Turbine Stator Sealing Pad Insertion With Robotic Assembly

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Solution Overview

Problem

The manual assembly of turbine stators in aeronautical turbomachines is time-consuming and prone to errors, leading to musculoskeletal disorders and reduced quality due to repetitive tasks involved in inserting sealing pads and anti-wear devices, which complicates the assembly process and increases production costs.

Innovation Solution

An automated system using robot arms to insert sealing pads into turbine stators, which includes a support for sectors, a robot arm for gripping pads, and a method for identifying and orienting pads according to specific slots, reducing manual intervention and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual assembly is used to insert sealing pads into turbine stator sectors, then operators can perform the task with simple equipment, but the assembly process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improveassembly speedVSAvoidcomplexity of assembly system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system uses automated robot arms with vision systems that enable the assembly process to perform self-identification and self-positioning of sealing pads, eliminating the need for manual intervention and significantly improving assembly speed while maintaining manageable system complexity through modular design

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations by operators are replaced with automated robot arms equipped with specialized end effectors, transforming the assembly process from labor-intensive manual work to automated mechanical systems that achieve high precision and speed without proportionally increasing overall system complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If operators perform repetitive manual tasks for inserting sealing pads, then the process remains simple to operate, but operators suffer from musculoskeletal disorders and quality errors increase

Engineering Contradiction:

Improveassembly qualityVSAvoidoperational simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The automated system performs self-positioning and self-insertion of sealing pads using robot arms with integrated vision systems, eliminating repetitive manual tasks that cause musculoskeletal disorders while ensuring consistent high-quality assembly through automated precision control

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates vision systems and sensors that provide real-time feedback on the position and orientation of sealing pads and sectors, enabling automated adjustment and verification to maintain high assembly quality while reducing reliance on manual inspection and operation

Inventive Principle:

Principle #23Feedback

3Loss of time

If manual identification and insertion of sealing pads is performed, then the process requires minimal equipment, but assembly time increases to ten hours per turbine stator

Engineering Contradiction:

Improveassembly cycle timeVSAvoidcomplexity of automation system

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The system performs preliminary identification and positioning of sealing pads using vision systems before insertion, and pre-positions multiple pads in ready-to-insert configurations, significantly reducing the overall assembly cycle time from ten hours to a few dozen minutes while the modular automated system maintains manageable complexity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The automated robot arms perform continuous insertion operations without the interruptions inherent in manual assembly, with multiple arms working in parallel on different sectors simultaneously, dramatically reducing total assembly time while the coordinated automation system maintains reasonable complexity through standardized procedures

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If operators manually insert sealing pads one by one, then the equipment required remains simple, but the repetitive operations reduce quality and increase errors

Engineering Contradiction:

Improveassembly throughputVSAvoidsealing pad positioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Manual insertion operations are replaced with automated robot arms that provide consistent, precise positioning and insertion of sealing pads, eliminating human error and variability while maintaining high throughput through automated continuous operation and parallel processing of multiple sectors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11781438B2Automated device for inserting sealing pads into one of the sectors of a turbine stator of a turbine

Publication Date: 2023.10.10 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A device is suitable for inserting sealing pads into one of the sectors of a turbine stator of a turbine, wherein the turbine stator includes a plurality of sectors with adjacent side faces abutting each other and slots arranged opposite each other in the adjacent side faces of two successive sectors. Each stator is configured to receive a predefined sealing pad. The device includes a support for supporting the sector; a robot arm configured to grip the sealing pads, each predefined in accordance with the slot intended to receive it. The robot arm is configured to insert each predefined sealing pad into the slot intended to receive it of one of the side faces of the sector.