Robotic In-Situ Engine Component Repair Through Casing Openings
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Solution Overview
Problem
The existing methods for repairing components of gas turbine engines, such as cracks or damage, require disassembly and removal of the engine from the aircraft, which is time-consuming and expensive.
Innovation Solution
A system utilizing two robotic arms with utility members, such as drills or welders, that can perform operations like drilling or welding on engine components within the engine's interior without disassembly, using openings in the engine casing to access the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the engine is removed from the aircraft and disassembled to expose the component for repair, then the component can be accessed and repaired, but the repair process becomes time-consuming and expensive
Solution Approach 1:
The repair system is segmented into multiple independent robotic arms, each capable of performing specific repair operations. This allows the system to access and repair components through existing engine openings without requiring complete engine disassembly or removal from the aircraft, thereby reducing repair time while maintaining component accessibility
Solution Approach 2:
Robotic arms serve as intermediaries between the repair operations and the engine components. These robotic arms can extend through engine openings and perform drilling, welding, and other repair operations on components that would otherwise require engine disassembly, enabling in-situ repair and reducing downtime
2Ease of repair
If the engine is removed from the aircraft and disassembled to expose the component for repair, then the component can be accessed and repaired, but the repair process becomes expensive
Solution Approach 1:
The robotic repair system enables the engine to be repaired in its installed position on the aircraft, eliminating the need for costly engine removal, transport, and reinstallation operations. The system performs repair operations through existing engine openings, allowing the engine to service itself without requiring extensive external support equipment or facilities
Solution Approach 2:
Traditional mechanical repair methods requiring engine disassembly and manual operations are replaced with automated robotic systems. The robotic arms can perform drilling, welding, and other repair operations with precision and consistency, reducing labor costs and eliminating the need for expensive engine removal and reinstallation procedures
3Productivity
If robotic arms are used to perform operations within the engine interior, then in-situ repair is enabled, but the system complexity increases
Solution Approach 1:
The robotic arms are designed with multi-functionality, capable of performing multiple repair operations including drilling, welding, and other maintenance tasks. This universality reduces the need for multiple specialized systems and simplifies the overall repair infrastructure while maintaining high productivity across different repair scenarios
Solution Approach 2:
The robotic arms incorporate dynamic positioning and control systems that allow them to adapt to different component locations and repair requirements within the engine interior. This dynamic capability enables the system to handle various repair tasks efficiently without requiring complex reconfiguration, balancing productivity with manageable system complexity
Data Source
AI summary
A system is provided for performing an operation on a component of an engine. The component includes a first side positioned within an interior of the engine. The system includes a first robotic arm defining a first distal end and including a first utility member positioned at the first distal end, the first robotic arm moveable to the interior of the engine to a location operably adjacent to the first side of the component; and a second robotic arm defining a second distal end and including a second utility member positioned at the second distal end, the second robotic arm also moveable to the interior of the engine to facilitate the first and second utility members performing the operation on the component of the engine.