AMI4BLISK

Automated Geometrical Measurment and Visual Inspection for Blisks

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 Obiettivo del progetto (Objective)

'The main impact of the following proposal of the three participants Hexagon Metrology GmbH, Hexagon Technology Center GmbH, and Fraunhofer Institute for Industrial Mathematics ITWM is an integrated approach to the measurement the geometry and automatical identification and characterization of surface defects of a BLISK (bladed disk). An automatic visual inspection of the BLISKs would create a significant contribution to better and safer processes at lower cost. The key innovations of AMI4BLISK is a unique and new approach for automated BILISK measurement and inspection; an innovative and new image processing algorithms and visual inspection sensor setup and a new sensor for defect characterization and measurement. In a first step the geometrical measurement with a coordinate-measuring-machine (CMM) will provide the information of the shape and surface of the BLISK in combination with the CAD model that provides basic information of the geometry. In a second step all possible defects need to be found with the use of an intelligent image-processing-system. The location and type of the questionable defects will then be qualified and stored automatically. In a third step the defects will be classified. With the known position of the defects a program to measure all the defects with another CMM is generated automatically. These measurements give a quantitative description of the possible defects. In some cases where a defect may be questionable the inspection by a person of skill will still be necessary.'

Introduzione (Teaser)

Nowadays, critical parts of aero engines are manufactured at different factories in different countries, requiring that their inspection is done in a unified way. For EU-funded researchers, the best way to ensure homogeneity is by automating the evaluation of these parts.

Descrizione progetto (Article)

With the growing complexity of aero engines, determining the reliability of critical components like the turbines' bladed disks is getting more and more demanding. To comply with stringent standards in terms of quality and safety, these so-called blisks are currently checked by specialists for hours. Even the most infinitesimal fracture could diminish the reliability and durability of a component.

The discovered defects are measured down to micrometre scale to obtain a quantitative description. Optical measurement systems provide accurate data on surface defects. State-of-the-art tactile measurement systems are more suitable for inspection because of their lower resolution. Consequently, inspection and precise measurements of blisks are carried out separately.

In the future, all steps could be carried out with a single system developed by the EU-funded 'Automated geometrical measurement and visual inspection for blisks' (http://www.ami4blisk.eu (AMI4BLISK)) project. This new solution for automated measuring and visual inspection of blisks consists of two coordinate measuring machines (CMMs) equipped with optical sensors.

The geometry of the blisk can be determined using the CMMs. In a first step, information about the actual shape of the component is collected along with data about possible deviations from desired dimensions. Its surface is also scanned by multiple cameras for irregularities. Both location and defect type (scratches, dips, etc) are stored for further analyses.

Project researchers have developed advanced algorithms for processing images of the blisks' surfaces. These need to be supplied with just a small number of samples specific to blisks to find and classify defects automatically. However, for those defects in question, additional inspection will need to be carried out by a specialist.

The final AMI4BLISK system will be able to complete the evaluation of a blisk, including visual inspection and automated measurement of defects, in less than eight hours. The reliability of blisk evaluation will be greater than what has been achieved until today, bringing with it technical as well as economical benefits for the aerospace industry.

AMI4BLISK has offered researchers the opportunity to develop an innovative solution that will allow the European aerospace industry to achieve tighter tolerances and remain ahead of the competition.