Vertical Thermal Hood Array for Coating Apparatus Downtime
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Solution Overview
Problem
Gas turbine engine components face failure due to thermal-mechanical stresses and fatigue, with existing thermal barrier coating systems experiencing degradation over time, requiring efficient methods for maintaining optimal coating performance and reducing downtime for hood replacement.
Innovation Solution
A coating apparatus with a vertical array of thermal hoods allows for sequential replacement of hoods based on power consumption thresholds, maintaining vacuum conditions and reducing thermal degradation, while an adjustable hood system ensures continuous coating operations with minimal downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal hoods are used to maintain part temperature during coating deposition, then coating quality and temperature control are improved, but thermal hoods degrade over time and require replacement, causing downtime and increased costs
Solution Approach 1:
The system divides the thermal hood function into multiple replaceable units arranged in a vertical array. Instead of using a single thermal hood that degrades over time, the system segments the thermal management function across multiple hoods (e.g., hood 1, hood 2, hood 3) that can be individually replaced based on their utilization and degradation level, thereby extending the overall system service life while maintaining coating quality.
Solution Approach 2:
The system monitors power consumption thresholds and hood utilization parameters to determine optimal replacement timing. By changing the operational parameters (power consumption levels, temperature maintenance effectiveness) and using these as indicators for hood replacement, the system extends service life while ensuring coating quality is maintained until the point of no return.
2Manufacturing precision
If thermal hoods are replaced frequently to maintain optimal performance, then coating quality is preserved, but downtime and operational costs increase
Solution Approach 1:
The system prepares multiple thermal hoods in advance in a vertical array, so when one hood reaches its replacement threshold, another ready-to-use hood is already in position. This preliminary preparation of backup hoods eliminates downtime associated with ordering, shipping, and installing replacement hoods, thereby maintaining productivity while ensuring coating quality through timely replacements.
Solution Approach 2:
The system maintains continuous coating operations by having multiple thermal hoods available in sequence. As one hood reaches its replacement point, the system can switch to the next hood in the array without interrupting the coating process, ensuring continuity of useful action and maintaining both coating quality and productivity.
3Productivity
If a single thermal hood is used for extended periods, then operational costs are reduced, but the hood degrades and coating quality deteriorates
Solution Approach 1:
The system dynamically manages thermal hood utilization by tracking power consumption thresholds and operational cycles for each hood. Instead of static hood usage, the system adaptively assigns parts to different hoods based on their current state and utilization history, optimizing the balance between operational efficiency and coating quality throughout the extended operational period.
4Duration of action of stationary object
If thermal hoods are made more durable and expensive, then replacement frequency decreases, but initial system cost increases
Solution Approach 1:
The system uses multiple relatively inexpensive, shorter-lived thermal hoods instead of a single expensive, long-lived hood. Each individual hood is designed for a limited service life and can be economically replaced, while the overall system achieves extended operational capability through the array of hoods. This approach reduces the complexity and cost of each individual component while maintaining system performance.
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 solution extends the interval between cooling and venting cycles, reduces thermal hood replacement costs, and maintains consistent coating quality by allowing hood replacement at a higher utilization level, thereby enhancing the durability and efficiency of gas turbine components.
Implementation Method 1
the source comprises an ingot and an electron source positioned to direct a beam to the ingot
Implementation Method 2
thermal hoods to maintain part temperature
Data Source
AI summary
An apparatus for depositing a coating on a part comprises: a chamber; a source of the coating material, positioned to communicate the coating material to the part in the chamber; a plurality of thermal hoods; and means for moving a hood of the plurality of thermal hoods from an operative position and replacing the hood with another hood of the plurality of hoods.