Laser Drilling Compensation for Deformed Component Surfaces
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Solution Overview
Problem
Existing machining assemblies struggle to accurately drill components deviating from a nominal shape, particularly in aircraft propulsion systems, due to deformation caused by manufacturing or operational use, which complicates the positioning of laser sources for precise hole formation.
Innovation Solution
A CNC assembly with a machining system and controller that measures surface deviations from a 3D component model using a position measurement probe, determines a compensation vector for nominal holes, and adjusts the laser source's stand-off position and orientation to accurately form component holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining assemblies are used to drill components, then the machining process can be performed, but the positioning accuracy deteriorates when components deviate from nominal shape due to deformation
Solution Approach 1:
The system performs preliminary scanning of the component surface to detect deviations from the nominal shape before the drilling operation. This advance detection allows the system to calculate compensation values and adjust the laser source positioning in advance, ensuring accurate hole formation despite component deformation
Solution Approach 2:
The system implements a feedback loop where the actual component geometry is measured during the machining setup, the deviations are compared against the nominal model, and compensation values are automatically calculated and applied to adjust the laser source position. This closed-loop control ensures manufacturing precision adapts to actual component variations
2Manufacturing precision
If laser source positioning is adjusted to compensate for surface deviations, then the manufacturing precision improves, but the device complexity increases due to additional measurement and calculation systems
Solution Approach 1:
The machining assembly is designed with multi-functional capabilities where the same system performs both measurement (scanning the component surface) and machining (laser drilling). The control system integrates geometry detection, deviation calculation, and positioning control functions, reducing the need for separate dedicated measurement equipment and simplifying the overall device architecture
Solution Approach 2:
The system uses its own machining tools and control systems to perform the measurement and compensation calculations, rather than requiring external specialized equipment. The laser source and positioning system serve dual purposes: both for the actual machining operation and for detecting and compensating for geometric deviations
3Manufacturing precision
If the laser source stand-off position and orientation are compensated for surface deviations, then the manufacturing precision improves, but the machining time increases due to additional measurement and calculation steps
Solution Approach 1:
The system performs the surface scanning and compensation calculation as a preliminary setup step before the actual drilling operation. By completing these measurements and calculations in advance, the system minimizes interruptions during the productive machining phase, thereby reducing overall time loss
Solution Approach 2:
The system maintains continuous operation by integrating the measurement and compensation processes into the machining workflow without significant interruptions. The scanning and calculation operations are performed efficiently in preparation for drilling, and the adjusted positioning is applied seamlessly, keeping the useful action continuous
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 solution enables precise formation of component holes in deformed components by compensating for surface deviations, ensuring accurate positioning of the laser source and improving the machining process's efficiency and accuracy.
Implementation Method 1
form a component hole in the component using the laser source by directing a laser beam to the drilling surface with the laser source in the compensated laser source stand-off position and the compensated laser source orientation
Data Source
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AI summary
A CNC assembly (68) includes a machining system (70) and a controller (72). The machining system (70) includes at least one machining tool. The controller (72) is configured to measure a surface deviation of a drilling surface of a component (54) from a 3D component model for the component using a position measurement probe to identify a position of the drilling surface at a plurality of points, determine a compensation vector of a nominal hole for the drilling surface using the measured surface deviation, determine a compensated laser source stand-off position and a compensated laser source orientation for the nominal hole using the determined compensation vector, position a laser source in the compensated laser source stand-off position and the compensated laser source orientation, and form a component hole in the component (54) using the laser source by directing a laser beam to the drilling surface with the laser source in the compensated laser source stand-off position and the compensated laser source orientation.