Automated Strain Indicator Placement on Turbine Blades
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Solution Overview
Problem
Turbomachine components, particularly turbine blades, experience creep due to high temperatures and stresses, leading to deformation and reduced performance, with existing strain sensing technologies being inefficient in accurately placing strain indicators on complex-shaped components.
Innovation Solution
A computer-implemented method for applying passive strain indicators to components, involving stress analysis, surface curve and data point creation, user input for selected locations and orientations, and control signals to apply the indicators precisely using a robotic arm and printer system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to place strain indicators on complex-shaped components, then flexibility in placement is maintained, but time consumption and placement errors increase significantly
Solution Approach 1:
The patent replaces manual mechanical placement methods with an automated robotic arm system that uses computer vision and control algorithms to precisely position strain indicators on complex-shaped components, thereby reducing both time consumption and placement errors
Solution Approach 2:
The system creates a digital model or map of the component's complex surface geometry, allowing the robotic arm to accurately replicate the intended strain indicator positions and orientations without manual measurement and marking
2Manufacturing precision
If automated robotic systems are used to apply strain indicators, then placement precision and speed improve, but system complexity increases
Solution Approach 1:
The robotic arm system is designed with multi-functionality, capable of performing surface scanning, digital modeling, strain indicator placement, and quality verification in a single integrated platform, thereby justifying the increased complexity through consolidated functionality
Solution Approach 2:
The system incorporates automated surface scanning and digital modeling capabilities that allow it to self-adapt to different component geometries without requiring extensive manual reconfiguration, reducing the operational complexity despite the sophisticated hardware
3Reliability
If strain indicators are placed on complex-shaped components with varying curvature, then comprehensive strain coverage is achieved, but determining accurate placement locations and orientations becomes more difficult
Solution Approach 1:
The system performs preliminary surface scanning and digital modeling to pre-determine the optimal placement locations and orientations of strain indicators on complex surfaces with varying curvature, allowing for comprehensive strain coverage while simplifying the actual application process
Solution Approach 2:
The system uses computer vision and image processing algorithms to dynamically calculate and adjust the placement parameters (position, orientation, angle) of strain indicators based on the local surface curvature and geometry, ensuring accurate alignment and reliable measurement across complex surfaces
Data Source
AI summary
A computer-implemented method for applying passive strain indicators to a component includes creating a plurality of surface curves and a plurality of data points on each of the plurality of surface curves, the plurality of surface curves and the plurality of data points defining the exterior surface of the component. The method further includes receiving data indicative of a user input selection of a selected surface curve of the plurality of surface curves, a selected data point of the plurality of data points on the selected surface curve, and a selected rotation angle. The method further includes determining an output dimension, location, and orientation of a passive strain indicator. The method further includes providing one or more control signals to a passive strain indicator application system to cause the system to apply the passive strain indicator having the output dimension, location, and orientation to the component.