Laser Cooling Hole Formation With Closed-Loop Airflow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming cooling holes in gas turbine components, such as vanes and blades, lack precision in determining the airflow through these holes, which is crucial for optimal engine performance, as the cooling flow provided by each hole can vary significantly.
Innovation Solution
A closed-loop method using a hole-forming machine with a sensor and image processing capabilities to capture images of the cooling holes, determine their cross-sectional areas, estimate total airflow, and adjust operational parameters to form additional holes, ensuring a predetermined airflow is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional laser hole-forming methods are used, then the process is simple and fast, but the precision of determining airflow through cooling holes is insufficient
Solution Approach 1:
The system captures images of formed cooling holes, processes them to determine cross-sectional areas, estimates airflow through the holes, and uses this feedback to adjust operational parameters for subsequent holes. This closed-loop feedback mechanism enables precise airflow determination while maintaining automated control.
Solution Approach 2:
The patent replaces traditional mechanical measurement methods with optical imaging and digital image processing. Instead of using physical probes or complex mechanical gauges to measure hole dimensions and estimate airflow, the system uses sensors to capture images and software to analyze cross-sectional areas, thereby achieving precise airflow measurement without increasing mechanical complexity.
2Productivity
If manual measurement and adjustment methods are used, then the equipment complexity is low, but the cycle time and rework increase
Solution Approach 1:
The system performs self-measurement and self-adjustment by automatically capturing images of the cooling holes, processing the images to determine cross-sectional areas, estimating airflow, and adjusting operational parameters without requiring manual intervention. This self-service capability reduces cycle time by eliminating manual measurement and adjustment steps.
Solution Approach 2:
The system maintains continuous operation by seamlessly integrating image capture, image processing, airflow estimation, and parameter adjustment within the hole-forming process. The automated feedback loop ensures that adjustments are made immediately after measurement, eliminating idle time and maintaining continuous productive action throughout the manufacturing process.
3Manufacturing precision
If laser parameters are not adjusted based on actual measurements, then the process is faster and simpler, but manufacturing precision of cooling hole airflow varies
Solution Approach 1:
The system performs preliminary measurement and analysis by capturing images and determining cross-sectional areas of cooling holes before finalizing the manufacturing process. This preliminary action allows the system to estimate airflow and adjust parameters for subsequent holes, ensuring manufacturing precision is achieved proactively rather than through repeated trial and error.
Solution Approach 2:
The system uses real-time feedback from image processing and airflow estimation to dynamically adjust laser parameters for subsequent cooling holes. This feedback mechanism ensures that each hole is formed with optimized parameters based on actual measurements from previous holes, maintaining high manufacturing precision while minimizing the time lost to adjustments.
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
This approach enhances precision and accuracy in forming cooling holes, reducing cycle time, rework, and costs while ensuring improved airflow characteristics, allowing for real-time adjustments during the hole-forming process.
Implementation Method 1
using a sensor controlled by the hole-forming machine, capturing an image of each cooling hole within the first set of cooling holes to create a set of image data
Implementation Method 2
Frequently, these cooling holes are formed by aiming a laser at a selected point on the component to form a hole through the component
Data Source
AI summary
An apparatus and method regarding forming a cooling hole in a component for a turbine engine, with the component held in a hole-forming machine with a laser carried on a multi-axis carriage and defining an optical path, the method comprising forming a set of cooling holes in the component with a laser mounted to the multi-axis carriage, estimating a total airflow through the set of cooling holes based on a set of data regarding the flow effectiveness of the set of cooling holes, and forming a second set of cooling holes with the laser.