Closed-Loop Grind Line Feedback for Turbine Blade Targeting
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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 and processes inspection data to adjust grind targeting, minimizing operator interaction by using filtered data and conditioning rules to provide offsets to the grinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single coordinate measuring machine is used to inspect the entire blade, then equipment cost is reduced, but inspection time and process control complexity increase significantly
Solution Approach 1:
The inspection process is divided into multiple independent coordinate measuring machines, each responsible for specific inspection tasks. The system segments the blade inspection into different measurement zones and operations, allowing parallel processing that reduces total inspection time while maintaining comprehensive coverage.
Solution Approach 2:
The system transitions from sequential single-machine inspection to a multi-dimensional parallel inspection architecture. Multiple CMMs operate simultaneously on different aspects of the blade, transforming the inspection process from a linear time sequence to a parallel spatial-temporal operation that reduces overall cycle time.
2Adaptability or versatility
If extensive manual calculations and operator decisions are used for grind targeting, then flexibility in handling complex part configurations is maintained, but operator workload and potential for error increase
Solution Approach 1:
The system implements self-service through automated calculation engines that perform grind targeting computations without operator intervention. The processor automatically receives inspection data, performs the required mathematics, and generates grind offsets, eliminating the need for operators to manually perform complex calculations while maintaining adaptability to complex part configurations.
Solution Approach 2:
Manual operator calculations and decision-making processes are replaced with an automated computational system. The processor executes mathematical algorithms and logic operations that previously required human operators, substituting mechanical human cognition with electronic computation to reduce workload and error while preserving flexibility.
3Reliability
If automated closed-loop control is implemented with multiple coordinate measuring machines, then process control consistency and accuracy improve, but system complexity and initial cost increase
Solution Approach 1:
The system implements closed-loop feedback control where inspection data from multiple coordinate measuring machines is continuously fed back to the processor, which then adjusts grind offsets in real-time. This feedback mechanism ensures process control consistency by automatically correcting deviations from target specifications, maintaining high reliability despite the increased system complexity.
Solution Approach 2:
The system achieves process control consistency through a universal processor that handles multiple functions: receiving data from various CMMs, performing calculations, generating offsets, and controlling multiple grinders. This multi-functional approach consolidates complexity into a single coordinating unit rather than requiring separate control systems for each function.
Data Source
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.