Turbine Blade Leading Edge Reinforcement Tooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for attaching a metal reinforcement to the leading edge of turbomachine blades made of composite material are manual, prone to variability, and costly, requiring strict control to ensure proper bonding and positioning, which limits productivity and increases thermal fatigue.
Innovation Solution
A tool and method using a blade support and leading edge reinforcement support with lateral wedges and heating elements to automate the attachment process, ensuring precise positioning and controlled polymerization of adhesive outside an autoclave, reducing operator dependency and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual process is used to attach metal reinforcement to the leading edge of composite blades, then flexibility in operation is maintained, but manufacturing precision and reliability deteriorate due to high variability in bond material quality and positioning
Solution Approach 1:
A specialized tooling system acts as an intermediary between the operator and the blade-reinforcement assembly. The tool includes a blade support with an imprint complementary to the blade shape, and a leading edge reinforcement support with lateral wedges and suction grids, which together enable precise positioning and clamping without direct manual handling of the blade and reinforcement components
Solution Approach 2:
The manual mechanical positioning and clamping operations are replaced by a tooling system that uses suction grids for gripping the metal reinforcement, lateral wedges for clamping, and an imprint-based support system for positioning the blade. This substitution eliminates operator variability while maintaining ease of operation through the tool's design
2Manufacturing precision
If stringent quality control systems are implemented to mitigate positioning and bonding variability, then manufacturing precision improves, but productivity deteriorates due to increased inspection and control requirements
Solution Approach 1:
The tooling system provides self-aligning and self-clamping functions through its design. The blade support with complementary imprint automatically positions the blade correctly, while the lateral wedges and suction grids automatically clamp the reinforcement in the correct position. This self-service capability eliminates the need for extensive quality control inspections, maintaining precision while improving productivity
3Strength
If adhesive curing is performed in an autoclave, then bond strength is improved, but productivity deteriorates due to long cycle times and thermal stress on the blade
Solution Approach 1:
The curing process is extracted from the autoclave environment and performed directly in the tooling system. The leading edge reinforcement support includes heating elements that can cure the adhesive in situ, eliminating the need for autoclave processing. This extraction maintains adequate bond strength while dramatically reducing cycle time and thermal stress on the blade
4Ease of operation
If the reinforcement is manually pre-positioned on the blade leading edge, then ease of operation is maintained, but manufacturing precision deteriorates due to misalignment between the blade and metal reinforcement
Solution Approach 1:
The tooling system serves as an intermediary that pre-positions both the blade and the metal reinforcement with high precision before assembly. The blade support with complementary imprint and the leading edge reinforcement support with lateral wedges work together to ensure accurate alignment, eliminating the need for manual pre-positioning while maintaining ease of operation through the tool's design
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 solution enables reproducible and precise attachment of metal reinforcements, increases productivity, reduces thermal fatigue, and ensures consistent adhesive thickness and aerodynamic continuity, while allowing for automated processing and controlled temperature cycles.
Implementation Method 1
each being provided with a suction grid intended to ensure gripping of the metal reinforcement
Implementation Method 2
The leading edge reinforcement support further includes heating elements intended to allow polymerization of an adhesive film applied to surfaces of the blade's leading edge
Implementation Method 3
heating elements intended to allow polymerization of an adhesive film
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to equipment for attaching a metal reinforcement (300) onto the leading edge (6) of a turbine engine blade (2), which includes a blade mounting (100) for receiving a blade while leaving surfaces of the leading edge of the blade exposed, and a mounting (200) for reinforcing the leading edge, onto which the blade mounting (100) is to be mounted, said mounting for reinforcing the leading edge including two side shims (208), between which the metal reinforcement (300) of the leading edge of the blade is positioned. The shims (208) can be moved closer and farther from one another and are each provided with a downdraft grate for grasping the metal reinforcement (300). The mounting (200) reinforcing the leading edge also includes heating elements for enabling polymerization of an adhesive film applied onto surfaces of the leading edge of the blade. The invention also relates to a method for attaching a metal reinforcement onto the leading edge (6) of a turbine engine blade (2) by means of such equipment.