Planetary Manipulator for Uniform PVD Coating
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Solution Overview
Problem
Existing coating systems face challenges in achieving uniform coating distribution on complex geometries and hard-to-reach areas of gas turbine engine components, particularly in the throat area between airfoils, due to limitations in workpiece manipulation.
Innovation Solution
A planetary manipulator assembly with a sun gear, planetary gear, and independent drive shafts allows for pseudo-random movement of workpieces, enabling even coating distribution by rotating the support shaft and carrier body around a common axis, independent of the primary drive shaft, and positioning a coating source in proximity for optimal coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple rotational manipulator is used, then the device complexity is reduced, but the coating uniformity on complex geometries deteriorates
Solution Approach 1:
The manipulator employs multiple independently controllable rotational axes (sun gear rotation, planetary gear orbit, carrier body rotation) that enable dynamic, pseudo-random workpiece movement patterns. This dynamic multi-axis coordination allows the workpiece to be continuously repositioned and reoriented during coating, achieving uniform coating distribution on complex geometries without requiring overly complex mechanical structures.
Solution Approach 2:
The invention adds rotational degrees of freedom by incorporating planetary gear mechanisms that move the workpiece through multiple spatial dimensions. The combination of sun gear rotation, planetary gear orbital motion, and carrier body rotation creates three-dimensional workpiece movement, enabling coating uniformity on complex surfaces by exposing all surfaces to the coating plume from multiple angles.
2Manufacturing precision
If a planetary manipulator with multiple drive shafts is used, then the coating uniformity is improved, but the device complexity increases
Solution Approach 1:
The planetary gear mechanism serves multiple functions simultaneously: it transmits rotational motion from the sun gear, provides orbital movement of the planetary gears, enables carrier body rotation, and allows independent control of multiple axes. This multi-functionality reduces the need for separate drive mechanisms for each degree of freedom, managing device complexity while achieving superior coating uniformity.
Solution Approach 2:
The planetary gear acts as an intermediary mechanism that converts simple rotational input from the sun gear into complex multi-axis motion patterns. The planetary gears mediate between the single sun gear rotation and the multiple independent rotational outputs, enabling precise control of workpiece orientation and position without requiring equally complex direct drive systems for each axis.
3Device complexity
If the support shaft is fixed, then the device complexity is reduced, but the adaptability to different coating angles deteriorates
Solution Approach 1:
The support shaft is made rotatable relative to the planetary gear through the bevel gear transmission system, enabling dynamic adjustment of the workpiece orientation. This rotational capability allows the manipulator to adapt to different coating angles and accommodate various workpiece geometries, improving versatility without significantly increasing overall device complexity through the use of standard gear mechanisms.
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
This solution facilitates consistent and even coating application on complex surfaces by mimicking random movement, improving coating thickness distribution and allowing for precise control over coating application on gas turbine engine components, such as vane segments, with adjustable angles and dwell times for optimal thermal barrier coating application.
Implementation Method 1
a planetary gear engaged with the sun gear; a second driveshaft rotationally fixed to the planetary gear for rotation therewith, such that torque is transmitted from the sun gear to the planetary gear to rotate the second driveshaft
Implementation Method 2
a coating source positioned in operative proximity to the planetary manipulator assembly
Data Source
Figure 1
Figure 2
AI summary
A coating system (10) includes a coating source (40) and a planetary manipulator assembly (11) that includes a first driveshaft (12) capable of receiving rotational input, a sun gear (14) rotationally fixed to the first driveshaft, a planetary gear (16) engaged with the sun gear, a second driveshaft (18) rotationally fixed to the planetary gear such that torque is transmitted from the sun gear to the planetary gear, a support shaft (24) operatively engaged with the second driveshaft, a carrier body (34) supporting the planetary gear relative to the sun gear, a third driveshaft (28) capable of receiving rotational input, and a drive gear (30) rotationally fixed to the third driveshaft. The support shaft is arranged substantially perpendicular to the second driveshaft. The carrier body is rotatable by the drive gear about a common axis (A) with the sun gear, and rotation of the carrier body rotates the planetary gear and the second driveshaft about the sun gear.