Contoured-Surface Component Repair With 3D Tool Position Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for repairing vehicle components, such as those in airplanes, are imprecise and labor-intensive due to the use of hand-guided cutting tools, which fail to accurately remove damaged material and prepare surfaces for repair.
Innovation Solution
A guided tool system with a position correction system that includes scanning damaged areas, creating a flattening shim for non-planar surfaces, generating repair plans from 3D CAD models, and using a position correcting controller to precisely adjust cutting tools in three dimensions, along with non-destructive inspection and plasma treatment, to accurately remove damaged material and prepare components for repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hand-guided cutting tools are used for component repair, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
A position correcting controller acts as an intermediary between the hand-guided tool and the cutting tool. The controller receives imprecise positioning input from the operator and automatically corrects the tool's position using feedback from position sensors, thereby maintaining ease of operation while achieving high manufacturing precision.
Solution Approach 2:
The system incorporates position sensors that continuously monitor the tool's location and provide feedback to the position correcting controller. This closed-loop feedback mechanism enables real-time correction of positioning errors, allowing hand-guided operation to achieve precision comparable to automated systems.
2Device complexity
If hand-guided cutting tools are used for component repair, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The position correcting controller performs automatic position correction and repair planning without requiring complex external automation systems. The system uses onboard sensors and processors to self-correct positioning errors and generate repair paths, improving productivity while keeping device complexity manageable.
Solution Approach 2:
The system performs preliminary scanning of the component surface and pre-planning of the repair path before actual cutting begins. This preliminary action prepares the position correcting controller with advance information about the workpiece geometry, enabling faster and more efficient cutting operations.
3Ease of operation
If conventional repair methods are used, then ease of operation is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The system replaces manual mechanical positioning with an automated position correcting controller that uses electronic sensors and digital processing. This substitution maintains the simplicity of hand-guided operation while achieving precision through electronic control rather than mechanical rigidity.
Data Source
AI summary
Disclosed herein is a method of repairing a component. The method includes scanning a damaged area of the component, and preparing a repair plan in response to the scanning. The method may also include providing the repair plan to a guided tool having a position correcting controller, and removing damaged material from the component in preparation for a repair operation. An apparatus is also disclosed that includes a computing device configured for performing actions. The computing device includes a processor and a local memory. The actions include detecting damage to the component, recording position information of the detected damage, and incorporating the position information in the repair plan.