Multi-Axis Drilling Sequence Optimization for Gas Turbine Components
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Solution Overview
Problem
Conventional CAD/CAM systems fail to optimize the drilling sequence for hole patterns in gas turbine engine components due to neglecting directional vectors and kinematics of multi-axis drilling machines, leading to inefficient and unpredictable travel times between holes.
Innovation Solution
A method for determining a drilling sequence that minimizes total displacement in all axes of a multi-axis hole drilling machine by considering the location and directional vector of each hole, optimizing the sequence to reduce cycle time and enable on-the-fly drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional CAD/CAM systems are used to determine hole drilling sequence based on shortest distance between entry points, then the sequencing process is simple, but the drilling cycle time becomes unduly long due to large axis displacements and repeated shutter operations
Solution Approach 1:
The invention changes the optimization parameters from simple Euclidean distance to a comprehensive metric that includes directional vectors and machine kinematics. The sequencing system now considers not just the distance between hole entry points but also the orientation changes required and the actual machine axis displacements, transforming the optimization from a simple geometric problem to a kinematically-aware sequencing problem that reduces total cycle time
Solution Approach 2:
The invention implements a feedback mechanism where the sequencing system continuously evaluates the impact of each hole selection on subsequent drilling operations. By using machine kinematics models and directional vector information, the system predicts and optimizes the cumulative effect of sequencing decisions, adjusting the sequence to minimize total axis travel and shutter operations based on predicted performance outcomes
2Loss of time
If the drilling sequence is optimized considering directional vectors and machine kinematics, then the total displacement and cycle time are minimized, but the sequencing calculation becomes more complex
Solution Approach 1:
The invention performs preliminary calculations of machine kinematics and axis displacements during the sequencing planning phase. By pre-computing the kinematic effects of potential drilling sequences and storing this information for rapid evaluation, the system avoids complex real-time calculations during actual drilling operations, thus minimizing axis travel time while managing computational complexity through advance preparation
Solution Approach 2:
The invention introduces an intermediary sequencing optimization layer that translates simple hole location and orientation data into machine-specific execution sequences. This intermediary system acts as a mediator between the geometric hole pattern and the physical machine constraints, converting complex kinematic optimization problems into optimized toolpath sequences that minimize axis travel time without requiring complex real-time control
3Productivity
If the laser shutter is closed and re-opened between consecutive holes, then each hole can be drilled with precise laser control, but the drilling efficiency is significantly reduced
Solution Approach 1:
The invention optimizes the drilling sequence to enable continuous or near-continuous laser operation by grouping holes that can be drilled in quick succession without shutter intervention. The sequencing algorithm identifies clusters of holes where the machine can maintain laser readiness, minimizing the number of times the shutter must close and reopen, thus maintaining manufacturing precision while dramatically improving drilling efficiency through reduced interruption cycles
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
The optimized drilling sequence significantly reduces cycle time by minimizing axis displacements and allowing continuous laser firing, eliminating the need for repeated shutter closure and reopening, thereby enhancing drilling efficiency.
Implementation Method 1
pulsed laser drilling machines
Data Source
AI summary
A method for drilling holes in a component according to an optimized sequence is provided. The sequence is determined so as to minimize a total displacement of all axes of a hole drilling machine that is required for moving between each hole in the sequence.