Abrasive Guide Mechanism for Precision Blending
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Solution Overview
Problem
The precision of blending added material with base material on manufactured components, such as blades used in the aeronautic and energy industries, is often inadequate due to imprecise control of abrasive devices, leading to deviations from nominal specifications.
Innovation Solution
An apparatus and method utilizing an abrasive device with a guide having multiple contact points, a positioning mechanism to control the abrasive surface's position and angle, and a force control mechanism to ensure precise removal of excess added material without affecting the base material, using a calculated trajectory based on a 3D model of the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a finishing tool with an abrasive device is used for blending, then the blending operation can be performed, but the precision of the blending process is insufficient and the final profile does not comply with nominal specifications
Solution Approach 1:
A guide element is introduced as an intermediary between the abrasive device and the manufactured component. The guide provides one or more contact points that engage with the component surface, serving as a reference for positioning the abrasive device. This mediator enables precise control of the abrasive surface position and angle relative to the component, ensuring the final profile complies with nominal specifications while maintaining reliable blending operation
Solution Approach 2:
The patent replaces manual or simple automated control of the abrasive device with a mechanically-guided system. Instead of relying on operator skill or basic automation, the system uses a guide element with contact points that mechanically constrain and direct the abrasive device along the component surface. This substitution provides consistent, repeatable positioning that achieves nominal specification compliance
2Ease of operation
If an abrasive device is operated manually or with basic automation, then the blending operation can be performed, but the control precision of the abrasive device is insufficient
Solution Approach 1:
The guide element acts as a mechanical intermediary that translates simple operational movements into precise abrasive device positioning. The contact points on the guide engage with the component surface and automatically establish the correct position and angle of the abrasive surface, eliminating the need for complex control systems while achieving high measurement precision
Solution Approach 2:
The guide element enables the abrasive device to self-position on the component surface through the contact points. As the guide moves along the component, the contact points automatically maintain the abrasive surface at the correct position and angle relative to the surface being blended, providing self-regulating precision control without external intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise blending that accurately conforms to nominal specifications, ensuring high precision and consistency in the blending process, even for complex shapes, by maintaining contact points that guide the abrasive surface along defined trajectories while preventing base material removal.
Implementation Method 1
an abrasive device having an abrasive surface, for removing exceeding added material and for blending the added material with the base material. The abrasive surface performs in operation an abrasive motion.
Data Source
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Figure 2A~2C
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AI summary
The present relates to an apparatus and method for blending added material with base material on manufactured components. The apparatus comprises an abrasive device having an abrasive surface for removing exceeding added material, and a guide fixed to the abrasive device. The method determines a trajectory of the abrasive surface with respect to a manufactured component; determines which of a plurality of contact points of the guide shall be in contact with the manufactured component along the trajectory; actuates the abrasive device; and controls position and angle of the abrasive surface on the manufactured component along the trajectory, while keeping the determined contact point in contact with the manufactured component. A force is applied to the abrasive device when the abrasive surface is in contact with the manufactured component, and transferred when the guide gets in contact with the base material.