Stationary Base Turning Machine for Gas Turbine Components
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Solution Overview
Problem
Conventional turning and rolling machines face challenges in high-precision machining of large, heavy components due to clamping issues, high energy requirements, and large machine dimensions, making them inflexible and difficult to transport, especially for maintenance tasks on gas turbines.
Innovation Solution
A lathe and/or roller burnishing machine design where an arm movably arranged on the longitudinal slide holds the tool holder, allowing the machine to be smaller, lighter, and more flexible, with a stationary base part that can be mounted on the workpiece, and a rotating part held between two base parts for improved rigidity, using a compressed air drive to minimize energy consumption and prevent centrifugal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional turning and rolling machines are used for high-precision machining of large components, then machining precision can be achieved, but the machine dimensions become large and transportation becomes difficult
Solution Approach 1:
Instead of rotating the large workpiece on a conventional lathe, the invention inverts the approach by keeping the workpiece stationary and rotating the cutting tool around the workpiece. This inversion allows achieving high-precision machining without requiring a large conventional lathe structure, thus reducing machine dimensions while maintaining machining precision
Solution Approach 2:
The invention introduces a stationary base part that can be mounted directly on the workpiece, serving as an intermediary between the workpiece and the rotating tool assembly. This mediator allows the machine to be compact and portable while still providing stable support for high-precision machining operations
2Manufacturing precision
If conventional machines rotate large heavy components for processing, then machining can be performed, but energy consumption becomes high
Solution Approach 1:
The invention inverts the traditional machining approach by keeping the heavy workpiece stationary and rotating the much lighter cutting tool instead. This eliminates the high energy consumption associated with rotating large heavy components while maintaining the ability to perform precise machining operations
Solution Approach 2:
The stationary workpiece serves itself as the support structure, eliminating the need for a large machine bed and complex support systems. The workpiece's own structure provides the stability needed for precise machining, reducing the energy required to move and support the workpiece during machining
3Manufacturing precision
If conventional machines are designed for large components, then processing capability is sufficient, but clamping of large-format components causes problems
Solution Approach 1:
The stationary base part acts as an intermediary that can be directly mounted on the workpiece surface, providing stable support and eliminating clamping problems. This base part serves as a reliable foundation for the rotating tool assembly, ensuring processing capability while simplifying the clamping and setup process for large-format components
Solution Approach 2:
The invention allows the base part to be adaptively mounted on different workpiece surfaces, providing dynamic adjustment capability. This enables easy adaptation to various large-format component geometries, making clamping and setup straightforward while maintaining processing capability
4Manufacturing precision
If machine tools are made larger for processing large components, then processing capability improves, but local flexibility and transportability decrease
Solution Approach 1:
By inverting the traditional approach and keeping the workpiece stationary while rotating the tool, the invention eliminates the need for large machine structures. This allows the machining system to be compact and portable, providing local flexibility and adaptability for on-site machining of large components while maintaining full processing capability
Solution Approach 2:
The invention segments the machining system into a stationary base part that mounts directly on the workpiece and a separate rotating tool assembly. This segmentation allows the system to be compact, easily transported, and adapted to different locations while maintaining the capability to process large components with high precision
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 high-precision, flexible machining of large components with reduced energy usage and compact machine design, allowing for easy transportation and local use, particularly suitable for gas turbine components like tie rods in power plant technology.
Implementation Method 1
using a compressed air drive to minimize energy consumption and prevent centrifugal forces
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a turning and/or roller burnishing machine (1) having a base part (3), which is designed as to be assembled in a stationary manner, particularly to a component to be processed (2), a drive (4), a rotation part (6) held on the base part (3) and rotatable relative thereto about a central axis (9) using the drive (4), and a tool holder (26, 35) which is arranged spaced apart from the central axis (9) on the rotation part (6) and is designed to receive a turning and/or roller burnishing tool (27, 36).