Internal Passage Arc Machining With Camera-Guided Repair
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Solution Overview
Problem
Complex components with internal holes or passages often form improperly or become clogged during manufacturing, leading to scrapping due to inaccessible defects.
Innovation Solution
A repair system utilizing an elongated repair tool with an electrode and camera, capable of forming an arc to melt and remove unwanted material from internal passages, guided by a camera's field of view and powered by an electrical current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting or forming methods are used to create internal holes or passages, then the component structure can be formed, but the holes may become clogged with debris or unwanted material, leading to scrapping
Solution Approach 1:
The system performs preliminary inspection and repair actions by introducing the electrode and camera system into the component before final assembly or use. The electrode can melt and remove debris proactively, preventing the clogging issue from affecting the component's functionality.
Solution Approach 2:
The patent replaces mechanical cleaning or drilling methods with an electrical discharge system. The electrode delivers electrical current to melt and remove debris through controlled arcing, substituting mechanical intervention with an electrical field-based approach that can access confined spaces more effectively.
2Ease of manufacture
If the location of internal holes is not accessible for inspection, then the component can be manufactured, but casting flaws cannot be detected, resulting in scrapping
Solution Approach 1:
The camera and electrode are nested within a flexible conduit that can be inserted into the component's internal passages. This nested configuration allows the inspection and repair tools to access confined internal spaces that would be impossible to reach with external inspection methods.
Solution Approach 2:
The flexible conduit acts as an intermediary medium that bridges the external inspection equipment and the internal passages of the component. It transmits both visual information (via the camera) and electrical energy (via the electrode) to locations that are otherwise inaccessible.
3Ease of operation
If an elongated repair tool with camera and electrode is used to access internal passages, then debris can be removed from inaccessible locations, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated tool: the flexible conduit, camera, electrode, and wiring are combined into one repair system. This consolidation allows simultaneous inspection and repair operations without requiring separate equipment, thereby reducing operational complexity despite the extended functionality.
Solution Approach 2:
The repair tool is designed with multi-functionality, serving both as an inspection device (via the camera) and a repair device (via the electrode). This universal tool can detect defects and perform corrective actions in the same operational sequence, eliminating the need for separate inspection and repair procedures.
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
Effectively repairs internal passages by removing debris, preventing component scrapping and enhancing manufacturing yield.
Implementation Method 1
the electrical current is sufficient to form an arc between the electrode tip and the component to remove material from the component
Data Source
AI summary
A repair system for use in repairing a component includes an elongated repair tool having a first end that supports an electrode and a second end opposite the first end. A camera has a field of view and is fixedly attached to the elongated repair tool such that the electrode is within the field of view. A power supply is coupled to the electrode and is operable to deliver an electrical current to the electrode, the electrical current sufficient to form an arc between the electrode and the component to remove material from the component, where the second end of the elongated repair tool is movable to position the electrode in a desired position.