3D Surface Repair Machining for Precise Defect Finishing
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Solution Overview
Problem
Current methods for repairing or finishing components, such as turbine blades, are manually driven and prone to inconsistency and health risks due to human intervention, leading to non-optimal repairs and health issues like vibration white finger.
Innovation Solution
A method involving scanning the component's surface to obtain 3D data, locating defects, and generating a tooling path using a patch with translated nodes to machine the surface automatically, reducing human error and health risks while improving finish quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual polishing is used to repair surface defects, then the process is flexible and easy to operate, but the repair consistency and precision deteriorate due to operator skill variation
Solution Approach 1:
The patent replaces the manual mechanical polishing system with an automated system that uses 3D scanning to capture surface defects and generates toolpaths for precise removal. The automated machining system executes the toolpath with consistent precision, eliminating operator skill variation while maintaining ease of operation through computer control.
Solution Approach 2:
The patent creates a digital copy of the defective surface through 3D scanning, then uses this digital model to generate the repair toolpath. This copying approach allows the repair process to be precisely replicated based on the digital twin, ensuring consistent results without manual intervention variability.
2Ease of manufacture
If manual polishing with vibrating equipment is used, then the repair process can be performed, but operator health deteriorates due to vibration white finger
Solution Approach 1:
The patent replaces the manual vibrating polishing equipment with an automated machining system. The vibration and harmful mechanical exposure are transferred from the operator to the automated machine, eliminating health risks like vibration white finger while maintaining the repair capability.
Solution Approach 2:
The automated system performs the repair task independently without requiring human operators to physically handle vibrating equipment. The machine serves itself by automatically executing the generated toolpath, removing the operator from direct exposure to harmful vibrations.
3Device complexity
If visual inspection and hand polishing are used, then the process is simple and requires minimal equipment, but repair effectiveness deteriorates due to reliance on operator experience
Solution Approach 1:
The patent replaces visual inspection and hand polishing with 3D scanning technology that objectively captures surface geometry. This substitution removes reliance on operator experience and visual judgment, providing reliable, measurable data for consistent repair effectiveness while keeping the overall process straightforward.
Solution Approach 2:
The 3D scanning system provides objective feedback about the surface defect geometry, which is then used to generate the repair toolpath. This feedback loop replaces subjective visual inspection with measurable data, ensuring repair effectiveness is based on actual surface conditions rather than operator perception.
4Manufacturing precision
If automated machining with 3D scanning is used, then repair precision and consistency improve, but process complexity increases
Solution Approach 1:
The patent integrates multiple functions into a unified automated system: 3D scanning for defect detection, digital modeling for repair planning, and automated machining for execution. This multi-functionality achieves high repair precision while managing complexity through integration rather than separate manual operations.
Solution Approach 2:
The patent replaces complex manual coordination (visual inspection + hand polishing + vibration equipment) with a single automated system that handles all functions through computer control. This substitution manages complexity by centralizing control logic in software rather than requiring coordinated manual skills.
Data Source
AI summary
A method of machining a surface of a component. The method comprises scanning the surface of the component to obtain scanned electronic 3D data representing the scanned surface of the component locating a surface defect of the scanned surface and identifying a defect region that surrounds and includes the surface defect, and providing electronic 3D data representing a patch having the desired shape of the defect region. The method also comprises transforming the patch to generate a tooling path for repairing the surface defect. The transformation comprising translating a plurality of nodes of the patch. The translation distance of each node based on the distance of that node from an origin node of the patch. The method further comprises machining the surface of the component according to the generated tooling path.