Microwave Imaging for Coated Blade Edge Localization
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Solution Overview
Problem
Existing methods for detecting substrate edges under dielectric coatings, such as thermal barrier coatings, are inefficient and require manual intervention, hindering the automation of edge dressing processes.
Innovation Solution
A substrate edge detection system utilizing a probe that emits scanning signals capable of penetrating dielectric coatings and reflecting off the substrate material, combined with a controller for precise edge localization and a dressing machine for automated machining, enabling accurate edge detection and machining without damaging the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to detect substrate edges under dielectric coatings, then detection can be performed, but the process is time-consuming and requires manual intervention
Solution Approach 1:
The patent replaces manual mechanical detection methods with an automated electromagnetic sensing system. The probe emits electromagnetic signals that penetrate the dielectric coating and detect substrate edges through signal reflection changes, eliminating the need for manual visual inspection or physical probing while maintaining detection accuracy.
Solution Approach 2:
The patent introduces electromagnetic signals as an intermediary to detect substrate edges indirectly through the dielectric coating. The signals act as a mediator that can penetrate the coating and interact with the substrate, providing edge location information without requiring direct physical contact or visual access to the substrate edge.
2Productivity
If automated machining is implemented without accurate edge detection, then productivity increases, but machining precision deteriorates due to inability to locate substrate edges
Solution Approach 1:
The patent implements a feedback mechanism where the probe continuously scans the workpiece surface and provides real-time edge location information to the control system. This feedback enables the automated machining system to adjust its operations based on actual substrate edge positions, maintaining machining precision while achieving full automation.
Solution Approach 2:
The patent performs edge detection scanning before and during machining operations to预先 locate substrate edges and establish reference positions. This preliminary action enables the automated system to plan and execute precise machining paths without manual intervention, ensuring both productivity and precision.
3Ease of operation
If the machining process removes coating material to expose substrate edges, then edge location becomes visible, but the coating integrity is compromised and additional material removal is required
Solution Approach 1:
The patent replaces mechanical methods of exposing edges (such as grinding or cutting through the coating) with electromagnetic sensing. The probe detects substrate edges through the intact coating by measuring changes in electromagnetic signal reflection, eliminating the need to remove coating material for edge location purposes.
Solution Approach 2:
The patent uses electromagnetic signals as an intermediary to detect edges through the dielectric coating without physical contact or material removal. The signals penetrate the coating and provide edge location information, allowing the coating to remain intact and preserving the workpiece's original geometry and protective coating.
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
Enables automated and precise detection of substrate edges under dielectric coatings, facilitating efficient and automated edge dressing processes, thereby improving machining accuracy and reducing manual labor.
Implementation Method 1
the probe is configured to emit scanning signals that can pass through the coating and be reflected by the substrate material
Implementation Method 2
emit microwave frequency scanning signals that can pass through the coating
Data Source
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AI summary
A substrate edge detection system including a substrate material having the substrate edge with a surface; a coating disposed on the surface of the substrate edge; a probe in operative communication with the coating and the substrate edge; and a controller in operative communication with the probe.