Turbine Vane 3D Scan Classification for Individual Airfoil Airflow

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Solution Overview

Problem

Conventional methods for vane classification in turbine engines, such as hard gage classification and coordinate measuring machines (CMM), are cumbersome, require frequent calibration, and fail to analyze individual airfoils accurately, often treating vane assemblies as a whole.

Innovation Solution

Utilizing structured light three-dimensional (3D) scanning to capture the geometry of turbine vanes, generating a point cloud, and constructing a mesh surface to determine airflow characteristics of individual airfoils without reference to adjacent vanes, thereby enabling precise vane classification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If hard gage classification or CMM is used for vane classification, then measurement can be performed, but the process becomes cumbersome and requires frequent calibration

Engineering Contradiction:

Improvevane classification accuracyVSAvoidclassification process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical measurement systems (hard gages and CMM) with a photogrammetric system using structured light scanning and image processing. This substitution eliminates the mechanical complexity and calibration requirements while maintaining measurement precision through optical field-based capture and computational analysis of vane geometries

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital copies of physical vanes through photogrammetric scanning, generating 3D point clouds and mesh models from multiple 2D images. These digital replicas enable virtual classification and analysis without requiring physical measurement devices, reducing device complexity while preserving measurement accuracy

Inventive Principle:

Principle #26Copying

2Ease of operation

If conventional methods treat vane assemblies as a whole, then classification is simplified, but individual airfoil analysis accuracy is lost

Engineering Contradiction:

Improveclassification operation simplicityVSAvoidindividual airfoil measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent segments the vane assembly into individual airfoil components through computational processing. The photogrammetric system captures and processes images to isolate and analyze each airfoil's geometry independently, enabling precise individual measurement while maintaining operational efficiency through automated image processing and 3D reconstruction algorithms

Inventive Principle:

Principle #1Segmentation

3Reliability

If CMM fixtures are used for vane measurement, then measurement stability is improved, but infrastructure requirements and cost increase

Engineering Contradiction:

Improvemeasurement stabilityVSAvoidfixture infrastructure requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical CMM fixtures with a photogrammetric measurement system that uses optical fields and computational methods. This substitution maintains measurement stability through repeated image capture and processing while eliminating the need for complex physical fixtures and their associated infrastructure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The photogrammetric system is self-contained and does not require external fixture infrastructure. The measurement process uses the camera system itself to capture, process, and analyze vane geometries independently, eliminating dependence on separate fixture systems and reducing overall infrastructure requirements

Inventive Principle:

Principle #25Self-service

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 method allows for accurate analysis of each vane's airflow, reducing infrastructure needs, eliminating the requirement for CMM fixtures, and improving turbine engine efficiency by constructing engines with vanes that meet precise airflow specifications.

Implementation Method 1

scanning, using a structured light scanner, a vane for a turbine engine to capture three-dimensional (3D) data about the vane

Methodology Applied

Scientific EffectStructured light: Light

Data Source

PatentUS20260112147A1Performing vane classification for turbine engines using structured light three-dimensional (3D) scans

Publication Date: 2026.04.23 RTX CORP

AI summary

An example method for vane classification includes scanning, using a structured light scanner, a vane for a turbine engine to capture three-dimensional (3D) data about the vane. The method further includes generating a point cloud from the 3D data about the vane. The method further includes connecting, using a processing system, points of the point cloud to generate a mesh surface. The method further includes determining, using the processing system, an airflow for an airfoil of the vane based at least in part on the mesh surface. The method further includes constructing the turbine engine based at least in part on the airflow for the airfoil of the vane without reference to an adjacent airfoil of the vane.