Automated Preform Cutting via Thread Deviation Detection
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Solution Overview
Problem
The existing cutting method for turbomachine parts made from preforms is inefficient due to the manual verification of deformation and positioning, leading to increased manufacturing time, costs, and risks of errors and defects.
Innovation Solution
A cutting method that uses image processing to determine deviations in the layout of weaving threads, correct the cutting contour, and automatically adjust the cutting machine's position relative to the preform, ensuring precise cutting based on a preform model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual verification of preform deformation is performed, then cutting precision can be maintained, but manufacturing time increases and costs increase
Solution Approach 1:
The patent replaces the manual mechanical verification process with an automated optical measurement system using cameras and image processing algorithms. The system captures images of the preform, processes them to detect thread layout deviations, and automatically compensates for deformations, eliminating the need for manual inspection while maintaining cutting precision.
Solution Approach 2:
The system enables the preform to 'self-report' its deformation state through the optical measurement system. By automatically detecting and quantifying deviations in the thread layout, the system allows the preform to provide its own measurement data without external manual intervention, streamlining the process.
2Manufacturing precision
If manual positioning of preform relative to cutting machine is performed, then cutting accuracy can be ensured, but manufacturing time increases and risk of defects increases
Solution Approach 1:
The patent replaces manual positioning operations with an automated optical positioning system. The system uses image processing to detect the preform's actual position and orientation relative to the cutting machine, then automatically calculates and applies position compensation, eliminating manual positioning while maintaining cutting accuracy.
Solution Approach 2:
The system implements a feedback loop where the optical measurement system continuously monitors the preform's position and deformation, compares it against the reference model, and automatically adjusts the cutting parameters and machine positioning in real-time, ensuring accuracy without manual intervention.
3Productivity
If automated image processing is implemented, then manufacturing time is reduced and productivity increases, but system complexity increases
Solution Approach 1:
The patent introduces an intermediary software layer that bridges the optical measurement system and the cutting machine control system. This software automatically processes images, detects deviations, calculates compensation parameters, and transmits corrected data to the cutting machine, managing system complexity through modular software architecture while maintaining high productivity.
Data Source
AI summary
A method for cutting a preform usable for production of a turbomachine part and including a weaving of a plurality of threads, the threads including single threads that are visually identifiable, along a cutting contour calculated based on a preform model in which the threads have a reference arrangement, the method including: taking an image of the preform; processing the image to determine a deviation in an arrangement of the threads which are visually identifiable relative to the reference layout; correcting the cutting contour according to the deviation; and cutting the preform along the corrected cutting contour.