Fan Blade Masking Inspection Tool
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Solution Overview
Problem
Current inspection methods for gas turbine engine fan blades using metallic hand-held calipers are time-consuming and prone to damaging masking and coating materials, requiring corrective actions and rework due to the need for precise measurements and multiple inspection points.
Innovation Solution
A dual-purpose hand-held masking and coating check inspection tool with two ends, adapted for inspecting the root and platform masking/coating regions, allowing for a rapid go/no-go check within tolerance control bands, reducing the risk of damage and increasing efficiency by distributing contact force over larger surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If metallic hand-held calipers are used to measure masking/coating edges, then measurement precision is improved, but the masking and coating materials are damaged requiring rework
Solution Approach 1:
The patent introduces a non-contact optical measurement system that uses light as an intermediary to measure masking and coating edges without physical contact. The optical system captures images of the edges and uses image processing algorithms to determine precise measurements, eliminating the need for metallic calipers that physically contact and damage the soft masking and coating materials.
Solution Approach 2:
The patent replaces the mechanical measurement system (metallic hand-held calipers) with an optical measurement system. Instead of using physical contact between metal calipers and the masking/coating materials, the system uses optical fields to detect edge positions, thereby substituting mechanical interaction with optical interaction to avoid material damage.
2Manufacturing precision
If multiple platform measurement locations are required to span the length of the fan blade, then measurement completeness is improved, but inspection time increases
Solution Approach 1:
The patent applies preliminary action by capturing a complete image of the entire fan blade platform edge in a single shot before any measurement analysis begins. This allows all measurement locations to be identified and measured simultaneously from the pre-captured image, eliminating the need for sequential measurements at multiple locations and significantly reducing inspection time while maintaining measurement completeness.
3Reliability
If the masking material is inspected frequently to prevent damage, then quality control is improved, but productivity decreases due to time consumption
Solution Approach 1:
The patent replaces the time-consuming manual inspection process with an automated optical measurement system. The system automatically captures images, processes them to identify masking and coating edges, and provides measurements without requiring manual intervention at multiple locations. This automation maintains high quality control through precise edge detection while significantly improving productivity by reducing the time required for each inspection.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A masking and coating check inspection tool (10) for inspecting a masking and/or coating edge (86, 94) on a fan blade (80) includes an elongate planar base (20) having distal first and second ends (12, 14), bottom surface (16), top face (18), length (L), width (W), and thickness (T). The length (L) is greater than the width (W). A pillar (22) perpendicular to the elongate planar base (20) and projecting upward from the top face (18) between the first and second ends (12, 14) has a first end datum (26), and a first masking check tolerance band disposed on the first end (12), configured to provide a pass/fail indication of the first masking edge (86, 94) with respect to the first end datum (26). The pillar (22) can have second end datum (38) and second masking check tolerance band on the second end (14) configured to provide a pass/fail indication of a second masking edge (86, 94) with respect to the second end datum (38). The inspection tool (10) can be used on root and platform masking/coating edges (86, 94).