Interior TBC Removal Tool With Adjustable Grinding Depth
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Solution Overview
Problem
Existing methods for removing thermal barrier coatings (TBCs) from gas turbine components require extensive downtime due to the need for transporting components to repair or manufacturing sites, which can take several months.
Innovation Solution
A tool and method for in situ removal of TBCs using a rotary device with a grinding and polishing attachment, allowing precise control over cutting depth and position, guided by a wheel assembly, enabling on-site operation to reduce downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If TBC removal is performed using conventional methods at repair sites, then manufacturing precision can be maintained, but loss of time increases significantly due to component transportation and extended repair duration
Solution Approach 1:
A portable grinding tool with controlled depth adjustment mechanism serves as an intermediary device, enabling precise TBC removal directly at the gas turbine site without requiring component removal to centralized repair facilities. The tool holder with adjustable collet assembly acts as the mediator between the operator and the TBC coating.
Solution Approach 2:
The patent replaces the traditional mechanical grinding system with a portable, hand-held grinding tool that can be manually operated on-site. This substitution eliminates the need for complex automated machining centers and component transportation infrastructure.
2Loss of time
If TBC removal is performed using portable on-site tools, then loss of time is reduced, but device complexity increases due to the need for precise positioning and depth control mechanisms
Solution Approach 1:
The tool is segmented into distinct functional modules: a tool holder for positioning, a collet assembly for securing the grinding attachment, handwheels for axial and radial adjustment, and a wheel assembly for guidance. This segmentation allows each component to perform a specific function while maintaining overall system manageability.
Solution Approach 2:
The tool incorporates dynamic adjustment capabilities through handwheels that enable real-time modification of the grinding attachment's axial position and radial depth during the TBC removal process, allowing operators to adapt to varying coating thicknesses and geometric complexities.
3Manufacturing precision
If precise control over cutting depth is implemented, then manufacturing precision is improved, but device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The tool holder and collet assembly are pre-configured with threaded shafts and handwheels that establish precise depth control before the grinding operation begins. The axial and radial positions are set in advance through manual adjustment, eliminating the need for complex automated control systems during operation.
Solution Approach 2:
The patent employs simple, mechanically robust adjustment mechanisms using standard threaded shafts and handwheels rather than expensive electronic control systems. These mechanical components provide sufficient precision for TBC removal while maintaining simplicity and ease of maintenance.
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 tool enables rapid and precise removal of TBCs, reducing downtime from months to weeks or days by allowing on-site operation, thus minimizing disruption to gas turbine systems.
Implementation Method 1
a grinding attachment attached to the rotary device
Implementation Method 2
a polishing attachment
Data Source
AI summary
A tool for removing a coating from an interior surface of a component. The tool includes a rotary device; a grinding attachment attached to the rotary device; a tool holder configured to: set an axial position of the grinding attachment coupled to the rotary device over the coating on the interior surface of the component; and set a radial position of the grinding attachment coupled to the rotary device, the radial position defining a cutting depth of the grinding attachment into the coating on the interior surface of the component; and a wheel assembly coupled to the tool holder for guiding the tool holder about an interior perimeter of the component. The tool holder has a base coupled to a collet assembly that has upper and lower sections and first and second handwheels that adjust grinding attachment axial position and cutting depth, respectively.