Patent Description:
Gas turbine engines (such as those used in electrical power generation or used in modern aircraft) typically include a compressor, a combustor section, and a turbine. The compressor and the turbine typically include a series of alternating rotors and stators. A rotor generally comprises a rotor disk and a plurality of blades. The rotor may be an integrally bladed rotor ("IBR") or a mechanically bladed rotor.

The rotor disk and blades in the IBR are one piece (i.e., integral) with the blades spaced around the circumference of the rotor disk. Conventional IBRs may be formed using a variety of technical methods including integral casting, machining from a solid billet, or by welding or bonding the blades to the rotor disk.

<CIT> discloses a system for inspecting surfaces of rotor blades for a surface characteristic including an assembly having a movable arm and a scanner mounted on the arm. A row of rotor blades is positioned near the assembly for inspection, and the row of rotor blades and the assembly may be moved relative to the other so as to index the rotor blades.

<CIT> discloses an apparatus for inspection of surface of a component include a probing device coupled to a traversing device which has at least one probe carrier to which at least one inspection mechanism is fitted. The inspection mechanism is an image pick-up unit.

According to an aspect of the invention, an inspection system is disclosed comprising: a support structure; a first scanner moveably coupled to the support structure; a second scanner moveably coupled to the support structure; a motor operably coupled to a shaft, the shaft rotatably coupled to the support structure, the shaft configured to be coupled to the bladed rotor; and a controller in electronic communication with the first scanner, the second scanner, and the motor, the controller configured to: command the first scanner to scan the bladed rotor; command the second scanner to scan the bladed rotor; and generate a point cloud for the bladed rotor based on scanning data received from the first scanner and the second scanner.

In various embodiments, the first scanner and the second scanner are both blue light scanners.

In various embodiments, the controller is further configured to: command the motor to rotate the shaft a fixed amount between scanning by the first scanner and the second scanner. In various embodiments, the controller is further configured to determine each portion of the bladed rotor has been scanned by the first scanner and the second scanner in response to determining an angular position of the bladed rotor is <NUM> degrees from an initial position of the bladed rotor.

In various embodiments, the point cloud has a point density twice that of a single scanner inspections system.

In various embodiments, the inspection system is configured to scan between <NUM>% and <NUM>% of an external surface area of the bladed rotor.

In various embodiments, the inspection system further comprises a first track system and a second track system, the first scanner configured to travel along the first track system, the second scanner configured to travel along the second track system. In various embodiments, the first track system and the second track system are distinct. In various embodiments, the first track system is disposed opposite the second track system on the support structure.

In various embodiments, the operations further comprise: commanding, via the processor, a motor to rotate a shaft coupled to the bladed rotor a fixed amount; commanding, via the processor, the first scanner to scan a third portion of the bladed rotor; and commanding, via the processor the second scanner to scan a fourth portion of the bladed rotor.

In various embodiments, the first portion of the bladed rotor is a first blade, and wherein the second portion of the bladed rotor is a second blade.

In various embodiments, the first scanner and the second scanner both comprise one of a blue light scanner.

In various embodiments, the operations further comprise receiving, via the processor, location data of the first scanner and the second scanner relative to a datum; and generating the point cloud relative to the datum.

According to an aspect of the invention, a method is disclosed as claimed in claim <NUM>.

In various embodiments, a blue light scanner scans the bladed rotor the first time and scanning the second time.

In various embodiments, scanning the bladed rotor the first time further comprises: scanning a first portion of the bladed rotor; rotating the bladed rotor a fixed amount; and scanning a second portion of the bladed rotor.

In various embodiments, scanning the bladed rotor the first time and scanning the bladed rotor the second time occurs simultaneously.

In various embodiments, scanning the bladed rotor the first time and scanning the bladed rotor the second time is performed with a blue light scanner.

In various embodiments, the point cloud is generated relative to a datum based on location data of a scanner that performs the scanning the first time and the scanning the second time.

As used herein, "aft" refers to the direction associated with the tail (e.g., the back end) of an aircraft, or generally, to the direction of exhaust of the gas turbine. As used herein, "forward" refers to the direction associated with the nose (e.g., the front end) of an aircraft, or generally, to the direction of flight or motion.

With reference to <FIG>, a gas turbine engine <NUM> is shown according to various embodiments. Gas turbine engine <NUM> may be a two-spool turbofan that generally incorporates a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM> and a turbine section <NUM>. In operation, fan section <NUM> can drive air along a path of bypass airflow B while compressor section <NUM> can drive air along a core flow path C for compression and communication into combustor section <NUM> then expansion through turbine section <NUM>. Although depicted as a turbofan gas turbine engine <NUM> herein, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures, single spool architecture or the like.

Gas turbine engine <NUM> may generally comprise a low speed spool <NUM> and a high speed spool <NUM> mounted for rotation about an engine central longitudinal axis A-A' relative to an engine static structure <NUM> or engine case via several bearing systems <NUM>, <NUM>-<NUM>, etc. Engine central longitudinal axis A-A' is oriented in the Z direction on the provided X-Y-Z axes. It should be understood that various bearing systems <NUM> at various locations may alternatively or additionally be provided, including for example, bearing system <NUM>, bearing system <NUM>-<NUM>, etc..

Low speed spool <NUM> may generally comprise an inner shaft <NUM> that interconnects a fan <NUM>, a low pressure compressor <NUM> and a low pressure turbine <NUM>. Inner shaft <NUM> may be connected to fan <NUM> through a geared architecture <NUM> that can drive fan <NUM> at a lower speed than low speed spool <NUM>. Geared architecture <NUM> may comprise a gear assembly <NUM> enclosed within a gear housing <NUM>. Gear assembly <NUM> couples inner shaft <NUM> to a rotating fan structure. High speed spool <NUM> may comprise an outer shaft <NUM> that interconnects a high pressure compressor <NUM> and high pressure turbine <NUM>. A combustor <NUM> may be located between high pressure compressor <NUM> and high pressure turbine <NUM>. A mid-turbine frame <NUM> of engine static structure <NUM> may be located generally between high pressure turbine <NUM> and low pressure turbine <NUM>. Mid-turbine frame <NUM> may support one or more bearing systems <NUM> in turbine section <NUM>. Inner shaft <NUM> and outer shaft <NUM> may be concentric and rotate via bearing systems <NUM> about the engine central longitudinal axis A-A', which is collinear with their longitudinal axes. As used herein, a "high pressure" compressor or turbine experiences a higher pressure than a corresponding "low pressure" compressor or turbine.

The core airflow may be compressed by low pressure compressor <NUM> then high pressure compressor <NUM>, mixed and burned with fuel in combustor <NUM>, then expanded over high pressure turbine <NUM> and low pressure turbine <NUM>. Turbines <NUM>, <NUM> rotationally drive the respective low speed spool <NUM> and high speed spool <NUM> in response to the expansion.

In various embodiments, and with reference to <FIG>, high pressure compressor <NUM> of the compressor section <NUM> of gas turbine engine <NUM> is provided. The high pressure compressor <NUM> includes a plurality of blade stages <NUM> (i.e., rotor stages) and a plurality of vane stages <NUM> (i.e., stator stages). The blade stages <NUM> may each include an integrally bladed rotor ("IBR") <NUM>, such that the blades <NUM> and rotor disks <NUM> are formed from a single integral component (i.e., a monolithic component formed of a single piece). The blades <NUM> extend radially outward from the rotor disk <NUM>. The gas turbine engine <NUM> may further include an exit guide vane stage <NUM> that defines the aft end of the high pressure compressor <NUM>. Although illustrated with respect to high pressure compressor <NUM>, the present disclosure is not limited in this regard. For example, the low pressure compressor <NUM> may include a plurality of blade stages <NUM> and stator stages <NUM>, each blade stage in the plurality of blade stages <NUM> including the IBR <NUM> and still be within the scope of this disclosure. In various embodiments, the plurality of blade stages <NUM> form a stack of IBRs <NUM>, which define, at least partially, a rotor module <NUM> of the high pressure compressor <NUM> of the gas turbine engine <NUM>.

In various embodiments, an IBR <NUM> disclosed herein may comprise a knife edge <NUM> of a knife edge seal assembly <NUM>. The knife edge <NUM> is disposed between adjacent rotor stages in the plurality of blade stages <NUM> and configured to interface with a vane assembly in the plurality of vane stages <NUM>. In various embodiments, the knife edge seal assembly <NUM> is configured to seal air flow from core flow path C from <FIG> during operation of the gas turbine engine <NUM> from <FIG>.

Referring now to <FIG>, a method <NUM> for repairing an IBR <NUM> from <FIG> from a compressor section (e.g., compressor section <NUM>) of a gas turbine engine <NUM> from <FIG> is illustrated, in accordance with various embodiments. For example, after a predetermined number of flight cycles, or due to an unscheduled maintenance, a gas turbine engine <NUM> from <FIG> is in operation, the method <NUM> may be performed for one or more of IBR <NUM> in the compressor section <NUM> of the gas turbine engine <NUM>. In various embodiments, method <NUM> may be performed for IBRs <NUM> from several gas turbine engines (e.g., in accordance with gas turbine engine <NUM>), which may facilitate various potential repair options as described further herein.

The method <NUM> comprises inspecting, via an IBR inspection system, an IBR <NUM> (step <NUM>). As described further herein, step <NUM> may be performed for numerous IBRs <NUM> prior to proceeding to step <NUM>. In various embodiments, step <NUM> may be performed for a single IBR <NUM> prior to proceeding to step <NUM>. The present disclosure is not limited in this regard.

In various embodiments, inspecting the IBR comprises scanning, via the IBR inspection system, the IBR <NUM>. In this regard, the IBR inspection system may comprise an optical scanner (e.g., structured light scanners, such as white light scanners, structured blue light scanners, or the like) and/or a coordinate-measuring machine. The present disclosure is not limited in this regard. In response to scanning the IBR <NUM>, a digital representation of the IBR <NUM> (e.g., a point cloud, a surface model, or the like) is received by a controller and converted to a three-dimensional model (e.g., a computer Aided Design (CAD) model or Finite Element Model (FEM). The three-dimensional model may be utilized for analyzing the IBR <NUM> in step <NUM> of method <NUM>.

The method <NUM> further comprises analyzing, via an IBR analysis system, the IBR (step <NUM>). In various embodiments, by inspecting a plurality of IBRs in step <NUM>, a system level analysis of various repair options may be performed in step <NUM>. For example, the three-dimensional model produced from step <NUM> may be used as an input for blade level analysis (e.g., low-cycle fatigue, high cycle fatigue, Goodman diagram analysis, frequency, modal assurance criterion, etc.), stage level analysis (e.g., mistuning, aerodynamic performance, fatigue, imbalance, solidity, area and speed rotor sizing, etc.), and/or module level analysis (e.g., aerodynamic performance, compressor stack stiffness, clocking, clearances, axial gapping, imbalance, secondary flow influence, etc.). In this regard, by generating a three-dimensional model via step <NUM> outlined above, various forms of analysis may be performed to generate an optimal repair configuration (e.g., optimized for aerodynamic performance, optimized for cost of repair, etc.). The optimal repair configuration may be for an airfoil of a respective IBR <NUM>, for the respective IBR <NUM> as a whole, or for stack of IBRs <NUM> from <FIG>. The present disclosure is not limited in this regard.

The method <NUM> further comprises repairing, via an IBR repair system, the IBR (step <NUM>). In various embodiments, a repair model may be generated from the analyzing step <NUM> of method <NUM>. In various embodiments, a plurality of repair models may be generated based on various factors as outlined previously herein. In this regard, a repair process may be determined based on the analyzing step <NUM>. In various embodiments, the repair performed in step <NUM> may be a partial repair. For example, in the analyzing step <NUM>, optimal repair configurations for remaining life of the IBR <NUM> may be determined as well. For example, typical repairs are determined based on the IBR <NUM> meeting manufacturing tolerances / specifications and meeting full life (e.g., <NUM>,<NUM> flight cycles, <NUM>,<NUM> flight cycles or the like). If the IBR <NUM> is set for only <NUM>,<NUM> additional flight cycles of when the IBR <NUM> is originally designed for <NUM>,<NUM> flight cycles, the analysis in step <NUM> may account for that and provide a partial repair option that meets full life to accomplish a faster and/or less expensive repair.

Referring now to <FIG>, a system <NUM> for repairing an IBR <NUM> is illustrated, in accordance with various embodiments. In various embodiments, the system <NUM> includes an IBR inspection system <NUM>, an IBR analysis system <NUM>, and an IBR repair system <NUM>. Although illustrated as separate systems with separate processors (e.g., processors <NUM>, <NUM>, <NUM>), the present disclosure is not limited in this regard. For example, the system <NUM> may include a single processor, a single memory, and a single user interface and still remain within the scope of this disclosure.

Similarly, although IBR inspection system <NUM> and IBR repair system <NUM> are illustrated as separate systems with separate processors, memories and user interfaces, the present disclosure is not limited in this regard. For example, the IBR inspection system <NUM> and the IBR repair system <NUM> may be combined into a single system that communicates with the IBR analysis system <NUM>, in accordance with various embodiments.

In various embodiments, the IBR analysis system <NUM> may include one or more processors <NUM>. In this regard, the IBR analysis system <NUM> may be configured to process a significant amount of data during the analysis step <NUM> from method <NUM>. In this regard, the IBR analysis system <NUM> may be configured for remote computing (e.g., cloud-based computing), or the like. Thus, a processing time and a volume of data analyzed may be greatly increased relative to typical repair systems, in accordance with various embodiments.

In various embodiments, the IBR inspection system <NUM>, the IBR analysis system <NUM>, and the IBR repair system <NUM> each include a computer system comprising a processor (e.g., processor <NUM>, processor(s) <NUM>, and/or processor <NUM>) and a memory (e.g., memory <NUM>, memory <NUM>, memory <NUM>). The IBR inspection system <NUM> and the IBR repair system <NUM> may each comprise a user interface (UI) (e.g., UI <NUM>, UI236). In various embodiments, the IBR inspection system <NUM> and the IBR repair system <NUM> may utilize a single user interface to control both systems. The present disclosure is not limited in this regard.

The IBR analysis system <NUM> may further comprise a database <NUM>. In various embodiments, the database <NUM> comprises various stored data for use in the IBR analysis system <NUM>. The database <NUM> may include an inspected IBR database (e.g., with data from various prior inspected IBRs), a repair data database (e.g., with data from various prior repairs performed / approved), a load data database (e.g., with engine load data from structural and/or aerodynamic analysis), a test data database (e.g., with engine specific test data used for validation of structural and/or aerodynamic analysis), a design data database (e.g., with design models having nominal dimensions according to a product definition of the IBR <NUM>), and/or a material data database (e.g., with material for each component utilized in an analysis step <NUM> of method <NUM>), in accordance with various embodiments.

System <NUM> may be configured for inspecting (e.g., step <NUM> of method <NUM>), analyzing (e.g., step <NUM> of method <NUM>), and repairing (e.g., step <NUM> of method <NUM>) an IBR <NUM>, in accordance with various embodiments. In this regard, a repair process for an IBR <NUM> may be fully automated, or nearly fully automated, in accordance with various embodiments, as described further herein.

In various embodiments, and as shown in <FIG>, systems <NUM>, <NUM>, <NUM> may each store a software program configured to perform the methods described herein in a respective memory <NUM>, <NUM>, <NUM> and run the software program using the respective processor <NUM>, <NUM>, <NUM>. The systems <NUM>, <NUM>, <NUM> may include any number of individual processors <NUM>, <NUM>, <NUM> and memories <NUM>, <NUM>, <NUM>. Various data may be communicated between the systems <NUM>, <NUM>, <NUM> and a user via the user interfaces (e.g., UI <NUM>, UI <NUM>). Such information may also be communicated between the systems <NUM>, <NUM>, <NUM> and external devices, database <NUM>, and/or any other computing device connected to the systems <NUM>, <NUM>, <NUM> (e.g., through any network such as a local area network (LAN), or wide area network (WAN) such as the Internet).

In various embodiments, systems <NUM>, <NUM>, <NUM> depicted in <FIG>, each processor <NUM>, <NUM>, <NUM> may retrieve and executes instructions stored in the respective memory <NUM>, <NUM>, <NUM> to control the operation of the respective system <NUM>, <NUM>, <NUM>. Any number and type of processor(s) (e.g., an integrated circuit microprocessor, microcontroller, and/or digital signal processor (DSP)), can be used in conjunction with the various embodiments. The processor <NUM>, <NUM>, <NUM> may include, and/or operate in conjunction with, any other suitable components and features, such as comparators, analog-to-digital converters (ADCs), and/or digital-to-analog converters (DACs). Functionality of various embodiments may also be implemented through various hardware components storing machine-readable instructions, such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs) and/or complex programmable logic devices (CPLDs).

The memory <NUM>, <NUM>, <NUM> may include a non-transitory computer-readable medium (such as on a CD-ROM, DVD-ROM, hard drive or FLASH memory) storing computer-readable instructions stored thereon that can be executed by the processor <NUM>, <NUM>, <NUM> to perform the methods of the present disclosure. The memory <NUM> may include any combination of different memory storage devices, such as hard drives, random access memory (RAM), read only memory (ROM), FLASH memory, or any other type of volatile and/or nonvolatile memory.

The system <NUM>, <NUM> may receive and display information via a respective user interface (e.g., UI <NUM> and/or UI <NUM>). The user interfaces (e.g., UI <NUM> and/or UI <NUM>) include various peripheral output devices (such as monitors and printers), as well as any suitable input or control devices (such as a mouse and keyboard) to allow users to control and interact with the software program.

In various embodiments, IBR inspection system <NUM> and IBR repair system <NUM> may each be in electronic communication with IBR analysis system <NUM>, directly or via a respective user interface (e.g., UI <NUM> and/or UI <NUM>). IBR inspection system <NUM> and IBR repair system <NUM> may comprise any suitable hardware, software, and/or database components capable of sending, receiving, and storing data. For example, IBR inspection system <NUM> and/or IBR repair system <NUM> may comprise a personal computer, personal digital assistant, cellular phone, smartphone (e.g., those running UNIX-based and/or Linux-based operating systems such as IPHONE®, ANDROID®, and/or the like), IoT device, kiosk, and/or the like. IBR inspection system <NUM> and/or IBR repair system <NUM> may comprise an operating system, such as, for example, a WINDOWS® mobile operating system, an ANDROID® operating system, APPLE® IOS®, a LINUX® operating system, and the like. IBR inspection system <NUM> and/or IBR repair system <NUM> may also comprise software components installed on IBR inspection system <NUM> and/or IBR repair system <NUM> and configured to enable access to various system <NUM> components. For example, IBR inspection system <NUM> and/or IBR repair system <NUM> may comprise a web browser (e.g., MICROSOFT INTERNET EXPLORER®, GOOGLE CHROME®, APPLE SAFARI® etc.), an application, a micro-app or mobile application, or the like, configured to allow the IBR inspection system <NUM> and/or IBR repair system <NUM> to access and interact with IBR analysis system <NUM> (e.g., directly or via a respective UI, as discussed further herein).

Referring now to <FIG> and <FIG>, a perspective view of an inspection system <NUM> for use in an inspection step <NUM> of method <NUM> from <FIG> and a control system <NUM> for the inspection system <NUM> (<FIG>) are illustrated in accordance with various embodiments. In various embodiments, the inspection system <NUM> comprises a controller <NUM>, a support structure <NUM>, a shaft <NUM>, and a scanner <NUM>. In various embodiments, the control system <NUM> comprises the controller <NUM>, the scanner <NUM>, a memory <NUM>, a motor <NUM>, a database <NUM>, and sensor(s) <NUM>, sensor(s) <NUM>, and inspection component <NUM>. In various embodiments, the inspection system <NUM> comprises a bladed rotor inspection device <NUM>.

In various embodiments, the support structure <NUM> comprises a base <NUM>, a first vertical support <NUM>, a second vertical support <NUM>. In various embodiments, the base <NUM> may be annular in shape. Although illustrated as being annular, the present disclosure is not limited in this regard. For example, the base <NUM> may be semi-annular in shape, a flat plate, or the like. In various embodiments, the vertical supports <NUM>, <NUM> extend vertically upward from the base <NUM> on opposite sides of the base (e.g., <NUM> degrees apart, or opposite sides if the base <NUM> where a square plate). The shaft <NUM> extends from the first vertical support <NUM> to the second vertical support <NUM>. The shaft <NUM> may be rotatably coupled to the motor <NUM>, which may be disposed within the first vertical support <NUM>, in accordance with various embodiments. The shaft <NUM> may be restrained vertically and horizontally at the second vertical support <NUM> but free to rotate relative to the second vertical support about a central longitudinal axis of the shaft <NUM>. In various embodiments, a bearing assembly may be coupled to the second vertical support <NUM> to facilitate rotation of the shaft, in accordance with various embodiments.

In various embodiments, the IBR <NUM> to be inspected in accordance with the inspection step <NUM> of the method <NUM> via the inspection system <NUM> may be coupled to the shaft <NUM> (e.g., via a rigid coupling, or the like). The present disclosure is not limited in this regard, and the shaft <NUM> may be coupled to the IBR <NUM> to be inspected by any method known in the art and be within the scope of this disclosure.

In various embodiments, the scanner <NUM> is operably coupled to a track system <NUM>. In various embodiments, the track system <NUM> may comprise a curved track <NUM> and a vertical track <NUM>. The vertical track <NUM> may slidingly coupled to the vertical track <NUM> (e.g., via rollers or the like). The scanner <NUM> may be slidingly coupled to the vertical track <NUM> (e.g., via a conveyor belt, linkages or the like). In various embodiments, the scanner <NUM> is configured to extend from the track system <NUM> towards the IBR <NUM> during inspection of the IBR <NUM> in accordance with step <NUM> of method <NUM>. In this regard, the inspection system <NUM> may further comprise a robot arm, an actuator or the like. Although described herein with tracks <NUM>, <NUM>, and a robot arm or actuator, the present disclosure is not limited in this regard. For example, any electronically controlled (e.g., wireless or wired) component configured to move the scanner <NUM> in six degrees of freedom relative to the IBR <NUM> is within the scope of this disclosure. In various embodiments, the inspection component <NUM> comprises rollers for the curved track, a conveyor belt for the vertical track, and/or a robotic arm coupled to the scanner <NUM>. In various embodiments, the inspection component <NUM> comprises only a robotic arm. In various embodiments, the inspection component <NUM> comprises only the rollers for the curved track <NUM> and the conveyor belt or linkages for the vertical track <NUM>. The present disclosure is not limited in this regard. In various embodiments, the inspection component <NUM> is stationary and the IBR <NUM> being inspected is moveable along three-axis, five-axis, or the like. The present disclosure is not limited in this regard.

In various embodiments, the scanner <NUM> comprises a coordinate measuring machine (CMM), a mechanical scanner, a laser scanner, a structured scanner (e.g., a white light scanner, a blue light scanner, etc.), a non-structured optical scanner, a non-visual scanner (e.g., computed tomography), or the like. In various embodiments, the scanner <NUM> is a blue light scanner. In various embodiments, the scanner <NUM> may be swapped with another scanner at any point during an inspection step <NUM> as described further herein. In various embodiments, the inspection system <NUM> may be configured to swap the scanner <NUM> with a different scanner during the inspection step <NUM> of method <NUM> as described further herein.

A "blue light scanner" as disclosed herein refers to a non-contact structure light scanner. The blue light scanner may have a scan range of between <NUM> × <NUM><NUM>- <NUM> × <NUM><NUM>, in accordance with various embodiments. In various embodiments, an accuracy of the blue light scanner may be between <NUM> and <NUM>. In various embodiments, the blue light scanner be able to determine distances between adjacent points in the point cloud of between <NUM> and <NUM> as measured across three axes. In various embodiments, a volume accuracy of the blue light scanner may be approximately <NUM>/m. In various embodiments, a scan depth may be between approximately <NUM> and <NUM>. In various embodiments, the blue light scanner may comprise a light source including a blue LED. In this regard, the blue light scanner may be configured to emit an average wavelength between <NUM> and <NUM>, in accordance with various embodiments. Although described with various specifications herein, the blue light scanner is not limited in this regard, and one skilled in the art may recognize the parameters of the blue light scanner may extend outside the exemplary ranges. Use of a blue light scanner provides a high resolution point cloud for a three dimensional object.

The controller <NUM> may be integrated into computer system of the inspection system <NUM> (e.g., in processor <NUM> and/or memory <NUM> from <FIG>). In various embodiments, the controller <NUM> may be configured as a central network element or hub to various systems and components of the control system <NUM>. In various embodiments, controller <NUM> may comprise a processor (e.g., processor <NUM>). In various embodiments, controller <NUM> may be implemented as a single controller (e.g., via a single processor <NUM> and associated memory <NUM>). In various embodiments, controller <NUM> may be implemented as multiple processors (e.g., a main processor and local processors for various components). The controller <NUM> can be a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programable gate array (FPGA) or other programable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof. The controller <NUM> may comprise a processor configured to implement various logical operations in response to execution of instructions, for example, instructions stored on a non-transitory, tangible, computer-readable medium configured to communicate with the controller <NUM>.

System program instructions and/or controller instructions may be loaded onto a non-transitory, tangible computer-readable medium having instructions stored thereon that, in response to execution by a controller, cause the controller to perform various operations. The term "non-transitory" is to be understood to remove only propagating transitory signals per se from the claim scope and does not relinquish rights to all standard computer-readable media that are not only propagating transitory signals per se.

In various embodiments, the motor <NUM> of the control system <NUM> is operably coupled to the shaft <NUM> of the control system <NUM>. In various embodiments, the motor <NUM> may comprise a direct current (DC) stepper, an alternating current (AC) motor or the like. The present disclosure is not limited in this regard. In various embodiments, the sensor(s) <NUM> include Hall effect sensor(s), optical sensor(s), resolver(s), or the like. In various embodiments, sensor(s) <NUM> may include sensor(s) configured to detect an angular position of the shaft <NUM> during an inspection step for an IBR <NUM> (e.g., step <NUM> from method <NUM>). In this regard, during inspection of the IBR <NUM>, the controller <NUM> receives sensor data from the sensor(s) <NUM>. The controller <NUM> can utilize the sensor data received from the sensor(s) <NUM> to correlate an angular position of the IBR <NUM> being inspected with a location of the scanner <NUM> as described further herein. In various embodiments, in an application with a robot arm, the IBR <NUM> may remain stationary throughout an inspection process (e.g., inspection step <NUM> of method <NUM>). Thus, coordinates of the robotic arm may be determined via sensor(s) <NUM> in a similar manner to orient and construct the IBR <NUM> being inspected as described further herein.

In various embodiments, the sensor(s) <NUM> are configured to detect a position of the scanner <NUM> during the inspection step <NUM> of method <NUM>. In this regard, sensor(s) <NUM> may be position sensors (e.g., capacitive displacement sensors, eddy-current sensors, Hall effect sensors, inductive sensors, optical sensors, linear variable differential transformer (LVDT) sensors, photodiode array sensors, piezoelectric sensors, encoders, potentiometer sensors, ultrasonic sensors or the like). The present disclosure is not limited in this regard. Thus, during inspection of the IBR <NUM> in accordance with step <NUM> of method <NUM>, controller <NUM> is able to determine a location of the scanner <NUM> and an angular position of the IBR <NUM> throughout the inspection. Thus, based on the location of the scanner <NUM>, an angular location of the IBR <NUM> and scanning data received from the scanner <NUM>, a digital map (e.g., a robust point cloud) can be generated during the inspection step <NUM> of method <NUM> for the IBR <NUM> being inspected. In various embodiments, the point cloud encompasses the entire IBR <NUM> (e.g., between <NUM>% and <NUM>% of a surface area of the IBR <NUM>, or between <NUM>% and <NUM>% of the surface area of the IBR <NUM>).

Referring now to <FIG>, a process <NUM> for inspecting an IBR <NUM> that is performed by the control system <NUM> of the inspection system <NUM> is illustrated, in accordance with various embodiments. In various embodiments, the process <NUM> comprises commanding, via a controller <NUM>, a scanner to scan a portion of the IBR <NUM> (step <NUM>). In various embodiments, the portion of the IBR <NUM> may comprise a blade <NUM> or the like. In various embodiments, a root, a platform, or the like of the IBR <NUM> may be the portion. The present disclosure is not limited in this regard. In various embodiments, the root and the platform of the IBR <NUM> may be scanned along with the blade <NUM>. In various embodiments, multiple blades <NUM> may be scanned with the portion of the IBR <NUM>.

In various embodiments, commanding the scanner <NUM> in step <NUM> may further comprise commanding rollers of the curved track <NUM>, commanding a conveyor belt or linkages of the vertical track <NUM> or the like in conjunction with scanning via the scanner <NUM>. In this regard, the controller <NUM> may provide a predetermined path for the scanner <NUM> to scan the portion of the IBR <NUM>, in accordance with various embodiments. However, the present disclosure is not limited in this regard, for example, step <NUM> may include commanding a scanner coupled to a robotic arm (e.g., robotic arm <NUM> in <FIG>) to scan a portion of the IBR <NUM>, or may include commanding a five-axis system (e.g., system <NUM> from <FIG>) to orient the IBR <NUM> for scanning, or the like. Thus, step <NUM> may include any command to position the IBR <NUM> being inspected relative to a scanner and scanning the portion of the IBR <NUM>, in accordance with various embodiments.

The process <NUM> further comprises receiving, via the controller, a three-dimensional model of the first portion of the IBR <NUM> (step <NUM>). In various embodiments, the three-dimensional model is a digital map (e.g., a point cloud). In this regard, in response to utilizing a CMM scanner or a structured light scanner, the scanner <NUM> measures discrete points of surfaces of the portion of the IBR being scanned and transmits the discrete points to the controller <NUM>. In various embodiments, the point cloud may be relative to a datum defined by the inspection system <NUM>. For example, the shaft <NUM> may be configured to couple to the IBR <NUM> being inspected in exactly the same place every time. In this regard, a datum for the inspection system <NUM> may be defined in the memory (e.g., memory <NUM>). In various embodiments, the datum is a center point of the IBR <NUM> (e.g., a center point of the disk of the IBR <NUM>). Thus, the controller <NUM> is configured to determine a location of each point scanned via the scanner <NUM> based on the datum, a location of the scanner <NUM> when a scan occurs during step <NUM> from sensor(s) <NUM>, measurement data from the scanner <NUM>, and an angular position of the IBR <NUM> from sensor(s) <NUM>.

The process <NUM> further comprises storing, via the controller <NUM>, the three-dimensional model in a database <NUM> (step <NUM>). Although described herein as intermittently storing scanned portions of the IBR <NUM>, the present disclosure is not limited in this regard. For example, the scanner <NUM> may scan the entire IBR prior to transmitting the three-dimensional model to the controller <NUM> and still be within the scope of this disclosure. In this regard, the controller <NUM> may be configured to determine an amount of the IBR <NUM> that has been scanned based on the angular position of the IBR <NUM> and the position of the scanner <NUM> throughout step <NUM>.

The process <NUM> further comprises determining whether the IBR has been scanned in its entirety (e.g., between <NUM>% and <NUM>% or between <NUM>% and <NUM>% or approximately <NUM>%). In this regard, the process <NUM> may determine whether the scanner <NUM> has performed a scan at each predetermined arc angle (e.g., <NUM> degree, <NUM> degrees, <NUM> degrees, or the like) and a total angular rotation of the IBR <NUM> for the scanning process has reached <NUM> degrees.

If the entire IBR has not been scanned, the process <NUM> further comprises commanding, via the controller <NUM>, rotation of the IBR <NUM> a fixed amount (e.g., <NUM> degree, <NUM> degrees, <NUM> degrees, <NUM> degrees, etc.). The present disclosure is not limited in this regard. The controller <NUM> may command the motor <NUM> to rotate the IBR <NUM> the fixed amount, in accordance with various embodiments.

In various embodiments, steps <NUM>, <NUM>, <NUM>, <NUM> are repeated until the entire IBR is scanned according to step <NUM>, at which point the process <NUM> further comprises generating, via the controller <NUM>, a three-dimensional model of the IBR <NUM> (step <NUM>). In this regard, in response to the scanner <NUM> being a CMM scanner or a structured light scanner, the controller <NUM> may stitch together the point clouds for each portion of the IBR scanned via step <NUM> to generate a robust point cloud of the entire IBR <NUM> (e.g., between <NUM>% and <NUM>% of an external surface area of the IBR <NUM>, or between <NUM>% and <NUM>% of the external surface area of the IBR <NUM>, or approximately <NUM>% of the external surface area of the IBR <NUM>). In various embodiments, the entire IBR <NUM> refers to approximately <NUM>% of an external surface area of all the blades of the IBR <NUM>.

In various embodiments, the process <NUM> further comprises storing, via the controller <NUM>, the three-dimensional model of the IBR in the database <NUM>. In this regard, the three-dimensional model may be utilized for analyzing the inspected IBR (e.g., in accordance with step <NUM> of method <NUM>), determining a repair for the inspected IBR (e.g., based on step <NUM> of method <NUM>) and/or in repairing the inspected IBR (e.g., in accordance with step <NUM> of method <NUM>).

In various embodiments, the process <NUM> may provide a fully automated solution for generating a robust three-dimensional model (e.g., a point cloud) for an inspected IBR <NUM>, in accordance with various embodiments.

Referring now to <FIG>, a perspective view of the inspection system <NUM> from <FIG> is illustrated, in accordance with various embodiments, with like numerals depicting like elements. In various embodiments, the inspection system <NUM> further comprises a second scanner <NUM>. In various embodiments, the second scanner <NUM> may be in accordance with scanner <NUM> as described further herein. In various embodiments, the second scanner <NUM> is a different scanner than scanner <NUM> as described further herein. In various embodiments, the second scanner <NUM> is coupled to a second track system <NUM>. The track system <NUM> may be in accordance with the track system <NUM>, in accordance with various embodiments. In various embodiments the track system <NUM> is independent (i.e., not connected to), the track system <NUM>. In this regard, an end of first track system <NUM> may be spaced apart from an end of the second track system <NUM>, in accordance with various embodiments. As described further herein, the second scanner <NUM> may be configured for simultaneous scanning of the IBR <NUM> with the first scanner <NUM> (i.e., at a different portion), configured for scanning in response to determinations by the controller <NUM> based on scanning data received from the first scanner <NUM>, or the like.

Referring now to <FIG>, a schematic view of the control system <NUM> for the inspection system <NUM> is illustrated, in accordance with various embodiments, with like numerals depicting like elements. In various embodiments, the control system <NUM> further comprises the second scanner <NUM> and sensor(s) <NUM>. Sensor(s) <NUM> may be in accordance with sensor(s) <NUM> described previously herein. In this regard, the sensor(s) <NUM> are configured to detect a location of the second sensor <NUM> to transmit to the controller for defining the three-dimensional model (e.g., a point cloud) as described previously herein.

Referring now to <FIG>, a process <NUM> for inspecting an IBR <NUM> that is performed by the control system <NUM> (from <FIG>) of the inspection system <NUM> (from <FIG>) is illustrated, in accordance with various embodiments. The process <NUM> comprises commanding, via a controller <NUM>, a first scanner <NUM> to scan a first portion of an integrally bladed rotor (IBR) (step <NUM>), and commanding, via the controller, a second scanner to scan a second portion of the IBR (step <NUM>). In this regard, the scanners <NUM>, <NUM> may be utilized simultaneously on distinct portions of the IBR, in accordance with various embodiments. In this regard, a single scan of the entire IBR may be halved in accordance with various embodiments. In various embodiments, utilizing two scanners (e.g., scanners <NUM>, <NUM>) may be used to enhance a fidelity (i.e., a point density) of the scan.

In this regard, in various embodiments, the process <NUM> further comprises determining whether the IBR has been scanned twice (step <NUM>). For example, in a similar manner to process <NUM>, the controller <NUM> may track an angular position of the IBR <NUM> throughout process <NUM>. In response to the angular position reaching <NUM> degrees from an initial position, the controller <NUM> can determine that the IBR <NUM> has been scanned twice (i.e., an entire external surface area of the IBR <NUM> would be scanned by both the first scanner <NUM> and the second scanner <NUM>).

In various embodiments, in response to the controller <NUM> determining the IBR <NUM> has not been scanned twice in step <NUM>, the controller <NUM> may command rotation of the IBR in accordance with step <NUM> of process <NUM> described previously herein and revert back to step <NUM>. In various embodiments, in response to determining the IBR <NUM> has been scanned twice in step <NUM>, the process <NUM> may further comprise generating, via the controller, a three-dimensional model of the IBR (step <NUM>).

In various embodiments, the three-dimensional model is a point cloud having a point density of approximately double that of a point density generated from process <NUM> (i.e., twice as many discrete points for the point cloud). In this regard, a higher fidelity scan of the IBR <NUM> may be achieved relative to process <NUM> in a similar amount of time. Although illustrated as being performed with two scanners (e.g., scanners <NUM>, <NUM>), the present disclosure is not limited in this regard. In various embodiments, generating the three-dimensional model of step <NUM> may include stitching together a first point cloud from the first scan with a second point cloud of the second scan. In this regard, the first scan may be used as a reference for stitching together the second scan, datums determined from the first scan may be utilized for stitching together the second scan, or any other method of stitching together a first point cloud with a second point cloud may be performed.

For example, a single scanner <NUM> could be utilized, the controller could continue process <NUM> until the IBR travelled <NUM> degrees (i.e., two revolutions), and achieve a similar point cloud to process <NUM>. However, with the single scanner, the process would take twice as much time. Yet, a system cost may be reduced relative to a two scanner configuration, in accordance with various embodiments.

In various embodiments, after generating the three-dimensional model in step <NUM>, the three-dimensional model may be stored via the controller <NUM>, in the database <NUM> in accordance with step <NUM> of process <NUM>.

In various embodiments, IBR <NUM> may include sharp edges (e.g., leading edges, trailing edges, tips, etc.). Thus, proper, and accurate, tuning of the blades <NUM> is desirable. In various embodiments, scanners <NUM>, <NUM> for the process <NUM> may both be structured light scanners, may be with a laser and a structured light scanner, or any other combination described previously herein. In this regard, a high-fidelity scan of the various sharp edges of the blades <NUM> for the IBR <NUM> being inspected may be achieved for use in analyzing in step <NUM> of method <NUM> and developing a repair process for the repair step <NUM> of method <NUM>, in accordance with various embodiments.

Referring now to <FIG>, a process <NUM> for feedback driven scan configured to be performed by the control system <NUM> (e.g., <FIG> or <FIG>) of the inspection system (e.g., <FIG> or <FIG>), is illustrated, in accordance with various embodiments.

The process <NUM> comprises commanding, via the controller <NUM>, a first scan of a bladed rotor (e.g., IBR <NUM>) (step <NUM>). The first scan of the bladed rotor may be in accordance with process <NUM> in accordance with various embodiments. In various embodiments, the first scan may be performed with a scanner configured to produce a quicker, lower density point cloud (e.g., a CMM). In this regard, the first scan of the bladed rotor may be considered a high-level initial scan of the bladed rotor, in accordance with various embodiments.

The process <NUM> further comprises generating, via the controller <NUM>, a three-dimensional model (e.g., a point cloud) of the bladed rotor based on the first scan (step <NUM>), and comparing, via the controller <NUM>, the three-dimensional model to a design model for the bladed rotor being inspected (step <NUM>). Although described herein with respect to comparing to a design model, the present disclosure is not limited in this regard. For example, the database <NUM> of the control system <NUM> may have various inspected bladed rotor point clouds stored therein. In various embodiments, the various inspected bladed rotors with point clouds in the database <NUM> may include designations (i.e., approved without repairs or the like). In this regard, the comparing step <NUM> may utilize previously approved inspected bladed rotor point clouds to compare the three-dimensional model generated from the first scan in step <NUM>.

In various embodiments, the process <NUM> further comprises determining, via the controller <NUM>, areas of interest on the bladed rotor based on the comparison in step <NUM> (step <NUM>). Although described herein as the controller <NUM> determining the areas of interest, the present disclosure is not limited in this regard. For example, the controller <NUM> may be configured to transmit the digital data through an application based software infrastructure that stores data on remote servers and may be configured for determining areas of interests of the IBR <NUM> (i.e., via cloud-based computing or the like), in accordance with various embodiments. For example, with brief reference to <FIG>, the controller <NUM> may transmit the digital data to the IBR analysis system <NUM> (e.g., via a WAN such as the Internet), the IBR analysis system <NUM> may perform analysis based on the three-dimensional model generated from the first scan in step <NUM>, and the IBR analysis system <NUM> may output areas of interest to the IBR inspection system <NUM>, in accordance with various embodiments. In this regard, the controller <NUM> may receive, via the processor, areas of interest on the bladed rotor after transmitting the digital data to a cloud based computing software instead of performing steps <NUM> and <NUM> of process <NUM> and still be within the scope of this disclosure.

In various embodiments, the comparing and determining of steps <NUM>, <NUM> of process <NUM> may be performed by manual processes. For example, fluorescent penetrant inspection (FPI) may be performed manually on the IBR <NUM>. In response to performing the FPI, a person may determine areas of interest of the IBR and input coordinates of the respective areas of interest into the processor (e.g., via a graphical user interface (GUI) or the like). In this regard, the process <NUM> may include receiving, from a GUI, areas of interest for the IBR <NUM> based on performing FPI or any other manual inspection process, in accordance with various embodiments.

In this regard, based on the sensor data received from the first scan in step <NUM>, and described previously herein with respect to process <NUM>, the process <NUM> further comprises commanding, via the controller <NUM>, a second scan of the areas of interest determined from step <NUM> (step <NUM>). In various embodiments, the second scan may include multiple scans with the scanner used for the first scan (e.g., in response to the scanner <NUM> being a CMM and having only a single scanner configuration). In various embodiments, the second scan may be performed with a higher resolution scanner (e.g., a structured light scanner). In this regard, the first scanner <NUM> may comprise a CMM scanner configured to perform step <NUM> of process <NUM>, and the second scanner <NUM> may comprise a structured light scanner configured to perform step <NUM> of process <NUM>, or a structured light scanner with a more optimal focal length for a higher resolution image of a detailed area of the IBR. In various embodiments, the second scan may be performed after swapping out a first scanner with a second scanner (e.g., for an inspection system <NUM> with a single scanner configuration). In this regard, a CMM scanner used for step <NUM> may be swapped out with a structured light scanner prior to performing the second scan, in accordance with various embodiments. In various embodiments, the inspection system <NUM> may be configured to automatically swap the scanners (e.g., in a similar manner to a spindle of a Computer Numerical Control (CNC) machine swapping out one machining tool for another). The present disclosure is not limited in this regard.

In various embodiments, the areas of interest comprise areas that are outside a threshold tolerance of the respective comparison model (e.g., a design model or an approved inspected model). In various embodiments, based on determining a first blade has an area of interest from step <NUM>, the controller <NUM> may identify adjacent blades to the first blade as areas of interest (e.g., immediately adjacent blades, blades that are within two blades from the first blade, or the like). In this regard, the adjacent blades may be held to tighter tolerances due to damage to the first blade, in accordance with various embodiments. Thus, the adjacent blades may receive an additional scan in step <NUM> as described further herein as a more dense point cloud for the adjacent blades may help facilitate a better repair disposition from the analyzing step <NUM> of method <NUM>, in accordance with various embodiments.

In various embodiments, the process <NUM> further comprises generating, via the controller <NUM>, a final three-dimensional model based on the first scan and the second scan (step <NUM>). In this regard, a point density in the areas of interest may be significantly greater than a point density outside the areas of interest, in accordance with various embodiments. In various embodiments, the process <NUM> facilitates efficient scanning of bladed rotors with a focus on achieving high definition of potential problem areas (e.g., defects or the like). In this regard, by inputting the point cloud developed from process <NUM> into an IBR analysis system from step <NUM> of method <NUM>, a margin of safety relative to any defect areas may be reduced, in accordance with various embodiments.

Referring now to <FIG>, a schematic view of the control system <NUM> for the inspection system <NUM> is illustrated, in accordance with various embodiments, with like numerals depicting like elements. In various embodiments, the control system <NUM> further comprises a contact probe <NUM>. In various embodiments, the contact probe <NUM> may be kept to aside from the inspection system <NUM> when not in use (e.g., in a tool holder or the like). In various embodiments, in response to the inspection component <NUM> comprising a robotic arm (e.g., a six-axis robotic arm), the robotic arm may be configured to couple to the contact probe (i.e., in response to receiving instructions from the controller <NUM>. In various embodiments, the contact probe <NUM> may configured to electrically couple to the controller <NUM> in response to the robotic arm being coupled to the contact probe <NUM>. In various embodiments, the contact probe <NUM> may be configured to electronically couple to the controller <NUM>. The present disclosure is not limited in this regard.

In various embodiments, the contact probe <NUM> is configured for non-destructive inspection (NDI). In this regard, any NDI probe is within the scope of this disclosure. For example, the contact probe <NUM> may comprise an eddy current inspection (ECI) probe, an eddy current array (ECA) probe, a thermoacoustic (TAI) probe, or the like.

Referring now to <FIG>, a process <NUM> for inspecting bladed rotor that is performed by the control system <NUM> (from <FIG>) of the inspection system <NUM> is illustrated, in accordance with various embodiments. In various embodiments, the process <NUM> includes steps <NUM>, <NUM>, <NUM>, and <NUM> of process <NUM>.

The process <NUM> further comprises commanding, via the controller <NUM>, a non-destructive inspection of the areas of interest (step <NUM>). In this regard, the controller <NUM> may command the inspection component <NUM> (e.g., a robotic arm or the like) to couple to a contact probe <NUM>. In response to coupling the inspection component <NUM> to the contact probe <NUM>, the controller <NUM> may become electronically (e.g., wirelessly or wired) coupled to the controller <NUM>. In this regard, any data detected from the contact probe <NUM> may be transmitted to the controller <NUM> and stored in the database <NUM> along with the three-dimensional models described previously herein. In this regard, non-destructive inspection may detect defects that may otherwise be undetectable by scanners <NUM>, <NUM>. Thus, by further inspecting the bladed rotor with the contact probe, additional data may be provided to the IBR analysis system in step <NUM> of method <NUM> to provide for a more robust repair analysis and determination, in accordance with various embodiments. In various embodiments, the non-destructive inspection performed in step <NUM> may be performed for the entire bladed rotor. The present disclosure is not limited in this regard. In various embodiments, although illustrated as replacing steps <NUM>, <NUM> of process <NUM>, the present disclosure is not limited in this regard. For example, in various embodiments, steps <NUM> and <NUM> are performed in addition to steps <NUM> and <NUM> of process <NUM>.

Referring now to <FIG>, a perspective view of a system <NUM> is illustrated, in accordance with various embodiments. In various embodiments, the system <NUM> includes an IBR inspection system <NUM> and/or an IBR repair system <NUM>. In various embodiments, the IBR inspection system <NUM> includes the IBR inspection system <NUM> with additional elements as described further herein. For example, the IBR inspection system <NUM> further comprises a robotic arm <NUM>. In various embodiments, the robotic arm <NUM> is utilized as a sole inspection component <NUM> of the inspection system <NUM>, in combination with the scanner <NUM> and/or scanner <NUM>, or the like. In various embodiments, the robotic arm <NUM> is utilized as an inspection component <NUM> in an inspection step <NUM> of method <NUM> and utilized as a repair component during the repair step <NUM> of method <NUM>. In this regard, the robotic arm <NUM> may be configured to couple to and uncouple from various tools (e.g., a scanner, such as scanner <NUM>, <NUM>, a probe, etc., a subtractive component, such as a mill, a lathe, a serrated cutter, etc., an additive component, such as a DED head, an auger, etc.). The present disclosure is not limited in this regard.

In various embodiments, the IBR repair system <NUM> comprises a robotic arm <NUM>. In this regard, the system <NUM> may comprise a robotic arm <NUM> for an inspection system <NUM> and a robotic arm <NUM> for a repair system <NUM>, in accordance with various embodiments. In various embodiments, the robotic arms <NUM>, <NUM> are not limited for use in a respective system (e.g., inspection system <NUM> or repair system <NUM>). For example, robotic arms <NUM>, <NUM> may be utilized in both systems <NUM>, <NUM>, in accordance with various embodiments.

Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within <NUM>%, within <NUM>%, within <NUM>%, within <NUM>%, or within <NUM>% of a stated value. Additionally, the terms "substantially," "about" or "approximately" as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the term "substantially," "about" or "approximately" may refer to an amount that is within <NUM>% of, within <NUM>% of, within <NUM>% of, within <NUM>% of, and within <NUM>% of a stated amount or value.

Claim 1:
An inspection system (<NUM>) for a bladed rotor (<NUM>), the inspection system (<NUM>) comprising:
a support structure (<NUM>);
a first scanner (<NUM>) moveably coupled to the support structure (<NUM>);
a second scanner (<NUM>) moveably coupled to the support structure (<NUM>);
a motor (<NUM>) operably coupled to a shaft (<NUM>), the shaft (<NUM>) rotatably coupled to the support structure (<NUM>), the shaft (<NUM>) configured to be coupled to the bladed rotor (<NUM>); and
a controller (<NUM>) in electronic communication with the first scanner (<NUM>), the second scanner (<NUM>), and the motor (<NUM>), the controller (<NUM>) configured to:
command the first scanner (<NUM>) to scan the bladed rotor (<NUM>);
command the second scanner (<NUM>) to scan the bladed rotor (<NUM>); and
generate a point cloud for the bladed rotor (<NUM>) based on scanning data received from the first scanner (<NUM>) and the second scanner (<NUM>).