Shop Floor Inspection Machine measures compressor blades

Non-contact, automated Lightscan measures compressor blade airfoils for comparison with CAD data (with 160,000-point 3D point cloud) to obtain immediate go/no go sentencing. In addition to measuring sensor and associated application software, blade gauging inspection solution uses white light technology and has typ inspection cycle of 20 sec. With accuracy exceeding 0.0005 in., machine can be programmed to inspect new parts in as little as 4 hr.

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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.

Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems

In operation, Lightscan uses LCD technology to project and move software-generated light patterns over the part to be inspected. The reflected pattern is detected by two CCD cameras, using the latest firewire technology. The modulated fringe is then analyzed by the software to create a point cloud, featuring 80,000 measuring points. The part is then turned very precisely rotated and the procedure repeated, so that a total 3-D point cloud of 160,000 measuring points is produced for comparison with the CAD-generated master part model. From this comparison, a surface deviation map is generated and a series of software gauges are used to determine standard gauge outputs such as contour, bow, warp, platform and thickness. These results are then displayed on the system's monitor so that the operator can make a simple go/no go sentencing decision. This entire process is completed in 20 seconds.

The application specific software features advance data filtering to ensure the rapid presentation of the highly accurate results, which can be printed as a report or saved to a data file in standard formats. This data can then be further analyzed to help in the improvement of upstream processes, such as enhanced tool design.

Lightscan is capable of handling blades with a wide range of surface finish. There is no need to tumble components or to apply a white coating, as is the case with competitive products and the system will even handle "benched" parts, which feature a mix of surface finishes.

About GE Inspection Technologies

GE Inspection Technologies is a global leader in technology-driven inspection solutions that deliver customer productivity, quality and safety. The company designs, manufactures and services radiographic, ultrasonic, eddy current and metrology equipment to inspect and test materials without deforming or damaging them. Its products are used in a wide range of industries, including Aerospace, Power Generation, Oil & Gas and Automotive. The company has 11 application centres around the globe and offers a range of services including repair,