Structured Light Overhaul of Engine Components With Additive Repair
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Solution Overview
Problem
Existing component overhaul processes result in material waste and increased manufacturing costs, necessitating a need for more efficient methods that reduce waste and costs while restoring components to a like-new condition.
Innovation Solution
A method and system utilizing structured light scanning to generate substrate and object scan data, followed by additive manufacturing and machining processes to deposit and remove material based on reference data, thereby forming a restored component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze material or weld filler processes are used to overhaul defects in a component, then the component can be restored, but material waste increases and manufacturing costs increase
Solution Approach 1:
The patent applies local quality by using additive manufacturing to deposit material only at the specific defect locations identified through structured light scanning. The system compares scan data to reference data to precisely locate defects, then deposits braze or weld material only where needed rather than applying material broadly across the entire component surface. This localized approach eliminates unnecessary material waste while maintaining restoration effectiveness.
Solution Approach 2:
The patent implements preliminary action by performing structured light scanning and comparing scan data to reference data before material deposition begins. This preliminary inspection and planning phase identifies all defects that need repair, allowing the system to prepare a precise material deposition plan that avoids waste. The preliminary action ensures that material is applied only where defects exist, preventing both under-application and over-application of material.
2Reliability
If traditional braze material or weld filler processes are used to overhaul defects in a component, then the component can be restored, but manufacturing costs increase
Solution Approach 1:
The patent implements feedback by using structured light scanning to capture the actual component geometry, comparing it to reference data to identify deviations and defects, then using this information to guide material deposition. After deposition, the system can scan again to verify the repair quality. This closed-loop feedback system ensures material is applied only where needed and at the correct amount, reducing material waste and associated costs while maintaining high restoration quality.
Solution Approach 2:
The patent replaces traditional mechanical material application methods with additive manufacturing technology. Instead of using conventional brazing or welding processes that require broad material application and extensive manual operation, the system uses automated additive manufacturing to precisely deposit material layer by layer only at defect locations. This substitution reduces both material waste and labor costs while improving restoration precision.
3Loss of substance
If additive manufacturing is used to deposit material based on scan data, then material waste is reduced, but manufacturing time is required for scanning and data processing
Solution Approach 1:
The patent merges multiple operations into an integrated workflow where structured light scanning, data comparison, defect identification, and material deposition planning are combined into a single automated process flow. The scanning system and additive manufacturing system are coordinated through a unified control system that processes scan data and generates deposition paths automatically. This merging eliminates the need for separate inspection and repair planning steps, reducing overall manufacturing time despite the added scanning step.
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
The method reduces manufacturing time, waste, and costs by precisely tailoring material deposition and removal, achieving components that meet design specifications with improved efficiency.
Implementation Method 1
a substrate is scanned using structured light to provide substrate scan data
Implementation Method 2
Material is deposited with the substrate using an additive manufacturing device based on the substrate scan data
Data Source
AI summary
A method of overhaul is provided. During this overhaul method, a substrate is scanned using structured light to provide substrate scan data. The substrate is from a component previously installed within an engine. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Material is deposited with the substrate using an additive manufacturing device based on the substrate scan data to provide a first object. The first object 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 is machined using the machining data.