Rotorcraft Component Scan-Based Geometry Validation
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Solution Overview
Problem
Current rotorcraft component design and analysis methods, relying on CAD-based finite element analysis, face challenges in accurately validating geometric differences between nominal and as-produced components, which can lead to defects and suboptimal performance.
Innovation Solution
A method involving three-dimensional scanning to obtain point cloud geometry, refining it to generate scan-based geometry, meshing for finite element analysis, and comparing with CAD-based data to quantify deviations and validate the analysis process, ensuring the detection of critical defects and optimal design solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CAD-based finite element analysis is used for rotorcraft component design, then design and analysis efficiency is improved, but accuracy in validating geometric differences between nominal and as-produced components deteriorates
Solution Approach 1:
The patent merges CAD-based geometry with scan-based point cloud geometry to create a hybrid modeling approach. The CAD model provides the nominal design geometry while the scan data captures the actual as-produced component geometry. By combining these two data sources, the system achieves both design efficiency (from CAD) and measurement accuracy (from scanning), resolving the contradiction between productivity and measurement precision.
Solution Approach 2:
The patent introduces a comparison and validation process as an intermediary between CAD-based FEA and actual component analysis. The scan-based point cloud serves as a mediator to bridge the gap between nominal CAD geometry and actual manufactured geometry, allowing accurate validation of geometric differences while maintaining the efficiency of CAD-based analysis workflows.
2Measurement precision
If scan-based geometry is used to capture as-produced component geometry, then measurement accuracy is improved, but device complexity and processing time increase
Solution Approach 1:
The patent makes the scanning system serve multiple functions: capturing geometry for validation, providing input for FEA analysis, and enabling defect detection. By making the scan-based geometry universally applicable across multiple analysis needs, the system justifies the increased device complexity through multi-functional utility, reducing the need for separate specialized systems.
3Manufacturing precision
If geometric differences between CAD and as-produced components are validated, then manufacturing precision is improved, but analysis time and computational resources increase
Solution Approach 1:
The patent performs preliminary geometry validation by comparing scan-based point cloud data with CAD geometry before conducting full FEA analysis. This preliminary action identifies significant geometric deviations early, allowing analysts to focus computational resources only on components with notable differences, thereby reducing overall analysis time while maintaining manufacturing precision validation.
Data Source
AI summary
A method of performing structural analysis relating to a component having CAD-based geometry, refined CAD-based geometry and CAD-based FEA data associated therewith. The method includes scanning the component to obtain scan-based point cloud geometry of the component, aligning the scan-based point cloud geometry with the CAD-based geometry of the component, generating scan-based geometry of the component by refining the scan-based point cloud geometry, comparing the scan-based geometry with the refined CAD-based geometry of the component to quantify geometric differences therebetween, generating scan-based FEA geometry of the component by meshing the scan-based geometry, performing finite element analysis on the scan-based FEA geometry to obtain scan-based FEA data and comparing the scan-based FEA data with the CAD-based FEA data of the component to quantify the effect of geometric difference therebetween.