Masking Plug Positioning Tool for Gas Turbine Cooling Apertures
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Solution Overview
Problem
In rotary machines, such as gas turbines, the repair of components with surface features like cooling apertures often requires masking plugs to prevent coating obstruction, but manually positioning and removing these plugs is time-consuming and labor-intensive, especially when numerous surface features are present.
Innovation Solution
A tool system that includes a body with a channel to securely hold and rotate masking plugs, allowing for efficient positioning and securement over surface features, using mechanisms like negative pressure, adhesive application, or electromagnetic forces to attach and detach the plugs from the component substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masking plugs are manually positioned over each surface feature, then the surface features are protected from coating obstruction, but the time and labor required increases significantly
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated system that uses a template aligned to the component geometry. The template contains pre-positioned openings that automatically guide plugs to the correct surface features, eliminating manual positioning while ensuring accurate placement over all cooling apertures and other surface features.
Solution Approach 2:
The template system is self-aligning to the component geometry through registration features that match predetermined locations on the component. Once the template is positioned, it automatically identifies and guides plugs to all required surface features without requiring manual measurement or calculation of plug positions.
2Ease of repair
If masking plugs are manually removed after coating, then the plugs can be retrieved for reuse, but the additional labor and time are required
Solution Approach 1:
The patent replaces manual plug removal with an automated extraction system. After the coating process, the template is repositioned on the component, and extraction tools are used to automatically remove all plugs through the template openings, significantly reducing the time and labor required compared to manual removal.
3Manufacturing precision
If precise manual positioning is used, then plug placement accuracy is high, but the skill level and training required increases
Solution Approach 1:
The patent replaces skilled manual positioning with a mechanically guided template system. The template contains pre-formed openings at exact positions determined by the component geometry, which automatically guide plugs to the correct locations. This eliminates the need for operator skill in measuring and calculating plug positions while maintaining high placement accuracy.
Solution Approach 2:
The template is pre-manufactured with openings positioned according to the specific geometry of the component being coated. This preliminary preparation of the template eliminates the need for operators to perform complex measurements or calculations during the actual plug positioning process, reducing skill requirements while maintaining precision.
Data Source
AI summary
A tool for positioning a masking plug relative to a surface feature on a component is provided. The tool includes a body extending from a first end to an opposite second end. The second end is configured to couple to an attachment tool. The tool further includes a channel defined in the first end. The channel is sized to receive at least a portion of the masking plug therein such that rotational motion of the tool about a longitudinal axis is transferred to the masking plug. The tool is operable to releasably secure the masking plug to the first end.