Composite Turbine Blade Shield Pairing With Hexapod Clearance Control
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Solution Overview
Problem
The manual pairing of metal shields on composite material preforms for aircraft turbomachine blades is prone to variability due to human error, leading to poor quality control and increased scrap rates, with the measurement of 'tip gap' clearance being the only control point after assembly, and the process being time-consuming.
Innovation Solution
An installation using a hexapod and automaton system with a computer unit for precise control and automation of the pairing process, allowing for digital trajectory planning and real-time monitoring of assembly parameters, including non-contact measurement of clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual pairing operation is used, then operator flexibility is maintained, but quality consistency and process control deteriorate due to human variability
Solution Approach 1:
The patent replaces the manual mechanical pairing operation with an automated system comprising a robotic manipulator, hexapod positioning device, and computer control unit. This substitution eliminates human variability while achieving precise pairing through digital control and automated measurement systems.
Solution Approach 2:
The automated pairing system performs self-measurement and self-adjustment through integrated sensors and feedback control. The system automatically measures the clearance between shield and preform, compares it to target values, and adjusts positioning without human intervention, enabling consistent high-precision pairing.
2Productivity
If manual pairing operation is used, then equipment simplicity is maintained, but operation time increases due to manual measurement and adjustment
Solution Approach 1:
The automated system enables continuous pairing operations without the intermittent manual measurements and adjustments required in manual processes. The robotic manipulator continuously positions the shield while integrated sensors continuously monitor clearance, eliminating idle time and enabling high-speed production.
Solution Approach 2:
Manual measurement and adjustment actions are replaced by automated sensing and positioning systems. Optical or laser sensors continuously measure clearance, and the robotic manipulator automatically adjusts position based on feedback, dramatically increasing pairing speed while maintaining precision.
3Reliability
If manual pairing operation is used, then process simplicity is maintained, but quality control capability deteriorates due to lack of process monitoring
Solution Approach 1:
The automated pairing system incorporates real-time feedback through integrated sensors that continuously measure the clearance between shield and preform. This measurement feedback is fed to the control system, which automatically adjusts positioning to maintain target clearance, ensuring consistent quality and enabling statistical process control.
Solution Approach 2:
Manual quality inspection is replaced by automated sensing systems that objectively measure pairing clearance with high precision. The computer control unit records all measurements and process parameters, enabling traceability and statistical quality analysis without human subjectivity.
4Loss of substance
If manual pairing operation is used, then equipment cost is reduced, but scrap rate increases due to undetected defects
Solution Approach 1:
The automated system performs preliminary quality verification during the pairing process itself rather than after completion. Sensors continuously monitor clearance and detect potential defects before they become critical, allowing immediate correction and preventing scrap generation.
Solution Approach 2:
Real-time feedback from sensors enables immediate detection and correction of pairing defects. The control system receives continuous measurement data and automatically adjusts positioning to maintain specifications, preventing defective assemblies from being produced and reducing scrap rates.
Data Source
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AI summary
The invention relates to a facility (1) for pairing a metal shield (60) to a leading edge (51 a) of a preform (51) made of composite material for the production of an aircraft turbine engine blade (50), the facility (1) comprising: - a support (10) configured to receive and hold the metal shield (60), - a movement hexapod (20) which carries said support (10) and is able to move the support (10) along and about the three axes of an XYZ coordinate system, - an automaton (30) which comprises jaws (31) and is configured to receive and hold the preform (51), and - a computing unit (49) for controlling the hexapod (20) and the automaton (30) with a view to producing the pairing. The invention also relates to a method for pairing the metal shield (60) to the leading edge (51 a) of the preform (51) made of composite material for the production of the aircraft turbine engine blade (50).