Closed-Loop Polishing Pressure Control for Component Repair
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Solution Overview
Problem
Components such as those in gas turbine engines experience damage like cracking, which can render them unusable if not timely repaired, leading to potential failure and costly replacement.
Innovation Solution
A polishing system comprising a polishing device with a housing, an interchangeable polishing tool, pressure applicators, a controller, and a component monitoring device, which allows for precise pressure application and material removal control to repair components effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machining is used to repair components, then cracking issues can be addressed, but it is not viable for all components due to deployment timescales, capital expenditure, and available operating envelope
Solution Approach 1:
The polishing device is designed with interchangeable polishing tools and holders that can be adapted to different component geometries and sizes. The system can polish various shapes including linear and non-linear components, making it universally applicable across different component types in gas turbine engines and other industries.
Solution Approach 2:
The system employs controllable pressure application through the holder and pressure applicators, allowing dynamic adjustment of polishing parameters. The controller regulates pressure and movement speed to adapt to different component requirements, enabling the same device to handle diverse repair scenarios.
2Manufacturing precision
If conventional polishing methods are used, then material removal can occur, but precise control over material removal rate and pressure application is difficult to achieve
Solution Approach 1:
The system incorporates sensors that provide feedback to the controller about pressure application and material removal rate. The controller uses this feedback to automatically adjust polishing parameters, maintaining precise control without requiring complex manual intervention. This closed-loop control achieves high precision while keeping the operational complexity manageable.
Solution Approach 2:
The system replaces manual mechanical control with automated electronic control through the controller and pressure applicators. This substitution enables precise digital control of pressure and movement speed, achieving high manufacturing precision while the automated systems handle the complexity.
3Reliability
If components are replaced instead of repaired, then reliability is maintained, but substantial costs are incurred
Solution Approach 1:
The polishing system enables recovery of damaged components by removing cracks and surface defects through controlled polishing. Instead of discarding cracked components, the system recovers them by eliminating damage and restoring surface integrity, allowing reuse and avoiding replacement costs while maintaining reliability.
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 polishing system provides a cost-effective and time-effective solution for repairing components across various industries, including gas turbine engines, by allowing for universal applicability and precise control over the polishing process.
Implementation Method 1
at least one pressure applicator disposed within the housing and configured to apply a pressure on the polishing tool to engage the polishing tool with the component
Implementation Method 2
The pressure sensor is configured to generate a pressure signal indicative of an amount of pressure being applied by the at least one pressure applicator and the holder on the polishing tool
Implementation Method 3
The polishing tool is configured to polish the component... generate a process signal indicative of a material removal rate from the component
Data Source
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AI summary
A polishing system (100) for polishing a component (200) has a polishing device (102) that has a housing (106) and a polishing tool (120) interchangeably coupled with the housing (106). The polishing tool (120) is configured to polish the component (200). The polishing device (102) further includes at least one pressure applicator (126) disposed within the housing (106) and configured to apply a pressure on the polishing tool (120) to engage the polishing tool (120) with the component (200). The polishing system (100) further includes a holder (104) interchangeably coupled with the housing (106) of the polishing device (102) to position the polishing device (102) relative to the component (200) and a controller (108) communicably coupled with the at least one pressure applicator (126). The controller (108) is configured to transmit a control signal (C1) to the at least one pressure applicator (126) to apply a predetermined amount of pressure on the polishing tool (120). The polishing device further includes a pressure sensor (128), which is disposed within the housing (106) and communicably coupled with the controller (108), and is configured to generate a pressure signal (P1) indicative of an amount of pressure being applied by the at least one pressure applicator (126) and the holder (104). The polishing system further includes a component monitoring device (132) that is communicably coupled with the controller (108) and is configured to generate a process signal (P2) indicative of a material removal rate from the component (200).