Miniature Laser End Effector for Restricted-Access Ablation
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Solution Overview
Problem
Current methods for laser ablation in complex assemblies, such as gas turbine engines, require disassembly due to the limitations of fixed-beam lasers and galvanometer systems, which are not suitable for accessing restricted areas within the engine.
Innovation Solution
A miniature laser end effector with a dynamic beam diverter, focal lens, and mirror, mounted on an automated machine, allows for precise laser beam manipulation and delivery through a small port, enabling laser ablation without disassembly, using a rotating wedge prism to divert the beam and a gas jet system to manage debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed-beam laser is mounted on a borescope to perform laser ablation, then the laser can be delivered to the workpiece through a small port, but the stationary beam cannot cover different areas or adjust the cutting path
Solution Approach 1:
The patent applies dynamics by replacing the stationary fixed-beam laser with a dynamic laser source mounted on a robotic manipulator. The laser beam position and orientation can be dynamically adjusted through robotic motion, enabling the beam to reach different areas and adjust cutting paths while maintaining access through restricted ports.
Solution Approach 2:
The patent introduces a robotic manipulator as an intermediary between the laser source and the workpiece. This intermediary enables flexible beam positioning and orientation adjustment, solving the contradiction between maintaining small port access and achieving beam versatility for different cutting paths.
2Measurement precision
If a galvanometer system with movable mirrors is used to direct the laser beam, then small adjustments in beam direction can be made, but the physical dimensions of the system preclude its use within a complex assembly
Solution Approach 1:
The patent replaces the mechanical galvanometer mirror system with a robotic manipulator system. This substitution eliminates the need for complex movable mirror mechanisms, significantly reducing system size and volume while enabling the laser to access restricted locations within complex assemblies through coordinated robotic motion.
Solution Approach 2:
The patent uses dynamic robotic positioning to achieve beam direction control without relying on mechanical mirror galvanometers. The robotic manipulator provides precise control through motion dynamics, achieving the necessary beam positioning precision with a more compact system suitable for complex assemblies.
3Ease of operation
If the engine is disassembled to access the component for repair, then the component can be easily reached and repaired, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent applies preliminary action by using the robotic laser system to perform repair operations before disassembly would be required. The system is configured to access and repair components through existing ports and openings, enabling maintenance to be performed on the assembled engine, thereby eliminating the time-consuming disassembly and reassembly process.
Solution Approach 2:
The robotic manipulator serves as an intermediary that enables access to components through restricted ports without requiring disassembly. This intermediary system bridges the gap between the limitation of small access openings and the need to perform repair operations, allowing maintenance to be performed on the assembled engine.
4Device complexity
If a fixed-beam laser is used, then the system is simple to implement, but it cannot perform laser ablation tasks that require beam movement or positioning in difficult to access locations
Solution Approach 1:
The patent transforms the simple fixed-beam laser system into a dynamic robotic laser system. The added robotic manipulator provides motion capabilities that enable the laser to perform various ablation tasks in difficult-to-access locations, significantly expanding the application range while maintaining reasonable system complexity through modular design.
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 efficient and precise laser ablation in restricted access locations, reducing the need for engine disassembly and reassembly, thus saving time and resources.
Implementation Method 1
perform laser ablation on a workpiece at a location with restricted access
Implementation Method 2
diverting the laser beam from an axial path by employing a dynamic beam diverter
Implementation Method 3
focusing the laser beam
Implementation Method 4
a gas jet system to manage debris
Data Source
AI summary
A system and method for automated laser ablation includes an end effector for performing laser ablation at a location with restricted access. The systems and methods of the present disclosure specifically provide for a miniature laser end effector which may be inserted through a port or bore in order to ablate the surface of an internal component of a complex assembly. In several embodiments of the present subject matter, the end effector is mounted on a machine and coupled to a laser system.