1. Evaluation of Turbine Blade Measuring
The new scanning generation
Daniel Görsch
Carl Zeiss © 2003

2. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003

3. BladePro Overview
Quality control of turbine blades based on external nominal and actual measuring data
Stand alone application for MS Windows 2000 or Windows XP
Build on the .NET framework of Microsoft
Data import and export via XML format
Communication with external application using a XML file interface (SPC)
Usage online in the production process as well as offline for data research
Schriftarten:
Headline- Arial Fett
Ü1 - Arial fett
Ü2 - Arial fett
Text - Arial 16-18
Aufzählungszeichen- Arial 16-18
Bildunterschriften - Arial Kursiv 12
Daniel Görsch
Carl Zeiss © 2003

4. BladePro Framework Concept
plugin
MTU
Nominals (one time)
Actuals
Header information
Probe radius
Inspection orders
Coordinate
systems
BladePro
XML
Files
(in future possible)
CMMs existing software BladePro plug-ins
packages
UMESS /
KUM
Calypso
HOLOS NT NN
(TSK, CT...)
CMM-OS /
DME
MASCH NN
CMMs
others
Daniel Görsch
Carl Zeiss © 2003

5. BladePro Application Concept – Evaluation
Four step evaluation of actual data:
Automatic or interactive identification of blade Specification
Automatic or interactive import of actual data
Automatic evaluation of actual data on the basis of the information contained in the Specification File
Export of the results as XML, HTML, or ASCII file
Daniel Görsch
Carl Zeiss © 2003

6. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003

7. BladePro Functional Range
Computation of geometric characteristics as thickness, length, stacking point, etc.
3D best fit by methods of Gauss, Tschebyscheff, and modifications of these types
Selectable degrees of freedom
New kind of best fit procedure implementing the extension/contraction of the nominal profile in order to deal with large length errors (patent applied)
Daniel Görsch
Carl Zeiss © 2003

8. BladePro Features An assortment of selectable characteristics:
Shape deviation of the section profile
Maximum blade thickness
Maximum blade length
Thickness of leading and trailing edge
Radius of leading and trailing edge
Thickness at arbitrary positions of the section profile
Twist angle of the section
Stacking point
Chord line length
Mean line, tangent line,
etc.
Daniel Görsch
Carl Zeiss © 2003

9. BladePro Features Selectable best fit methods:
Method by Gauss (least error squares)
Method by Gauss (weighted by tolerances)
Method by Tschebyscheff (minimal maximal error)
L1-Method (least absolute error values)
Selectable best fit degrees of freedom:
Standard degrees of freedom (rotation, translation, offset)
Degrees of freedom for extension/contraction of section profiles
Daniel Görsch
Carl Zeiss © 2003

10. BladePro Best Fit Transformations
Selectable best fit transformations:
Standard (the same as in KUM, Calypso, etc.)
Standard with offset
Elongation - compensation of global length errors
(changes the entire profile)
Shift Elongation - compensation of local length errors at the edges (changes only edges of the profile)
The last two transformations change the nominal section profile data!
Daniel Görsch
Carl Zeiss © 2003

11. BladePro Best Fit Transformations - Elongation
Right Profile
Left Profile
Left Mean Line Point
Right Mean Line Point
Rotation Center
The section profile is
split into two parts.
These parts are rotated
along a circle formed by
three points.
This transformation
does not alter the radius
of the edges.
It is recommended for
global length errors.
Daniel Görsch
Carl Zeiss © 2003

12. BladePro Best Fit Transformations – Shift Elongation
The points of the edge profile
are shifted along a projection
line.
The shifting value is the same
for all points.
Transformed Edge Profile
Projection Center
Original Edge Profile
This transformation alters the radius of the edges. It is recommended for local length errors at the profile edges.
Daniel Görsch
Carl Zeiss © 2003

13. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003

14. BladePro XML Interface Communication
Shared network path (Samba Server)
Computer for the external measuring application
Computer for BladePro
Daniel Görsch
Carl Zeiss © 2003

15. BladePro Calypso 3d-Curve
Create 3d-Curves for each blade section
Daniel Görsch
Carl Zeiss © 2003

16. BladePro CurveBlade Characteristic
Add the Characteristic for CurveBlade
Daniel Görsch
Carl Zeiss © 2003

17. BladePro Calypso Curve to BladePRO
Enter name of BladePRO Specification File
Enter directory for measured data to transfer to BladePRO
Enter directory for Nominal points and vectors. Used in the BladePRO to design Blade Specification.
Choose desired curve sections
Daniel Görsch
Carl Zeiss © 2003

18. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003

19. BladePro User Interface - Handling
Based on Microsoft guide lines for standard office applications
Document oriented working and management of blades
For all user actions there are several way of realization
Intensive use of context menus - expect an action for an element at the element itself
All dialogs are non modal and realize an instant preview of changes
Daniel Görsch
Carl Zeiss © 2003

20. BladePro User Interface – Main Form
Blade property folder
Protocol header
Table for section selection
Text protocol for all sections
Table for protocol page selection
Tab control to switch between several graphics
Daniel Görsch
Carl Zeiss © 2003

21. BladePro User Interface – Multiple Sections Forms
Multiple drawings and texts
in one form.
All forms can have different
orientation and paper sizes.
All texts and drawings are
free floating, can be rotated and shifted.
Daniel Görsch
Carl Zeiss © 2003

22. BladePro User Interface – Section Forms
Plot of the section as well
as information on the
computed characteristics.
Information on best fit
options are displayed.
Detailed plots are available for
leading and trailing edge.
Daniel Görsch
Carl Zeiss © 2003

23. BladePro User Interface – Options & Settings
Daniel Görsch
Carl Zeiss © 2003

24. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003

25. BladePro Characteristic Geometries
Blades – Rotating
Vanes - Stationary
Pressure Side
Flow
Suction Side
Daniel Görsch
Carl Zeiss © 2003

26. BladePro Characteristic Geometries
Leading / Trailing Edge:
Daniel Görsch
Carl Zeiss © 2003

27. BladePro Characteristic Geometries
Profile:
Daniel Görsch
Carl Zeiss © 2003

28. BladePro Characteristic Geometries
Profile Tolerance Segment:
Daniel Görsch
Carl Zeiss © 2003

29. BladePro Characteristic Geometries
Mean Line:
Daniel Görsch
Carl Zeiss © 2003

30. BladePro Characteristic Geometries
Chord Line:
Daniel Görsch
Carl Zeiss © 2003

31. BladePro Characteristic Measures
Chord Line Length:
Daniel Görsch
Carl Zeiss © 2003

32. BladePro Characteristic Measures
Chord Line Angle:
Daniel Görsch
Carl Zeiss © 2003

33. BladePro Characteristic Geometries
Tangent Line:
Daniel Görsch
Carl Zeiss © 2003

34. BladePro Characteristic Geometries
Bearing Surface:
Daniel Görsch
Carl Zeiss © 2003

35. BladePro Characteristic Measures
Bow Location:
y-Part of the best fit translation
Lean Location:
x-Part of the best fit translation
Twist Angle:
Angle of the best fit rotation
Extreme Deviation:
Maximal or minimal deviation (nominal to actual profile)
Daniel Görsch
Carl Zeiss © 2003

36. BladePro Characteristic Measures
Edge Radius:
Smallest tangential circle for actual edge profile
Mean Edge Radius:
Gaussian best fit circle through the edge profile points
Maximal Length:
Largest distance of two points form leading/trailing edge
Maximal Thickness:
Largest circle lying inside the actual profile
Daniel Görsch
Carl Zeiss © 2003

37. BladePro Characteristic Measures
Maximal Length :
Daniel Görsch
Carl Zeiss © 2003

38. BladePro Characteristic Measures
Maximal Distance:
Stacking Axis
Daniel Görsch
Carl Zeiss © 2003

39. BladePro Characteristic Measures
Edge Asymmetry:
Daniel Görsch
Carl Zeiss © 2003

40. BladePro Characteristic Measures
Thickness at Basic Distance:
Daniel Görsch
Carl Zeiss © 2003

41. BladePro Characteristic Measures
Distance at Basic Thickness (KPoint Distance):
Daniel Görsch
Carl Zeiss © 2003

42. BladePro Characteristic Measures
Edge Angle:
Daniel Görsch
Carl Zeiss © 2003

43. BladePro Characteristic Measures
Bearing Surface Distance:
Daniel Görsch
Carl Zeiss © 2003

44. BladePro – Training Introduction Functions & Features
Calypso Interface
User Interface
Characteristics
Part I
Part II
Part III
Part IV
Part V
Daniel Görsch
Carl Zeiss © 2003