Print Head Interface Scanning for Aligned Blade Extension Printing

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Solution Overview

Problem

Current methods for additively printing extension segments on turbomachine blades, such as those in gas turbine engines, face challenges in accurately aligning the printed segments due to separate measurement systems, leading to potential misalignment and rework or scrapping of workpieces.

Innovation Solution

An additive manufacturing system and method where a print head scans the workpiece interface with an electromagnetic radiation beam, using reflection data to determine the location and control the printing of extension segments directly on the workpiece, ensuring precise alignment without the need for external measurement systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If separate measurement systems are used to determine workpiece interface location, then measurement capability is provided, but alignment accuracy deteriorates due to potential misalignment between measurement and printing systems

Engineering Contradiction:

Improveworkpiece interface location detectionVSAvoidextension segment alignment

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The patent combines the measurement system (electromagnetic radiation beam scanner) and the additive printing system into a single integrated machine. The same build plate serves both for positioning workpieces during measurement and for executing the printing process, eliminating the alignment errors that occur when transferring workpieces between separate measurement and printing systems.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If workpieces are transferred between separate measurement and printing systems, then specialized measurement and printing functions are achieved, but alignment accuracy and rework rates worsen due to transfer errors

Engineering Contradiction:

Improveseparate measurement and printing capabilitiesVSAvoidextension segment alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The additive manufacturing machine is designed with multi-functionality, serving both as a measurement system (using electromagnetic radiation beam scanning) and as a printing system. This universal platform eliminates the need to transfer workpieces between separate specialized systems, thereby preventing alignment errors during transfer while maintaining both measurement and printing capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If traditional additive printing methods are used without integrated scanning, then printing capability is provided, but alignment accuracy deteriorates requiring rework or scrapping

Engineering Contradiction:

Improveextension segment printingVSAvoidworkpiece interface alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The system uses electromagnetic radiation beam scanning to detect the actual location of the workpiece interface, then feeds this information back to the printing system. The printing process is controlled based on the detected location, allowing real-time adjustment and ensuring accurate alignment without requiring rework or scrapping of misaligned workpieces.

Inventive Principle:

Principle #23Feedback

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

This approach ensures accurate alignment and reduces rework by integrating the scanning and printing process within the additive manufacturing machine, improving the efficiency and accuracy of extension segment addition on turbomachine blades.

Implementation Method 1

receiving data associated with reflections of the electromagnetic radiation beam off of the build plate

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

an extension segment is additively printed on the determined workpiece interface

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Dielectric Heating

Data Source

PatentUS12151431B2System and method for additively printing extension segments on workpieces

Publication Date: 2024.11.26 GENERAL ELECTRIC CO

AI summary

A method for additively printing extension segments on workpieces using an additive manufacturing machine includes controlling, with a computing system, an operation of a print head of the machine such that a region of interest of a build plate of the machine is scanned with an electromagnetic radiation beam. Additionally, the method includes receiving, with the computing system, data associated with reflections of the beam off of the build plate as the region interest is scanned. Furthermore, the method includes receiving, with the computing system, data associated with a location of the beam relative to the build plate. Moreover, the method includes determining, with the computing system, a location of a workpiece interface based on the received data. In addition, the method includes controlling, with the computing system, the operation of the print head such that an extension segment is additively printed on the determined workpiece interface.