Systems and methods for automated sensing and machining for repairing airfoils of blades

A system for measuring and machining a blade having a weld-repaired region, the weld-repaired region being selected from the group consisting of a plate welded to a surface of the blade, a weld-filled crack repair volume, and combinations thereof, the system comprising:

• a displacement-sensing probe operable for measuring a plurality of dimensions of the blade in the weld-repaired region;
• a computer-controlled multi-axis machine operable for moving the displacement-sensing probe in the x, y and Z directions as well as other rotational degrees of freedom to scan the shape of the blade in the weld-repaired region;
• an adjustable platform operable for holding and positioning the blade having the weld-repaired region;
• a tool holder comprising a plurality of cutting tools;
• and
• a computer in connection with and operable for controlling the displacement-sensing probe, the multi-axis machine, the adjustable platform and the tool holder, wherein the computer is further operable for recognizing a deviation of the blade geometry from a nominal shape and creating a numerically-controlled tool path customized for machining the blade having the weld-repaired region, and wherein the computer is programmed to locate the weld-repair region on the blade for measuring the weld-repair region.

A method for repairing an airfoil having a weld-repaired region, the weld-repaired region being selected from the group consisting of a plate welded to a surface of the airfoil, a weld-filled crack repair volume, and combinations thereof, comprising:

• providing the airfoil on a measurement and machining system;
• creating a nominal numerically-controlled tool path based on a nominal shape of the airfoil and the airfoil's position on the measuring and machining system;
• measuring the airfoil in the weld-repair region using a sensor to acquire a plurality of readings from the sensor corresponding to the actual shape of the airfoil;
• creating a three-dimensional map by synchronizing a plurality of x, y and z coordinates for the measurement and machining system and the readings from the sensor;
• modifying the nominal numerically controlled (NC) tool path based on the three-dimensional map to generate a customized NC tool path;
• and
• blending the weld-repair region on the airfoil using the customized NC tool path.

A system for measuring and machining an airfoil having a weld-repaired region, the weld-repaired region being selected from the group consisting of a plate welded to a surface of the airfoil, a weld-filled crack repair volume, and combinations thereof, comprising:

• a numerically-controlled machine;
• a displacement-sensing probe mounted on the numerically-controlled machine and operable for acquiring a plurality of displacement-sensing probe readings corresponding to the actual shape of the airfoil in the weld-repair region;
• a computer operable for acquiring the displacement-sensing probe readings from the displacement-sensing probe and for generating a numerically-controlled tool path for the numerically-controlled machine using the displacement-sensing probe readings, wherein the computer is programmed to locate the weld-repair region on the airfoil for measuring the weld-repair region;
• and
• a cutting tool holder mounted on the numerically controlled machine and being equipped with a plurality of cutting tools, the cutting tools being adapted to blend the weld-repair region on the airfoil.