Rotating Blade Tip Welding Fixture for Multi-Airfoil Repair
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Solution Overview
Problem
Gas turbine system blades, particularly compressor and turbine blades, experience wear due to rapid rotation and high operating temperatures, necessitating efficient repair methods for their tips.
Innovation Solution
A multiframe blade tip welding fixture with adjustable bases and rotating cans that can accommodate various blade shapes and heights, allowing for simultaneous repair of multiple blades with a single welder, utilizing a gas distribution system to concentrate shielding gas for effective welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple blades are repaired simultaneously using a multiframe welding fixture, then productivity increases, but device complexity increases
Solution Approach 1:
The welding fixture is divided into multiple independent frames (e.g., four frames) that can be rotated around a central axis. Each frame can independently hold and position a blade for repair, allowing simultaneous processing of multiple blades while maintaining operational simplicity through modular design
Solution Approach 2:
The welding fixture is designed as a universal multi-functional device that can accommodate various blade shapes and sizes through adjustable positioning mechanisms. The same fixture can repair different types of airfoils (compressor blades, turbine blades) by adjusting the frame positions and orientations, eliminating the need for multiple specialized fixtures
2Manufacturing precision
If shielding gas is distributed to multiple work cavities simultaneously, then gas consumption increases, but welding quality is maintained
Solution Approach 1:
The welding fixture employs periodic action by rotating the frames sequentially to bring each blade's work cavity to the welding position in turn. The shielding gas distribution system is synchronized with this rotation, activating gas flow only when a specific frame is in the welding position. This ensures adequate shielding gas protection for each weld while minimizing overall gas consumption compared to continuous simultaneous distribution to all cavities
3Adaptability or versatility
If the welding fixture accommodates various blade shapes and heights, then adaptability increases, but device complexity increases
Solution Approach 1:
The welding fixture incorporates dynamic adjustable mechanisms that allow the frames to be positioned at different radial distances from the central axis and rotated to various orientations. These mechanisms enable the fixture to adapt to different blade shapes and heights through movement and repositioning, providing versatility while maintaining reasonable structural simplicity through standardized adjustment components
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
Enables efficient and cost-effective repair of multiple airfoil tips by maintaining a single welder position, reducing shielding gas consumption, and accommodating diverse blade shapes and sizes, while providing additional cooling through gas distribution to the blades.
Implementation Method 1
The first can is configured to receive a first gas flow, and the first can is configured to distribute the first gas flow to a first work cavity around the first tip of the first airfoil
Implementation Method 2
The first arm is configured to rotate about the axis and the second arm is configured to rotate about the axis
Data Source
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AI summary
A system (40) includes a stand (42) having a first axis (90), a first arm (44), and a second arm (44). The first arm (44) and the second arm (44) extend from the axis (90). The first arm (44) is configured to rotate about the axis (90) and the second arm (44) is configured to rotate about the axis (90). The system (40) includes a first can (48) coupled to the first arm (44). The first can (48) is configured to be disposed around a first tip (100) of a first airfoil (80), the first can (48) is configured to receive a first gas flow, and the first can (48) is configured to distribute the first gas flow to a first work cavity (56) around the first tip (100) of the first airfoil (80). The system (40) further includes a second can (48) coupled to the second arm (44). The second can (48) is configured to be disposed around a second tip (100) of a second airfoil (82), the second can (48) is configured to receive a second gas flow, and the second can (48) is configured to distribute the second gas flow to a second work cavity (56) of the second airfoil (82).