Portable Jig Fixture Alignment for Precision Turbomachining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The machining of turbomachinery components, such as gas turbines, requires high precision jigs and fixtures due to non-standard sizing and complex geometries, which existing tooling often fails to provide, leading to inefficiencies and safety concerns like fuel leakage in axial fuel injection systems.
Innovation Solution
A portable jig and fixture system comprising a base plate, column assembly, slide assembly, power feed head, spindle unit, and cutter/drill assemblies, optimized for strength and stiffness, allowing precise machining of non-standard apertures and shapes without modifying the turbomachine, using alignment mounting structures for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard tooling is used for machining turbomachinery components, then the machining process is simpler and faster, but the precision and fitup capability are insufficient for non-standard sizing and complex geometries
Solution Approach 1:
The portable jig and fixture system is divided into modular components including base plates with alignment mounting structures, column assemblies, slide assemblies, power feed heads, and spindle units. These segmented modules can be independently manufactured, positioned, and assembled to achieve complex geometries and high precision machining of non-standard turbomachinery components
Solution Approach 2:
The system incorporates movable and adjustable components such as slide assemblies that can move along guide ways, adjustable column assemblies, and reconfigurable mounting structures. This dynamic capability allows the tooling to adapt to various non-standard component sizes and geometries while maintaining machining precision
2Manufacturing precision
If high precision portable jig and fixture system is used, then machining accuracy and fitup capability improve, but the device complexity and manufacturing cost increase
Solution Approach 1:
The portable jig and fixture system is designed as a universal platform that can machine various types of turbomachinery components including casings, impellers, and combustors with different geometries and tolerances. The alignment mounting structures and modular components can be reconfigured for different applications, reducing the need for multiple specialized tooling sets
Solution Approach 2:
The base plates with alignment mounting structures serve as intermediary elements between the portable tooling system and the turbomachinery components. These intermediaries provide precise positioning and registration features that enable accurate fitup without requiring complex direct coupling between the tooling and workpiece
3Reliability
If conventional axial fuel injection assemblies are installed without precise machining, then installation time is reduced, but fuel leakage risk and safety concerns increase
Solution Approach 1:
The portable jig and fixture system performs preliminary precision machining of mounting openings, seal surfaces, and alignment features before fuel injection assembly installation. This preliminary action ensures that all mating surfaces and geometric features are within tolerance, preventing fuel leakage and eliminating the need for post-installation adjustments or repairs
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A portable jig and fixture (80) having at least one base plate (82), a column assembly (83) removably coupled to the at least one base plate (82), a slide assembly (100) removably coupled to the column assembly (83), a power feed head (104) removably coupled to the slide assembly (100), and a spindle unit (108) removably coupled with the slide assembly (100) having a motor (112) removably engaged it. At least one cutter assembly (120) is removably engaged with the spindle unit (108) and at least one drill jig (130) is also removably engaged with the spindle unit (108). Also, a turbomachine (10) having complementary structure (70) on the compressor discharge casing (21) can engage with the at least one base plate alignment mounting structure (72) on the portable jig and fixture (80).