Linear Friction Welding Rotor Blade Alignment

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Solution Overview

Problem

The existing method of linear friction welding rotor blades to disks is time-consuming and costly due to the need for sacrificial components and coordinate measuring machine analysis, which restricts efficient alignment within the limited working volume of the linear friction welding machine.

Innovation Solution

Incorporating a dummy blade with measurement devices to align the blade tooling in situ within the machine, eliminating the need for sacrificial components and CMM analysis by measuring the position and orientation of the dummy blade relative to the disk, allowing for precise alignment and storage of the tooling position for subsequent production blade welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If sacrificial set-up disk and blades are used for alignment, then manufacturing precision is improved, but loss of time and loss of substance worsen

Engineering Contradiction:

Improvealignment precisionVSAvoidsetup time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical CMM measurement system with optical measurement devices (lasers, cameras) integrated into the LFW machine. This substitution eliminates the need to dismount components for external measurement, enabling in-situ alignment verification and significantly reducing setup time while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements preliminary alignment verification using measurement devices before the actual welding process. By checking and adjusting alignment in advance within the machine, the need for iterative sacrificial components is eliminated, reducing both time and material waste.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If sacrificial set-up disk and blades are used for alignment, then manufacturing precision is improved, but loss of time and loss of substance worsen

Engineering Contradiction:

Improvealignment precisionVSAvoidsacrificial components

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The measurement devices are integrated directly into the LFW machine, allowing the machine to perform its own alignment verification and adjustment. This self-service capability eliminates the need for external CMM equipment and sacrificial components, reducing both material waste and process complexity.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If conventional alignment method with CMM analysis is used, then measurement precision is improved, but device complexity and loss of time worsen

Engineering Contradiction:

Improvealignment measurement precisionVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the measurement devices with the LFW machine structure, integrating alignment verification functionality directly into the welding equipment. This consolidation eliminates the need for separate CMM equipment and reduces overall system complexity while maintaining measurement precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces optical measurement devices (lasers, cameras) as intermediaries between the alignment system and the control system. These intermediaries enable direct in-situ measurement and feedback, simplifying the overall measurement process compared to external CMM analysis while maintaining high precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces costs and time by enabling in situ alignment and measurement, eliminating the need for sacrificial components and CMM analysis, thereby improving efficiency and quality of the welding process.

Implementation Method 1

Friction welding is the process for welding together two bodies or workpieces by converting mechanical energy to heat energy by the friction between the engaging weld surfaces of the two workpieces

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

mounting a dummy blade at the blade tooling, the dummy blade carrying one or more first measurement devices which interact with the mounted disk to measure the position and orientation of the dummy blade relative to the disk

Methodology Applied

Scientific EffectMeasurement interaction:

Data Source

PatentUS10239151B2Linear friction welding method

Publication Date: 2019.03.26 ROLLS ROYCE PLC

AI summary

A method linear friction welds a rotor blade to a disk. The method includes: providing a linear friction welding machine having disk tooling at which a disk is mounted, and further having blade tooling at which a blade is mountable; mounting a dummy blade at blade tooling, dummy blade carrying one or more first measurement devices which interact with mounted disk to measure position of dummy blade relative to disk; adjusting position and orientation of blade tooling relative to mounted disk until first measurement devices indicate that dummy blade is in a suitable alignment with disk to start linear friction welding a blade to disk; releasing dummy blade from blade tooling and mounting a production blade thereat; and linear friction welding the production blade to the disk with the blade tooling starting at adjusted position and orientation.