Helical Anode Tooling for Consistent Turbine Component Plating
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Solution Overview
Problem
Manual anode placement in gas turbine component coating processes is labor-intensive, time-consuming, and challenging to achieve consistent spacing, leading to inconsistent plating layers and potential rework.
Innovation Solution
A tooling assembly with a multi-axis pathway, specifically a helical pathway, is used to movably retain gas turbine components, allowing for precise positioning of an anode relative to the component, facilitating efficient and consistent electroplating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual anode placement is used in gas turbine component coating processes, then flexibility in handling different component types is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The tooling assembly is designed to automatically position and retain the anode relative to the component through its multi-axis pathway mechanism, eliminating the need for manual intervention. The system self-adjusts to maintain consistent spacing and positioning throughout the electroplating process, thereby reducing labor intensity while maintaining operational flexibility across different component types.
Solution Approach 2:
The tooling assembly incorporates a versatile multi-axis pathway design that can accommodate various gas turbine component geometries and sizes. The adjustable carrier and guide mechanism allow the same device to handle different component types effectively, maintaining flexibility while automating the positioning process to improve productivity.
2Device complexity
If manual anode placement is used, then equipment complexity is minimized, but consistency of anode spacing and plating layer quality deteriorates
Solution Approach 1:
The tooling assembly employs a dynamic multi-axis pathway mechanism with a movable carrier that can adjust its position along the guide. This dynamic capability enables precise control of anode spacing and positioning, ensuring consistent plating layer quality while maintaining a relatively simple overall device structure that builds upon conventional tooling concepts.
Solution Approach 2:
The guide and carrier mechanism serve as an intermediary between the simple tooling base and the precise anode positioning requirement. This intermediate mechanism translates simple operational inputs into precise, consistent anode placement, thereby achieving high manufacturing precision without requiring overly complex direct positioning systems.
3Manufacturing precision
If consistent anode positioning is achieved through automated tooling, then plating layer consistency improves, but device complexity increases
Solution Approach 1:
The tooling assembly is segmented into distinct functional modules: a tooling base for component retention, a guide for pathway definition, a carrier for anode mounting and movement, and a multi-axis pathway mechanism. This segmentation allows each component to perform its specific function efficiently, achieving consistent plating layer quality while keeping the overall device complexity manageable through modular design.
4Manufacturing precision
If multi-axis helical pathway tooling is used, then positioning precision and plating consistency improve, but device complexity and initial time investment increase
Solution Approach 1:
The tooling assembly is pre-configured with a multi-axis helical pathway guide and carrier mechanism designed specifically for consistent anode positioning. This preliminary setup eliminates the need for complex real-time adjustments during operation, achieving high positioning precision and plating consistency while the initial complexity is paid off through streamlined operational procedures and reduced rework requirements.
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 tooling assembly enables precise and consistent positioning of the anode, reducing labor and time requirements, improving the consistency of the plating layer, and minimizing the need for rework.
Implementation Method 1
the device is an electrode, wherein the device facilitates processing of the component
Implementation Method 2
at least one of the plurality of plates is positionable adjacent at least one of the plurality of vanes along the multi-axis pathway
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
An assembly is provided for movably retaining a component (100) and includes a tooling assembly and a device (114). The tooling assembly (115) includes a tooling base (130) and a carrier (132). The tooling base includes a frame (134) and a guide (142). The frame is configured to retain the component. The guide is associated with a multi-axis pathway. The carrier is movably coupled to the guide. The device is coupled to the carrier and is movable with the carrier along the multi-axis pathway.