Robotic Rotary Shear Tool for Gas Turbine Weld Flash Removal
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Solution Overview
Problem
The manual removal of weld flash from weld joints in gas turbine engine components using a hammer and chisel is hazardous, inaccurate, and risks damage to the components, necessitating a more controlled and safer method.
Innovation Solution
A rotary shear tool with a rotary blade and a fixed blade, mounted on a robotic arm, is used to shear the weld flash, allowing precise control and minimizing risk of damage or injury.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hammer and chisel method is used to remove weld flash, then equipment simplicity is maintained, but manufacturing precision and operator safety deteriorate
Solution Approach 1:
The patent replaces the manual hammer and chisel mechanical system with a controlled rotary shear tool system. The rotary blade rotates at controlled speed and shears the weld flash between the rotary blade and a fixed blade, providing precise control over the removal process while eliminating manual labor hazards.
Solution Approach 2:
The patent changes the operational parameters from manual impact forces to controlled rotational speed and shear force. The rotary blade rotates at a controlled speed (e.g., 500-2000 rpm) to optimize the shearing action, allowing precise control of weld flash removal depth and direction while maintaining equipment simplicity.
2Device complexity
If manual hammer and chisel method is used to remove weld flash, then equipment complexity is minimized, but component damage risk and operator safety deteriorate
Solution Approach 1:
The patent replaces the unpredictable impact mechanics of hammer and chisel with controlled rotational shear mechanics. The rotary blade rotates at controlled speed and shears the weld flash between the rotary blade and a fixed blade, providing precise control over the removal process while eliminating manual labor hazards.
Solution Approach 2:
The patent introduces a fixed blade as an intermediary element that works in conjunction with the rotary blade. The weld flash is sheared between the rotary blade and the fixed blade, distributing the cutting action and reducing the risk of direct contact damage to the underlying component surfaces.
3Manufacturing precision
If rotary shear tool with robotic arm is used, then manufacturing precision and safety are improved, but device complexity increases
Solution Approach 1:
The rotary shear tool is designed with multi-functionality to justify the increased complexity. The tool can be mounted on different positioning systems (manual or robotic), the rotary blade can be adjusted for different weld flash configurations, and the fixed blade can be positioned to accommodate various component geometries, making the system adaptable to multiple welding scenarios.
4Productivity
If rotary shear tool is used to shear weld flash, then productivity is improved, but initial equipment investment increases
Solution Approach 1:
The rotary blade rotates continuously during the weld flash removal process, maintaining constant contact with the weld flash material. This continuous shearing action eliminates the intermittent striking motion of manual methods, significantly improving productivity by removing weld flash more quickly and consistently without requiring repeated positioning adjustments.
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 method enables accurate and controlled removal of weld flash, reducing the risk of damage to components and personnel safety issues, while improving the precision of the process.
Implementation Method 1
shearing the weld flash from the weld joint by passing the weld flash between the rotary blade and second blade of the rotary shear tool
Implementation Method 2
mounting the rotary shear tool on a robotic arm and moving the rotary shear tool using the robotic arm such that the weld flash passes between the blades of the rotary shear tool
Data Source
AI summary
Method of trimming weld flash from a weld joint formed between a first component and a second component. The method provides a rotary shear tool having a rotary blade and a second blade. The second blade may be a fixed blade. The method further includes shearing the weld flash from the weld joint by passing the weld flash between the rotary blade and second blade of the rotary shear tool. Also provides a rotary shear tool for trimming weld flash from a weld joint formed between a first component and a second component. The rotary shear tool includes: a rotary blade; a second blade; and a mounting portion for mounting the rotary shear tool on a robotic arm.