Turbine Vane Airfoil Classification Using Structured Light 3D Scans
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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, leading to inefficiencies in airflow determination and engine construction.
Innovation Solution
Utilizing structured light three-dimensional (3D) scanning to capture vane geometry, generate a point cloud, and construct a mesh surface to determine airflow for each airfoil independently, eliminating the need for hard gage fixtures and CMM fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods such as hard gage classification and CMM are used, then infrastructure and fixtures are required, but the process becomes cumbersome and requires frequent calibration
Solution Approach 1:
The patent replaces mechanical measurement systems (hard gage fixtures, CMM fixtures) with an optical scanning system using structured light. The method captures 3D data of vanes through optical projection and imaging, eliminating the need for physical contact with mechanical fixtures while maintaining measurement reliability through digital processing and analysis of the captured geometric data.
Solution Approach 2:
The patent creates digital 3D copies of the vane geometry through structured light scanning. Instead of using physical fixtures to measure and classify vanes, the system captures accurate 3D representations and performs classification on these digital models, eliminating the need for repeated physical fixture setup and calibration.
2Measurement precision
If conventional methods are used for vane classification, then general measurements are obtained, but individual airfoil analysis is inaccurate
Solution Approach 1:
The patent segments the vane into individual airfoils for separate analysis. The system identifies and isolates each airfoil within the vane structure, capturing and analyzing their geometric characteristics independently. This segmentation enables precise airflow determination for each individual airfoil while maintaining high classification efficiency through automated processing of the segmented data.
3Measurement precision
If structured light scanning is used, then individual airfoil analysis is precise, but data processing complexity increases
Solution Approach 1:
The patent performs preliminary processing of the 3D scanned data to organize and structure the geometric information before detailed analysis. The system pre-processes the point cloud data, identifies airfoil boundaries, and prepares the data for efficient individual airfoil analysis, thereby reducing the complexity of subsequent processing steps while maintaining high measurement precision.
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
Enables precise airflow analysis of individual vanes, improving turbine engine efficiency by ensuring vanes are within tolerance, reducing infrastructure requirements, and allowing for automated high-point detection and multiple part alignments.
Implementation Method 1
scanning, using a structured light scanner, a vane for a turbine engine to capture three-dimensional (3D) data about the vane
Data Source
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.