Adaptively machining component surfaces and hole drilling

• US 9,817,389 B2
• Filed: 03/05/2014
• Issued: 11/14/2017
• Est. Priority Date: 03/05/2013
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Rhodes, Jeffrey F., Fuesting, Timothy Paul, Henderkott, Joseph Peter, Snyder, Ronald J., Click, John F., Junod, Larry Allen
• Primary Examiner(s): Coyer, Ryan
• Application Number:
  US14/197,876
• Publication Number:
  US 20140257543A1
• Time in Patent Office: 1,350 Days
• Field of Search: 700 97
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 19/4207 in which a model is traced or scanned and corresponding data recorded
• CPC Class Codes: G05B 2219/45147 Machining blade, airfoil

Abstract

A method includes receiving a design surface data set, obtaining a component surface data set from the inspection of a component, creating a modified surface data set in response to the design surface data set and the component surface data set, generating a machining path in response to the modified surface data set, and machining the component in response to the machining path to produce a machined component according to the modified surface data set. The machined component deviates from the design surface data set.

Claims

1. A method comprising:

receiving a design surface data set;

for each of a batch of components, obtaining a component surface data set from the inspection of a component, wherein multiple components in the batch of have slight variations in size and/or surface geometries as compared to the design surface data set;

for each of the batch of components, creating a modified surface data set in response to the design surface data set and the component surface data set;

for each of the batch of components, creating an orientation offset data set in response to the design surface data set, the modified surface data set and a rate of contour deviation constraint, wherein the rate of contour deviation constraint is less than 0.005 inch/inch;

for each of the batch of components, creating a new surface data set in response to the orientation offset data set and the modified surface data set;

for each of the batch of components, generating a machining path in response to the modified surface data set, wherein generating the machining path in response to the modified surface data set includes generating the machining path in response to the new surface data set; and

for each of the batch of components, machining the component in response to the machining path to produce a machined component according to the modified surface data set, wherein the machined component deviates from the design surface data set and is consistent with the new surface data set.

2. The method of claim 1, for each of the batch of components, further comprising inspecting the component with a non-contact optical inspection system to obtain the component surface data set.

3. The method of claim 1, further comprising, for each of the batch of components, prior to machining the component, determining the component meets a quality control standard by comparing the modified surface data set with the design surface data set.

4. The method of claim 1, further including, for each of the batch of components, prior to machining the component, determining a degree of variation in response to the new surface data set and the design surface data set and predicting a quality outcome in response to the degree of variation.

5. The method of claim 1, further comprising, for each of the batch of components, securing the component in a fixture, wherein the inspection of the component includes inspection of the component in relation to the fixture.

6. The method of claim 5, further comprising, for each of the batch of components, determining a hole location in response to the component surface data set of the component in relation to the fixture.

7. The method of claim 6, wherein, for each of the batch of components, machining the component in response to the machining path further includes machining the component in response to the machining path and the hole location.

8. An adaptive machining system comprising:

a processor configured to;

compare electronic measured component surface data set of a component with a design surface data set of the component,

create an orientation offset data set in response to the design surface data set, the modified surface data set and a rate of contour deviation constraint, wherein the rate of contour deviation constraint is less than 0.005 inch/inch,

create a new surface data set in response to the orientation offset data set and the modified surface data set, and

create a modified surface data set in response to the design surface data set and the component surface data set, and generate a machining path in response to the modified surface data set, wherein generating the machining path in response to the modified surface data set includes generating the machining path in response to the new surface data set; and

a numerical control machine configured to machine the component according to the machining path to produce a machined component according to the modified surface data set, wherein the machined component sufficiently deviates from the design surface data set to be consistent with the new surface data set.

9. The adaptive machining system of claim 8, wherein the processor is further configured to determine the component meets a quality control standard by comparing the modified surface data set with the design surface data set.

10. The adaptive machining system of claim 8, wherein the processor is further configured to:

determine a degree of variation in response to the new surface data set and the design surface data set; and

predict a quality outcome in response to the degree of variation.

11. The adaptive machining system of claim 8, further comprising a non-contact optical inspection system configured to inspect the component to obtain the component surface data set.

12. The adaptive machining system of claim 11, further comprising a fixture configured to secure the component, wherein the non-contact optical inspection system is configured to inspect the component in relation to the fixture.

13. The adaptive machining system of claim 12, wherein the processor is further configured to determine a hole location in response to the component surface data set of the component in relation to the fixture.

14. The adaptive machining system of claim 13, wherein the numerical control machine is configured to machine the component in response to the machining path and the hole location.

15. A non-transitory computer system-readable storage medium that stores computer system-executable instructions that, when executed, configure a computer system to:

receive a design surface data set;

obtain a component surface data set from the inspection of a component;

create a modified surface data set in response to the design surface data set and the component surface data set;

create an orientation offset data set in response to the design surface data set, the modified surface data set and a rate of contour deviation constraint, wherein the rate of contour deviation constraint is less than 0.005 inch/inch;

create a new surface data set in response to the orientation offset data set and the modified surface data set, wherein generating the machining path in response to the modified surface data set includes generating the machining path in response to the new surface data set;

generate a machining path in response to the modified surface data set; and

communicate the machining path to numerical control machine configured to machine the component according to the machining path to cause the machined component to sufficiently deviate from the design surface data set to be consistent with the new surface data set.

16. The non-transitory computer system-readable storage medium of claim 15, comprising further instructions that, when executed, configure the computer system to determine the component meets a quality control standard by comparing the modified surface data set with the design surface data set.

17. The non-transitory computer system-readable storage medium of claim 15, comprising further instructions that, when executed, configure the computer system to determine a hole location in response to the component surface data set of the component.