Intelligent system for turbine blade overhaul using robust profile re-construction algorithm

Repairing and servicing of aerospace components usually involve tedious work processes and are highly labor-intensive, one typical example is the overhauling of turbine blade. The overhauling process involves reconstruction of the blade tip through cutting off the worn tip and rebuilding it through the welding and finally polishing the welded material to its original shape. Traditionally the polishing process is carried out manually; this is largely due to the difficulty in re-establishing the "used" blade profile which suffered minor distortion through usage. This project introduced and developed a profile reconstruction algorithm namely the robust profile re-construction (RPR) algorithm. The algorithm adopted the neutral line concept and the interpretation vector method by finding the relationship between the original profile of the unused blade and the used blade under each section layers in two-dimensional plan. Experimental result shows that the system and algorithm can provide the required accuracy for the aerospace overhaul industry. Consequently, the algorithm and process could provide the turnkey solution for the blade overhauling industry and forward to fully automation opportunity.