Optimal profile generation in distorted surface finishing

We present a template-based optimal profile fitting method to generate optimal profiles for robotic surface finishing of repairing parts. By using the design profile as a template, only a few measurement points are required for the fitting. A series of steps of the template-based optimal profile fitting are performed to generate the final fitted profile. A fast converging direct search minimization algorithm has been developed for the optimal fitting. The fitted profile is used to compute robotic paths for surface finishing. The template-based optimal profile fitting method has been successfully implemented as a core technique in a robotic surface finishing system for turbine vane airfoil repairing. It enables the system, which has been operating in a production line, to effectively adapt to the part variations.