Robotic Deep Rolling Tool for Complex Blade Root Geometry

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Solution Overview

Problem

Existing deep rolling tools for fan blades are expensive, complex, and inefficient due to their hydraulic systems, which require constant pressure adjustments and result in slow production and surface oil residue issues.

Innovation Solution

A system for deep rolling fan blades using a roller tool with an adaptor plate, an arm with an offset to prevent contact, a roller disk, and a fixture to support the fan blade, allowing for controlled contact stress and efficient processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If hydraulic burnishing tools with ball bearing are used for complex geometries, then processing precision is improved, but device complexity and cost increase due to hydraulic systems requiring constant pressure adjustments

Engineering Contradiction:

Improveprocessing precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent removes the hydraulic system entirely from the deep rolling tool, extracting the complex pressure control mechanism while retaining the core rolling function. The tool uses a simple mechanical roller that can be directly actuated by the robotic arm without requiring hydraulic pumps, valves, or pressure sensors.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The simplified roller tool design can be universally applied to various complex blade geometries without requiring hydraulic system reconfiguration. The same basic tool structure works for different airfoil shapes and root configurations, eliminating the need for hydraulic pressure adjustments for different part geometries.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If hydraulic burnishing tools with small ball bearing surface area are used, then processing precision is improved, but productivity decreases due to slow production time

Engineering Contradiction:

Improveprocessing precisionVSAvoidproductivity

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent merges multiple rolling operations into a single continuous pass using the linear roller geometry. Instead of using a small ball bearing that requires multiple overlapping passes to cover the surface, the elongated roller contacts a larger surface area simultaneously, combining what would be multiple discrete operations into one efficient pass.

Inventive Principle:

Principle #5Merging (Combining)

3Stress or pressure

If hydraulic systems with constant pressure adjustments are used, then contact stress control is improved, but loss of time increases due to constant adjustments and maintenance

Engineering Contradiction:

Improvecontact stress controlVSAvoidloss of time

Core Design Contradiction:

Stress or pressureVSLoss of time

Solution Approach 1:

The mechanical roller tool self-regulates the contact stress through its inherent compliance and geometry. The roller naturally conforms to the blade surface geometry and distributes load appropriately without requiring external pressure control systems. The tool serves itself by using the robotic arm's motion and gravity to provide consistent contact force.

Inventive Principle:

Principle #25Self-service

4Manufacturing precision

If hydraulic burnishing tools are used, then surface treatment quality is improved, but object-generated harmful factors increase due to oil residue on the treated surface

Engineering Contradiction:

Improvesurface treatment qualityVSAvoidoil residue

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the hydraulic lubrication system with a dry mechanical rolling system. Instead of using oil-lubricated hydraulic actuators that leave residue, the tool uses a simple mechanical roller that can operate dry or with minimal lubrication, eliminating the oil residue problem entirely while maintaining surface treatment quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively induces deep compressive residual stresses in fan blades, improving fatigue life and corrosion resistance while reducing production time and costs by eliminating the need for hydraulic systems.

Implementation Method 1

The Deep Rolling process uses a roller to roll the surface under controlled load & speed. The rolling pressure induces a deep layer of compressive residual stress.

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

The rolling pressure induces a deep layer of compressive residual stress.

Methodology Applied

Scientific EffectCompressive residual stress: Compression

Data Source

PatentUS20250162011A1Robotic deep rolling tool design for mechanical surface treatment of complex blade root geometry

Publication Date: 2025.05.22 RTX CORP

AI summary

A system for deep rolling a workpiece including a roller tool comprising an adaptor plate proximate an adapter end; an arm attached to the adaptor plate, the arm comprising an adapter end proximate the adaptor plate, the arm comprising a roller end opposite the adapter end, the arm comprising a midspan portion between the adapter end and the roller end, an offset formed in the arm configured to prevent contact with the workpiece; a roller disk joined to the roller end, the roller disk configured to contact the workpiece; and a fixture supporting the workpiece.