Laser Scanning for Obstructed Film Cooling Hole Orientation
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Solution Overview
Problem
Current methods for determining the location and angular orientation of film cooling holes in gas turbine engine components with obstructed openings are labor-intensive, inaccurate, or ineffective, especially for small holes on complex, three-dimensional surfaces with thermal barrier coatings.
Innovation Solution
A laser scanning system comprising a laser spot projector, sensor, memory device, and processor projects a laser beam onto the surface to create a point cloud of digital coordinate points, allowing for precise calculation of hole locations and angular orientations relative to pre-existing datums, enabling automated determination and reaming of obstructed holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual vision system is used to locate holes, then operator can view hole openings, but the method is labor intensive and cannot accurately determine angular orientation
Solution Approach 1:
The patent replaces the manual mechanical vision system with an automated laser scanning system that uses optical laser beams to automatically detect and map hole locations and orientations on the component surface, eliminating manual labor and significantly reducing restoration time
Solution Approach 2:
The patent changes the measurement parameters by using laser scanning to capture not only the 2D position of hole openings but also the 3D angular orientation data, providing comprehensive hole geometry information that manual methods cannot obtain
2Reliability
If coating is applied to protect component, then thermal protection is improved, but film cooling hole openings become obstructed
Solution Approach 1:
The patent performs preliminary laser scanning and 3D mapping of the component surface before coating application, capturing the exact locations and orientations of all film cooling holes. This preliminary data storage enables subsequent precise reaming operations without requiring manual inspection of coated surfaces
Solution Approach 2:
The patent creates a digital 3D copy or map of the component surface including hole geometries through laser scanning. This digital replica preserves all hole location and orientation information even when physical hole openings are obstructed by coating, allowing accurate restoration without visual inspection
3Extent of automation
If laser scanning is used to map surface, then automated hole location is achieved, but system complexity increases
Solution Approach 1:
The patent employs a laser scanning system that performs multiple functions: it maps the component surface geometry, locates all film cooling holes, determines their angular orientations, and creates a 3D digital model. This multi-functional approach consolidates what would otherwise require multiple separate inspection systems into a single automated platform
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 method significantly reduces restoration time and cost by accurately determining and reaming film cooling holes, even those partially or wholly obstructed with thermal barrier coatings, enhancing the efficiency of gas turbine engine maintenance.
Implementation Method 1
A laser beam is projected onto the surface of the article in a region containing a hole and the spot sensor receives light reflections
Data Source
AI summary
Provided are systems 10 and methods 100 for determining both the location and angular orientation of holes 12 with openings 14 on a surface 16 of an article 18 that are at least partially obstructed. In a method of the present invention, a scanning system 10 that includes a laser spot projector 40, a laser spot sensor 42, a memory device 48 and a processor 50 is provided. A laser beam 44 is projected onto the surface 16 of the article 18 in a region 24 containing at least one hole 12 and the spot sensor receives light reflections 46. A series of points 52 representing the scanned region is stored as a point cloud 54 in the memory device 48. The point cloud 54 is then manipulated to calculate the location and angular orientation of each hole in the region in relation to one or more pre-existing, article datums 22.