Automated Robotic Welding for Gas Turbine End Cover Insert Repair
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Solution Overview
Problem
The existing methods for repairing openings in gas turbine end covers are prone to human error and are time-consuming, leading to costly downtime and inefficiencies due to manual welding and brazing, which results in wear and cracking that can cause leakage of combustion gases.
Innovation Solution
An automated system and method using a robotic manipulator with a welding torch and consumable welding wire to precisely apply annular welds or cladding to the end cover openings, guided by a digital model and position sensing, allowing for efficient repair of wear and cracking without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual welding and brazing of inserts is used to repair openings in end covers, then the repair can be performed with simple equipment, but the repair process is time-consuming and prone to human error
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated robotic welding system. The robotic manipulator equipped with a welding torch automatically performs the welding of inserts to end cover openings, eliminating manual intervention while maintaining precise control over the welding process. This substitution resolves the contradiction by significantly increasing repair speed and consistency without requiring complex manual dexterity.
Solution Approach 2:
The system incorporates automated positioning and sensing capabilities that allow the robotic manipulator to autonomously locate openings, determine their geometry, and position inserts for welding without human guidance. The digital model of the end cover enables the system to self-navigate and self-adjust during the repair process, achieving high productivity through automation while keeping the overall system relatively simple.
2Device complexity
If manual welding and brazing of inserts is used to repair openings in end covers, then the equipment required is simple, but human error and time consumption increase
Solution Approach 1:
The patent replaces manual welding operations with an automated robotic welding system. The robotic manipulator equipped with a welding torch automatically performs the welding of inserts to end cover openings, eliminating manual intervention while maintaining precise control over the welding process. This substitution resolves the contradiction by significantly increasing repair speed and consistency without requiring complex manual dexterity.
Solution Approach 2:
The system uses a probe to sense and record the actual positions of opening surfaces, then compares this data with the digital model to determine precise locations and orientations. This feedback loop ensures high accuracy in insert positioning and welding, achieving reliable repairs while the automated nature of the system maintains relatively simple equipment requirements.
3Reliability
If end covers are periodically removed for inspection and repair, then wear and cracking can be detected, but the gas turbine must be shut down causing power loss and increased costs
Solution Approach 1:
The patent replaces manual welding operations with an automated robotic welding system. The robotic manipulator equipped with a welding torch automatically performs the welding of inserts to end cover openings, eliminating manual intervention while maintaining precise control over the welding process. This substitution resolves the contradiction by significantly increasing repair speed and consistency without requiring complex manual dexterity.
Solution Approach 2:
The system uses a probe to sense and record the actual positions of opening surfaces before repair, creating a digital model that guides the subsequent welding process. This preliminary action of capturing geometric data enables the automated system to efficiently perform repairs without requiring extended downtime, as the preparation and execution are streamlined through automation.
4Productivity
If automated robotic welding is used to repair end cover openings, then repair time is reduced and accuracy is improved, but the complexity of the repair system increases
Solution Approach 1:
The robotic manipulator is designed to perform multiple functions: it can position the probe for sensing, maneuver the welding torch for welding, and potentially perform other repair tasks. This multi-functionality reduces the need for separate specialized equipment, achieving high productivity while keeping the overall system complexity manageable through consolidation of functions into a single robotic platform.
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
This approach significantly reduces repair time, minimizes human error, and ensures precise restoration of the end cover openings, thereby reducing downtime and operational costs while maintaining the integrity of the gas turbine by preventing combustion gas leakage.
Implementation Method 1
The probe is a consumable welding wire extending from the welding torch and the sensing of the positions is determined based on conductivity between a tip of the consumable welding wire and the surface of the opening.
Implementation Method 2
apply an annular weld to join an insert to the opening by a welding torch maneuvered automatically by the manipulator
Data Source
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AI summary
A method to repair an end cover (24) of a can-type combustor (16) of a gas turbine including: remove the end cover (24) from the combustor of a gas turbine and mount (102) the end cover on a positioner (56); while the end cover is mounted on the positioner, sense and record positions (108) of a surface of an opening (30) in the end cover using a probe (65) operated by a manipulator; based on the recorded positions determine (110) at least one of a centerline of the opening, a center point on an inside surface of the opening, and a diameter of the opening; orient a digital model of the opening with respect to the opening of the end cover based on at least one of the centerline, the center point and the diameter, and apply (116) a weld to join an insert to the opening by a welding torch (62) maneuvered automatically by a manipulator (60) and based on the oriented digital model of the opening.