3D Coating Slotting With Robotic Laser Focus Control
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Solution Overview
Problem
Existing systems struggle to efficiently and accurately form slots in thermal barrier coatings on complex 3D surfaces of gas turbine components, such as airfoils and deflectors, due to the need for repositioning the components during laser slotting, which is time-consuming and prone to errors.
Innovation Solution
A system and method using an electromagnetic radiation beam emitting device with a movable scan head and computing system to form slots on 3D surfaces by moving the beam relative to the component, allowing for precise slot formation without repositioning the component, utilizing a base, arm, and scan head with five degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing laser slotting systems are used on complex 3D surfaces, then slots can be formed in thermal barrier coatings, but the component requires frequent repositioning which reduces efficiency and increases errors
Solution Approach 1:
Instead of moving the component to maintain laser focus on complex 3D surfaces, the patent inverts the approach by moving the laser beam delivery system (scan head on robotic arm) relative to the stationary component. This allows the laser to track the surface geometry without requiring component repositioning, thereby maintaining productivity while eliminating time loss from repositioning operations.
Solution Approach 2:
The patent implements a dynamic laser beam delivery system where the scan head can move in multiple degrees of freedom (X, Y, Z, pitch, yaw, roll) to dynamically adapt to complex 3D surface geometries. This dynamic positioning capability allows continuous slotting without component repositioning, improving productivity while eliminating time loss.
2Reliability
If existing laser slotting systems are used on complex 3D surfaces, then slots can be formed in thermal barrier coatings, but frequent repositioning reduces repeatability and increases errors
Solution Approach 1:
The patent inverts the traditional approach by making the laser delivery system mobile rather than the component. This inversion improves repeatability because the component remains stationary in its fixture, eliminating repositioning errors. The increased device complexity is acceptable because it directly trades off against improved reliability and reduced errors.
Solution Approach 2:
The system incorporates feedback mechanisms where the position and orientation of the scan head are continuously monitored and adjusted to maintain precise laser focus on the 3D surface. This feedback control ensures repeatable slot formation despite the complexity of the multi-degree-of-freedom beam delivery system.
3Productivity
If laser beam is moved relative to stationary component, then slots can be formed on complex 3D surfaces without repositioning, but the system requires five degrees of freedom increasing device complexity
Solution Approach 1:
The patent implements a dynamic robotic arm system with five degrees of freedom that can position and orient the scan head to follow complex 3D surface geometries at high speeds. This dynamic capability enables continuous high-speed slotting without repositioning the component, improving productivity despite the increased device complexity of the multi-axis robotic system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves the efficiency and repeatability of slot formation on complex 3D surfaces, increasing component durability and extending operational life by maintaining focus on the coating, enabling high-speed slotting up to 1000mm/s without repositioning the component.
Implementation Method 1
an electromagnetic radiation beam emitting device (10) having a base (14), an arm (16), and a scan head (24) configured to emit the electromagnetic radiation beam
Data Source
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AI summary
A system (100) for forming slots in a coating present on a component includes an electromagnetic radiation beam emitting device (10) having an arm (16) and a scan head (32) configured to emit an electromagnetic radiation beam at a surface of the component. A computing system (110) is configured to control an operation of the electromagnetic radiation beam emitting device (10) such that a portion of the surface is scanned with the electromagnetic radiation beam. Additionally, the computing system (110) is configured to determine a three-dimensional profile of the scanned portion of the surface and generate a slot pattern based on the determined three-dimensional profile. Moreover, the computing system (110) is configured to control the operation of the arm (16) to adjust a position of the electromagnetic radiation beam relative to the surface of the component such that material is ablated from the coating to form the slot pattern in the coating.