Coater Platter Alignment Tool for Gas Turbine Coating
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Solution Overview
Problem
Current alignment verification methods for gas turbine engine components during cathodic arc coating are inefficient, as they require removing shielding and the platter from the coating machine, taking over 30 minutes and prone to errors due to the need for manual checks post-cooling, and can misalign if the gear is rotated 180 degrees.
Innovation Solution
An alignment tool with a first arm member coupled to a locating feature on the gear and a pivotable second arm member that fits underneath the platter to verify proper alignment, allowing for quick and accurate checks without removing the platter or shielding, using a hinge connection and sockets to ensure correct positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a locating plate is used to verify alignment, then alignment can be checked, but the shielding must be removed and the platter taken out of the coating machine, taking over 30 minutes
Solution Approach 1:
The patent introduces an alignment tool with arm members as an intermediary device that can verify gear alignment without removing the shielding or platter from the coating machine. The arm members engage with the gear teeth and platter surface to detect misalignment, serving as a mediator between the alignment verification requirement and the constraint of maintaining the coating setup intact.
Solution Approach 2:
The patent replaces the manual mechanical alignment check method (using locating plates that require disassembly) with a mechanical alignment tool that can operate within the existing coated setup. The tool uses arm members with contact points to mechanically detect alignment status without requiring the complex disassembly and reassembly of the coating apparatus.
2Measurement precision
If the locating plate method is used, then alignment can be verified, but the process is prone to errors if the gear is rotated 180 degrees
Solution Approach 1:
The patent employs asymmetric features in the alignment tool design, where the arm members have specific contact point configurations that are sensitive to the direction and position of gear teeth. The tool includes reference surfaces and contact points arranged asymmetrically to detect not only alignment status but also the rotational orientation of the gear, preventing 180-degree rotation errors.
Solution Approach 2:
The alignment tool provides feedback mechanisms through the arm members that indicate both alignment status and rotational orientation. The contact points between the arm members and the gear/platter surfaces create a feedback system that can detect incorrect orientations, alerting the operator to correct the gear position before coating begins.
3Ease of operation
If shielding is removed for alignment check, then locating plate can be attached, but the tooling fixture components must cool sufficiently first
Solution Approach 1:
The alignment tool serves as an intermediary that can operate in the high-temperature environment without requiring removal of the shielding. The tool is designed to withstand the thermal conditions and can perform alignment verification through the shielding, eliminating the need to wait for cooling.
Solution Approach 2:
The alignment tool is designed and prepared in advance to withstand high temperatures and can be inserted through the shielding opening without requiring the tooling fixture to cool down first. This preliminary preparation of the alignment tool allows immediate alignment verification upon completion of the coating process.
Data Source
AI summary
An alignment tool is used to ensure proper alignment of a component on a rotating gear relative to a non-rotating platter. The alignment tool includes a first arm member coupled to a locating feature on the gear, and a second arm member that is coupled to the first arm member such that the second arm member is movable relative to the first arm member. When the first arm member is coupled to the locating feature, the second arm member locates off the platter to verify proper alignment. The second arm member is cannot be fitted to the platter when there is improper alignment.