Patent Description:
Various systems and methods are known in the art for determining a moment weight of a component such as a rotor blade of a turbine engine. While these systems and methods have various benefits, there is still room in the art for improvement. For example, a typical moment weight measurement system requires a rotor blade to be properly positioned in a fixture. However, if the rotor blade is improperly positioned, the moment weight measurement system may provide an inaccurate moment weight measurement.

<CIT> discloses a method of distributing rotor blades in a turbomachine.

<CIT> discloses a method for manufacturing a turbomachine fan having a reduced noise level at multiple rotational frequencies of said turbomachine.

<CIT> discloses a surface shape measurement apparatus, a surface shape measurement method, and a surface state graphic apparatus.

<CIT> discloses a method for ordering blades on a rotor of a turbomachine.

<CIT> discloses methods and apparatus for assembling rotatable machines.

According to an aspect of the present invention, a manufacturing method is provided in accordance with claim <NUM>.

According to another aspect of the present invention, an inspection method is provided in accordance with claim <NUM>.

The surface inspection system may be configured as or otherwise include a blue-light inspection system.

The rotor blade may be configured as or otherwise include a fan blade.

During the method, a surface geometry of the rotor blade may be measured using a surface inspection system to provide surface data indicative of the surface geometry. The model data may be generated based on the surface data.

During the method, a weight of the rotor blade may be measured using a scale to provide the measured weight of the rotor blade.

<FIG> is a schematic illustration of a system <NUM> for use in manufacture of an apparatus such as, but not limited to, a rotor for a turbine engine. This system <NUM> includes a component (e.g., rotor blade) inspection system <NUM> and an apparatus (e.g., rotor) balancing system <NUM>. Note, while the component inspection system <NUM> and the apparatus balancing system <NUM> are illustrated in <FIG> as two separate systems, the present disclosure is not limited to such a configuration. In other embodiments, for example, the component inspection system <NUM> and the apparatus balancing system <NUM> may be configured as a single system or may share at least one common element; e.g., a computer.

The component inspection system <NUM> includes a scale <NUM>, a surface inspection system <NUM> and a computer <NUM>. The scale <NUM> is configured to measure a weight of a component placed therewith (e.g., thereon). Various scale types and configurations are known in the art, and the present disclosure is not limited to any particular ones thereof.

The surface inspection system <NUM> is configured to measure (e.g., map) a surface geometry of the component. This surface geometry may represent a select portion of a surface of the component, or an entirety of surface(s) exposed to the surface inspection system <NUM>. The surface inspection system <NUM> may be a contact surface inspection system or a non-contact surface inspection system. The term "contact surface inspection system" may describe a surface inspection system that physically contacts a component to measure its surface geometry. An example of a contact surface inspection system is a coordinate measuring machine (CMM). The term "non-contact surface inspection system" may describe a surface inspection system that does not physically contact a component to measure its surface geometry. Examples of a non-contact surface inspection system include, but are not limited to, a blue light inspection system (e.g., a blue light optical scanner), a white light inspection system (e.g., a white light optical scanner), a laser inspection system (e.g., a laser scanning device) and a radiological inspection system (e.g., a computed axial tomography scanning (CAT Scan) device).

Referring to <FIG>, an exemplary embodiment of the surface inspection system <NUM> configured as a non-contact (e.g., blue or white light) surface inspection system is shown. This inspection system <NUM> includes an electronic measurement device <NUM> and a support stand <NUM>.

Referring to <FIG>, the electronic measurement device <NUM> can include a non-contact sensor <NUM> (e.g., a blue or white light optical scanner) adapted to map at least a portion of a surface <NUM> of a component <NUM>; e.g., a rotor blade. The term "map" is used herein to describe a process of applying a (e.g., high density) triangulated mesh of surface data points to a component surface. In the embodiment shown in <FIG>, the non-contact sensor <NUM> includes a fringe pattern projector <NUM> and one or more cameras <NUM>. The projector <NUM> is adapted to project a point, line and/or pattern of light (e.g., blue or white light). Each camera <NUM> is adapted to capture an image of the projected light. An example of such a projector and cameras is disclosed in <CIT>.

Referring to <FIG>, the support stand <NUM> includes a base <NUM>, a component support <NUM> and a sensor support <NUM>. The component support <NUM> extends from the base <NUM> to a component support surface <NUM>. The sensor support <NUM> extends from the base <NUM> to a first end <NUM>. The sensor support <NUM> includes a sensor mount <NUM> disposed axially between the base <NUM> and the first end <NUM>, which connects the non-contact sensor <NUM> to the sensor support <NUM>.

Referring to <FIG>, the computer <NUM> is in signal communication (e.g., hardwired and/or wirelessly connected) with the scale <NUM> and/or the surface inspection system <NUM> (e.g., the non-contact sensor <NUM> of <FIG>). The computer <NUM> may be implemented with a combination of hardware and software. The hardware may include memory and at least one processing device, which may include one or more single-core and/or multi-core processors. The hardware may also or alternatively include analog and/or digital circuitry other than that described above. The memory is configured to store software (e.g., program instructions) for execution by the processing device, which software execution may control and/or facilitate performance of one or more operations such as those described in the methods below. The memory may be a non-transitory computer readable medium. For example, the memory may be configured as or include a volatile memory and/or a nonvolatile memory.

The apparatus balancing system <NUM> is configured to determine placement of individual components (e.g., rotor blades) in a rotor <NUM> (see <FIG>) based on associated component (e.g., rotor blade) moment weights, which rotor <NUM> is rotatable about a rotational axis <NUM>. The apparatus balancing system <NUM>, for example referring to <FIG>, may be configured to assign rotor blade locations about a rotor disk <NUM> such that the combined moment weights of the rotor blades 50A-H (generally referred to as "<NUM>"), once properly located about and connected to a hub <NUM> of the rotor disk <NUM>, cancel each other out; e.g., substantially zero out. For example, the rotor blade 50A may be diametrically located relative to the rotor blade 50E where those rotor blades 50A and 50E have substantially equal, but opposite acting, moment weights subsequent to being connected to the rotor disk <NUM>. Various types and configuration of apparatus balancing systems are known in the art, and the present disclosure is not limited to any particular ones thereof.

<FIG> is a flow diagram of a method <NUM> utilizing a system such as the system <NUM> of <FIG>. The method <NUM> is described below with reference to the component being a rotor blade <NUM> and the apparatus being a rotor <NUM>.

In step <NUM>, a weight (e.g., a pan weight) of the rotor blade <NUM> is measured. The rotor blade <NUM>, for example, may be placed on the scale <NUM>. The scale <NUM> outputs weight data to the computer <NUM>, which weight data is indicative of a measured (e.g., actual, pan) weight of the rotor blade <NUM>. Alternatively, the weight of the rotor blade <NUM> may be determined later in step <NUM> by processing model data (see step <NUM>) with a known material density and/or other parameter of the rotor blade <NUM>.

In step <NUM>, a surface geometry of a surface <NUM> of the rotor blade <NUM> is measured (e.g., mapped). The surface inspection system <NUM>, for example, may be operated to measure (e.g., map a mesh of coordinates of) at least a portion or an entirety of the rotor blade surface <NUM>. The surface inspection system <NUM> outputs surface data to the computer <NUM>, which surface data is indicative of the measured surface geometry of the rotor blade <NUM>.

In step <NUM>, a solid model of the rotor blade <NUM> is provided. This solid model may electronically represent of an entirety (or a portion) of the rotor blade <NUM>. The computer <NUM>, for example, may be operated to process the surface data with one or more algorithms and/or programs to generate model data indicative of the solid model of the rotor blade <NUM>. Various algorithms and programs for generating a solid model based on a surface geometry are known in the art, and the present disclosure is not limited to any particular ones thereof.

In step <NUM>, a center of gravity (CG) distance of the rotor blade <NUM> is determined. Herein, the term "center of gravity distance" describes a distance (e.g., distance <NUM> of <FIG>) between a rotational axis (e.g., the rotational axis <NUM>) and a center of gravity point (CG) of an object (e.g., the rotor blade <NUM>). The computer <NUM>, for example, may be operated to process the model data and a known material density or other parameter of the rotor blade <NUM> with one or more algorithms and/or programs to generate CG data indicative of the center of gravity distance of the rotor blade <NUM>. Various algorithms and programs for generating a center of gravity based on a solid model and a material density are known in the art, and the present disclosure is not limited to any particular ones thereof.

In step <NUM>, a moment weight of the rotor blade <NUM> is determined. The computer <NUM>, for example, may be operated to process the CG data and the weight data to provide moment weight data indicative of the moment weight. In particular, the computer <NUM> may multiply the center of gravity distance of the rotor blade <NUM> by the measured weight of the rotor blade <NUM> to determine the moment weight of the rotor blade <NUM>.

In step <NUM>, the moment weight is associated with (e.g., communicated with and/or assigned to) the rotor blade <NUM>. The moment weight, for example, may be handwritten, printed and/or otherwise displayed on a root and/or airfoil of the rotor blade <NUM>. The moment weight may also or alternatively be displayed on packaging material (e.g., a box or crate) for the rotor blade <NUM>. The moment weight may still also or alternatively be electronically associated with the rotor blade <NUM>. For example, a rotor blade serial number may be electronically linked with the moment weight. The present disclosure, of course, is not limited to the foregoing exemplary techniques for communicating / assigning the moment weight of a rotor blade.

In step <NUM>, a location for the rotor blade <NUM> to be connected to the rotor hub <NUM> is determined. The apparatus balancing system <NUM> receives the moment weight data associated with the rotor blade <NUM>, as well as moment weight data associated with other rotor blades <NUM>. Alternatively, the moment weight associated with the rotor blade <NUM>, as well as the moment weights associated with other rotor blades <NUM>, may be input into the apparatus balancing system <NUM>. Note, the moment weight data / moment weights associated with other rotor blades <NUM> may be determined and provided to the apparatus balancing system <NUM> following additional iterations of steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM> for the other rotor blades <NUM>. The apparatus balancing system <NUM> processes the received moment weight data / moment weights with one or more algorithms and/or programs to determine locations at which the rotor blades <NUM> may be connected to the hub <NUM> such that the rotor <NUM> is rotationally balanced (as much as possible) during rotor rotation. The apparatus balancing system <NUM> then provides (e.g., outputs data indicative of, displays, etc.) the locations associated with each of the rotor blades <NUM>.

In step <NUM>, each of the rotor blades <NUM> (represented by the moment weight data / moment weights processed by the apparatus balancing system <NUM>) is connected to the rotor hub <NUM> at a respective one of the locations determined in the balancing step <NUM>. These connections may be mechanical connections (e.g., dovetail blade root into corresponding slot in the hub <NUM>) or bonded connections in the case of an integrally bladed rotor (IBR) (also referred to as a "blisk") for example.

Referring to <FIG>, a moment weight of each rotor blade <NUM> may be categorized into three components: an axial moment weight (e.g., along x-axis); a tangential moment weight (e.g., along y-axis); and a radial moment weight (e.g., along z-axis). The axial moment weight is measured along the rotational axis <NUM> of the rotor <NUM>. The tangential moment weight is measured in a direction than is tangent to a circle around the rotational axis <NUM>. The radial moment weight is measure along a ray projecting out from the rotational axis <NUM> of the rotor <NUM>. The method <NUM> above may be performed for all three components of the moment weight. Alternatively, the method <NUM> may be performed for a single one (or select two) of the three components of the moment weight. For example, in some embodiments, the moment weight determined in the step <NUM> may be a radial moment weight. In such embodiments, the center of gravity distance determined in the step <NUM> may be a radial center of gravity distance.

The inventor of the present disclosure has discovered that a radial moment weight of a rotor blade is typically significantly larger than an axial or a tangential moment weight of the same rotor blade. Therefore, focusing the method <NUM> on the radial moment weight may reduce complexity while still providing accurate results.

The rotor blade <NUM> may be any type of rotor blade included in a turbine engine. The rotor blade <NUM>, for example, may be configured as a fan blade, a compressor blade or a turbine blade.

<FIG> is a side cutaway illustration of a geared turbofan turbine engine <NUM> in which the rotor blade <NUM> or rotor blades <NUM> involved in the method <NUM> may be included. This turbine engine <NUM> extends along an axial centerline <NUM>, which may be coaxial with the rotational axis <NUM> (see <FIG>), between an upstream airflow inlet <NUM> and a downstream airflow exhaust <NUM>. The turbine engine <NUM> includes a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM> and a turbine section <NUM>. The compressor section <NUM> includes a low pressure compressor (LPC) section 65A and a high pressure compressor (HPC) section 65B. The turbine section <NUM> includes a high pressure turbine (HPT) section 67A and a low pressure turbine (LPT) section 67B.

The engine sections <NUM>-<NUM> are arranged sequentially along the centerline <NUM> within an engine housing <NUM>. This housing <NUM> includes an inner case <NUM> (e.g., a core case) and an outer case <NUM> (e.g., a fan case). The inner case <NUM> may house one or more of the engine sections 65A-67B; e.g., an engine core. The outer case <NUM> may house at least the fan section <NUM>.

Each of the engine sections <NUM>, 65A, 65B, 67A and 67B includes a respective rotor <NUM>-<NUM>; e.g., see <FIG>. Each of these rotors <NUM>-<NUM> includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).

The fan rotor <NUM> is connected to a gear train <NUM>, for example, through a fan shaft <NUM>. The gear train <NUM> and the LPC rotor <NUM> are connected to and driven by the LPT rotor <NUM> through a low speed shaft <NUM>. The HPC rotor <NUM> is connected to and driven by the HPT rotor <NUM> through a high speed shaft <NUM>. The shafts <NUM>-<NUM> are rotatably supported by a plurality of bearings <NUM>; e.g., rolling element and/or thrust bearings. Each of these bearings <NUM> is connected to the engine housing <NUM> by at least one stationary structure such as, for example, an annular support strut.

During operation, air enters the turbine engine <NUM> through the airflow inlet <NUM>. This air is directed through the fan section <NUM> and into a core gas path <NUM> and a bypass gas path <NUM>. The core gas path <NUM> extends sequentially through the engine sections 65A-67B. The air within the core gas path <NUM> may be referred to as "core air". The bypass gas path <NUM> extends through a bypass duct, which bypasses the engine core. The air within the bypass gas path <NUM> may be referred to as "bypass air".

The rotor <NUM> and its rotor blades <NUM> may be included in various turbine engines other than the one described above as well as in other types of rotational equipment. The rotor <NUM> and its rotor blades <NUM>, for example, may be included in a geared turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section. Alternatively, rotor <NUM> and its rotor blades <NUM> may be included in a turbine engine configured without a gear train. The rotor <NUM> and its rotor blades <NUM> may be included in a geared or non-geared turbine engine configured with a single spool, with two spools (e.g., see <FIG>), or with more than two spools. The turbine engine may be configured as a turbofan engine, a turbojet engine, a propfan engine, a pusher fan engine or any other type of turbine engine. The present disclosure therefore is not limited to any particular types or configurations of turbine engines or other equipment.

Claim 1:
A manufacturing method, comprising:
receiving model data indicative of a solid model of a rotor blade (<NUM>,<NUM>) of a gas turbine engine (<NUM>) having a rotational axis (<NUM>); and
determining a center of gravity distance (<NUM>) of the rotor blade (<NUM>,<NUM>) using the model data, wherein the center of gravity distance (<NUM>) is a distance between the rotational axis (<NUM>) and a center of gravity point (CG) of the rotor blade (<NUM>, <NUM>),
characterized in that the method further comprises:
determining a moment weight of the rotor blade (<NUM>,<NUM>) based on the center of gravity distance (<NUM>) of the rotor blade (<NUM>,<NUM>) and a measured weight of the rotor blade (<NUM>,<NUM>);
determining a location for the rotor blade (<NUM>,<NUM>) to be connected to a rotor hub (<NUM>) based on the moment weight; and
connecting the rotor blade (<NUM>,<NUM>) to the rotor hub (<NUM>) at the location.