Turbine Blade Manufacturing Precision via Deviation Data Feedback
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Solution Overview
Problem
Current manufacturing systems face challenges in consistently producing turbine blades with complex three-dimensional external and internal structural characteristics, leading to deviations and variations that result in components that often stray from specified requirements, causing inefficiencies and increased scrap rates.
Innovation Solution
A manufacturing method and system that utilizes accumulated component data to adjust manufacturing operations in real-time, allowing for continuous compensation for deviations and variations throughout the process, ensuring that final components meet specified requirements by feeding forward analytical data to subsequent steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard manufacturing operations are used to produce turbine blades with complex three-dimensional structures, then manufacturing complexity is managed, but manufacturing precision deteriorates due to accumulated deviations from specifications
Solution Approach 1:
The patent implements feedback by measuring actual deviations of the cast blade form from specifications using analytical devices, then using this measured data to adjust subsequent manufacturing operations. This closed-loop feedback system compensates for variations in the cast form and prevents deviation accumulation, thereby improving manufacturing precision without requiring complete redesign of the manufacturing process complexity.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting manufacturing parameters (such as tool paths, cutting depths, drilling positions) based on measured deviations of the actual cast blade form from the master model. This allows the manufacturing process to adapt to variations in each workpiece, improving precision while managing complexity through systematic parameter adjustment rather than process redesign.
2Manufacturing precision
If multiple sequential manufacturing operations are performed on turbine blades, then manufacturing completeness is achieved, but manufacturing precision deteriorates due to accumulation of deviations
Solution Approach 1:
The patent applies preliminary action by measuring and characterizing the cast blade form deviations before entering the sequential manufacturing operations. This preliminary measurement data is then used to pre-calculate adjusted tool paths and parameters for all subsequent operations, allowing compensation for deviations to be built into each operation in advance rather than requiring iterative adjustments during the manufacturing sequence, thus maintaining precision without significantly extending cycle time.
3Manufacturing precision
If accumulated component data is used to adjust manufacturing operations, then manufacturing precision is improved, but device complexity increases due to data management requirements
Solution Approach 1:
The patent implements feedback by creating a data management system that collects measured deviation data from analytical devices, stores this information, and automatically uses it to adjust manufacturing parameters for subsequent operations. The system feeds this accumulated data back into the manufacturing process control, enabling continuous improvement of precision while managing complexity through automated data processing and parameter adjustment algorithms.
Data Source
AI summary
A manufacturing system and manufacturing method for adjusting the performance of manufacturing operations or steps in manufacturing components having three-dimensional external structural characteristics. An embodiment of the system broadly comprises: (a) a plurality of manufacturing operations for processing a component having three-dimensional external structural characteristics; (b) at least one analytical device for analyzing at least one characteristic of the component after the performance of one or more manufacturing operations to generate a component data set; (c) at least one data storage device for storing the generated component data sets and for providing at least a relevant portion of accumulated component data; and (d) a communication mechanism for transmitting at least a relevant portion of accumulated component data to one or more manufacturing operations so that the performance thereof can be adjusted in response to the transmitted portion of accumulated component data. An embodiment of the method broadly comprises the following steps: (a) providing a component having three-dimensional external structural characteristics; (b) providing at least a relevant portion of accumulated component data comprising at least two different component data sets; and (c) performing a manufacturing step on the component to provide a processed component, wherein the at least relevant portion of accumulated component data is used to adjust the manner in which the manufacturing step is performed.