Turbine Blade Insertion Tool With Swivel Alignment
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Solution Overview
Problem
Existing methods for inserting turbine blades into rotor slots face challenges in precision alignment and safety due to the physical weight and length of rotor blades, leading to manual exhaustion, potential damage, and impracticality of current tools like robotic arms and pneumatic lifts in field environments.
Innovation Solution
A turbine blade insertion tool with a vertically supported blade lift fixture and a three-axis degree of freedom joint for precise alignment, combined with swivel rollers and spring-biased ball casters for stability, allows for manual maneuvering and supported alignment of the blade root and rotor slot from under a suspended rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual blade manipulation by human operators using portable hand dollies is used, then the blade can be positioned vertically, but the operators become physically exhausted and risk blade damage due to lack of support
Solution Approach 1:
The patent introduces a portable support stand as an intermediary device between the operators and the blade. The support stand vertically supports the blade during insertion, eliminating the need for operators to manually hold or lift the blade. This mediator device bears the blade's weight and provides stable positioning, thereby preventing operator exhaustion and eliminating the risk of blade damage from mishandling.
2Manufacturing precision
If robotic blade manipulation arms are used, then blade alignment precision is improved, but the tool size becomes too large and range of motion is limited for field environments
Solution Approach 1:
The patent segments the alignment function from the support function. The support stand provides vertical support while a separate alignment device with adjustable arms provides precise positioning. This segmentation allows each component to be simpler and more maneuverable than a monolithic robotic arm, enabling the system to fit in field environments while maintaining alignment precision through the adjustable alignment device.
3Force
If pneumatic table blade lifts are used, then blade lifting capability is provided, but the table footprint is too large for field sites and oscillatory motion complicates alignment
Solution Approach 1:
The patent extracts the lifting function from a large pneumatic table and implements it through a compact telescoping column mechanism integrated into the portable support stand. The telescoping column provides controlled vertical movement to lift and position the blade without requiring a large table footprint. This extraction eliminates the oscillatory motion problem by using a direct, controlled mechanical lifting mechanism rather than a large table system.
4Force
If overhead cranes and hoists are used, then heavy blade lifting is enabled, but blade insertion must occur at elevated 12 o'clock position rather than ground level
Solution Approach 1:
The patent inverts the traditional approach by supporting the blade from below rather than suspending it from above. The portable support stand positioned at ground level provides upward support through the telescoping column, enabling blade insertion at the convenient 6 o'clock ground-level position rather than requiring elevated 12 o'clock insertion from an overhead crane. This inversion of the support direction fundamentally changes the operational ergonomics.
Data Source
AI summary
Turbine blade insertion tool (20) facilitates supported vertical and lateral alignment of a turbine blade root (18) and corresponding rotor slot (14) from under a suspended rotor (12). The blade lift fixture (46) slidably retains the blade root while manually biasable slide (38) provides supported relative vertical alignment between the blade root and rotor slot Supported lateral root/slot alignment is provided by manually swinging the blade lift fixture (46) on three-dimensional motion capable swivel eye (50) and corresponding lift hook (44) that are coupled to the slide (38). The blade insertion tool (20) optionally is maneuverable on swivel rollers (24) under the rotor (12).