Patent Description:
Vacuum furnaces may often be used in repair processes for aerospace components and assemblies, such as brazing, heat treatment vacuum cleaning, annealing, and sintering. Components to be process may be loaded into baskets, and stacked in the furnace to maximize loading capacity prior to the repair process. After the repair process within a respective vacuum furnace, the baskets may be removed from the furnace and inspected. Information regarding location and placement of the respective components and baskets may be lost after removal from the vacuum furnace.

<CIT> discloses plate stacking equipment and a sintering production line, wherein the plate stacking equipment comprises a rack, a first conveying mechanism, a second conveying mechanism a plate stacking mechanism and a visual detection mechanism.

According to an aspect of the invention, there is provided a method of generating a loaded layout in a vacuum furnace corresponding to an actual layout in the vacuum furnace during operation of the vacuum furnace as claimed in claim <NUM>.

The method may further comprise storing, via the processor, the loaded layout for a batch load in the furnace for at least one of traceability, root cause analysis, or quality investigations. The visual data may include a visual image for each row of components disposed in the vacuum furnace. The visual data may be video data.

In various embodiments, the method may further comprise: capturing the visual data of the vacuum furnace, the first row of components may be disposed on a loading stand and the second row of components may be disposed on the loading stand in the vacuum furnace, the loading stand may be configured to be placed in the vacuum furnace; and the loaded layout may further include images of one or more baskets disposed in a location of the vacuum furnace corresponding to an actual location of the respective basket in the vacuum furnace during operation of the vacuum furnace, each basket has one or more components disposed therein.

In various embodiments, capturing the visual data may be captured via a camera. The first image and the second image may be captured as still images. The first row of components may include a first basket with a first set of components and a second basket with a second set of components. The first set of components may be different from the second set of components.

According to a further aspect of the invention, there is provided a control system for vacuum furnace post processing as claimed in claim <NUM>.

In various embodiments, arranging the visual data into the loaded layout may be in response to comparing the visual data to the predetermined maximum capacity layout. The control system may further comprise a plurality of cameras, the plurality of cameras including the camera. The controller may further be configured to generate a three-dimensional image for the loaded layout. The plurality of baskets may include a first row of baskets and a second row of baskets, the first row of baskets disposed between the loading stand and the second row of baskets.

A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures.

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosures, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein.

The scope of the disclosure is defined by the appended claims and their legal equivalents rather than by merely the examples described. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Also, any reference to attached, fixed, coupled, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

Disclosed herein are systems and methods for vacuum furnace post-processing. In particular, the system may include a controller in operable communication with a camera. A "camera" as disclosed herein refers to a device for recording visual images in the forms of photographs, film or video signals. In various embodiments, a lens of the camera is aligned into a vacuum furnace for an aircraft repair process (i.e., brazing, heat treatment, vacuum cleaning, annealing, sintering, etc.). In various embodiments, the controller is configured to receive visual data from the camera. In various embodiments, visual data may correspond to various images captured during a loading process (i.e., loading a plurality of components into the vacuum furnace). In various embodiments, the controller is further configured to arrange the visual data captured and match the visual data to an arrangement of the plurality of components within the vacuum furnace after loading. In other words, the controller may arrange the visual data and send an arranged image to a display device. In various embodiments, the arranged image corresponds to a <NUM>-dimensional image (<NUM>-D) or a <NUM>-dimensional (<NUM>-D) image of the plurality of components as they were loaded in the vacuum furnace. In various embodiments, the <NUM>-D or <NUM>-D output by the controller may comprise a loaded layout within the furnace. In this regard, whether a component was disposed proximate a front, rear, bottom, top, or middle of the vacuum furnace may be determined from the loaded layout.

In various embodiments, the systems and methods disclosed herein may provide visual records of components loaded within a vacuum furnace, in accordance with various embodiments. In various embodiments, the loaded layout may allow visualization and referencing of a position in which components or baskets are loaded in the vacuum furnace. In various embodiments, the systems and methods may further allow better traceability during post-processing root cause analysis, quality investigations or the like.

Referring now to <FIG>, a schematic view of a control system <NUM> for vacuum furnace post-processing is illustrated, in accordance with various embodiments. The control system <NUM> includes a controller <NUM>, memory <NUM> (e.g., a database or any appropriate data structure; hereafter "memory <NUM>" also may be referred to as "database <NUM>"), and a camera <NUM>. The controller <NUM> may include one or more logic devices such as one or more of a central processing unit (CPU), an accelerated processing unit (APU), a digital signal processor (DSP), a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), or the like (e.g., controller <NUM> may utilize one or more processors of any appropriate type/configuration, may utilize any appropriate processing architecture, or both). In various embodiments, the controller <NUM> may further include any non-transitory memory known in the art. The memory <NUM> may store instructions usable by the logic device to perform operations. Any appropriate computer-readable type/configuration may be utilized as the memory <NUM>, any appropriate data storage architecture may be utilized by the memory <NUM>, or both.

The database <NUM> may be integral to the control system <NUM> or may be located remote from the control system <NUM>. The controller <NUM> may communicate with the database <NUM> via any wired or wireless protocol. In that regard, the controller <NUM> may access data stored in the database <NUM>. The database <NUM> may be configured to store images (i.e., 2D or 3D images) of loaded layouts for vacuum furnace post-processing as described further herein.

In various embodiments, the camera <NUM> may be in operable communication with the controller <NUM>. For example, the camera <NUM> may be operably coupled to the camera <NUM> via a network, a router, an electrical cable, or the like. In various embodiments, the camera <NUM> is configured to obtain visual data during loading of a vacuum process, as described further herein. In various embodiments, a user may manually operate the camera <NUM>, or automatically through the controller <NUM>. In various embodiments, the controller <NUM> may be operated through at least one other controller that is separate and distinct from controller <NUM>. In various embodiments, the camera <NUM> may be coupled to controller <NUM> after the fact (e.g., post-processing).

In various embodiments, the camera <NUM> may be positioned vertically above a loading stand within a furnace as described further herein. In various embodiments, the control system <NUM> may include a plurality of the camera <NUM>. In this regard, visual data may be obtained from each camera <NUM> in a plurality of cameras <NUM>. In various embodiments, the controller <NUM> may be configured to receive the visual data and send a loaded layout (e.g., a 2D or 3D image) of a respective loaded vacuum furnace to be used for post processing, as described further herein.

In various embodiments, the control system <NUM> may further comprise a display device <NUM> in operable communication with the controller <NUM>. A display device <NUM> may comprise a phone, a tablet, an iPad®, a laptop, a monitor, and/or any other suitable electronic device. In various embodiments, a display device <NUM> may comprise an iPhone®, a Blackberry®, a device running an Android® operating system, a Nokia® phone, a Windows® phone, and/or any other data access and/or telephony device.

Referring now to <FIG>, a first step in a vacuum furnace loading process is illustrated, in accordance with various embodiments. In various embodiments, a vacuum furnace <NUM> may be in accordance with any vacuum furnace known in the art. For example, vacuum furnace <NUM> may comprise a vacuum vessel, a hot zone, a pumping system, a cooling system, a control system (e.g., temperature and vacuum), and/or a handling system. In various embodiments, vacuum furnace <NUM> is a vertically loaded vacuum furnace. Although illustrated as a vertically loaded vacuum furnace, the present disclosure is not limited in this regard. For example, the vacuum furnace may be a horizonal loaded vacuum furnace in accordance with various embodiments. In various embodiments, the loading stand <NUM> may be inside the vacuum furnace <NUM> during loading or outside the vacuum furnace <NUM> during loading. The present disclosure is not limited in this regard. For example, the various components may be loaded onto the loading stand <NUM> outside of the vacuum furnace <NUM> and then the loading stand <NUM> is placed in the vacuum furnace <NUM> thereafter.

In various embodiments, camera(s) <NUM> may have a line of sight to a loading stand <NUM> disposed within a housing <NUM> of the vacuum furnace <NUM>. For example, camera(s) <NUM> may be mounted adjacent to a door to the housing, the camera(s) <NUM> may be placed within the furnace during loading (e.g., via a mounting mechanism, a tripod, etc.) and removed prior to operation, the camera(s) <NUM> may be held and operated by a user during loading, or the like.

During loading of a vacuum furnace <NUM>, visual data is obtained by the camera <NUM> throughout the loading process. For example, in response to a first row of components <NUM> being loaded (e.g., a first basket of components <NUM> and a second basket of components <NUM> as shown in <FIG>), camera(s) <NUM> may capture a first visual image. Similarly, in response to a second row of components <NUM> being loaded (e.g., a third basket of components <NUM> and a fourth basket of components <NUM> as shown in <FIG>), camera(s) <NUM> may capture a second visual image. Additionally, in various embodiments, in response to a third row of components <NUM> (e.g., fifth basket <NUM> as shown in <FIG>), camera(s) <NUM> may capture a third visual image.

In various embodiments, a visual image may be captured by camera(s) <NUM> manually by a user or automatically by detecting a row of components being loaded, a basket of components being loaded, or the like. For example, in various embodiments, the system <NUM> from <FIG> may further comprise a sensor configured to detect when a row of components and/or a basket of components has been loaded on the loading stand <NUM>, in accordance with various embodiments. For example, a sensor could include a radio frequency identification (RFID) reader and each basket (e.g., baskets <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc.) may comprise an RFID tag (although any appropriate data storage device/reader may be utilized). Thus, in response to an RFID reader sensing an RFID tag, the camera(s) <NUM> may capture a visual image of the basket on the loading stand during loading, or the like. In various embodiments, the sensor could comprise a weight sensor on the loading stand <NUM> configured to send a signal to the camera to take a picture in response to a weight detected by the sensor increasing. In various embodiments, a visual image may be delayed in response to a change in weight being detected (e.g., <NUM> seconds, <NUM> seconds, or the like).

Referring now to <FIG>, a method <NUM> of producing a loaded layout of components (or baskets of components) is illustrated, in accordance with various embodiments. In various embodiments, the method <NUM> comprises receiving, via a processor, visual data from a camera (step <NUM>). In various embodiments, the visual data may be received from a single camera or a plurality of cameras. In various embodiments, the visual data may include a visual image of each row of components disposed in a vacuum furnace, as illustrated in <FIG>. The visual data includes a first image showing a first row of components (e.g., first row of components <NUM> from <FIG>), a second image showing a second row of components (e.g., second row of components <NUM> from <FIG>), and may include a third image showing a third row of components (e.g., third row of components <NUM> from <FIG>). In various embodiments, the visual data may be video data. In this regard, the loading process (e.g., <FIG>) may be captured via video by the camera(s) (e.g., camera(s) <NUM> from <FIG>).

The method <NUM> may further comprise comparing, via the processor, the visual data to a predetermined maximum capacity layout (step <NUM>). In various embodiments, components being repaired for gas turbine engines as described herein may be placed in containers, baskets, or some type of component configured to at least partially house the component being repaired within the vacuum furnace. For example, a basket may be configured to at least partially house a first set of components (e.g., baskets <NUM>, <NUM>, <NUM>, <NUM>, <NUM> from <FIG>). In various embodiments, a predetermined maximum capacity layout comprises X number of baskets wide, by Y number of baskets long by Z number of baskets high. For example, a predetermined maximum capacity layout may comprise two baskets wide by one basket long by three baskets high for vacuum furnace <NUM> from <FIG>, in various embodiments. Although described as having a specific size, the present disclosure is not limited in this regard. For example, various predetermined maximum capacity layout sizes are within the scope of this disclosure, which is determined by the appended claims.

In various embodiments, the method <NUM> further comprises arranging, via the processor, the visual data into a loaded layout in response to comparing the visual data (step <NUM>). In various embodiments, the loaded layout may match an actual layout of the components within the vacuum furnace (i.e., during operation of the vacuum furnace <NUM> from <FIG>). In various embodiments, in response to an actual layout having less baskets relative to the predetermined maximum capacity layout, the loaded layout may show a placeholder image, or the like, where a basket was missing in the actual layout of the vacuum furnace.

In embodiments, the method <NUM> further comprises sending, via the processor, the loaded layout to a display device (step <NUM>). In this regard, the method <NUM> allows visualization by a user looking to post-process a batch in a vacuum furnace when root cause analysis, quality investigations, or the like are desired.

In various embodiments, the loaded layout produced from method <NUM> may allow visualization and referencing of a position in which components or baskets are loaded in the vacuum furnace. In various embodiments, the method <NUM> may further allow better traceability during post-processing root cause analysis, quality investigations or the like.

Referring now to <FIG>, a display device <NUM> displaying the loaded layout <NUM> from loading a vacuum furnace as illustrated in <FIG> and sent to the display device <NUM> via the processor in step <NUM> of method <NUM> is illustrated, in accordance with various embodiments. In various embodiments, the display device <NUM> may display the loaded layout <NUM> produced in step <NUM> and the loaded layout <NUM> may be sent in step <NUM> of method <NUM>. The loaded layout <NUM> may include images of each basket (e.g., baskets <NUM>, <NUM>, <NUM>, <NUM>) disposed in a location of the vacuum furnace corresponding to an actual location of the respective basket in the vacuum furnace during operation of the vacuum furnace. In various embodiments, each basket may have a component (e.g., component <NUM>), or a set of components (e.g. sets of components <NUM>, <NUM>, <NUM>, <NUM>) disposed therein. As described with respect to step <NUM> for method <NUM>, as actual loaded capacity was less than a maximum loaded capacity, a placeholder image <NUM> may be disposed where a sixth basket may have been placed, in accordance with various embodiments. In various embodiments, the components disposed in the various baskets may be all the same components, all different components, or anywhere in between. The present disclosure is not limited in this regard. Although illustrated as a <NUM>-D image in <FIG>, the present disclosure is not limited in this regard. For example, by using multiple cameras, as described previously herein, a <NUM>-D layout could be generated in accordance with the method <NUM> from <FIG> and/or the control system <NUM> from <FIG>, in accordance with various embodiments.

In various embodiments, the loaded layout <NUM> produced from method <NUM> may allow visualization and referencing of a position in which components or baskets are loaded in the vacuum furnace. In various embodiments, the loaded layout <NUM> may further allow better traceability during post-processing root cause analysis, quality investigations or the like.

However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosures. The scope of the disclosures is accordingly to be limited by nothing other than the appended claims and their legal equivalents, in which reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more.

In the detailed description herein, references to "various embodiments", "one embodiment", "an embodiment", "an example embodiment", etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.

Claim 1:
A method (<NUM>) of generating a loaded layout (<NUM>) in a vacuum furnace (<NUM>) corresponding to an actual layout in the vacuum furnace during operation of the vacuum furnace, the method comprising:
receiving, via a processor, a visual data of the vacuum furnace from a camera (<NUM>), the visual data including a first image showing a first row of components (<NUM>) and a second image showing a second row of components (<NUM>);
comparing, via the processor, the first image and the second image of the visual data to a predetermined maximum capacity layout for the vacuum furnace, the predetermined maximum capacity layout including X number of baskets (<NUM>; <NUM>; <NUM>; <NUM>; <NUM>) wide by Y number of baskets long by Z number of baskets high; and
arranging, via the processor, the visual data into the loaded layout in response to comparing the visual data, wherein the loaded layout includes a two-dimensional image or a three-dimensional image, and wherein the loaded layout includes a placeholder image (<NUM>) where a basket was missing in the actual layout in the vacuum furnace; and
sending, via the processor, the loaded layout (<NUM>) to a display device (<NUM>) for at least one of traceability, root cause analysis, or quality investigations.