Robotic Turbine Blade Repair With Track-Guided Tool Positioning
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Solution Overview
Problem
The existing methods for inspecting and repairing blades in gas turbine engines are time-consuming, labor-intensive, and prone to human error due to the geometry and sharp edges of the blades, often requiring manual handling which can be hazardous and results in inconsistent inspection and repair.
Innovation Solution
An automated robotic system with a mechanical arm and track system is used to inspect and repair blades, equipped with tools such as a vision tool, cleaning tool, scanning tool, and repair tool, controlled by a computing device to ensure precise and efficient operation, including rotation of the rotor for access and use of tools along a 7th axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and repair methods are used, then flexibility and adaptability are maintained, but the process becomes time-consuming, labor-intensive, and prone to human error
Solution Approach 1:
The robotic system performs inspection, cleaning, and repair operations autonomously without continuous human intervention. The system self-navigates to blade locations, self-adjusts tool positions, and self-executes repair procedures based on pre-programmed sequences and real-time sensor feedback, thereby dramatically improving productivity while maintaining consistent quality
Solution Approach 2:
Manual mechanical operations by human workers are replaced with automated robotic systems equipped with specialized end effectors. The robotic arm with multiple degrees of freedom substitutes human hands, while automated tools replace manual instruments for tasks such as visual inspection, cleaning, blending, and coating, eliminating human error and increasing operational efficiency
2Reliability
If manual handling of blades is performed, then human judgment and adaptability are utilized, but safety risks increase and consistency decreases
Solution Approach 1:
The robotic system acts as an intermediary between human operators and the hazardous blade environment. Humans program and monitor the system from a safe distance, while the robot performs all direct interactions with blades, including close-up inspection and physical repair operations. This intermediary approach eliminates exposure to sharp edges and inconsistent human handling while maintaining operational control
Solution Approach 2:
The system creates a digital replica or model of the blade geometry and defect locations through 3D scanning and vision systems. This digital copy allows for precise planning and simulation of repair operations before physical execution, ensuring consistent application of repair techniques and enabling quality verification without repeated manual measurements that could introduce variability
3Ease of operation
If complex blade geometries are inspected and repaired manually, then human dexterity is utilized, but the process becomes more difficult and time-consuming
Solution Approach 1:
The robotic system employs dynamic motion control with multiple degrees of freedom to adapt to complex blade geometries. The robotic arm dynamically adjusts its position, orientation, and tool angles in real-time to access difficult-to-reach areas of turbine blades. This dynamic capability allows the system to handle complex geometries as easily as simple shapes, maintaining consistent operation speed and eliminating the time penalties associated with manual dexterity requirements
Solution Approach 2:
The robotic system is designed with universal end effectors and tools that can perform multiple functions: visual inspection, cleaning, blending, coating, and quality verification. This multi-functionality allows a single automated system to handle the entire repair workflow for various blade types and defect conditions, eliminating the need for multiple specialized manual operations and significantly reducing total operation time
Data Source
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AI summary
The present invention is related to a system (100) for inspecting, cleaning, and/or repairing one or more blades (102) attached to a rotor (104) of a gas turbine engine. The system (100) includes a track (110) disposed adjacent to the rotor (104), a mechanical arm (108) moveable along the track (110), a number of tools (128) attachable to an end (142) of the mechanical arm (108), and a controller (106) configured to control a position of at least one of the tools (128) that is attached to the mechanical arm (108) about the one or more blades (102). The system (100) further comprises means (116, 120) for determining axial and angular position of the tool (128) with respect to the rotor (104). The system (100) also comprises a rotational actuator (112) for modifying the angular position of the rotor (104) with respect to the tool (128).