Boroscope Diffractive Optical Element Laser Processing
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Solution Overview
Problem
Flexible boroscopes used for laser processing within assembled apparatuses face challenges in accurately and repeatably positioning the remote end to achieve adequate laser processing due to limitations in motor-controlled cable systems, which are suitable for viewing but not for precise laser manipulation.
Innovation Solution
A boroscope design incorporating a transmissive diffractive optical element that produces a laser beam with a predetermined shape, combined with a focal length probe, allows for precise laser processing without needing to move the boroscope's first end, enabling efficient processing of components within assembled apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible boroscopes are manoeuvred using motors and cables in the control unit, then the boroscope can be continuously inserted and manoeuvred to view components deeper within the apparatus, but the remote end cannot be moved at the required speed, accuracy and repeatability for laser processing
Solution Approach 1:
The patent replaces the mechanical motor-and-cable control system with a magnetic field-based control system. Magnets embedded in the boroscope interact with magnetic fields generated by the control unit, enabling direct torque transmission to the boroscope segments. This substitution eliminates the intermediate cable mechanism, achieving both the flexibility needed for deep component access and the precision required for laser processing positioning.
2Productivity
If the remote end of the boroscope is moved for laser processing, then laser beams can be directed at components, but the positioning cannot achieve the required speed, accuracy and repeatability
Solution Approach 1:
The patent replaces the mechanical motor-and-cable control system with a magnetic field-based control system. Magnets embedded in the boroscope interact with magnetic fields generated by the control unit, enabling direct torque transmission to the boroscope segments. This substitution eliminates the intermediate cable mechanism, achieving both the flexibility needed for deep component access and the precision required for laser processing positioning.
Solution Approach 2:
The patent employs periodic magnetic field pulses to actuate the boroscope segments. By applying alternating magnetic fields in a controlled sequence, the system achieves precise, repeatable positioning of the remote end. This periodic actuation method enables the boroscope to return to predetermined positions with high repeatability, which is essential for consistent laser processing operations.
3Productivity
If a laser beam is supplied through an optical fibre to process components, then laser processing can be performed, but adequate processing cannot be achieved due to difficulty in moving the remote end
Solution Approach 1:
The patent replaces the mechanical motor-and-cable control system with a magnetic field-based control system. Magnets embedded in the boroscope interact with magnetic fields generated by the control unit, enabling direct torque transmission to the boroscope segments. This substitution eliminates the intermediate cable mechanism, achieving both the flexibility needed for deep component access and the precision required for laser processing positioning.
Solution Approach 2:
The patent incorporates feedback mechanisms that monitor the position and orientation of the boroscope remote end. This feedback information is used to adjust magnetic field application in real-time, ensuring the boroscope maintains the precise position and angle required for adequate laser processing. The feedback loop enables continuous optimization of positioning accuracy to achieve the required manufacturing precision.
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
This solution enables accurate and repeatable laser processing of components, such as compressor blades, by maintaining the focal length probe in contact with the component and directing a shaped laser beam, ensuring maximum efficiency and minimizing collateral damage, while allowing for cleaning, ablation, or rebuilding of surfaces within a prescribed operating window.
Implementation Method 1
a transmissive diffractive optical element arranged to produce a laser beam with a predetermined shape and a focal length
Implementation Method 2
a lens provided between the optical fibre and the transmissive diffractive optical element
Implementation Method 3
an optical fibre extends from the first end of the boroscope to the second end of the boroscope
Implementation Method 4
a laser source arranged to direct a laser beam into the laser optical fibre
Data Source
AI summary
A boroscope has a first end and a second end and the first end of the boroscope has an optical fiber, a light source, a lens, a beam expander and a transmissive diffractive optical element. The optical fiber extends from the first end of the boroscope to the second end of the boroscope. A laser optical fiber extends from the lens at the first end of the boroscope to the second end of the boroscope and a laser source is arranged to direct a laser beam into the laser optical fiber. The beam expander is provided between the laser optical fiber and the lens and the lens is provided between the beam expander and the transmissive diffractive optical element. The transmissive diffractive optical element is arranged to produce a laser beam with a predetermined shape and a focal length probe extends from the first end of the boroscope.