Cooling Fluid Opening Analysis for Precise Reopening After Coating
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Solution Overview
Problem
Existing methods for reopening cooling fluid openings on components, such as turbine blades, after coating are inaccurate and time-consuming, leading to potential human error and increased maintenance costs due to deviations in design data and operational geometry changes.
Innovation Solution
A method utilizing a two-part surface analysis with different measuring devices to determine the precise position and three-dimensional shape of cooling fluid openings, allowing for automated and high-precision reopening, and generating a corrected model based on measured data for improved accuracy and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If design data is used to determine opening positions, then the process is simple, but accuracy is insufficient due to tolerances and operational geometry changes
Solution Approach 1:
The patent applies preliminary action by performing surface analysis and creating a digital model of the component before the coating process. This allows the actual positions of cooling fluid openings to be captured and stored in advance, so that after coating, the openings can be reopened at precisely the correct locations using the stored reference data, eliminating the need to rely on potentially inaccurate design data.
2Ease of operation
If manual methods are used to reopen cooling fluid openings, then flexibility is maintained, but time consumption and human error increase
Solution Approach 1:
The patent replaces manual mechanical methods with an automated system that uses a digital model and computer-controlled laser drilling. The system automatically calculates the positions of cooling fluid openings based on the stored surface analysis data and controls the laser drilling process without manual intervention, significantly reducing maintenance time and eliminating human error while maintaining precision.
3Device complexity
If existing measurement methods are used, then equipment complexity is low, but measurement precision and reliability are insufficient
Solution Approach 1:
The patent creates a precise digital copy (3D model) of the component's surface geometry through laser scanning and surface analysis. This digital model accurately represents the actual positions and orientations of cooling fluid openings, serving as a reliable reference for the reopening process. The digital copy can be stored, analyzed, and reused without degradation, ensuring consistent reliability.
4Reliability
If coating is applied to close cooling fluid openings, then corrosion protection is improved, but the openings must be precisely reopened afterward
Solution Approach 1:
The patent performs preliminary surface analysis and creates a digital model before coating, capturing the exact positions of cooling fluid openings. After coating is applied to provide corrosion protection, the stored digital model enables precise calculation of opening locations for laser drilling, ensuring that the protective coating is maintained while openings are accurately reopened without compromising either protection or precision.
Data Source
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AI summary
The invention relates to a method for coating a part comprising a surface that has cooling fluid openings that adjoin cooling fluid ducts inside the part. The invention further relates to a device for analyzing the surface of a part comprising a surface that has cooling fluid openings which adjoin cooling fluid ducts inside the part, said device being usable in the aforementioned method. The invention also relates to the use of the disclosed device and/or the disclosed method during the manufacturing and/or overhauling of parts of a turbomachine.