Vision-Calibrated 3D Printing on Compressor Blades
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Solution Overview
Problem
Traditional additive manufacturing methods are inefficient and labor-intensive for repairing and rebuilding damaged compressor blades in turbomachines, requiring extensive post-processing and being unsuitable for batch processing, leading to high costs and potential machine failure.
Innovation Solution
An additive manufacturing system that uses a vision system to calibrate and align workpieces with precision, allowing for the direct additive printing of extension segments onto pre-existing workpieces, including compressor blades, using a controller and computer-executable instructions to generate print commands based on digital representations of calibration marks and CAD models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional additive manufacturing methods are used to repair compressor blades, then the repair process can be performed, but the process is labor-intensive and requires extensive post-processing
Solution Approach 1:
The patent replaces traditional mechanical repair methods with an automated additive manufacturing system that uses digital models and computer-controlled deposition processes. This substitution eliminates manual labor and extensive post-processing while maintaining repair quality, directly resolving the contradiction between ease of manufacture and time loss.
2Ease of repair
If traditional additive manufacturing is used for compressor blade repair, then individual blades can be repaired, but batch processing is not suitable
Solution Approach 1:
The patent merges multiple individual blade repairs into a single batch processing operation by securing multiple blades to a build plate simultaneously and processing them together through the additive manufacturing system. This combining approach maintains the ease of repair while dramatically improving productivity through batch processing.
3Manufacturing precision
If traditional additive manufacturing methods are used, then components can be printed on a build plate, but precision alignment with workpieces is difficult
Solution Approach 1:
The patent introduces a vision system as an intermediary between the additive manufacturing system and the workpieces. This vision system captures images, identifies workpiece locations and orientations, and provides feedback for automatic alignment adjustments. The intermediary system achieves high precision alignment without requiring complex manual positioning or specialized fixtures.
4Manufacturing precision
If additive printing is performed on pre-existing workpieces, then near net shape components can be produced, but calibration and location precision are challenging
Solution Approach 1:
The patent implements a feedback loop where the vision system continuously monitors workpiece locations and orientations, compares them against the digital model, and automatically adjusts the additive manufacturing process parameters. This closed-loop feedback system ensures high printing accuracy on pre-existing workpieces by compensating for measurement uncertainties and variations in workpiece positioning.
Data Source
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AI summary
Additive manufacturing systems (100), methods, and computer readable media may be configured to perform a calibration. Calibrating an additive manufacturing system (100) may include comparing a digital representation of one or more calibration marks (1602) to a calibration-CAD model (1400) that includes one or more model calibration marks (1402), and applying a calibration adjustment to one or more CAD models (800, 850) based at least in part on the comparison. The digital representation of the one or more calibration marks (1602) may have been obtained using a vision system (102), and the one or more calibration marks (1602) may have been printed on a calibration surface (1500) according to the calibration-CAD model (1400) using an additive manufacturing machine (104). The calibration adjustment may be configured to align the one or more CAD models (800, 850) with one or more coordinates of the additive manufacturing system (100).