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.

A process for shaping a part (12) of the turbine vane type, includes providing a part (12) comprising a blade (14) in an initial shape, providing a nominal definition representing the part in a nominal shape, comparing the initial shape with the nominal definition to determine compliance or non-compliance, for a non-compliant datum, determining a force to be applied to the part to deform said part, applying a force to obtain the part in a deformed shape, comparing the deformed shape with the nominal definition to determine compliance or non-compliance, and training a self-learning algorithm (82).

This invention concerns improvements in the inspection, assessment and re-working of manufactured components such as nozzle guide vanes (NGVs) and blades, in particular by improving the comparison of the component with nominal data. Dimensional data of a physical component is obtained and used to create a virtual digitized model of the component which is aligned with a nominal CAD model of the component in a virtual space. The correspondence is assessed and used to adjust weightings of different regions of the digitized model to improve the alignment. This process is repeated within the digital space until either conformance is reached or it is determined that this is not possible.

Systems and methods that include and/or leverage a cluster of machine-learned models to recontour components of gas turbine engines are provided. In one exemplary aspect, the systems and methods leverage a cluster of machine-learned models to predict repair machining offsets for certain sections of the component that can be used to adjust or set a material removal tool path.

A method of forming a guide vane is disclosed. The method includes forming a vane blank with sufficient material to fabricate the guide vane in accordance with any one of a plurality of different vane classes. The vane blank is inspected for material inconsistencies, and material is removed from the vane blank to form a desired guide vane in accordance with one of the plurality of vane classes. The inspection process includes disregarding at least one material inconsistency in a region of the vane blank that is removed to form the guide vane.

A system may include at least one sensor, at least one machining device, and a computing device. The computing device may be operable to control the at least one sensor to inspect at least a portion of a coversheet of a dual walled component to generate dimensional surface data for the at least a portion of the coversheet and compare the dimensional surface data to surface model data. The comparison may indicate portions of the coversheet that include additional material. The computing device also may be operable to generate a compromise surface model based on the comparison between the dimensional surface data and the surface model data and control the at least one machining device to machine the dual walled component based on the compromise surface model to remove the additional material.

A method for the maintenance of a used gas turbine includes the at least partially automated steps of: determining the geometry of a flow-guiding component, in particular a rotating blade or a guide vane, of the gas turbine; prognosticating the aerodynamics and/or thermodynamics of the component based on the determined geometry; and classifying the component into one of several predetermined classes based on the prognosticated aerodynamics and/or thermodynamic, where the predetermined classes denote different properties and parameter ranges indicating unusable components to usable components with poor performance.

Systems and method relating to machining parts include a CNC system including CNC machining tools, and a computer including a processor and a computer-readable medium, wherein the computer-readable medium encodes instructions of a single NC program that, when run on the processor, causes the computer to control a selected CNC machining tool to perform operations including alternating between (i) moving the selected CNC machining tool along a semi-finishing toolpath segment using a first set of spindle speed and feed rate values to remove a next portion of rough stock material in a next region of a part being manufactured, and (ii) moving the selected CNC machining tool along a finishing toolpath segment to remove a semi-finishing thickness portion of the part in the next region, wherein the first set of spindle speed and feed rate values are different from the second set of spindle speed and feed rate values.

A method for manufacturing a turbine engine blade including an airfoil with a profile defined by a theoretical digital model, the method including: manufacturing a blank having a thickened portion along a trailing edge of the airfoil relative to the theoretical profile; removing the thickened portion by adaptive machining, including: positioning the blank in a reference frame; acquiring, by probing at a predetermined number of points on a first surface of the blank along the trailing edge, positions of the points in the reference frame; determining differences, in one direction, in position from corresponding points of the theoretical model; producing machining grids on the blank surface, peaks of the grids determined from the points; determining an amount of material to be removed from the surface of the grids, based on the position of the points relative to the peaks and the deviations in position; and machining the airfoil.

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.