Nutplate Faying Surface Laser Cleaning for Batch Preparation
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Solution Overview
Problem
Existing methods for cleaning nutplate faying surfaces are inefficient and often require expensive packaging to prevent contamination, which increases costs and complicates the attachment process, especially when accessing internal surfaces of aircraft or boat hulls.
Innovation Solution
A laser cleaning system that uses a Nd:YAG laser to remove contaminants from nutplate faying surfaces, with a tray configuration allowing multiple passes at varying angles to ensure thorough cleaning and reduce the need for special packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cleaning methods are used for nutplate faying surfaces, then the cleaning process is simple, but the cleaning efficiency is low and contamination prevention requires expensive packaging
Solution Approach 1:
The patent replaces traditional mechanical cleaning methods (abrasive blasting, chemical cleaning) with a laser-based cleaning system. The laser beam directly ablates contaminants from the faying surface through optical energy, eliminating the need for mechanical tools, chemicals, and expensive protective packaging while achieving superior cleaning efficiency and surface quality.
Solution Approach 2:
The patent utilizes controllable laser parameters (power, pulse duration, scanning speed, beam diameter) to optimize the cleaning process. By adjusting these parameters, the system achieves efficient contaminant removal while maintaining surface integrity, resolving the contradiction between cleaning effectiveness and surface damage prevention.
2Productivity
If multiple nutplates are cleaned individually, then the cleaning process is simple, but the time consumption and cost increase
Solution Approach 1:
The patent merges multiple nutplate cleaning operations into a single batch process by configuring a tray to hold multiple nutplates in positions accessible to the laser beam. This allows simultaneous cleaning of multiple components, dramatically improving productivity while the modular tray design keeps the system configuration manageable.
Solution Approach 2:
The patent arranges nutplates in a three-dimensional tray configuration that allows the laser beam to access faying surfaces from multiple angles and positions. This spatial arrangement enables batch processing of multiple components without requiring complex mechanical manipulation, resolving the contradiction between batch cleaning capability and system complexity.
3Manufacturing precision
If the laser beam is positioned at a single angle, then the system configuration is simple, but the cleaning coverage is insufficient
Solution Approach 1:
The patent divides the cleaning process into multiple passes with the laser beam positioned at different angles and locations. By segmenting the cleaning operation into discrete passes targeting different areas of the faying surface, the system achieves complete coverage while keeping each individual laser position simple and manageable.
Solution Approach 2:
The patent employs periodic scanning motion of the laser beam across the faying surface, systematically moving the beam through multiple positions and angles. This periodic action ensures complete coverage of the surface area while using simple, repeatable motion patterns that minimize system complexity.
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 system efficiently cleans multiple nutplates simultaneously, enhancing the bond strength between nutplates and surfaces by ensuring cleaner faying surfaces, thereby reducing costs and simplifying the attachment process.
Implementation Method 1
a laser configured to conduct a cleaning cycle that includes producing a laser beam capable of cleaning a faying surface
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A system (200) includes a laser (210) configured to conduct a cleaning cycle that includes producing a laser beam capable of cleaning a faying surface (108) of each of a plurality of nutplates (102), and conducting a first pass to clean each of the faying surfaces (108), wherein the laser (210) is at a first position having a first angle relative to an axis orthogonal to the faying surfaces (108) during the first pass. The system (200) also includes a nutplate tray (206) configured to hold the plurality of nutplates (102) such that each faying surface (108) is oriented such that the laser beam is capable of contacting each faying surface (108) at least once during the cleaning cycle.