Micromixer Tube EDM Electrode for Vibration-Free End Removal
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Solution Overview
Problem
Conventional machining methods for repairing damaged micromixer tubes in gas turbine combustors are inefficient and cause damage to undamaged tubes and clog flow passages due to vibration and debris, necessitating the removal and replacement of all tubes, which is time-consuming and costly.
Innovation Solution
An EDM tool electrode system with a disk and elongated member is used to cut damaged end regions from micromixer tubes internally, minimizing physical forces and debris, allowing individual tube repair without damaging neighbors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional machining methods are used to remove damaged micromixer tube ends, then the damaged tubes can be repaired, but vibration from the repair tools causes damage to brazed joints in other portions of the micromixer
Solution Approach 1:
The patent replaces conventional mechanical machining tools with an electrical discharge machining (EDM) system. The EDM process uses electrical discharges through a dielectric fluid to erode the micromixer tube material, eliminating mechanical contact and vibration. This substitution allows repair of damaged tubes without transmitting harmful vibrations to brazed joints in other portions of the micromixer assembly.
2Ease of repair
If conventional cutting tools are used to remove damaged micromixer tube ends, then the tubes can be repaired, but physical cutting produces debris that clogs or impedes flow passages in the micromixer tubes
Solution Approach 1:
The patent replaces mechanical cutting operations with electrical discharge machining. The EDM process removes material through controlled electrical erosion rather than mechanical shearing, producing minimal debris. The dielectric fluid carries away eroded particles, preventing clogging of the micromixer tube flow passages while enabling repair of damaged tube ends.
3Reliability
If all micromixer tubes are removed and replaced regardless of damage, then complete repair is achieved, but repair time and expense increase significantly
Solution Approach 1:
The patent applies repair treatment locally only to the damaged portions of individual micromixer tubes using EDM. The electrical discharge process can be precisely controlled to remove only the damaged end regions of specific tubes that require repair, rather than requiring removal and replacement of the entire micromixer tube assembly. This localized approach significantly reduces repair time and costs while maintaining reliability by addressing only the affected areas.
4Ease of repair
If conventional machining tools are used on inward micromixer tubes, then damaged tubes can be accessed, but the process damages or requires removal of outer undamaged micromixer tubes
Solution Approach 1:
The patent replaces mechanical cutting tools with an EDM system that can access and repair inward micromixer tubes without requiring removal of outer undamaged tubes. The electrical discharge process can be applied through the dielectric fluid environment, allowing precise repair of damaged tube ends in the inward position without transmitting mechanical forces that would damage adjacent undamaged tubes or require their removal.
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
The EDM system reduces damage to braze joints and eliminates debris, minimizing repair time and costs by enabling precise, debris-free removal of damaged tube ends.
Implementation Method 1
An electrical discharging machine (EDM) system is used to remove an end portion of a micromixer tube
Implementation Method 2
repetitively applying voltage to the tool electrode and to the micromixer tube to gradually remove the end portion of the micromixer tube
Implementation Method 3
a dielectric liquid delivery system configured to deliver a dielectric liquid between the tool electrode and an inner surface of the micromixer tube
Data Source
AI summary
A tool electrode for an EDM system for repairing a micromixer tube of a combustor, the EDM system and a related method, are provided. The tool electrode includes an elongated member; and a disk having a first side, a second side, an opening in a center thereof, and a slot extending from the first side to the second side and from the opening to an outer periphery of the disk. The elongated member is coupled to the disk and extends through the opening from the first side of the disk and beyond the second side of the disk. The disk is used to remove a damaged end portion of a micromixer tube from within the tube, and without debris damaging the tube or a cutting tool damaging other tubes in a set of micromixer tubes.