Structured Light Component Overhaul for Precision Additive Repair
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Solution Overview
Problem
Current methods for overhauling components, such as those in gas turbine engines, face challenges in reducing material waste and manufacturing costs, as they often rely on traditional braze and weld processes that are inefficient and wasteful.
Innovation Solution
The method involves scanning a substrate using structured light to generate data for additive manufacturing, where material is deposited to create a first object, which is then scanned and machined based on reference data to restore the component to a like-new condition, utilizing a system comprising a scanning device, additive manufacturing device, and machining device controlled by a controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze and weld processes are used to overhaul components, then defects can be repaired, but material waste increases and manufacturing costs rise
Solution Approach 1:
The additive manufacturing device deposits material only at specific locations where defects are detected through structured light scanning. The system creates a digital model of the component's actual geometry, compares it to the ideal design, and selectively adds material only where needed to restore dimensional accuracy, rather than applying material uniformly across the entire component surface.
Solution Approach 2:
The system performs structured light scanning and creates a digital twin of the component before any material deposition occurs. This preliminary digital modeling and comparison allows the system to plan and execute material addition with high precision, minimizing waste by knowing exactly where and how much material is needed before the overhaul process begins.
2Reliability
If traditional braze and weld processes are used to overhaul components, then defects can be repaired, but manufacturing costs increase
Solution Approach 1:
The system replaces traditional mechanical braze and weld processes with additive manufacturing technology. The additive manufacturing device deposits material layer by layer under digital control based on scanned geometry data, eliminating the need for manual or semi-automated braze and weld operations, thereby reducing labor costs and improving process consistency.
Solution Approach 2:
The system automatically scans the component, creates a digital model, compares it to design specifications, generates deposition paths, and executes material addition without requiring extensive manual intervention. The process is self-guided by the digital twin and automated control algorithms, reducing dependency on skilled manual labor and associated costs.
3Manufacturing precision
If material is deposited to restore component geometry, then defects are corrected, but achieving precise dimensional accuracy becomes challenging
Solution Approach 1:
The system uses structured light scanning to capture the actual geometry of the component before and after material deposition. The scanned data is continuously compared to the digital twin and ideal design specifications, providing real-time feedback that allows the system to adjust deposition parameters and ensure dimensional accuracy is achieved. This closed-loop feedback mechanism compensates for the complexity of the multi-step process.
Solution Approach 2:
The system creates a digital twin (virtual copy) of the component's actual geometry through structured light scanning. This digital copy is then compared to the ideal design model, and the difference drives the material deposition process. The digital copying and comparison enable precise control over dimensional accuracy without requiring complex manual measurements and calculations during the overhaul process.
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 reduces material waste and manufacturing costs by enabling precise restoration of components, tailoring material deposition and removal to match design specifications, thereby improving the efficiency and quality of the overhaul process.
Implementation Method 1
a substrate is scanned using structured light to provide substrate scan data
Data Source
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AI summary
A method of overhaul is provided. During this overhaul method, a substrate (44) is scanned using structured light to provide substrate scan data. The substrate (44) is from a component (22) previously installed within an engine. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Material (82) is deposited with the substrate (44) using an additive manufacturing device (24) based on the substrate scan data to provide a first object (80). The first object (80) is scanned using the structured light to provide first object scan data. The first object scan data is compared to first object reference data to provide machining data. The first object (80) is machined using the machining data.