Vision-Guided Braze Dispensing for Complex Substrate Repair
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Solution Overview
Problem
Current brazing techniques face challenges in accurately and efficiently applying braze material to complex substrates, such as those with cracks or holes, especially in high-temperature environments like aircraft engine components, where precision and automation are crucial for maintaining component integrity and extending lifespan.
Innovation Solution
An automated brazing system comprising a vision system, a braze dispenser, a robot with an articulating arm, and a processing module that communicates to control the application of braze material based on real-time substrate analysis, ensuring precise application and potential rework, using a braze material that meets the substrate's material properties and geometry needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated brazing systems are implemented to improve precision and efficiency, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The vision system captures images of the substrate before and during the brazing process, processes these images to determine the precise location and characteristics of defects, and feeds this information back to the braze dispenser to adjust the application of braze material in real-time, ensuring high precision while maintaining a manageable system through intelligent control
Solution Approach 2:
The patent replaces manual mechanical positioning and visual inspection with an automated vision system that uses cameras and image processing algorithms to detect substrate features and guide the brazing process, reducing the need for complex mechanical adjustment mechanisms while improving precision
2Measurement precision
If vision systems are used to detect substrate features in real-time, then measurement precision is improved, but use of energy increases
Solution Approach 1:
The vision system operates periodically rather than continuously, capturing images at key moments (before brazing and during the process) rather than maintaining constant monitoring, which reduces energy consumption while still achieving the necessary measurement precision for defect detection and brazing guidance
3Reliability
If multiple passes are used to apply braze material to ensure complete coverage, then reliability is improved, but loss of time increases
Solution Approach 1:
The vision system performs preliminary detection and mapping of substrate defects before the brazing process begins, allowing the braze dispenser to plan the optimal application path and material distribution in advance, enabling complete coverage in fewer passes and reducing overall production time while maintaining high reliability
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 system enables precise and efficient application of braze material, improving the usability and re-usability of components, meeting quality standards, reducing production costs, and extending the working life of components by forming strong metallurgical bonds across various temperatures and stresses.
Implementation Method 1
a vision system having a camera, a sensor, and a vision processor module
Implementation Method 2
it is brought slightly above its melting temperature to melt and flow over the base metal in a technique called wetting, which fills in an opening in the substrate by capillary action
Implementation Method 3
Brazing is technique used to join metals together by applying heat to melt and flow a braze material onto a substrate
Data Source
AI summary
Systems and methods for moving a substrate to a vision system using a robot; using the vision system to determine where a braze material is to be applied to the substrate; moving the substrate to a braze dispenser using the robot; applying a braze material to the substrate using the braze dispenser based on the determination from the vision system; and using the vison system to determine whether to apply additional braze to the substrate, including for the substrate of a component for gas turbine engine, such as configured for use in an aircraft.