Sensor-Guided Blade Repair Tool for Autonomous Turbine Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas turbine engine maintenance, particularly for remote locations, is hindered by the need for skilled engineers and costly, time-consuming repair processes due to damaged fan or compressor blades, which existing automated grinding systems do not adequately address.
Innovation Solution
A tool comprising a rotatable member, a sensor, and a joint enabling relative movement, with a sensor for image and measurement data, and an energy transmission member for fluid-driven rotation, integrated with a machine tool and a controller for autonomous machining path determination and execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated grinding systems are used, then productivity is improved, but they cannot adequately handle damaged fan or compressor blades requiring skilled engineering judgment
Solution Approach 1:
The system uses onboard sensors to automatically detect and measure blade geometry and damage characteristics, eliminating the need for manual inspection by skilled engineers. The tool self-adjusts its machining parameters based on real-time sensor feedback about the blade condition
Solution Approach 2:
Traditional mechanical inspection methods performed by skilled engineers are replaced with optical sensors, lasers, and automated measurement systems that can detect blade geometry, damage extent, and machining requirements without human intervention
2Manufacturing precision
If skilled engineers perform manual repair, then repair quality is maintained, but repair time increases by up to fifty times
Solution Approach 1:
Manual inspection and measurement techniques are replaced with automated optical sensors and laser scanners that rapidly capture blade geometry data, reducing inspection time from hours to minutes while maintaining measurement accuracy
Solution Approach 2:
The system continuously monitors blade geometry and machining progress using onboard sensors, automatically adjusting machining parameters to maintain precision. Real-time feedback loops ensure quality control without requiring manual intervention at each step
3Manufacturing precision
If complex machining operations are performed, then repair quality is improved, but device complexity increases
Solution Approach 1:
Multiple functions (inspection, measurement, machining, and quality control) are integrated into a single unified tool system. The sensor array, machining mechanism, and control system are combined in one portable device, reducing the need for multiple separate equipment pieces
Solution Approach 2:
The tool is designed to handle various blade types and damage conditions with a single system. The sensor array and machining mechanism can adapt to different geometries and repair requirements, eliminating the need for specialized equipment for each repair scenario
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, automated, and precise machining of gas turbine engine components, reducing repair time by up to fifty times and allowing for remote operation without human intervention, thereby improving maintenance efficiency and reducing costs.
Implementation Method 1
a sensor for sensing an object to be machined
Implementation Method 2
a rotatable member, the rotatable member being rotatable to cause rotation of a machine tool
Implementation Method 3
a joint coupling the first part and the second part to enable relative movement between the first part and the second part
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A tool for machining an object comprising: a first part including a rotatable member, the rotatable member being rotatable to cause rotation of a machine tool; a second part; a joint coupling the first part and the second part to enable relative movement between the first part and the second part; and a sensor to sense an object to be machined.