Blisk Feature Classification With Region-Specific Tolerance Ranges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Components manufactured using a production process often face high reject rates due to deviations in measured variables exceeding uniform tolerance ranges, leading to unnecessary extended inspections and scrap classification, despite being suitable for technical applications.
Innovation Solution
A method that classifies component features using both a first and a second feature specification, with the second tolerance range extended in specific regions where production-induced deviations are reproducible and tolerable, allowing for more components to be classified as usable and reducing reject rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a uniform tolerance range is applied to the entire component, then quality control is simplified and inspection is easier, but the component reject rate increases significantly
Solution Approach 1:
The patent applies different tolerance ranges to different regions of the component based on local requirements. The first region (where deviations are not reproducible) receives a first tolerance range, while the second region (where reproducible deviations occur) receives a second, extended tolerance range. This local differentiation allows the inspection process to remain systematic while accommodating known production variations in specific areas, thereby reducing unnecessary rejections.
Solution Approach 2:
The patent changes the tolerance parameter from a uniform value across the entire component to region-specific values. By defining multiple tolerance ranges (first tolerance range and second extended tolerance range) corresponding to different regions, the system adapts the acceptance criteria to match actual production characteristics, reducing the reject rate while maintaining quality control.
2Reliability
If extended inspection is performed on components with deviations outside uniform tolerance, then quality assurance is improved, but inspection complexity and cost increase
Solution Approach 1:
The patent implements local quality control by assigning different tolerance criteria to different regions. Regions with reproducible deviations use extended tolerance ranges, eliminating the need for extended inspection in those areas. This regional differentiation maintains quality assurance where needed while avoiding unnecessary complexity in regions where production variations are expected and acceptable.
3Manufacturing precision
If components with reproducible deviations are sorted out, then quality consistency is maintained, but material loss and production efficiency decrease
Solution Approach 1:
The patent changes the acceptance parameter (tolerance range) based on the characteristics of different regions. For regions with reproducible deviations, an extended tolerance range is applied, allowing these components to be accepted rather than sorted out. This parameter adaptation maintains quality consistency in critical areas while preventing unnecessary material loss in regions where deviations are known and acceptable.
4Manufacturing precision
If a first tolerance range is applied to ensure high quality, then component quality is maintained, but the reject rate increases due to reproducible production deviations
Solution Approach 1:
The patent applies local quality control by defining different tolerance ranges for different regions. The first region maintains the first tolerance range for high quality assurance, while the second region uses an extended second tolerance range to accommodate reproducible production deviations. This localized approach maintains manufacturing precision where critical while reducing the overall reject rate.
Solution Approach 2:
The patent implements parameter changes by transitioning from a single uniform tolerance range to multiple region-specific tolerance ranges. The extended second tolerance range is specifically applied to regions with reproducible deviations, allowing more components to meet specifications without compromising quality in critical areas, thereby reducing the reject rate.
Data Source
AI summary
A method classifies a component feature of a component, the component including a blisk or a part of a blisk for a turbomachine, which has been manufactured using a production process. The method includes classifying the component feature as a function of a first feature specification and a second feature specification for a measured variable of the component feature. A second tolerance range of the second feature specification is extended as compared to a first tolerance range of the first feature specification. A second region of applicability of the component for the second feature specification is smaller than a first region of applicability of the component for the first feature specification. The production process reproducibly and/or systematically causes a larger mean deviation of the measured variable in the second region of applicability than in the first region of applicability.