wherein extracting the cooling hole orientation includes connecting the maximum cross-sectional depths of each of the plurality of cross-sections along a Z-axis.

[0048] The method of any preceding clause, wherein analyzing the overlay of the two-dimensional data and the three-dimensional data to determine the scan area includes determining a first boundary of the scan area at a first end of the part and a second boundary of the scan area at a second end of the part, wherein the first end and the second end of the part are along a first axis.

[0049] 10. The method of claim 1, wherein measuring the part within the scanned area to identify the locations of the cooling holes includes measuring the reflection of a light beam that reflects back from an outer surface of the part along a first axis from a first end to a second end, and calculating X-axis data points, Y-axis data points, and Z-axis data points based on the measurements of the reflection of the light beam.

[0050] 10. The method of claim 1, wherein measuring the reflection of the light beam further comprises measuring the light along a second axis, the second axis being approximately perpendicular to the first axis.

[0051] 1. A positioning method for use with a turbine engine component, the method comprising: collecting a plurality of cross sections of a cooling hole along a surface height, the plurality of cross sections being respectively along an X-axis and a Y-axis, each of the plurality of cross sections correlating a depth of the cooling hole to a surface width; analyzing each of the plurality of cross sections; detecting a maximum cross section depth for each of the plurality of cross sections; and extracting an orientation of the cooling hole along a Z-axis, the orientation comprising the maximum cross section depth for each of the plurality of cross sections.

[0052] A positioning system for use with a turbine engine component, the system comprising: a data acquisition system configured to inspect cooling holes on an exterior surface of the component, the data acquisition system including an imaging device configured to acquire images of the component; and a processor in operative communication with the data acquisition system, the processor configured to: measure the exterior surface of the component along X-axis, Y-axis, and Z-axis to obtain three-dimensional data including X-axis data points, Y-axis data points, and Z-axis data points; extract two-dimensional data along the X-axis and Y-axis, including X-axis data points and Y-axis data points; and analyze the two-dimensional data to find common geometric features of the component. analyzing the two-dimensional data to determine a scan area based on a common geometric feature of the part; measuring the part in the scan area along X-axis, Y-axis, and Z-axis to identify locations of cooling holes on an exterior surface of the part; extracting at least one surface profile of the cooling hole along the X-axis and Y-axis; extracting an orientation of the cooling hole along the Z-axis; and calculating a three-dimensional coordinate set of the cooling hole along the X-axis, Y-axis, and Z-axis based on the at least one surface profile and orientation, the three-dimensional coordinate set including X-axis data points, Y-axis data points, and Z-axis data points.

[0053] 10. The system of claim 1, wherein the cooling hole comprises a surface width, a surface height, the surface height being greater than the surface width in a generally elliptical shape, and a depth, the depth having a maximum depth at one end of the generally elliptical shape along the surface height, extending from the exterior surface into the part, the depth varying across the surface width and the surface height.

[0054] The system of any preceding clause, wherein analyzing the two-dimensional data to find common geometric features of the parts further comprises locating a leading edge of an exterior surface of the parts.

[0055] The system of any preceding clause, wherein measuring the part within the scanned area to identify the location of the cooling holes includes calculating the location of the cooling holes relative to the leading edge.

[0056] The system of any preceding clause, wherein measuring the part within the scanned area to identify the location of the cooling holes includes calculating the location of the cooling holes relative to a reference feature of the part.

[0057] The system of any preceding clause, wherein the data collection system further comprises a laser line projector configured to identify locations of cooling holes configured on an exterior surface of the component within the scan region.

[0058] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. [Explanation of symbols]

[0059] 100 parts 102 Cooling hole 104 Exterior 106 length 108 width 109 Side 110 Surface Height 111 Upper end 112 Surface width 113 Bottom end 114 depth 116 immersion point 118 channels 200 Positioning System 202 Data Collection System 204 processors 206 Imaging device 208 light 209 Laser Line Projector 210 Sensors 212 Robot Arm 300 Positioning Method 400 3D images 402 X-axis 404 Y axis 405 Z axis 406 X-axis data points 408 Y-axis data points 412 Z-axis data points 414 leading edge 415 Reference angle 500 2D images 600 First Plot 600a First Example 600b Second Example 602 Surface Profile 604 Maximum Depth Marker 606 First Axis 608 Second Axis 610 Third Axis 700 Second Plot 800 Third Plot 802 orientation 900 Fourth Plot

Claims

1. A positioning method (300) for use with a turbine engine component (100), said method (300) comprising: measuring an outer surface (104) of the part (100) along an X-axis (402), a Y-axis (404), and a Z-axis (405) to obtain three-dimensional data including X-axis data points (406), Y-axis data points (408), and Z-axis data points (412); extracting two-dimensional data along the X-axis (402) and the Y-axis (404), including the X-axis data points (406) and the Y-axis data points (408); analyzing the two-dimensional data to find common geometric features of the part (100); analyzing the two-dimensional data to determine a scan area based on the common geometric feature of the part (100); measuring the component (100) within the scan area along the X-axis (402), the Y-axis (404), and the Z-axis (405) to identify locations of cooling holes (102) on the outer surface (104) of the component (100); extracting at least one surface profile (602) of the cooling hole (102) along the X-axis (402) and the Y-axis (404); extracting an orientation (802) of the cooling holes (102) along the Z-axis (405); calculating a set of three-dimensional coordinates of the cooling hole (102) along the X-axis (402), the Y-axis (404), and the Z-axis (405) based on the at least one surface profile (602) and the orientation (802), the set of three-dimensional coordinates including X-axis data points (406), Y-axis data points (408), and Z-axis data points (412); The method (300) includes:

2. 10. The method of claim 1, wherein measuring the component to identify the location of the cooling holes comprises measuring a surface height and a surface width, the surface height being greater than the surface width.

3. 3. The method of claim 2, wherein measuring the component to identify the location of cooling holes comprises measuring a depth extending from the exterior surface into the component, the depth varying along the surface height and the surface width.

4. 2. The method of claim 1, wherein analyzing the two-dimensional data to find common geometric features of the part further comprises locating a leading edge of the exterior surface of the part.

5. 5. The method (300) of claim 4, wherein analyzing the two-dimensional data to determine a scan area based on the common geometric feature of the part (100) further comprises locating a reference angle (415) of the leading edge (414).

6. 6. The method of claim 5, wherein measuring the component within the scanning area to identify the location of a cooling hole includes calculating the location of the cooling hole relative to the reference angle of the leading edge.

7. 6. The method of claim 5, wherein measuring the component within the scanning area to identify the location of the cooling holes comprises calculating the location of the cooling holes relative to a reference feature of the component.

8. 4. The method of claim 3, wherein measuring the component to identify the location of the cooling holes further comprises measuring a maximum depth of the depths, the maximum depth being at one end of the surface elevation.

9. Extracting the surface profile (602) of the cooling hole (102) along the X-axis (402) and the Y-axis (404) comprises: collecting a plurality of cross sections of the cooling hole (102) along the surface elevation (110), each of the plurality of cross sections correlating the depth (114) of the cooling hole (102) to the surface width (112); analyzing each of the plurality of cross sections; detecting a maximum cross-section depth (114) for each of the plurality of cross-sections; The method (300) of claim 3, comprising:

10. 10. The method of claim 9, wherein extracting the orientation of the cooling holes comprises connecting the maximum cross-sectional depths of each of the plurality of cross-sections along the Z-axis.

11. 2. The method (300) of claim 1, wherein analyzing the overlay of the two-dimensional data and the three-dimensional data to determine a scan area comprises determining a first boundary of the scan area at a first end of the part (100) and a second boundary of the scan area at a second end of the part (100), wherein the first end and the second end of the part (100) are along a first axis.

12. Measuring the component (100) within the scanning area to identify the location of the cooling holes (102) comprises: measuring the reflection of a light beam reflected back from the outer surface (104) of the part (100) along the first axis from the first end to the second end; calculating an X-axis data point (406), a Y-axis data point (408), and a Z-axis data point (412) based on the measurements of the reflection of the light beam; 12. The method (300) of claim 11, comprising:

13. 13. The method (300) of claim 12, wherein measuring the reflection of the light beam further comprises measuring a ray of light along a second axis, the second axis being approximately perpendicular to the first axis.

14. A positioning method (300) for use with a turbine engine component (100), said method (300) comprising: collecting a plurality of cross sections of the cooling hole (102) along a surface elevation (110), the plurality of cross sections being along an X-axis (402) and a Y-axis (404), each of the plurality of cross sections correlating a depth (114) of the cooling hole (102) to a surface width (112); analyzing each of the plurality of cross sections; detecting a maximum cross-section depth (114) for each of the plurality of cross-sections; extracting an orientation (802) of the cooling hole (102) along a Z-axis (405), the orientation (802) including the maximum cross-section depth (114) of each of the plurality of cross-sections; The method (300) includes:

15. A positioning system (200) for use with a turbine engine component (100), said system comprising: a data acquisition system (202) configured to inspect cooling holes (102) on an exterior surface (104) of the component (100), the data acquisition system (202) comprising an imaging device configured to acquire images of the component (100); a processor (204) in operative communication with the data collection system (202), the processor (204) comprising: measuring the outer surface (104) of the part (100) along an X-axis (402), a Y-axis (404), and a Z-axis (405) to obtain three-dimensional data including X-axis data points (406), Y-axis data points (408), and Z-axis data points (412); extracting two-dimensional data along the X-axis (402) and the Y-axis (404), including the X-axis data points (406) and the Y-axis data points (408); analyzing the two-dimensional data to find common geometric features of the part (100); analyzing the two-dimensional data to determine a scan area based on the common geometric feature of the part (100); measuring the component (100) within the scan area along the X-axis (402), the Y-axis (404), and the Z-axis (405) to identify locations of cooling holes (102) on the outer surface (104) of the component (100); extracting at least one surface profile (602) of the cooling hole (102) along the X-axis (402) and the Y-axis (404); extracting an orientation (802) of the cooling holes (102) along the Z-axis (405); calculating a set of three-dimensional coordinates of the cooling hole (102) along the X-axis (402), the Y-axis (404), and the Z-axis (405) based on the at least one surface profile (602) and the orientation (802), the set of three-dimensional coordinates including X-axis data points (406), Y-axis data points (408), and Z-axis data points (412); a processor (204) configured to: A system (200) comprising:

16. The cooling holes (102) The surface width (112); a surface height (110), said surface height (110) being greater than said surface width (112) in a generally elliptical shape; a depth (114) extending from the outer surface (104) into the component (100) with a maximum depth (114) at one end of the generally elliptical shape along the surface height (110), the depth (114) varying across the surface width (112) and the surface height (110); The system (200) of claim 15, comprising:

17. 16. The system (200) of claim 15, wherein analyzing the two-dimensional data to find common geometric features of the part (100) further comprises locating a leading edge (414) of the outer surface (104) of the part (100).

18. 20. The system of claim 17, wherein measuring the component within the scanning region to identify the location of a cooling hole includes calculating the location of the cooling hole relative to the leading edge.

19. 16. The system (200) of claim 15, wherein measuring the part (100) within the scanning area to identify the location of the cooling holes (102) includes calculating the location of the cooling holes (102) relative to a reference feature of the part (100).

20. 16. The system (200) of claim 15, wherein the data acquisition system (202) further comprises a laser line projector (209) configured to identify the location of the cooling holes (102) configured in the outer surface (104) of the part (100) within the scanning area.

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