Aero-Engine Blade LSP Clamping and 3D Path Positioning
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Solution Overview
Problem
Current laser shock peening (LSP) processes for aero-engine blades face issues such as movement clamping mechanism loosening during laser pulses, precision challenges in repeated clamping, and potential interference between the manipulator and laser, leading to inconsistent LSP effects and safety risks.
Innovation Solution
An automated LSP process equipment system is developed, featuring a loading and unloading manipulator linked with diffuse reflection-type photoelectric sensors for precise clamping, a reverse engineering mechanism for generating three-dimensional digital data of the blade, and a working manipulator with photoelectric sensors for accurate positioning and coating of the absorption layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a set screw is used as the locking apparatus, then the clamping structure is simple, but the set screw loosens due to vibration accumulation during LSP, resulting in unreliable clamping
Solution Approach 1:
The patent replaces the traditional mechanical set screw locking system with a magnetic field-based locking mechanism. The magnetic field exerts a holding force on the set screw, preventing it from loosening due to vibration accumulation during LSP operations, while maintaining the simplicity of the overall clamping structure.
2Ease of operation
If a molding fixture with the same shape as the tenon is used, then both locating and clamping are achieved, but the processing difficulty is almost equal to that of a steam turbine wheel, and slight changes in relative position occur after repeated clamping
Solution Approach 1:
The patent divides the clamping system into separate locating and clamping components rather than using a single complex molding fixture. The locating plane provides precise positioning while the clamping mechanism applies force, simplifying the manufacturing of each individual component while maintaining overall functionality.
Solution Approach 2:
The patent creates a precise copy or replica of the tenon shape in the locating fixture, allowing for accurate positioning without requiring the entire fixture to be as complex as the workpiece itself. This selective copying approach reduces manufacturing difficulty while maintaining precision.
3Adaptability or versatility
If the absorption belt is attached to the surface of the workpiece, then LSP can be performed on large planes, but the absorption belt cannot be attached to the surface of the blade root with a free plane, resulting in poor LSP effect
Solution Approach 1:
The patent introduces a magnetic field as an intermediary mechanism to hold the absorption layer in place on the blade root surface. Instead of relying on mechanical attachment that requires surface features, the magnetic field provides a contactless holding force, enabling the absorption layer to remain positioned during LSP operations on complex geometries.
4Device complexity
If manual screwing of the top rod is used to achieve clamping, then the equipment is simple, but the blade produces bending moment at the tenon part, resulting in slight displacement and shifted laser focus position
Solution Approach 1:
The patent replaces manual mechanical screwing with an automated clamping mechanism that applies force more uniformly and controllably. This eliminates the bending moments caused by manual tightening at the tenon, preventing blade displacement and maintaining accurate laser focus positioning throughout the LSP process.
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
The automated system achieves improved clamping efficiency, refined precision in blade processing, and enhanced safety by eliminating human intervention, thereby ensuring consistent and reliable LSP effects for aero-engine blades.
Implementation Method 1
a loading and unloading manipulator is linked with a diffuse reflection-type photoelectric sensor to complete clamping of the blade
Implementation Method 2
a high-frequency, high-power, short-pulse laser beam is used to penetrate the intermediate confinement layer (water) to impact the surface of a workpiece with an absorption layer
Implementation Method 3
The absorption layer is rapidly vaporized and ionized by laser irradiation to form plasma
Implementation Method 4
The plasma continuously absorbs the energy, and the volume of the plasma expands rapidly. The expansion process of the plasma is confined by the confinement layer, thereby generating a strong shock wave propagating into a target material
Data Source
AI summary
An automated laser shock peening (LSP) process equipment system for an aero-engine blade, including: a base, where a loading and unloading manipulator, working manipulator, reverse engineering mechanism, coating apparatus, and LSP apparatus are disposed; the loading and unloading manipulator is configured to grab a blade and place it on the reverse engineering mechanism, which includes a reverse engineering instrument and controller that are connected, the instrument can generate three-dimensional digital data of the blade, and the controller generates a working path for coating and LSP according to the data, and transmits the path to the working manipulator; the loading and unloading manipulator places the blade into the pallet, and the working manipulator drives the blade to a corresponding position according to the path. Independent locating and clamping systems of the pallet and the blade and the pallet and the manipulator fix a position of the blade relative to the manipulator.