Closed-Loop Grind Line Feedback for Turbine Blade Process Control
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Solution Overview
Problem
Current grind processes for gas turbine engine blades require extensive manual calculations and operator decisions, making it challenging to maintain process control consistency, economy, and safety due to the complexity of information and mathematics involved.
Innovation Solution
A closed-loop system comprising multiple grinders, coordinate measuring machines, and a processor that receives inspection data from both machines to condition, filter, and adjust grind targeting, providing offsets to the grinders to maintain process control with minimal operator interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single coordinate measuring machine (CMM) is used to inspect the entire blade and maintain process control, then equipment cost is reduced, but measurement time and operator complexity increase significantly
Solution Approach 1:
The inspection process is divided into multiple independent CMM stations, each responsible for specific features or sections of the blade. This segmentation allows parallel inspection operations, reducing total measurement time while maintaining comprehensive process control capability.
Solution Approach 2:
Multiple CMMs are positioned and configured in advance to inspect different blade features simultaneously. The system performs preliminary setup of measurement programs and coordinates inspection operations before the blade completes its grinding cycle, enabling real-time feedback without extending total process time.
2Adaptability or versatility
If extensive manual calculations and operator decisions are used for grind targeting, then flexibility and adaptability are maintained, but operator error risk and complexity increase
Solution Approach 1:
The system implements closed-loop feedback where measurement data from CMMs is automatically fed into the control system, which then adjusts grinder parameters in real-time. This automated feedback loop eliminates manual calculation errors while maintaining the ability to adapt to measured variations through programmed decision logic.
Solution Approach 2:
Manual operator calculations and decisions are replaced with automated computer-based systems that perform mathematical computations and decision-making algorithms. The control system automatically processes measurement data, determines grind offsets, and adjusts machine parameters, eliminating human error while preserving adaptability through programmable logic.
3Productivity
If multiple coordinate measuring machines are deployed for simultaneous inspection, then measurement time is reduced, but system complexity and cost increase
Solution Approach 1:
The multiple CMMs are designed with standardized interfaces and unified control software that can inspect various blade types and features. This universal design reduces system complexity by using common measurement programs, coordinate systems, and data processing routines across all CMM stations, making the expanded system easier to manage despite having multiple machines.
Data Source
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AI summary
A closed loop system for a grind line including at least one grinder configured to machine a part with the grind line; a first coordinate measuring machine operatively coupled to the at least one grinder; a second coordinate measuring machine operatively coupled to the at least one grinder; and a processor operatively coupled to the at least one grinder and the first coordinate measuring machine and the second coordinate measuring machine, the processor configured to provide processor outputs to the at least one grinder responsive to data collected from the first coordinate measuring machine and the second coordinate measuring machine.