System and method for performing internal machining

Abstract

A repair system for repairing a component includes an elongated repair tool having a first end supporting an electrode and a second end opposite the first end. A camera has a field of view and is fixedly attached to the elongated repair tool such that the electrode is within the field of view. An electrical power supply is coupled to the electrode and is operable to deliver an electrical current to the electrode, the electrical current being sufficient to form an arc between the electrode and the component to remove material from the component, where the second end of the elongated repair tool is movable to position the electrode in a desired position.

Description

Background Art

[0001] The manufacture of complex parts sometimes requires casting or forming internal holes or passages. In some cases, these holes may not be properly formed or may become blocked with debris or unwanted material. If the location of these holes is not accessible, these casting defects may cause the part to be scrapped. Summary of the invention

[0002] In one aspect, a repair system for repairing a component includes an electrode catheter extending along a longitudinal axis and defining a first end and a second end. An electrode is attached to the first end of the electrode catheter and defines an electrode tip. A camera is connected to the electrode catheter near the first end and has a field of view encompassing the electrode tip. A camera wire is coupled to the camera and extends to the second end of the electrode catheter. The camera wire is operable to transmit a camera signal from the camera. A sheath is arranged to enclose a portion of the electrode catheter and a portion of the camera wire, and a power supply is operable to deliver a current to the electrode tip, the current being sufficient to form an arc between the electrode tip and the component to remove material from the component.

[0003] In another aspect, a repair system for repairing a component includes an elongated repair tool having a first end supporting an electrode and a second end opposite the first end. A camera has a field of view and is fixedly attached to the elongated repair tool such that the electrode is within the field of view. A power supply is coupled to the electrode and is operable to deliver a current to the electrode sufficient to form an arc between the electrode and the component to remove material from the component, wherein the second end of the elongated repair tool is movable to position the electrode in a desired position.

[0004] In another aspect, a method of removing material from a component includes positioning a first end of an elongated repair tool within the component, the first end supporting an electrode and a camera, the camera having a field of view encompassing the electrode, transmitting an image of the electrode from the camera, and manipulating a second end of the elongated repair tool based on the transmitted image to position the electrode in a desired position relative to the component. The method also includes providing power to the electrode, the electrode generating an arc between the electrode and the component in response to receiving the power, the arc being operable to melt a portion of the component.

[0005] The foregoing has generally summarized some of the technical features of the present disclosure so that those skilled in the art can better understand the detailed description below. Other features and advantages of the present disclosure will be described below, and the features and advantages form the subject matter of the claims. Those skilled in the art will appreciate that they can easily use the disclosed concepts and specific embodiments as a basis for modifying or designing other structures to achieve the same purpose of the present disclosure. Those skilled in the art will also recognize that such equivalent structures do not depart from the spirit and scope of the broadest form of the present disclosure.

[0006] Moreover, before embarking upon the following detailed description, it should be understood that various definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that these definitions apply in many, if not most, cases to prior and future uses of these defined words and phrases. Although some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] To easily identify the discussion of any particular component or act, the most significant digit or digits in a reference number refer to the figure number in which the component is first introduced.

[0008] Figure 1 Components comprising openings to the interior space are illustrated.

[0009] Figure 2 Illustration of the repair Figure 1 Repair system of the components characteristics.

[0010] Figure 3A Pictured Figure 2 A portion of the repair system which is positioned adjacent to Figure 1 Internal passages within components that are blocked or improperly formed.

[0011] Figure 3B Pictured Figure 2 A portion of the repair system which is positioned adjacent to Figure 1 The internal passages within the components are blocked or improperly formed, with the open passages shown in the foreground.

[0012] Figure 3C Illustration of the repair system after operation Figure 3A channel.

[0013] Figure 4A Pictured Figure 2 part of a repair system that is being positioned adjacent to Figure 1 Internal passages within components that are blocked or improperly formed.

[0014] Figure 4B Illustration of the repair system after operation Figure 4A channel. DETAILED DESCRIPTION

[0015] Before explaining any embodiment of the present invention in detail, it should be understood that the application of the present invention is not limited to the structural details and component arrangements set forth in this description or illustrated in the following drawings. The present invention is capable of other embodiments and can be implemented or executed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting.

[0016] Various techniques related to systems and methods will now be described with reference to the accompanying drawings, wherein the same reference numerals represent the same elements throughout the text. The various embodiments of the principles of the present disclosure described in this patent document in the accompanying drawings discussed below and in this patent document are for illustration only and should not be construed as limiting the scope of the present disclosure in any way. Those skilled in the art will appreciate that the principles of the present disclosure can be implemented in any appropriately arranged device. It should be understood that the functions described as being performed by certain system elements can be performed by multiple elements. Similarly, for example, an element can be configured to perform the functions described as being performed by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0017] In addition, it should be understood that the words or phrases used in this article should be interpreted broadly, unless there are clear limitations in some examples. For example, the terms "include", "have" and "include" and their derivatives mean including without limitation. The singular forms "one", "an" and "the" are also meant to include plural forms, unless the context clearly indicates otherwise. In addition, the term "and / or" used in this article refers to and covers any and all possible combinations of one or more of the associated listed items. The term "or" is inclusive and means and / or, unless the context clearly indicates otherwise. The phrases "associated with..." and "associated with this" and their derivatives may refer to including, including within, interconnected with, containing, contained within, connected to or connected with, connected to or connected with, able to communicate with, cooperate with, interlaced, juxtaposed, near, coupled to or coupled with, having, having the properties of, etc. In addition, although multiple embodiments or configurations may be described herein, any features, methods, steps, components, etc. described with respect to one embodiment are equally applicable to other embodiments if there is a lack of specific instructions to the contrary.

[0018] In addition, although the terms "first", "second", "third", etc. can be used herein to refer to various elements, information, functions or behaviors, these elements, information, functions or behaviors should not be limited to these terms. Instead, these digital adjectives are used to distinguish between different elements, information, functions or behaviors. For example, without departing from the scope of the present disclosure, the first element, information, function or behavior may be referred to as the second element, information, function or behavior, and similarly, the second element, information, function or behavior may be referred to as the first element, information, function or behavior.

[0019] Additionally, the term "adjacent" may refer to an element being relatively close to another element but not in contact, or to an element being in contact with another part, unless the context clearly indicates otherwise. Additionally, the phrase "based on" means "based at least in part on," unless otherwise clearly indicated. The term "approximately" or "substantially" or similar terms are meant to encompass variations in the value of the dimension within normal industry manufacturing tolerances. If no industry standard is available, a twenty percent variation will fall within the meaning of these terms unless otherwise indicated.

[0020] Figure 1 A component 100 is illustrated, which may be manufactured using many different manufacturing processes, including forging, casting, machining, additive manufacturing, etc., or a combination thereof. The illustrated component 100 is a turbine blade, such as a gas turbine blade for a large gas turbine. Typically, turbine blades, as well as other components 100, include internal features and passages that allow for internal flow or support. For example, Figure 1 The turbine blade illustrated in FIG. 1 may include a plurality of internal holes or passages that direct cooling air throughout the interior of the component 100. A plurality of openings 102 to the interior of the component 100 are provided.

[0021] In some structures, Figure 1 Turbine blades are formed using casting processes, additive manufacturing processes, or a combination thereof. These processes can form holes or passages in the interior of the turbine blade, but in some cases, the holes may be blocked or incompletely formed. In some cases, these defects cannot be repaired using conventional techniques, which requires scrapping the turbine blade.

[0022] Although Figure 1 The component 100 is illustrated in the form of a turbine blade, but it will be apparent that the systems and methods described herein are applicable to nearly any component 100, and are particularly applicable to components 100 that include small enclosed spaces and passages that may become blocked. A turbine blade is just one example of a component 100, which is provided for ease of description of the repair system 200 and method.

[0023] Figure 2A repair system 200 is shown, which is suitable for repairing a component 100, such as Figure 1 In particular, the repair system 200 is well suited for repairing incomplete or blocked holes or passages within the component 100 to reduce the scrap rate of the component 100.

[0024] Repair system 200 includes display 202, power supply 204, and elongated repair tool 218 defining an overall length 220 and a diameter 222. In most configurations, elongated repair tool 218 has a length 220 that is at least 50 times the diameter 222, and in most applications, includes a length 220 between 50 and 1000 times the diameter 222.

[0025] The long repair tool 218 includes an electrode catheter 206 extending between a first end 226 and a second end 228. The electrode 212 is attached to the first end 226 of the electrode catheter 206 and is fixed in a desired operating position using an electrode holder 224 in the form of a set screw. In the illustrated structure, the electrode 212 includes a ninety-degree bend so that the electrode tip 214 is spaced apart from the electrode catheter 206. Of course, other structures may include different arrangements of the electrode 212, including straight electrodes or electrodes with bends other than ninety degrees. The electrode 212 and the electrode tip 214 can be any desired shape, but in most structures, a circular cross-section or cylindrical shape is used. In most structures, the electrode 212 is formed of a conductive material such as copper or graphite, and other materials are also possible.

[0026] The electrode 212 is electrically connected to the electrode catheter 206, which in turn is electrically connected to the power supply 204 to allow power to be delivered from the power supply 204 to the electrode 212. The power supply 204 is arranged to deliver AC or DC power at a desired voltage and amperage as required for a particular application. The power supply 204 can be powered by any available power source, including but not limited to 120V or 240V AC power.

[0027] The camera 208 is positioned at or near the first end 226 and defines a field of view 230 that allows the camera 208 to image at least the electrode tip 214 and the area immediately surrounding the electrode tip 214. To accomplish this, the camera 208 can be positioned at an angle (e.g., 45 degrees) relative to the electrode catheter 206. In yet other configurations, the camera 208 can be movable to allow the field of view 230 to be adjusted and repositioned.

[0028] The camera line 210 is connected to the camera 208 and operates to conduct the camera signal from the camera 208 to the display 202, where the images captured by the camera (video, still, black and white, color, infrared, etc.) can be displayed to the user. In other constructions, the display 202 is replaced by or used in conjunction with a data storage device or computer to capture and store the data captured by the camera 208 in other ways.

[0029] The sheath 216 is positioned between the first end 226 and the second end 228 such that it surrounds and covers a portion of the electrode lead 206 and a portion of the camera line 210. The sheath 216 is flexible and provides some protection for the electrode lead 206 and the camera line 210 disposed therein. In addition, the sheath 216 is an electrical insulator that reduces the likelihood of unwanted contact and short circuits between the electrode lead 206 and the component 100 during positioning or use of the repair system 200.

[0030] Sheath 216, electrode catheter 206 and camera wire 210 are flexible enough to enable the user to manipulate second end 228 of elongated repair tool 218 to position electrode 212 and, more importantly, electrode tip 214 in a desired position. Camera 208 captures images (video or still) of electrode 212 and electrode tip 214 and the surrounding area. These images can be displayed on display 202 to help the user position electrode tip 214 in a desired position.

[0031] Once the electrode tip 214 is positioned as desired, the user initiates operation of the power supply 204 to deliver power to the electrode 212. The power in the form of voltage and current forms an arc between the electrode tip 214 and the part 100 in the area near the electrode tip 214. The current and voltage are sufficient to quickly melt the material constituting the part 100 in the area near the electrode tip 214. In contrast, the electrode 212 is formed of a highly conductive material (e.g., copper) and / or a high melting point material (e.g., graphite) so that the electrode tip 214 does not melt and is therefore not consumed. The repair system 200 operates as an electrical discharge machining (EDM) system that can be used to remove small amounts of material from the part 100. In particular, the repair system 200 is capable of positioning the electrode tip 214 within the part 100 by passing the electrode tip 214 through one or the other of the openings 102 and into a location that is not accessible to conventional tools. The power supply 204 then provides sufficient power to melt any unwanted material that may be located within the passages or holes to melt and remove the material, thereby allowing repair of the component 100 that might otherwise need to be scrapped.

[0032] FIG. 3A to FIG. 3CThe process of opening an internal passage 302 that is blocked or partially filled with an obstruction in a component 100 is illustrated. During the casting process, debris or unwanted material may block or partially block the small internal passage 302. Figure 3A , electrode 212 and electrode tip 214 are positioned in a desired location within component 100 and adjacent to an area where one of internal passages 302 is to be formed.

[0033] Go to Figure 3B , electrode 212 is positioned within a narrow conduit within component 100 and oriented such that electrode tip 214 is directly adjacent to where one of internal passages 302 would otherwise be formed. In this position, when power supply 204 is activated, an arc will form between electrode tip 214 and unwanted material within internal passage 302, thereby melting and removing the unwanted material and leaving internal passage 302 open.

[0034] Figure 3C The interior passage 302 is better illustrated after removal of unwanted material.

[0035] Figure 4A is used Figure 2 1. Another example of a repair system 200 in FIG. 1. In this example, an electrode 212 is positioned within a narrow conduit formed within a component 100. A second end 228 of an elongated repair tool 218 is manipulated to position an electrode tip 214 adjacent to a volume of unwanted material 402 that is within and obstructing an internal passage 302. As can be seen, the internal passage 302 is one of a series of internal passages 302 that extend along the length of the conduit. Without the repair system 200, a plug or obstruction such as the unwanted material 402 in the internal passage 302 may render the component 100 scrapped.

[0036] Figure 4B The internal passage 302 is illustrated after activation of the power supply and removal of the unwanted material 402. As described, the repair system 200 operates as an EDM system to generate an arc that melts the unwanted material 402 to open the internal passage 302, thereby avoiding the need to scrap the component 100.

[0037] Although the exemplary embodiments of the present disclosure have been described in detail, those skilled in the art will understand that they may make various changes, substitutions, variations, and alterations as disclosed herein without departing from the spirit and scope of the disclosure in its broadest form.

[0038] Nothing in the description of this application should be read as implying that any particular element, step, act, or function is essential to be included in the scope of the claims: the scope of the patented subject matter is limited only by the claims that issue. Furthermore, unless the specific word "means for" is followed by a participle, these claims are not intended to employ a means-plus-function claim structure.

Claims

1. A repair system for repairing a component, the repair system comprising: an electrode conduit extending along a longitudinal axis and defining a first end and a second end, the first end being positionable within the lumen of the component; an electrode attached to the first end of the electrode catheter, the electrode defining an electrode tip; a camera connected to the electrode catheter near the first end and having a field of view encompassing the electrode tip; a camera wire coupled to the camera and extending to the second end of the electrode catheter, the camera wire being operable to transmit a camera signal from the camera; a sheath arranged to surround a portion of the electrode catheter and a portion of the camera wire; as well as An electrical power supply is operable to deliver an electrical current to the electrode tip sufficient to form an arc between the electrode tip and the component to remove material from the component.

2. The repair system of claim 1, wherein: The electrode catheter defines a diameter and a length in the longitudinal direction, and wherein the length is between 50 and 1000 times the diameter.

3. The repair system of claim 1, wherein: The camera is fixedly attached to the electrode catheter.

4. The repair system of claim 1, wherein: The electrode lead, the electrode, and the sheath cooperate to at least partially define an elongated repair tool having a working end corresponding to the first end of the electrode lead and a manipulation end corresponding to the second end of the electrode lead.

5. The repair system of claim 4, wherein: Movement of the manipulator end produces corresponding movement of the working end and the electrode tip.

6. The repair system of claim 1, wherein: The power supply and the electrode tip cooperate to perform an electrical discharge machining (EDM) operation.

7. The repair system of claim 1, wherein: The component is formed using one of a casting process and an additive manufacturing process.

8. A repair system for repairing a component, the repair system comprising: an elongated repair tool having a first end supporting an electrode and a second end opposite the first end, the electrode being sized to fit within an internal cavity formed in the component; a camera having a field of view, the camera fixedly attached to the elongated repair tool such that the electrode is within the field of view; as well as a power supply coupled to the electrode and operable to deliver current to the electrode sufficient to form an arc between the electrode and the component to remove material from the component, wherein the second end of the elongated repair tool is movable to position the electrode in a desired position.

9. The repair system of claim 1, wherein: The elongated repair tool defines a diameter and a length in a longitudinal direction, and wherein the length is between 50 and 1000 times the diameter.

10. The repair system of claim 1, wherein: The elongated repair tool includes an electrode lead, the electrode, and a sheath surrounding a portion of the electrode lead.

11. The repair system of claim 1, wherein: The power supply and the electrode cooperate to perform an electrical discharge machining (EDM) operation.

12. The repair system of claim 1, wherein: The component is formed using one of a casting process and an additive manufacturing process.

13. A method of removing material from a component, the method comprising: positioning a first end of an elongated repair tool within the component, the first end supporting an electrode and a camera having a field of view encompassing the electrode; transmitting an image of the electrode from the camera; manipulating a second end of the elongated repair tool to position the electrode in a desired position relative to the component based on the transmitted image; as well as Power is provided to the electrode, which in response to receiving the power generates an arc between the electrode and the component, the arc being operable to melt a portion of the component.

14. The method of claim 13, wherein: The elongated repair tool is operable to perform an electrical discharge machining (EDM) operation.

15. The method of claim 13, further comprising forming the component using a casting process.

16. The method of claim 13, further comprising forming the component using an additive manufacturing process.

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