Patent Publication Number: US-2018052946-A1

Title: Component deformation detection system, computer program product and related methods

Description:
TECHNICAL FIELD 
     The subject matter disclosed herein relates to analyzing manufactured components. More particularly, the subject matter disclosed herein relates to detecting deformation in a manufactured part, e.g., a turbomachine component such as a gas turbine component, using localized data 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 rotating systems such as turbomachines (e.g., gas turbines), require taking measurements of reference components within the system (e.g., a centerline of a gas turbine or other datum structures) and also accounting for manufacturing process capability in order to develop significant comparisons. These approaches can be time consuming, costly, and inaccurate. 
     BRIEF DESCRIPTION 
     Various embodiments of the disclosure include systems, methods and computer program products for detecting deformation in a manufactured component. In some cases, a system includes: at least one computing device configured to detect dimensional information (e.g., deformation information) about a manufactured component by: obtaining a post-deployment three-dimensional (3D) depiction of the manufactured component; obtaining a model of the manufactured component including: a nominal shape model indicating a nominal shape of the manufactured component prior to operational deployment, and an expected deformation model indicating expected deformation of the manufactured component after operational deployment; aligning a localized region of the manufactured component in the post-deployment 3D depiction with the localized region of the manufactured component in the nominal shape model; identifying a first set of points in the localized region not subject to deformation between the post-deployment 3D depiction and the nominal shape model; and identifying a second set of points in the localized region subject to deformation between the post-deployment 3D depiction and the nominal shape model. 
     A first aspect of the disclosure includes a system having: at least one computing device configured to detect dimensional information about a manufactured component by: obtaining a post-deployment three-dimensional (3D) depiction of the manufactured component; obtaining a model of the manufactured component including: a nominal shape model indicating a nominal shape of the manufactured component prior to operational deployment, and an expected deformation model indicating expected deformation of the manufactured component after operational deployment; aligning a localized region of the manufactured component in the post-deployment 3D depiction with the localized region of the manufactured component in the nominal shape model; identifying a first set of points in the localized region not subject to deformation between the post-deployment 3D depiction and the nominal shape model; and identifying a second set of points in the localized region subject to deformation between the post-deployment 3D depiction and the nominal shape model. 
     A second aspect of the disclosure includes a system having: a measurement system, for capturing a post-deployment three-dimensional (3D) depiction of a manufactured component; and at least one computing device coupled with the measurement system and configured to detect dimensional information (e.g., deformation information) about the manufactured component, by performing actions including: obtaining a model of the manufactured component including: a nominal shape model indicating a nominal shape of the manufactured component prior to operational deployment, and an expected deformation model indicating expected deformation of the manufactured component after operational deployment; aligning a localized region of the manufactured component in the post-deployment 3D depiction with the localized region of the manufactured component in the nominal shape model; identifying a first set of points in the localized region not subject to deformation between the post-deployment 3D depiction and the nominal shape model; and identifying a second set of points in the localized region subject to deformation between the post-deployment 3D depiction and the nominal shape model. 
     A third 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 detect dimensional information (e.g., deformation information) about a manufactured component, by performing actions including: obtaining a post-deployment three-dimensional (3D) depiction of the manufactured component after operational deployment; obtaining a model of the manufactured component including: a nominal shape model indicating a nominal shape of the manufactured component prior to operational deployment, and an expected deformation model indicating expected deformation of the manufactured component after operational deployment; aligning a localized region of the manufactured component in the post-deployment 3D depiction with the localized region of the manufactured component in the nominal shape model; identifying a first set of points in the localized region not subject to deformation between the post-deployment 3D depiction and the nominal shape model; and identifying a second set of points in the localized region subject to deformation between the post-deployment 3D depiction and the nominal shape model. 
    
    
     
       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 a schematic depiction of a manufactured component according to various embodiments of the disclosure. 
         FIG. 4  shows a close-up view of a localized region of the manufactured component of  FIG. 3 . 
     
    
    
     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 analyzing manufactured components. More particularly, the subject matter disclosed herein relates to detecting deformation of a manufactured part, e.g., a turbomachine component such as a gas turbine component, using localized data about that component. 
     In contrast to conventional approaches, various embodiments of the disclosure include methods, systems and computer program products for effectively isolating areas of deformation in a component, while not requiring dimensional stack-up information relative to predefined datum structures. Approaches according to various embodiments of the disclosure can be used to detect deformation and/or predict deformation in a component, such as a rotating 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 detect and/or predict creep in a manufactured component. 
     As is known in the art of material science, when a solid material is placed under mechanical stress and elevated temperature, 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 manufactured component  170 . In various embodiments, measurement system  150  can include a vision system and/or a tactile measurement system, such as a coordinate measurement machine (CMM), capable of collecting 3D depictions (measured data  160 ) about component  170 . In some cases, measurement system  150  can include a camera system, e.g., a conventional blue-light camera system configured to capture a 3D depiction of manufactured component  170 . In some cases, measurement system  150  can include at least one camera, but may include a plurality of cameras in various embodiments. Manufactured component  170  can include any component capable of manufacture, for example, a combustion component such as a gas turbomachine blade, nozzle, shroud, vane, etc., or other component(s) manufactured by casting, forging, and/or additive manufacturing. 
       FIG. 2  shows a flow chart illustrating a method according to various embodiments of the disclosure.  FIG. 3  shows a schematic depiction of manufactured component  170  illustrating various aspects of the disclosure. The flow chart is referred to simultaneously with the system diagram of  FIG. 1  and the schematic depiction of manufactured component  170 . In various embodiments, processes can include: 
     Process P 1 : obtaining a post-deployment three-dimensional (3D) depiction (image data  160 ) of manufactured component  170 . In various embodiments, the post-deployment 3D depiction  160  is captured by measurement system  150 , e.g., on demand or in advance. As used herein, deployment 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. 
     Process P 2 : obtaining a model  180  of manufactured component  170  including: a nominal shape model  182  indicating a nominal shape of manufactured component  170  prior to operational deployment, and an expected deformation model  184  indicating expected deformation of manufactured component  170  after operational deployment. Nominal shape model  182  can include 3D coordinates for manufactured component  170 , and can include a data file used to form manufactured component  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  170 , and/or a data file used to instruct an additive manufacturing system in forming manufactured component  170 . In various embodiments, expected deformation model  184  indicates an expected deformation of manufactured component  170 , over a period, due to deployment 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  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. 
     Process P 3 : aligning a localized region  190  ( FIGS. 3, 4 ) of manufactured component  170  in the post-deployment 3D depiction  160  with the localized region  190  of manufactured component  170  in nominal shape model  182 . In various embodiments, this can include using a conventional best fit alignment process (e.g., least sums fit, or other statistical distribution fit) to align data points representing localized region  190  in post-deployment 3D depiction  160  and nominal shape model  182 . An example of this best fit approach is illustrated in  FIG. 3 , where best fit surfaces  200  are illustrated along with post-deployment 3D depiction  160  (representing actual shape of component  170  after deployment) and nominal shape model  182 . In other embodiments, the best fit alignment process can include using a best fit of points (e.g., data points in localized region  190 ) and/or alignment of those points to certain feature (e.g., local features) in the nominal shape model  182 .  FIG. 4  shows a close-up view of localized region  190 , which illustrates the distinction between post-deployment 3D depiction  160  and nominal shape model  182 . In various embodiments, localized region  190  is selected based upon a common manufacturing process used to manufacture a portion of component  170 . In some cases, the common manufacturing process can include at least one of casting, forging or 3D printing. Selecting localized region  190  with a common (e.g., uniform) manufacturing process across its data points allows for comparison of deformation in particular areas of localized region  190  while controlling for a significant variable (manufacturing process). In various embodiments, the common manufacturing process includes at least one of casting, forging or 3D printing. 
     Process P 4 : identifying a first set of points  210  in localized region  190  not subject to deformation between post-deployment 3D depiction  160  and nominal shape model  182 . In this case, first set of points  210  can be a single data point or set of a plurality of data points that does not exhibit significant deformation in the post-deployment 3D depiction  160  as compared with nominal shape model  182 . This first set of points  210  can exhibit a deformation small enough so as to distinguish itself from a greater-deformed set of points (e.g., second set of points  220 ) relative to its original nominal shape, due to deployment, e.g., where in some example embodiments, second set of points  220  exhibits deformation of an order of magnitude greater than first set of points  210 . 
     Process P 5 : identifying a second set of points  220  in localized region  190  subject to deformation between post-deployment 3D depiction  160  and nominal shape model  182 . Second set of points  220  can exhibit a deformation of greater than the deformation in first set of points  210 , as noted with respect to process P 4  (e.g., order of magnitude difference or other differentiating factor). According to various embodiments, the difference between the deformation at first set of points  210  and second set of points  220  can provide the localized deformation within region  190 . That is, as shown in  FIG. 4 , where X 2  indicates a substantially non-deformed location at first set of points  210 , X 1  indicates a deformed location at second set of points  220 . 
     In some cases, according to various embodiments, the process can include obtaining a pre-deployment 3D depiction (e.g., image data  160 ) of manufactured component  170  prior to operational deployment. Computing device(s)  126  can further compare pre-deployment 3D depiction (e.g., image data  160 ) of manufactured component  170  with nominal shape model  182  to identify a manufacturing variation in the manufactured component  170 , if such a variation exists. This process may be used to verify that the deformation analysis in processes P 3 -P 5  is valid based upon operational deformation, and not due to manufacturing variation in forming manufactured component  170  prior to operational deployment. 
     It is understood that processes P 1 -P 5 , can be iterated on a periodic, or constant basis. Further, processes P 1 -P 5  can be performed in any order, and particular processes may be omitted in various embodiments. Additionally, processes P 1 -P 5  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 detection 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 detect deformation in a manufactured component  170 . In particular, computer system  102  is shown as including the deformation detection system  104 , which makes computer system  102  operable to detect 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 detection 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 detection 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 detection system  104 . Further, the deformation detection system  104  can manage (e.g., store, retrieve, create, manipulate, organize, present, etc.) data, such as image data  60  (including post-deployment and pre-deployment depictions of manufactured component  170 ), nominal shape model (data)  182  and/or 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 detection 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 detection system  104  can be embodied as any combination of system software and/or application software. It is further understood that the deformation detection 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 detection 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 detection system  104 , and can be separately developed and/or implemented apart from other portions of the deformation detection 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 detection system  104  fixed thereon (e.g., one or more modules  132 ). However, it is understood that the computer system  102  and deformation detection 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 detection 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 detecting 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 detect deformation in a manufactured component  170 , if present. To this extent, the computer-readable medium includes program code, such as the deformation detection 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 detection 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 detecting 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 deployment 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 detection system  104 , is to monitor a manufactured component (e.g., component  170 ), e.g., for potential deformation. It is understood that according to various embodiments, deformation detection system  104  could be implemented to monitor a plurality of manufactured components, such as manufactured component  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.