Patent Publication Number: US-2018052444-A1

Title: Component deformation modeling system

Description:
TECHNICAL FIELD 
     The subject matter disclosed herein relates to analyzing and modeling manufactured components. More particularly, the subject matter disclosed herein relates to analyzing and modeling deformation in a manufactured part, e.g., a combustion component, by excluding part-to-part variation about that component. 
     BACKGROUND 
     Conventional methods of calculating component deformation can suffer from undesirable complexity and/or inaccuracy. For example, conventional approaches of calculating component deformation, e.g., in combustion systems within gas turbines, require taking measurements of reference points within the system (e.g., deformation of the transition piece seal surface) and/or manufacturing multiple components in order to develop statistically significant comparisons. These approaches can be time consuming, costly, and inaccurate, such as to render them unusable depending on the requirements of the process. 
     BRIEF DESCRIPTION 
     Various embodiments of the disclosure include systems, methods and computer program products for modeling deformation in a manufactured component. In some cases, a system includes: at least one computing device configured to model deformation in a set of manufactured components by: forming a pre-exposure statistical distribution of measured coordinates describing the set of manufactured components from a pre-exposure three-dimensional (3D) depiction of a first sample of the manufactured component, and forming a post-exposure statistical distribution of measured coordinates describing the set of manufactured components from a post-exposure 3D depiction of a second sample of the manufactured component; calculating a difference between parameters of the pre-exposure statistical distribution and parameters of the post-exposure statistical distribution; and adjusting an expected deformation model for the set of manufactured components based upon the difference between the parameters of the pre-exposure statistical distribution and the post-exposure statistical distribution, to model the deformation of the manufactured component. 
     A first aspect of the disclosure includes a system having: at least one computing device configured to model deformation in a set of manufactured components by: forming a pre-exposure statistical distribution of measured coordinates describing the set of manufactured components from a pre-exposure three-dimensional (3D) depiction of a first sample of the manufactured component, and forming a post-exposure statistical distribution of measured coordinates describing the set of manufactured components from a post-exposure 3D depiction of a second sample of the manufactured component; calculating a difference between parameters of the pre-exposure statistical distribution and the parameters of the post-exposure statistical distribution; and adjusting an expected deformation model for the set of manufactured components based upon the difference between the parameters of the pre-exposure statistical distribution and the post-exposure statistical distribution, to model the deformation of the manufactured component. 
     A second aspect of the disclosure includes a computer program product having program code, which when executed by at least one computing device, causes the at least one computing device to model deformation in a set of manufactured components, by performing actions including: forming a pre-exposure statistical distribution of measured coordinates describing the set of manufactured components from a pre-exposure three-dimensional (3D) depiction of a first sample of the manufactured component, and forming a post-exposure statistical distribution of measured coordinates describing the set of manufactured components from a post-exposure 3D depiction of a second sample of the manufactured component; calculating a difference between parameters of the pre-exposure statistical distribution and parameters of the post-exposure statistical distribution; and adjusting an expected deformation model for the set of manufactured components based upon the difference between the parameters of the pre-exposure statistical distribution and the post-exposure statistical distribution, to model the deformation of the manufactured component. 
     A third aspect of the disclosure includes a system having: at least one computing device configured to model deformation in a set of manufactured components by performing actions including: forming a pre-exposure statistical distribution of measured coordinates describing the set of manufactured components from a pre-exposure three-dimensional (3D) depiction of a sample of the manufactured component, and forming a post-exposure statistical distribution of measured coordinates describing the set of manufactured components from a post-exposure 3D depiction of the same sample of the manufactured component; calculating a difference between parameters of the pre-exposure statistical distribution and parameters of the post-exposure statistical distribution; and adjusting an expected deformation model for the set of manufactured components based upon the difference between the parameters of the pre-exposure statistical distribution and the post-exposure statistical distribution, to model the deformation of the manufactured component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features of this invention will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings that depict various embodiments of the invention, in which: 
         FIG. 1  shows a schematic depiction of a system according to various embodiments of the disclosure. 
         FIG. 2  shows a flow diagram illustrating a method performed according to particular embodiments of the disclosure. 
         FIG. 3  shows an example statistical distribution illustrating example parameters according to various embodiments of the disclosure. 
         FIG. 4  shows an example aging parameter graph including an example fitted model, formed according to various embodiments of the disclosure. 
         FIG. 5  shows a flow diagram illustrating an additional method according to various embodiments. 
     
    
    
     It is noted that the drawings of the invention are not necessarily to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings. 
     DETAILED DESCRIPTION 
     As indicated above, the subject matter disclosed herein relates to modeling and analyzing manufactured components. More particularly, the subject matter disclosed herein relates to modeling and analyzing deformation in a manufactured part, e.g., a combustion component, excluding part-to-part variation about that component. 
     In contrast to conventional approaches, various embodiments of the disclosure include methods, systems and computer program products for effectively modeling areas of deformation in a component, while minimizing errors due to part-to-part new make variation. Approaches according to various embodiments of the disclosure can be used to model deformation in a component, such as a combustion component (e.g., in a gas turbomachine). However, these approaches can be applied to any number of manufactured components according to various embodiments. In some cases, these approaches may be used to model creep in a manufactured component. 
     As is known in the art of material science, when a solid material is placed under mechanical stress, over time, that material may have a tendency to slowly move, and even deform permanently, due to that stress. In some cases, the stress applied can be below the yield strength of the material, but due to prolonged exposure, the material may nonetheless deform. This deformation is known in the art as creep. Creep is one form of deformation that may be detected using one or more approaches described according to embodiments of the disclosure. 
     In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific example embodiments in which the present teachings may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present teachings and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present teachings. 
       FIG. 1  shows a schematic depiction of a system  100  according to various embodiments. System  100  can include a computer system  102 , including at least one computing device  126 , and a measurement system  150  coupled (e.g., wirelessly and/or via hard-wired means) with computing device(s)  126  for communicating measured data (three-dimensional (3D) depictions)  160  about a set of manufactured components  170 . In various embodiments, measurement system  150  can include a camera system, such as a conventional blue-light camera configured to capture a 3D depiction of manufactured component  170 , however a camera system can include any conventional camera or optical device capable of capturing 3D measurement data  160  (e.g., 3D image data and/or 3D coordinate data) about manufactured component  170 . In some other cases, measurement system  150  can include a tactile measurement system such as a CMM (coordinate measurement machine). Manufactured component  170  can include any component capable of manufacture, for example, a gas turbomachine component such as a blade, nozzle, shroud, etc., or other component(s) manufactured by casting, forging, and/or additive manufacturing. In various embodiments, the set of manufactured components  170  can include one or more manufactured components  170 , e.g., a batch of manufactured components. 
       FIG. 2  shows a flow chart illustrating a method according to various embodiments of the disclosure. The flow chart is referred to simultaneously with the system diagram of  FIG. 1  and the graphical depictions in  FIGS. 3 and 4 . In various embodiments, processes can include: 
     Process P 1 A (optional pre-process): obtaining (e.g., at deformation modeling system  104 ) a pre-exposure three-dimensional (3D) depiction (pre-exposure measured data  160   a ) of a first sample (e.g., sample A) of manufactured component  170 , and a post-exposure 3D depiction (post-exposure measured data  160   b ) of a second sample (e.g., sample B) of manufactured component  170 . In various embodiments, the first sample (sample A) can include one or more samples of manufactured component  170 , which can include a plurality of samples having, e.g., the same serial number, or in some cases, the first sample can be a statistical distribution of a set (one or more) of samples. Similarly, the second sample (Sample B) can include one or more samples of manufactured component  170 , which can include a plurality of samples having, e.g., the same serial number, or in some cases, the first sample can be a statistical distribution of a set (one or more) of samples. According to various embodiments, measured data  160  (in part or in whole), including pre-exposure measured data  160   a  and post-exposure measured data  160   b , can be obtained from measurement system (e.g., camera and/or CMM)  150 , either directly, or indirectly, via one or more data stores, databases, etc. (e.g., storage component  106 ). Further, in some cases, deformation modeling system  104  can obtain measured data  160  from a user  112  and/or a third party, either directly or indirectly, or may obtain stored data from storage component  106 . It is understood that measured data  160  can be obtained by any conventional means. In various embodiments, first sample (sample A) of manufactured component  170  is a distinct sample from second sample (sample B) of manufactured component  170 . That is, first sample may be a substantially similar sample of component  170  as second sample, e.g., formed from a same manufacturing batch of components  170  or distinct batches formed from a common underlying model (e.g., model  180 , including a common nominal shape model  182 ). However, it is understood that first sample (e.g., sample A) and second sample (e.g., sample B) are not the same physical component, and in the case that first sample and second sample represent statistical distributions of a set of samples, the underlying samples representing those distributions are distinct. In various embodiments, the pre-exposure measured data  160   a  and post-exposure measured data  160   b  is captured by measurement system  150 , e.g., on demand or in advance. As used herein, exposure is equivalent to at least some usage of component  170  in its intended environment. For example, a combustion component is deployed when it is placed into use in a combustion environment, an automobile component is deployed when it is placed in an automobile that runs for at least some period, etc. It is understood that according to various embodiments, process P 1 A need not be performed actively, as measured data  160  may already be obtained, stored or otherwise available to deformation modeling system  104  for analysis as described herein. 
     Process P 1 : forming a pre-exposure statistical distribution of measured coordinates (coordinate distribution data  175 ) describing manufactured component  170  from the pre-exposure 3D depiction (pre-exposure measured data  160   a ) and a post-exposure statistical distribution of the measured coordinates (coordinate distribution data  175 ) describing manufactured component  170  from the post-exposure 3D depiction (post-exposure measured data  160   b ). The pre-exposure statistical distribution (a first part of distribution data  175 ) and post-exposure statistical distribution (a second part of distribution data  175 ) are both of a common distribution type. For example, both statistical distributions (pre and post-exposure) can include at least one of: a least sums distribution, a normal distribution, a binomial distribution, a lognormal distribution, a Poisson distribution, etc. However, both distributions have a common type so that the distribution parameters from the pre and post-exposure match one another. 
     Process P 2 : calculating a difference between parameters the pre-exposure statistical distribution of coordinates (coordinate distribution data  175 ) and the post-exposure statistical distribution of coordinates (coordinate distribution data  175 ). In various embodiments, this process includes calculating a difference in parameters in each statistical distribution, e.g., average measurements of exposed set minus average measurement of pre-exposure set, standard deviation of exposed set minus standard deviation of pre-exposure set, etc.  FIG. 3  shows an example statistical distribution illustrating example parameters, while  FIG. 4  shows an example aging parameter graph including an example fitted model, formed according to various embodiments. As shown,  FIG. 3  illustrates a statistical distribution fit for a pre-exposure set of data as compared with a statistical distribution fit for data representing an exposed component.  FIG. 4  illustrates example statistical parameters, for an exposed component (exposed set) and a pre-exposure component (pre-exposure set), along with a fitted model (e.g., polynomial) for the two parameters (pre and post-exposure). 
     Process P 3 : adjusting an expected deformation model  184  for the set of manufactured components  170  based upon the difference (process P 2 ) between the pre-exposure statistical distribution of coordinates and the post-exposure statistical distribution of coordinates (coordinate distribution data  175 ). In various embodiments, expected deformation model  184  is derived from a nominal shape model  182 , which are both part of a model  180  of manufactured component(s)  170 . Nominal shape model  182  can indicate nominal coordinates of manufactured component(s)  170  prior to operational exposure, and expected deformation model  184  can indicate expected deformation of manufactured component(s)  170  due to exposure. Nominal shape model  182  can include 3D coordinates for manufactured component(s)  170 , and can include a data file used to form manufactured component(s)  170 , for example, a data file used to form a mold or cast into which a material (e.g., metal, composite, etc.) is poured to form manufactured component(s)  170 , and/or a data file used to instruct an additive manufacturing system in forming manufactured component(s)  170 . In various embodiments, nominal shape model  182  includes a data model of a desired version of manufactured component(s)  170  or a pre-exposure three-dimensional (3D) depiction of a model sample of manufactured component(s)  170 . In various embodiments, expected deformation model  184  indicates an expected deformation of manufactured component(s)  170 , over a period, due to exposure in operation. Expected deformation model  184  can include, for example, a data file indicating deformation (e.g., creep, strain, material fatigue) of one or more locations within manufactured component(s)  170  due to operational exposure (e.g., due to heating, cooling, moisture, etc.). Expected deformation model  184  can be customizable to particular operational conditions, with variables such as length of operation, temperature, moisture level, revolutions per period, etc. While nominal shape model  182  can indicate a nominal (e.g., ideal) manufactured version of a component, expected deformation model  184  can indicate how that nominal manufactured version of the component will deform over a period under particular conditions. 
       FIG. 5  shows a flow diagram illustrating an additional method according to various embodiments. Some processes in this method may be similar to those described with respect to processes P 1 -P 4  in  FIG. 2 , however, in contrast to the method described with respect to  FIG. 2 , this methodology involves measuring a same physical part (e.g., Sample A) of manufactured component  170  both before and after exposure. This method can include: 
     Process P 101 A: obtaining a pre-exposure three-dimensional (3D) depiction (pre-exposure measured data  160   a ) of a sample (e.g., sample A) of manufactured component(s)  170 , and a post-exposure 3D depiction (post-exposure measured data  160   b ) of the same sample (e.g., sample A) of manufactured component(s)  170 . It is understood that sample (e.g., sample A) in pre-exposure measured data  160   a  and post-exposure measured data  160   b  are the same physical component, set of physical components, or statistical sample of an underlying common set of physical components. In various embodiments, the pre-exposure measured data  160   a  and post-exposure measured data  160   b  is captured by measurement system  150 , e.g., on demand or in advance. 
     Process P 101 : forming a pre-exposure statistical distribution of coordinates (coordinate distribution data  175 ) describing manufactured component(s)  170  from the pre-exposure 3D depiction (pre-exposure measured data  160   a ) and a post-exposure statistical distribution of coordinates (coordinate distribution data  175 ) describing manufactured component(s)  170  from the post-exposure 3D depiction (post-exposure measured data  160   b ). The pre-exposure statistical distribution (a first part of distribution data  175 ) and post-exposure statistical distribution (a second part of distribution data  175 ) are both of a common distribution type. 
     Process P 102 : calculating a difference between parameters of the pre-exposure statistical distribution of coordinates (coordinate distribution data  175 ) and the post-exposure statistical distribution of coordinates (coordinate distribution data  175 ) for the manufactured component(s)  170 . This process may be performed in a substantially similar manner as process P 3  in  FIG. 2 . 
     Process P 103 : adjusting expected deformation model  184  for manufactured component(s)  170  based upon the difference (process P 3 ) between the parameters of the pre-exposure statistical distribution of coordinates and the post-exposure statistical distribution of coordinates. This process may be performed in a substantially similar manner as process P 3  in  FIG. 2 . 
     It is understood that processes P 1 A-P 3  and/or processes P 101 A-P 0103 , can be iterated on a periodic, or constant basis. Further, processes P 1 -P 4  and/or processes P 101 A-P 0103  can be performed in any order, and particular processes may be omitted in various embodiments. Additionally, processes P 1 A-P 3  and/or processes P 101 A-P 0103  can be performed on any number of manufactured components  170 , 
     It is understood that in the flow diagrams shown and described herein, other processes may be performed while not being shown, and the order of processes can be rearranged according to various embodiments. Additionally, intermediate processes may be performed between one or more described processes. The flow of processes shown and described herein is not to be construed as limiting of the various embodiments. 
     Returning to  FIG. 1 , system is shown including deformation modeling system  104 , for performing the functions described herein according to various embodiments of the invention. To this extent, the system  100  includes computer system  102  that can perform one or more processes described herein in order to model deformation in a manufactured component  170 . In particular, computer system  102  is shown as including the deformation modeling system  104 , which makes computer system  102  operable to model deformation (if present) in manufactured component  170  by performing any/all of the processes described herein and implementing any/all of the embodiments described herein. 
     The computer system  102  is shown including computing device  126 , which can include a processing component  104  (e.g., one or more processors), a storage component  106  (e.g., a storage hierarchy), an input/output (I/O) component  108  (e.g., one or more I/O interfaces and/or devices), and a communications pathway  110 . In general, the processing component  104  executes program code, such as the deformation modeling system  104 , which is at least partially fixed in the storage component  106 . While executing program code, the processing component  104  can process data, which can result in reading and/or writing transformed data from/to the storage component  106  and/or the I/O component  108  for further processing. The pathway  110  provides a communications link between each of the components in the computer system  102 . The I/O component  108  can comprise one or more human I/O devices, which enable a user (e.g., a human and/or computerized user)  112  to interact with the computer system  102  and/or one or more communications devices to enable the system user  112  to communicate with the computer system  102  using any type of communications link. To this extent, the deformation modeling system  104  can manage a set of interfaces (e.g., graphical user interface(s), application program interface, etc.) that enable human and/or system users  112  to interact with the deformation modeling system  104 . Further, the deformation modeling system  104  can manage (e.g., store, retrieve, create, manipulate, organize, present, etc.) data, such as measured data  160  (including post-exposure  160   b  and pre-exposure  160   a  measured data of manufactured component  170 ), coordinate distribution data  175 , and/or model data  180  (including nominal shape model (data)  182  and expected deformation model (data)  184 ) using any solution, e.g., via wireless and/or hardwired means. 
     In any event, the computer system  102  can comprise one or more general purpose computing articles of manufacture (e.g., computing devices) capable of executing program code, such as the deformation modeling system  104 , installed thereon. As used herein, it is understood that “program code” means any collection of instructions, in any language, code or notation, that cause a computing device having an information processing capability to perform a particular function either directly or after any combination of the following: (a) conversion to another language, code or notation; (b) reproduction in a different material form; and/or (c) decompression. To this extent, the deformation modeling system  104  can be embodied as any combination of system software and/or application software. It is further understood that the deformation modeling system  104  can be implemented in a cloud-based computing environment, where one or more processes are performed at distinct computing devices (e.g., a plurality of computing devices  126 ), where one or more of those distinct computing devices may contain only some of the components shown and described with respect to the computing device  126  of  FIG. 1 . 
     Further, deformation modeling system  104  can be implemented using a set of modules  132 . In this case, a module  132  can enable the computer system  102  to perform a set of tasks used by the deformation modeling system  104 , and can be separately developed and/or implemented apart from other portions of the deformation modeling system  104 . As used herein, the term “component” means any configuration of hardware, with or without software, which implements the functionality described in conjunction therewith using any solution, while the term “module” means program code that enables the computer system  102  to implement the functionality described in conjunction therewith using any solution. When fixed in a storage component  106  of a computer system  102  that includes a processing component  104 , a module is a substantial portion of a component that implements the functionality. Regardless, it is understood that two or more components, modules, and/or systems may share some/all of their respective hardware and/or software. Further, it is understood that some of the functionality discussed herein may not be implemented or additional functionality may be included as part of the computer system  102 . 
     When the computer system  102  comprises multiple computing devices, each computing device may have only a portion of deformation modeling system  104  fixed thereon (e.g., one or more modules  132 ). However, it is understood that the computer system  102  and deformation modeling system  104  are only representative of various possible equivalent computer systems that may perform a process described herein. To this extent, in other embodiments, the functionality provided by the computer system  102  and deformation modeling system  104  can be at least partially implemented by one or more computing devices that include any combination of general and/or specific purpose hardware with or without program code. In each embodiment, the hardware and program code, if included, can be created using standard engineering and programming techniques, respectively. 
     Regardless, when the computer system  102  includes multiple computing devices  126 , the computing devices can communicate over any type of communications link. Further, while performing a process described herein, the computer system  102  can communicate with one or more other computer systems using any type of communications link. In either case, the communications link can comprise any combination of various types of wired and/or wireless links; comprise any combination of one or more types of networks; and/or utilize any combination of various types of transmission techniques and protocols. 
     While shown and described herein as a method, computer program product and system for model deformation in a manufactured component  170 , it is understood that aspects of the invention further provide various alternative embodiments. For example, in one embodiment, the invention provides a computer program fixed in at least one computer-readable medium, which when executed, enables a computer system to model deformation in a manufactured component  170 . To this extent, the computer-readable medium includes program code, such as the deformation modeling system  104  ( FIG. 1 ), which implements some or all of the processes and/or embodiments described herein. It is understood that the term “computer-readable medium” comprises one or more of any type of tangible medium of expression, now known or later developed, from which a copy of the program code can be perceived, reproduced, or otherwise communicated by a computing device. For example, the computer-readable medium can comprise: one or more portable storage articles of manufacture; one or more memory/storage components of a computing device; paper; etc. 
     In another embodiment, the invention provides a method of providing a copy of program code, such as the deformation modeling system  104  ( FIG. 1 ), which implements some or all of a process described herein. In this case, a computer system can process a copy of program code that implements some or all of a process described herein to generate and transmit, for reception at a second, distinct location, a set of data signals that has one or more of its characteristics set and/or changed in such a manner as to encode a copy of the program code in the set of data signals. Similarly, an embodiment of the invention provides a method of acquiring a copy of program code that implements some or all of a process described herein, which includes a computer system receiving the set of data signals described herein, and translating the set of data signals into a copy of the computer program fixed in at least one computer-readable medium. In either case, the set of data signals can be transmitted/received using any type of communications link. 
     In still another embodiment, the invention provides a method of modeling deformation in a manufactured component  170  ( FIG. 1 ). In this case, a computer system, such as the computer system  102  ( FIG. 1 ), can be obtained (e.g., created, maintained, made available, etc.) and one or more components for performing a process described herein can be obtained (e.g., created, purchased, used, modified, etc.) and deployed to the computer system. To this extent, the exposure can comprise one or more of: (1) installing program code on a computing device; (2) adding one or more computing and/or I/O devices to the computer system; (3) incorporating and/or modifying the computer system to enable it to perform a process described herein; etc. 
     In any case, the technical effect of the various embodiments of the disclosure, including, e.g., deformation modeling system  104 , is to model deformation in a manufactured component (e.g., component  170 ). It is understood that according to various embodiments, deformation modeling system  104  could be implemented to model deformation in a plurality of manufactured components, such as manufactured component(s)  170  described herein. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.