Robotic Hot-Engine Servicing for On-Wing Fastener Loosening
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Solution Overview
Problem
Traditional methods for servicing gas turbine engines require costly and time-consuming disassembly and inspection, which can be inefficient and hazardous due to the need for cooling before maintenance can be performed.
Innovation Solution
A robotic assembly equipped with a lubrication dispenser and tools that can operate on engine components at elevated temperatures, using temperature gradients to reduce torque requirements for loosening fasteners, allowing for autonomous or semi-autonomous servicing while the engine is still hot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional servicing methods are used, then safety is improved by cooling the engine before maintenance, but productivity deteriorates due to extended downtime and cooling time
Solution Approach 1:
The patent replaces human operators with a robotic assembly that can safely operate in high-temperature environments. The robotic system includes temperature sensors, lubrication dispensers, and torque tools that function autonomously at elevated temperatures, eliminating the need to wait for cooling while maintaining safety through automation and sensor-based monitoring.
Solution Approach 2:
The patent changes the operational temperature parameter from traditional cool-down requirements to elevated temperature operation. The robotic assembly is specifically designed to operate at temperatures up to 200°C or higher, using temperature-compensated lubrication, heat-resistant materials, and adaptive torque control that adjusts based on real-time temperature measurements.
2Ease of operation
If the engine is cooled before servicing, then ease of operation is improved for human workers, but loss of time increases due to extended cooling and disassembly requirements
Solution Approach 1:
The robotic assembly performs self-service operations by autonomously navigating to fasteners, applying temperature-compensated lubrication, and executing torque-controlled fastening/loosening operations without human intervention. The system uses onboard sensors to detect fastener conditions and automatically adjusts its operations, eliminating the need for human workers to wait for cooling or perform time-consuming manual preparation.
Solution Approach 2:
The robotic system applies lubrication to fasteners before attempting to loosen them, and uses real-time temperature monitoring to prepare appropriate torque parameters in advance. This preliminary conditioning of fasteners with lubrication at elevated temperatures reduces the torque required for loosening and prevents galling, enabling faster operations without waiting for cooling.
3Measurement precision
If disassembly is performed to access components, then measurement precision is improved for inspection, but device complexity increases and productivity decreases
Solution Approach 1:
The patent replaces complex manual disassembly operations with a robotic assembly equipped with specialized end effectors, torque tools, and sensors. The robotic system can access fasteners in confined spaces through programmed motion paths and uses force sensors and vision systems to perform precise operations without requiring extensive disassembly of the engine structure.
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
Enables efficient and safe on-wing maintenance by reducing the need for cooling, minimizing downtime, and allowing for the use of robotic systems to perform inspections and repairs at elevated temperatures, thus lowering costs and increasing operational efficiency.
Implementation Method 1
the robotic assembly is configured to utilize temperature gradients between the one or more fasteners and a remainder of the engine to reduce a torque requirement to loosen the one or more fasteners
Implementation Method 2
applying, from the robotic assembly, lubrication to one or more adjustable components of the engine
Data Source
AI summary
Systems and methods of servicing engines including a method of servicing an engine, the method including navigating at least a portion of a robotic assembly to a location associated with the engine; applying, from the robotic assembly, a medium to one or more adjustable components of the engine while the engine is at an elevated temperature; waiting a duration of time; and with the robotic assembly, operating on the one or more adjustable components.