Aerodynamic Quality Analysis for Manufactured Parts
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Solution Overview
Problem
Current quality assurance methods for manufactured parts, such as helicopter rotor blades or airplane wings, often fail to account for aerodynamic performance, leading to unnecessary rejections and increased time spent on secondary analysis due to point-specific tolerances, which do not necessarily impact the part's functionality.
Innovation Solution
A quality assurance system that uses aerodynamic performance data calculated from measured coordinates to determine if manufactured parts meet minimum requirements, allowing for the identification of flaws in the manufacturing process and suggesting modifications to parts that fail, thereby reducing rejections and streamlining the approval process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If point-specific tolerances are used for quality assurance, then manufacturing precision can be measured, but aerodynamic performance may not be accurately reflected leading to unnecessary rejections
Solution Approach 1:
The patent transitions from checking geometric parameters (point-specific tolerances) to evaluating aerodynamic performance parameters (lift, drag, moment coefficients). This parameter change allows assessment of actual functional performance rather than just geometric conformity, resolving the contradiction between manufacturing precision measurement and reliable aerodynamic performance assessment.
Solution Approach 2:
The patent introduces computational fluid dynamics (CFD) analysis as an intermediary between manufacturing measurements and aerodynamic performance assessment. The CFD simulations act as a mediator that translates geometric measurements into aerodynamic performance predictions, enabling accurate assessment without direct wind tunnel testing while maintaining reliability.
2Manufacturing precision
If point-specific tolerances are enforced strictly, then manufacturing quality can be controlled, but time is wasted on secondary aerodynamic analysis and approval of parts that actually meet performance requirements
Solution Approach 1:
The patent performs preliminary aerodynamic analysis using CFD simulations on the as-manufactured geometry before final quality decisions are made. This preliminary action predicts aerodynamic performance early in the inspection process, allowing parts that meet performance requirements to be approved without time-consuming secondary analysis or wind tunnel testing.
Solution Approach 2:
The patent replaces mechanical wind tunnel testing with computational fluid dynamics (CFD) simulations. This substitution eliminates the need for time-consuming physical testing while maintaining accurate aerodynamic performance assessment, significantly reducing the time required for quality assurance.
3Manufacturing precision
If parts are rejected based on point-specific tolerances, then manufacturing quality standards are maintained, but useful parts with acceptable aerodynamic performance are discarded
Solution Approach 1:
The patent changes the acceptance criteria from geometric parameters (dimensional tolerances) to aerodynamic performance parameters (lift, drag, moment coefficients). This allows parts with minor geometric deviations that still meet functional requirements to be approved, increasing the part approval rate while maintaining quality standards.
Solution Approach 2:
The patent applies local quality assessment by evaluating aerodynamic performance at specific operating conditions and locations rather than requiring uniform geometric precision across the entire part. This allows regions with minor deviations that do not affect overall performance to be accepted, reducing unnecessary rejections.
Data Source
AI summary
According to one embodiment, a quality analyzer receives aerodynamic performance data for a part that has been manufactured according to a design. The aerodynamic performance data expresses aerodynamic performance of the part as calculated from a plurality of coordinates measured on the part. The quality analyzer determines whether the aerodynamic performance data for the part satisfies minimum aerodynamic performance requirements.