This method for generating a tool path for processing a workpiece is provided with: a step for setting a first reference plane with respect to the workpiece; a step for setting, with respect to the workpiece, a second reference plant which is not parallel to the first reference plane; a step for interpolating, on the basis of the first reference plane and the second reference plane, a plurality of third reference planes, which are not parallel to each other, between the first reference plane and the second reference plane; a step in which partial tool paths for processing the workpiece are generated for each of the plurality of third reference planes on the basis of the corresponding third reference plane; and a step for generating a tool path by sequentially connecting the partial tool paths of the plurality of third reference planes.

A system for use in performing maintenance on a turbine rotor. The system includes a rotor mount configured to receive the turbine rotor, a robotic device, a visual inspection device removably coupleable to the robotic device, and a computing device. The computing device is configured to direct the robotic device to evaluate, with the visual inspection device, the turbine rotor at different circumferential locations thereof to obtain rotor axis data, determine a centerline of the turbine rotor based on the rotor axis data, generate a coordinate system including the centerline of the turbine rotor, direct the robotic device to evaluate, with the visual inspection device, each blade on at least one stage of the turbine rotor to obtain blade position data relative to the centerline, and populate the coordinate system with the blade position data.

A target path is corrected using an imaging result of a workpiece and a moving distance of a control object for each control cycle is kept constant. The PLC generates a connected path for each control cycle so that a length of the corrected path for each control cycle substantially matches a length of a normative path for each control cycle.

An apparatus for processing a component includes a multi-axis positioning device, a processing tool, and a control device for controlling the multi-axis positioning device. The multi-axis positioning device is configured to move the processing tool relative to the component and to move each axis of the processing tool within a corresponding work envelope. The control device is configured to limit the movement of the multi-axis positioning device along or about at least one limited axis within the corresponding work envelope to a subregion or subspace. The multi-axis positioning device and/or the component is configured to move about and/or along an external axis to compensate for the limitation of the movement along or about the limited axis.

A method of forming an airfoil includes casting the airfoil with an internal cooling circuit and an exterior surface with a positive feature. The exterior surface of the airfoil is scanned with a first probe. A size and a location of the positive feature are identified based on the scan of the exterior surface. A transformation matrix is created with a controller such that the transformation matrix includes toolpath transformation instructions. A transformed set of machine toolpath instructions is created by applying the transformation matrix using the controller to a first set of machine toolpath instructions to align the first set of machine toolpath instructions relative to the positive feature. A contour is then machined into the exterior surface of the airfoil based on the transformed set of machine toolpath instructions.

An automated airflow inspection system for airfoil blades or vanes includes an operator station for mounting the airfoil and a robotic station for pressure tapping the airfoil. The robotic station includes a vision system and a pressure tapper mounted to a robotic arm. The vision system identifies a pattern of holes of the airfoil blade or vane. The system identifies a hole within the pattern of holes by comparing the pattern of holes to a pre-loaded program associated with the airfoil blade or vane. The system is monitored and controlled by a human to machine interface.

There are provided a system and a method of use thereof for executing a manufacturing process. For example, a method can include executing, by a system configured to drive the manufacturing process, a set of manufacturing functions based on a digital model of a first part. The method can include fetching, by the system, from an in-field scoring system, performance data relating to a second part. The method can further include constructing the digital model based on the performance data relating to the second part. The method can further include generating, based on the digital model, a forecast representative of a performance of the first part and generating the set of manufacturing functions based on the digital model and the forecast. The method further includes manufacturing the first part according to the set of manufacturing functions.

Producing a component having an in use gas washed surface includes: obtaining a reference component having a reference shape with an in use gas washed surface; setting one or more performance threshold for the reference shape, the threshold defining an acceptable performance for the reference shape; obtaining a manufactured component made to the reference shape; measuring the manufactured component and determining a displacement distribution indicative of the geometric deviation of the manufactured component from the reference shape; determining a performance sensitivity distribution for the reference component, the sensitivity distribution having a plurality of points, each point indicative of a performance factor for the reference component; combining the sensitivity distribution and displacement distribution to determine a performance prediction for the manufactured component; determining whether the performance prediction is within the performance threshold; accepting or rejecting the component for use if the predicted performance is within or outside the performance threshold, respectively.

A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

A method of sentencing, accepting or rejecting, a cast component is disclosed. Initially, scanning the component to determine a number of datum points; this can be done using optical scanning techniques. The datum points from the scanned results are then aligned with an ideal design computer aided design (CAD) model of the component. A comparison of the scanned datum points of the component is performed against the data from the ideal design CAD model of the component, and any geometric deviations between the scan and the ideal design CAD model are determined. Using the datum points from the scan of the component an assessment is performed of at least one performance prediction factor for the component. Finally, using dimensional data extracted from the scan and/or the performance prediction factor the component is sentenced for either acceptance or rejection. Additionally, if the component is determined to have a deviation that lies within a pre-determined limit for the dimensional data and/or the performance factor a determination may be made as to whether the component can be reoriented.