IBR Defect Repair Assessment Using 3D Matching and Simulation
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Solution Overview
Problem
Current repair methods for integrally bladed rotors (IBRs) in gas turbine engines are limited, as they often focus on maintaining geometric tolerances without considering functional assessment criteria such as aerodynamic stability and structural durability. This can lead to IBRs being scrapped even if they could be repaired to meet functional criteria.
Innovation Solution
A method is disclosed for determining a repair process for defects in bladed rotors by comparing the defect in a 3D model of an inspected IBR to a database of known defects. If a match is found, a repair process associated with the known defect is generated, and this process can be performed using CNC machines or additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional geometric assessment constraints (tolerances, material removal, material addition) are used to evaluate IBR repairability, then manufacturing precision is maintained, but the rotor may be scrapped even when functional criteria could be met
Solution Approach 1:
The patent changes the assessment parameters from purely geometric constraints to include functional performance parameters. The system evaluates repairs based on aerodynamic stability, structural durability, and operational performance rather than just geometric tolerances, allowing IBRs to be repaired and reused when functional criteria are met even if geometric constraints are exceeded
Solution Approach 2:
The patent prevents the premature disposal of IBRs by implementing a comprehensive assessment system. Instead of scrapping rotors that fail geometric tolerance checks, the system evaluates whether functional performance can be restored through repair, thereby extending the service life of expensive components
2Duration of action of stationary object
If functional assessment criteria (aerodynamic stability, structural durability) are considered in repair decisions, then rotor life is extended, but assessment complexity increases
Solution Approach 1:
The patent segments the assessment process into distinct modules: geometric assessment, structural assessment, aerodynamic assessment, and repair feasibility assessment. Each module evaluates specific criteria independently, making the overall complex assessment manageable and systematic
Solution Approach 2:
The patent creates a multi-functional assessment system that evaluates geometric, structural, and aerodynamic criteria within a single integrated platform. The system can assess various defect types (cracks, erosion, corrosion) across different IBR locations using unified assessment protocols
3Reliability
If optimal repairs considering aerodynamic and structural capability are implemented, then rotor performance is improved, but repair process complexity increases
Solution Approach 1:
The patent performs preliminary assessments of aerodynamic and structural capability before finalizing repair decisions. The system evaluates potential repair outcomes using computational models to predict performance, allowing optimal repair strategies to be determined in advance
Solution Approach 2:
The patent uses computational models and digital twins to simulate repair outcomes without physically performing the repairs first. Virtual assessments of aerodynamic and structural performance allow optimal repair strategies to be identified before implementation
Data Source
AI summary
A method of determining a repair method for a defect in a bladed rotor can comprise comparing the defect in a three-dimensional model of an inspected integrally bladed rotor (IBR) to a plurality of known defects from a repair database; determining the defect is matching a known defect in the plurality of known defects in the repair database; and generating a repair process associated with the known defect in response to determining the defect is matching the known defect. A method can also comprise determining a potential repair process; performing a structural simulation of a finite element model for the inspected IBR with the potential repair; performing an aerodynamic simulation of an aerodynamic model for the inspected IBR with the potential repair; and generating the potential repair process for the defect in response to determining the inspected IBR with the potential repair meets structural and the aerodynamic criteria.