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, integrated into an automated machine, allows for precise laser beam manipulation and delivery through a small port, enabling laser ablation without disassembly by diverting the beam from an axial path and focusing it onto the workpiece.
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 restricted access locations, but the stationary beam cannot achieve precise positioning or follow complex paths required for effective ablation
Solution Approach 1:
The patent transforms the stationary fixed-beam laser into a dynamic system by introducing a rotating wedge prism that can deflect the laser beam along circular or linear paths. This dynamic beam steering mechanism allows the laser to follow precise trajectories while maintaining access through restricted openings, resolving the contradiction between accessibility and positioning precision.
2Manufacturing precision
If a galvanometer system with movable mirrors is used to move the laser beam, then beam positioning can be adjusted, but the physical dimensions of the system preclude its use within a complex assembly
Solution Approach 1:
The patent embeds the beam steering optics (wedge prism, mirrors, lenses) within a compact end effector housing that can be inserted through small ports. This nested configuration allows the entire beam positioning system to fit within the constrained space of a borescope, eliminating the need for large external galvanometer systems while maintaining positioning precision.
Solution Approach 2:
The patent replaces the mechanical galvanometer mirror system with an optical beam steering approach using a rotating wedge prism and fixed mirrors. This substitution reduces the mechanical complexity and physical size of the system while achieving similar or superior beam positioning capabilities through optical rather than mechanical means.
3Productivity
If the laser beam is delivered through a small port without disassembly, then repair time and cost are reduced, but the beam must navigate through a restricted aperture which limits positioning flexibility
Solution Approach 1:
The patent introduces a third dimension of beam control by using a rotating wedge prism that deflects the laser beam out of the axial path into circular or linear trajectories. This additional degree of freedom allows the beam to access various positions on the workpiece surface while still entering through the same small port, maintaining adaptability without requiring disassembly.
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 effective laser ablation in restricted access locations, reducing the need for engine disassembly and improving repair efficiency by using a rotating wedge prism to create a circular beam path and a gas jet system to manage debris, ensuring precise machining within complex assemblies.
Implementation Method 1
A repair system for performing laser ablation on a workpiece
Implementation Method 2
a focal lens coupled to a focal adjustment mechanism... focusing the laser beam
Implementation Method 3
a dynamic beam diverter... diverting the beam from an axial path... employing a rotating wedge prism to create a circular beam path
Implementation Method 4
a mirror contained within the effector housing downstream of the focal lens... directing the laser beam through the aperture
Implementation Method 5
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 an automated machine and coupled to a laser system.