Rolls-royce Corporation

Other

Kong Ma

Robert M Moriarty

Joseph Peter Henderkott

Amir Shirkhodaie

Quinlan Yee Shuck

Matthew T Kush

Jacque Sue Bader

John T Pinder

Raymond Ruiwen Xu

Michael George Glavicic

Andrew J Ritchey

Matt Kush

The disclosure describes a method by a controller that includes: executing a model of a material based on a geometric template of the material defined by geometric parameters and at least one geometric constraint of the material; determining a value of an objective function based on differences between a three-dimensional representation of the material based on measurements of the material and the model of the material based on the geometric template of the material; and determining updated values of the geometric parameters of the geometric template. The method further includes iterating the executing the model of the material, the determining the value of the objective function, and the determining the updated values of the geometric parameters until a parameter associated with the objective function satisfies a criterion and, outputting the updated values of the geometric parameters associated with the objective function that satisfies the criterion.

Representation-based hybrid model

A method may include controlling, by a computing device, a directed energy deposition material addition (DED MA) technique based at least in part on a thermal model. The thermal model may define a plurality of default operating parameters for the DED MA technique. The method also may include detecting, by at least one sensor, at least one parameter related to the DED MA technique. Further, the method may include, responsive to determining, by the computing device, that a value of the at least one detected parameter is different from an expected value of a corresponding parameter predicted by the thermal model, determining, by the computing device and using a neuro-fuzzy algorithm, an updated value for at least one operating parameter for the DED MA technique, and controlling, by the computing device, the DED MA technique based at least in part on the updated value.

Neuro-fuzzy logic for controlling material addition processes

A material deposition system and method for cooling a component after material deposition. The method of deposition and cooling comprising a platform, a deposition head, and a cooling mechanism. The platform adapted to support a component for the addition of material. The deposition head including a material depositor configured to deposit material on a surface of a component supported on the platform an and an energy source configured to energize material deposited onto a surface of a component supported on the platform to bond the material to the component. The cooling system including bristles.

Directed energy deposition with cooling mechanism

In some examples, a technique includes delivering, using a material delivery device, material adjacent to a repair surface of a component and delivering, using a gas delivery device, a gas adjacent to the repair surface. The technique also may include delivering, from an energy source, energy to the material adjacent the repair surface to fuse the material to the repair surface; and receiving, by a computing device, at least one parameter indicative of at least one of a temperature or a geometry of the component. The technique may further include, responsive to the at least one parameter indicative of the at least one of the temperature or the geometry of the component, controlling, by the computing device, at least one processing parameter to control the temperature of the component.

Repair of gas turbine engine components

A system may include a thermal camera and a computing device configured to receive master image data representative of a geometry and thermal response of at least one of a theoretical component, a fabricated gold standard component, or an average of a plurality of components; receive, from the thermal camera, thermographic image data representative of a thermal response of a tested component; morph the thermographic image data to substantially align with the three-dimensional image data and produce morphed thermographic image data; and output a representation based on the morphed thermographic image data for display.

Thermographic inspection techniques

A system may include a fluid source fluidically coupled to a plenum; a thermal camera; at least one flow meter; and a computing device communicatively connected to the at least one flow meter and the thermal camera. The computing device may be configured to receive flow rate values from the at least one flow meter relating to flow testing of a first component fluidically coupled to the plenum; receive thermographic image data captured by the thermal camera during flowing thermographic testing of a second component fluidically coupled to the plenum; and associate the flow rate values with the thermographic image data to produce quantitative flowing thermographic image data.

A system may include a source of dry ice, a thermal camera, and a computing device. The computing device may be configured to control the source of dry ice to cause dry ice to be introduced into an internal passage of a tested component. The tested component may include debris within the internal passage, and the dry ice may remove at least some of the debris from the internal passage. The computing device also may be configured to receive, from the thermal camera, thermographic image data representative of the thermal response of the tested component and output a representation based on the thermographic image data.

One form of the present application provides a system comprising an illumination source capable of providing an electromagnetic illumination of an engine component, an imaging system structured to capture illumination of the engine component, a component manipulation system structured to position the engine component in a variety of orientations relative to one of the illumination source and the imaging system, a computer based user interface capable of identifying an inspection protocol defined to acquire an image of the engine component at the variety of positions using the illumination system, the imaging system and the component manipulation system, and a processor configured to process the inspection protocol for the purposes of analyzing the acquired image in response to the inspection protocol.

Protocol-based inspection system

An apparatus of an automated object manipulation system includes a support base; a finger assembly mechanically coupled to the support base; a first drive unit operable to rotate the finger assembly about a first axis; a second drive unit operable to rotate the finger assembly about a second axis; a third drive unit operable to rotate the finger assembly about a third axis, and a processor capable of conducting a profile assessment; determining a manipulation program in response to the profile assessment; and controlling the finger assembly in response to the manipulation program where the finger assembly has a support bracket with a set of parallel jaws and the support bracket is mechanically coupled to the first drive unit, a linking bracket mechanically coupled to the second drive unit and a circular frame mechanically coupled to the finger assembly and the third drive unit.

Automated object manipulation system

A system including a positioning system with a component manipulator structured to position a component in response to a positioning algorithm; a scanning system capable of producing a set of light waves directed at a surface of the component, detecting a set of reflected light waves from the surface of the component, and producing a reflectivity data set in response to the set of reflected light waves; and a microprocessor structured to apply a fuzzy logic algorithm to the reflectivity signal to determine a solution set and produce a grain structure characterization in response to the solution set.

Intelligent airfoil component grain defect inspection

An apparatus includes a positioning system; a surface indicator system to collect an indication data set from a surface of a component utilizing a fluorescent penetration process; an indication data processing system to create an output data set in response to the indication data set utilizing a fuzzy logic algorithm; and a microprocessor to provide at least one surface variance in response to the indication data set and the output data set. A method including conducting a surface indication technique for a component; utilizing a positioning algorithm to manipulate positioning equipment in response to the component; directing an indication source to a surface of the component; collecting an indication data set in response to directing the indication source; applying a fuzzy logic analysis in response to the indication data set to provide an output data set; and providing at least one surface variance in response to the output data set.

Intelligent airfoil component surface inspection

A method for inspecting surfaces including acquiring a surface image from a surface of a component; providing an image registration for the surface image; inspecting the component in response to the image registration to produce an input data set; creating an output data set in response to the input data set utilizing a fuzzy logic algorithm; and identifying a surface feature in response to the surface image and the output data set where acquiring the surface image further includes generating a radiation media; directing the radiation media at the component; detecting a responding radiation media in response to the directed radiation media and the component; creating the surface image in response to detecting the responding radiation media; and adjusting the generation of the radiation media in response to the surface image and a standard image.

Intelligent airfoil component surface imaging inspection

An apparatus for an illumination system including a concentric light source providing a quantity of light; a diffusion shield to diffuse the light and produce a diffused illumination where the diffused illumination is provided to a component positioned in an interior portion of the diffusion shield; a support structure where the diffusion shield is mechanically coupled with the support structure at a first base portion of the diffusion shield and where the concentric light sources are mechanically coupled with the support structure and positioned radially outward from the first base portion of the diffusion shield; and a harvesting shield where the harvesting shield is mechanically coupled with the support structure and positioned radially outward from the concentric light sources and where the harvesting shield redirects at least a portion of the quantity of light from the concentric light sources towards the diffusion shield.

Illumination system with illumination shield

A barrier for use in laser drilling. The barrier is placed in front of those surfaces that one wishes to protect from the laser beam. The barrier comprises a thixotropic medium, for example polyacrylamide suspension in water. The medium includes material which will disperse the laser light and material which will emit light when exposed to the laser light. The light emitter materials could be luminescent materials, phosphorescent materials, or fluorescent materials.

Barrier materials for laser drilling

A method and apparatus for drilling holes through a component (16) from a first surface to a second surface. The method includes the step of applying a thixotropic water soluble medium to the second surface. The medium contains material to disperse the laser light and light emitting material (which could be fluorescent, phosphorescent or luminescent). Monitoring means and beam splitter are provided for monitoring light emitted, or reflected, by the component 16, along the length of the hole drilled by the laser and for monitoring light emitted by the medium. In this way one can detect when the laser breaks through the second surface and also produce an image indicative of the size and shape of the hole.

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Carmel, IN, United States of America

Kong Ma