Method and system for drilling with a limited laser drill.

专利摘要:
A method of drilling a hole (52) in a component is provided. The method has a laser beam (64) which is limited by means of light guiding and focusing mechanisms of a laser drill (62). The method includes directing a limited laser beam (64) toward a first hole location on a nearby wall (66) of the component. The method further includes sensing a property of light within a cavity (46) defined by the component. The nearby wall (66) is positioned adjacent to the cavity (46) and the sensor is positioned outside of the cavity (46). The method further includes determining a first breakthrough of the confined laser beam (64) through the nearby wall (66) of the component at the first hole location based on the light from the interior of the cavity (46) sensed by the sensor. Such a method (120, 200, 300, 400) can enable a more convenient and time-efficient method in gas turbine components.
公开号:CH710615B1
申请号:CH00013/16
申请日:2016-01-05
公开日:2021-01-15
发明作者:Hu Zhaoli；Denis Darling Abe；Elijah Mcdowell Shamgar；Anthony Serieno Douglas
申请人:Gen Electric；
IPC主号:

专利说明:

FIELD OF THE INVENTION
The present invention relates to a method and system for drilling one or more holes in a component using a limited laser drill.
BACKGROUND TO THE INVENTION
Turbines are widely used in industrial and commercial operations. A typical commercial steam or gas turbine used to generate electrical power contains alternating stages of stationary and rotating blades. For example, stationary vanes can be attached to a stationary component such as a casing surrounding a turbine, and rotating blades can be attached to a rotor located along an axial centerline of the turbine. A compressed working fluid, such as, but not limited to, steam, combustion gases, or air, flows through the turbine, and the guide vanes accelerate and direct the compressed working fluid onto the subsequent stage of rotating blades to cause the rotating blades to move, thereby causing the The rotor rotates and work is done.
An efficiency of the turbine generally increases with increasing temperatures of the compressed working fluid. However, excessive temperatures within the turbine can reduce the longevity of the airfoils in the turbine and thus increase repairs, maintenance, and failures associated with the turbine. As a result, various designs and methods have been developed to achieve cooling on the airfoils. For example, a cooling medium can be supplied to a cavity inside the airfoil to remove heat from the airfoil in a convective and / or conductive manner. In certain embodiments, the cooling medium can flow out of the cavity through cooling channels in the airfoil to achieve film cooling over the outer surface of the airfoil.
As temperatures and / or performance standards continue to rise, materials used for the airfoil become increasingly thin, making reliable manufacture of the airfoil increasingly difficult. For example, the airfoil can be cast from a high alloy metal and a thermal barrier coating can be applied to the outer surface of the airfoil to increase thermal insulation. A jet of water can be used to create cooling channels through the thermal barrier coating and the outer surface, but the water jet can cause portions of the thermal barrier coating to peel off. Alternatively, the thermal barrier coating can be applied to the outer surface of the airfoil after the cooling channels have been created by an electrical discharge machine (EDM), but this requires additional processing to remove any thermal barrier coating covering the newly created cooling channels. In addition, this process of reopening the cooling holes after the coating process becomes increasingly difficult and requires more man-hours and skills as the sizes of the cooling holes decrease and the number of the cooling holes increase.
A laser drill that uses a focused laser beam can also be used to create the cooling passages through the airfoil with reduced risk of peeling of the thermal barrier coating. However, the laser drill may require precise control due to the presence of the cavity inside the airfoil. Once the laser drilling breaks through a nearby wall of the airfoil, continued operation of the laser drill by conventional methods can result in damage to the opposite side of the cavity, possibly resulting in a damaged airfoil that must be refurbished or scrapped.
Accordingly, an improved method and system for drilling a hole in a component of a gas turbine would be beneficial. In particular, a method and system for drilling a hole in a component of a gas turbine and determining one or more operating conditions during such a drilling process would be particularly useful.
BRIEF DESCRIPTION OF THE INVENTION
Aspects and advantages of the invention are set forth below in the following description, or may be apparent from the description, or may be learned from practicing the invention.
In the invention a method according to claim 1 is described.
In the aforementioned method, the component can be an airfoil of a gas turbine.
In addition or as an alternative, the sensor can be an optical sensor.
In any of the foregoing methods, the confined laser beam can define a beam axis, and the sensor can be positioned at a location that does not intersect the beam axis and defines a line of sight to the beam axis within the cavity.
In one embodiment, the method may further include activating a kickback protection mechanism and interfering with the limited laser beam within the cavity with the kickback protection mechanism.
In this embodiment, the confined laser beam may define a beam axis, and activating a kickback protection mechanism may include introducing a gas into the cavity of the component in such a manner that the gas crosses the beam axis within the cavity of the component.
Additionally or as an alternative, the confined laser beam can define a beam axis, wherein the confined laser beam can comprise a liquid column and a laser, wherein perturbing the confined laser beam within the cavity can comprise perturbing the liquid column of the confined laser beam in such a manner that a liquid from the liquid column intersects the beam axis, and wherein the liquid intersecting the beam axis can be at least partially irradiated by the laser of the limited laser beam within the cavity.
Further, detecting a light property within the cavity may include detecting a light intensity from the portion of the liquid of the liquid column of the limited laser beam that is irradiated by the laser of the limited laser beam.
Still further, determining the first breakthrough of the limited laser beam may include determining the first breakthrough of the limited laser beam based on the detected light intensity from the portion of the liquid of the liquid column of the limited laser beam irradiated by the laser of the limited laser beam.
In some embodiments, the component can define an opening leading to the cavity, wherein the sensor can be positioned adjacent the opening and directed through the opening as well as into the cavity.
In further embodiments, the method may further include directing the confined laser beam of the confined laser drill toward a second hole location on the nearby wall of the component, sensing a property of light within the cavity defined by the component using the sensor directing the limited laser beam of the limited laser drill toward the second hole position on the near wall of the component and detecting a second breakthrough of the limited laser beam through the near wall of the component at the second hole position based on the detected property of light from inside the cavity wherein the sensor remains stationary between the detection of the first breakthrough and the detection of the second breakthrough.
Furthermore, a system according to claim 10 is described in the invention.
In the aforementioned system, the sensor can be configured to detect one or more of an amount of light, a light intensity and a light wavelength.
In preferred embodiments of the system, the sensor can be an optical sensor.
In some embodiments, the confined laser beam can define a beam axis, and the sensor can define a line of sight to the beam axis of the confined laser beam within the cavity.
In the system of any type mentioned above, the component may be an airfoil of a gas turbine.
In various embodiments, the kickback protection mechanism can be configured to interfere with the confined laser beam within the cavity of the component.
In these embodiments, the laser beam can define a beam axis, wherein the limited laser beam can have a liquid column and a laser, wherein the liquid column of the limited laser within the cavity of the component can be disturbed by the kickback protection mechanism such that a liquid from the liquid column intersects the beam axis, and wherein the liquid intersecting the beam axis can be at least partially irradiated by the laser of the confined laser beam within the cavity.
In addition, the sensor can be directed into the cavity of the component in order to detect a property of the light from the part of the liquid irradiated by the laser.
In some embodiments, the sensor may be positioned outside of the cavity and directed into the cavity such that the sensor is configured to detect light within the cavity of the component at multiple locations.
These and other features, aspects, and advantages of the present disclosure will be better understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete and executable disclosure of the present subject matter of the disclosure, including the best mode thereof, for a person skilled in the art is explained in greater detail in the remainder of the description, which includes reference to the accompanying figures, in which:
Fig. 1 shows a simplified cross-sectional view of a turbine section of an exemplary gas turbine that may incorporate various embodiments of the present invention.
Fig. 2 shows a perspective view of an exemplary airfoil in accordance with an embodiment of the present invention.
FIG. 3 shows a schematic view of a system for manufacturing an airfoil according to an embodiment of the present invention.
Figure 4 shows a schematic view of the exemplary system of Figure 3 after a limited laser beam has penetrated a nearby wall of the airfoil.
Fig. 5 shows a flow diagram of a method for manufacturing an airfoil according to an example of the invention.
Figure 6 is a graph showing light intensity readings during operation of a limited laser drill in accordance with an exemplary embodiment of the present invention.
Figure 7 is a graph showing wavelength readings during operation of a limited laser drill in accordance with an exemplary embodiment of the present invention.
8 is a graph showing noise in light intensity measurements during operation of a limited laser drill in accordance with an exemplary embodiment of the present disclosure.
9 shows a schematic view of a system for manufacturing an airfoil in accordance with a further exemplary embodiment of the present invention.
Figure 10 shows a schematic view of the exemplary system of Figure 9 after a confined laser beam has penetrated a nearby wall of the airfoil.
FIG. 11 shows a flow diagram of a method for producing an airfoil according to a further exemplary aspect of the present invention.
Fig. 12 shows a schematic view of a system for manufacturing an airfoil in accordance with yet another exemplary embodiment of the present invention.
Figure 13 shows a schematic view of the exemplary system of Figure 12 after a confined laser beam has penetrated a nearby wall of the airfoil.
14 shows a schematic view of a system for manufacturing an airfoil in accordance with yet another exemplary embodiment of the present invention.
Figure 15 shows a schematic view of the exemplary system of Figure 14 after a confined laser beam has penetrated a nearby wall of the airfoil.
Fig. 16 shows a flow diagram of a method for manufacturing an airfoil according to yet another example of the present invention.
Figure 17 shows a schematic view of a system for manufacturing an airfoil in accordance with yet another exemplary embodiment of the present invention.
Fig. 18 shows a flow diagram of a method of making an airfoil in accordance with yet another example of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided to illustrate the invention, not to limit the disclosure. Indeed, it will be apparent to those skilled in the art that various modifications and changes can be made in the present invention without departing from the scope or scope of the invention. For example, features illustrated or described as part of a single embodiment can be used on another embodiment to yield yet another embodiment. Thus, it is intended that the present invention cover such modifications and changes as come within the scope of the appended claims and their equivalents. While exemplary embodiments of the present invention are generally described in the context of making an airfoil 38 for a turbomachine, for purposes of illustration, one of ordinary skill in the art will readily appreciate that embodiments of the present invention may and may not be applied to other articles of manufacture are limited to a system or method for making an airfoil 38 for a turbomachine, unless specifically stated in the claims. For example, in other exemplary embodiments, aspects of the present invention may be used to make an airfoil 38 for use in the aerospace context or to make other components of a gas turbine.
As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the arrangement or meaning of the individual components. Likewise, the terms “nearby” and “distant” can be used to indicate a relative position of an object or component and are not intended to indicate a function or construction of the object or component.
Referring now to the drawings, FIG. 1 shows a simplified cross-sectional side view of an exemplary turbine section 10 of a gas turbine in accordance with various embodiments of the present invention. As shown in FIG. 1, the turbine section 10 generally includes a rotor 12 and a housing 14 that at least partially define a gas path 16 through the turbine section 10. The rotor 12 is substantially aligned with an axial centerline 18 of the turbine section 10 and may be connected to a generator, compressor, or other machine to perform work. The rotor 12 may include alternating portions of rotor impellers 20 and rotor spacers 22 that are interconnected by a bolt 24 to rotate together. The housing 14 circumferentially surrounds at least a portion of the rotor 12 to receive a compressed working fluid 26 that flows through the gas path 16. The compressed working fluid 26 may include, for example, combustion gases, compressed air, saturated steam, unsaturated steam, or a combination of these.
As illustrated in FIG. 1, the turbine section 10 further includes alternating stages of rotating blades 30 and stationary blades that extend radially between the rotor 12 and the housing 14. The rotating blades 30 are circumferentially disposed around the rotor 12 and may be connected to the rotor impellers 20 using various means. In contrast to this, the stationary guide vanes 32 can be arranged on the edge around the inside of the housing 14 opposite the rotor spacers 22. The rotating blades 30 and the stationary guide vanes 32 essentially have the shape of an airfoil profile with a concave pressure side, a convex suction side and a leading and a trailing edge, as is known in the art. The compressed working fluid 26 flows along the gas path 16 through the turbine section 10 from left to right, as can be seen in FIG. 1. As the compressed working fluid 26 passes over the first stage of the blades 30, the compressed working fluid expands causing the blades 30, impellers 20, rotor spacers 22, pin 24, and rotor 12 to rotate. The compressed working fluid 26 then flows over the next stage of stationary vanes 32 which accelerate and divert the compressed working fluid 26 to the next stage of blades 30, and the process repeats for the following stages. In the exemplary embodiment, as illustrated in FIG. 1, the turbine section 10 has two stages of stationary vanes 32 between three stages of rotating blades 30; however, one of ordinary skill in the art will readily recognize that the number of stages of rotating blades 30 and stationary vanes 32 is not a limitation on the present invention unless specifically stated in the claims.
FIG. 2 shows a perspective view of an exemplary airfoil 38 as it may be received in the blades 30 or stationary vanes 32, in accordance with an embodiment of the present invention. As illustrated in FIG. 2, the airfoil 38 generally includes a pressure side 42 having a concave curvature and a suction side 44 opposing the pressure side 42 and having a convex curvature. The pressure and suction sides 42, 44 are separated from one another in order to define a cavity 46 in the interior of the airfoil 38 between the pressure and suction sides 42, 44. The cavity 46 may provide a serpentine or tortuous path for a cooling medium to flow within the airfoil 38 to conductively and / or convectively remove heat from the airfoil 38. Additionally, the pressure and suction sides 42, 44 are further joined together to form a leading edge 48 on an upstream portion of the airfoil 38 and a trailing edge 50 downstream of the cavity 46 on a downstream portion of the airfoil 38. Several cooling passages in the pressure side 42, the suction side 44, the leading edge 48 and / or the trailing edge 50 can provide a flow connection with the cavity 46 through the airfoil 38 in order to supply the cooling medium via an outer surface 34 of the airfoil 38. For example, as illustrated in Figure 2, the cooling passages may be located on the leading and trailing edges 48, 50 and / or along either or both of the pressure and suction sides 42, 44. The exemplary airfoil 38 further defines an opening at a base of the airfoil 38, wherein a cooling medium, such as compressed air, can be supplied to the cavity 46 from a compressor section of the gas turbine.
One skilled in the art will readily recognize from the teachings herein that the number and / or location of the cooling passages can vary in accordance with certain embodiments, as can the construction of the cavity 46 and the construction of the cooling passages. Accordingly, the present invention is not limited to any particular number or positioning of the cooling passages or any construction of the cooling passages or cavity 46 unless specifically indicated in the claims.
In some exemplary embodiments, a thermal barrier coating 36 may be applied over at least a portion of an outer surface 34 of a metal part 40 of the airfoil 38 (see FIG. 3), which covers the underlying metal part 40 of the airfoil 38. The thermal barrier coating 36, when applied, may have low emissivity or high reflectivity to heat, a smooth surface finish, and / or good adhesion to the underlying outer surface 34.
Coaxial acquisition
Referring now to Figures 3 and 4, a perspective view of an exemplary system 60 in accordance with the present invention is provided. The system 60 can be used, for example, in the manufacture of a component for a gas turbine. In particular, in the illustrated embodiment, the system 60 is used to produce / drill one or more holes or cooling passages in an airfoil 38 of a gas turbine, such as the airfoil 38 discussed above with reference to FIG. 2. It should be recognized, however, that although system 60 is used herein in the context of making theAs described in the airfoil 38, in other exemplary embodiments, the system 60 may be used in the manufacture of any other suitable component for a gas turbine. For example, the system 60 can be used in the manufacture of transition pieces, nozzles, combustor liner, effusion or baffle plates, vanes, shrouds, or any other suitable part.
The exemplary system 60 generally includes a confined laser drill 62 configured to direct a confined laser beam 64 toward a nearby wall 66 of the airfoil 38 to drill a hole 52 in the nearby wall 66 of the airfoil 38 . The confined laser beam 64 defines a beam axis A and the nearby wall 66 is disposed adjacent to the cavity 46. In particular, various embodiments of the confined laser drill 62 may generally include a laser mechanism 68, a collimator 70, and a controller 72. The laser mechanism 68 may include any device capable of generating a laser beam 74. By way of example only, in some exemplary embodiments, the laser mechanism 68 may be a diode-pumped Nd: YAG laser capable of generating a laser beam having a pulse frequency of approximately 10-50 kHz, a wavelength of approximately one micrometer, or if so Frequency doubling "SHG", Second Harmonic Generation) is used to generate between 500-550 nanometers and an average power of around 10-200 W. However, in other embodiments, any other suitable laser mechanism 68 may be employed.
In the particular embodiment, as illustrated in FIGS. 3 and 4, the laser mechanism 68 directs the laser beam 74 through a focusing lens 75 onto a collimator 70. The collimator 70 converts a diameter of the beam 74, to achieve a better focus feature when the beam 74 is focused into another medium, such as fiberglass or water. Accordingly, as used herein, the collimator 70 includes any device that constricts and / or directs a bundle of particles or waves to cause the bundle to narrow in cross-section. For example, as illustrated in Figures 3 and 4, the collimator 70 may include a chamber 76 that receives the laser beam 74 along with a fluid such as deionized or filtered water. An orifice or nozzle 78, which may be between approximately 20 and 150 micrometers in diameter, directs the laser beam 74 within a column of liquid 80 toward the airfoil 38 - forming a confined laser beam 74. The column of liquid 80 can have a pressure of be approximately 907.18 kg to 1,360.78 kg (2000 to 3000 pounds) per 6.45 square centimeter (1 square inch). However, the present disclosure is not limited to any particular pressure for the liquid column 80 or diameter for the nozzle 78 unless specifically indicated in the claims. In addition, it should be recognized that, as used herein, approximate terms such as "about" or "approximately" refer to a margin of error within 10%.
As illustrated in the enlarged view in FIGS. 3 and 4, the liquid column 80 can be surrounded by air, for example a protective gas, and serve as a light guiding and focusing mechanism for the laser beam 74. Accordingly, the column of liquid 80 and the laser beam 74 passed through column of liquid 80, as discussed above, may collectively form the confined (constricted) laser beam 64 used by the confined (constricted) laser drill 62 and directed onto the airfoil 38.
As mentioned, the confined laser beam 64 can be used by the confined laser drill 62 to drill one or more cooling passages through the airfoil 38, for example. In particular, the limited laser beam 64 can ablate the outer surface 34 of the airfoil 38, ultimately creating the desired cooling passage through the airfoil 38. In particular, FIG. 3 shows the system 60 before the confined laser beam 64 “breaks &” the nearby wall 66 of the airfoil 38, while FIG. 4 shows the system 60 after the confined laser beam 64 has penetrated the nearby wall 66 of the airfoil 38. As used herein, the terms "breakthrough", "breakthrough" and related terms refer to when the confined laser beam 64 forms a continuous portion of the material forming the nearby wall 66 of the airfoil 38 along the beam axis A of the confined Laser beam 64 has removed. After the confined laser beam 64 has broken through the nearby wall 66 of the airfoil 38, at least a portion of the confined laser beam 64 can pass therethrough, e.g., into the cavity 46 of the airfoil 38.
With continued reference to FIGS. 3 and 4, the system 60 further includes an exemplary anti-kickback mechanism 82. The illustrated exemplary anti-kickback mechanism 82 includes a gas 84 that flows within the airfoil 38. As used herein, the term “gas” can include any gaseous medium. For example, the gas 84 can be an inert gas, a vacuum, a saturated steam, a superheated steam, or any other suitable gas 84 that can form a gaseous flow inside the cavity 46 of the airfoil 38. The gas 84 flowing within the airfoil 38 may have a pressure approximately equal to the pressure of the liquid in the liquid column 80 or any other pressure sufficient to perturb the confined laser beam 64. In particular, the gas 84 may have any other pressure sufficient to generate sufficient kinetic moment or velocity to perturb the liquid column 80 within the cavity 46 of the airfoil 38. For example, the gas 84 flowing within the airfoil 38 may, in some exemplary embodiments, have a pressure greater than about 11.34 kg (25 pounds) per 6.45 square centimeters (1 square inch), although the present invention is not directed to any particular one Pressure for the gas 84 is limited unless specifically stated in the claims.
As best illustrated in FIG. 4, the gas 84 may be directed to cross the confined laser beam 64 within the cavity 46 of the airfoil 38. In certain embodiments, the gas 84 may be oriented substantially perpendicular to the liquid column 80, while in other specific embodiments the gas 84 may be oriented at an oblique or acute angle with respect to the liquid column 80 and / or the limited laser beam 64. As the gas 84 crosses the liquid column 80 inside the airfoil 38, the gas 84 perturbs the liquid column 80 and disperses the laser beam 74 of the confined laser beam 64 inside the cavity 46 of the airfoil 38. In this way, the gas 84 prevents the confined Laser beam 64 impinges on an inner surface of cavity 46 of airfoil 38 on the opposite side to the newly created cooling passage in nearby wall 66. In particular, the gas 84 prevents the confined laser beam 64 from impinging on a distant wall 86 of the airfoil 38.
The exemplary system 60 according to FIGS. 3 and 4 additionally contains a sensor 88 which is functionally connected to the control device 72, which is explained further below. In the embodiment shown, the sensor 88 is set up to detect a light property and to send a signal 68 to the control device 72 which characterizes the detected light property. In particular, the sensor 88 is positioned to sense a property of the light directed along the beam axis A away from the nearby wall 66 of the airfoil 38, such as light reflected and / or deflected by the cooling passage. In some exemplary embodiments, the sensor 88 may be an oscilloscope sensor suitable for detecting one or more of the following properties of light: a light intensity, one or more wavelengths of light, an amount of light, a temporal shape of a light pulse, and a frequency shape of a light pulse. In addition, the sensor 88 for the embodiment shown is offset from the beam axis A and is set up to measure a property of the reflected light along the beam axis A by deflecting at least part of the reflected light that is directed along the beam axis A to the sensor 88 with a Detect deflection lens 90. The deflection lens 90 is positioned in the beam axis A, i.e., intersecting the beam axis A, at an angle of approximately 45 ° to the beam axis A. However, in other exemplary embodiments, the deflecting lens 90 may define any other suitable angle with respect to the beam axis A. Although in the embodiment according to FIGS. 3 and 4 the deflecting lens 90 is arranged in the collimator 70, in other embodiments the lens 90 may instead be between the collimator 70 and the focusing lens 75 or alternatively between the focusing lens 75 and the laser mechanism 68 be positioned. The deflector lens 90 may include a coating on a first side (i.e., the side closest to the proximal wall 66 of the airfoil 38) that redirects at least a portion of the reflected light flowing along the beam axis A to the sensor 88. The coating may be what is referred to as a "one-way" coating so that essentially no light flowing along the beam axis toward the nearby wall 66 of the airfoil 38 is deflected by the lens or its coating. For example, in some embodiments, the coating may be a coating from an electron beam coating (“EBC”).
Still referring to the exemplary system 60 of FIGS. 3 and 4, the controller 72 may be any suitable processor-based computing device and may be in operative communication with, for example, the limited laser drill 62, the sensor 88, and the kickback protection mechanism 82 stand. For example, suitable controllers 72 may include one or more personal computers, cell phones (including smartphones), personal digital assistants, tablets, laptops, desktops, workstations, game consoles, servers, other computers, and / or any other suitable computing device. As illustrated in FIGS. 3 and 4, the controller 72 may include one or more processors 92 and an associated memory 94. The processor (s) 92 may generally be one or more of any suitable processor devices known in the art. Likewise, memory 94 may generally be any suitable computer readable medium or media, including, but not limited to, RAM, ROM, hard drives, flash drives, or other storage devices. As is generally understood, the memory 94 may be configured to store information accessible to the processor (s) 92, including instructions or logic 96 executed by the processor (s) 92 can / can. Instructions or logic 96 can be any set of instructions that, when executed by processor (s) 92, cause processor (s) 92 to provide a desired functionality. For example, the instructions or logic 96 may be software instructions that are rendered in a computer readable form. If software is used, any suitable programming, scripting, or other suitable language or combinations of languages can be used to implement the teachings contained herein. In particular embodiments of the present invention, for example, the instructions or logic 96 may be configured to implement one or more of the methods described below with reference to Figures 5, 11, 16, or 18. Alternatively, the instructions may be implemented by hardwired logic 96 or other circuitry including, but not limited to, application specific circuitry. Additionally, while controller 72 is illustrated schematically as being separate from sensor 88, in other exemplary embodiments, sensor 88 and controller 72 may be integrated into a single device that may be positioned in any suitable location.
Referring now to FIG. 5, a flow diagram of an exemplary method 120 of making an airfoil 38 of a gas turbine is provided. In particular, the flowchart of FIG. 5 illustrates an exemplary method 120 for drilling a hole 52 in an airfoil 38 of a gas turbine. The example method 120 of FIG. 5 may be used with the example system illustrated in FIGS. 3 and 4 and described above. Accordingly, while the example method 120 is discussed in the context of drilling a hole 52 in an airfoil 38, it may alternatively be used to drill a hole 52 in any other suitable component of a gas turbine.
The method 120 includes, generally at 122, directing a confined laser beam 64 of a confined laser drill 62 toward a nearby wall 66 of the airfoil 38 to drill the hole 52 in the nearby wall 66 of the airfoil 38. The limited laser beam 64 defines a beam axis and the nearby wall 66 is positioned adjacent to a cavity 46 defined in the airfoil 38. The method 120 further includes, at 124, sensing a property of light directed away from the airfoil 38 along the beam axis with a sensor 88. The light directed away from the airfoil 38 along the beam axis may, in some aspects, open up obtain the light reflected from the nearby wall 66 of the airfoil 38. In some exemplary aspects, sensing a property of the light at 124 may include sensing at least one of a light intensity, one or more wavelengths of the light, a temporal shape of a light pulse, and a frequency shape of a light pulse. In addition, the sensor 88 may be offset from the beam axis so that sensing a property of the light at 124 may further include deflecting at least a portion of the light directed along the beam axis away from the airfoil 38 to the sensor 88 with a lens.
Still referring to FIG. 5, the example method 120 further includes, at 126, determining one or more operating conditions based on the property of the light sensed by the sensor 88 at 124. The one or more operating conditions include at least one of a depth of the hole 52 being drilled with the confined laser drill 62 and a material into which the confined laser beam 64 of the confined laser drill 62 is directed.
For example, sensing a property of light at 124 may, in some example aspects, include sensing an intensity of light. For illustration, reference is now also made to FIG. 6, which provides a graphical representation 150 of exemplary light intensity values that are detected at 124. The example graph 150 shows light intensity on the Y-axis and time on the X-axis. In one such exemplary aspect, determining one or more operating conditions at 126 may include determining either a reflected pulse rate of the limited laser drill 62 or a reflected pulse width (measured in units of time) of the limited laser drill 62, or both, based on the intensity of the beam axis A directed away from the airfoil 38 and detected at 124. For example, as illustrated in FIG. 6, the light intensity detected at 124 during drilling operations - ie, during an operation with the limited laser drill 62 - shows heights 152 and depths 154. The reflected pulse rate can thus be determined by the number of heights 152 per Unit of time is counted and the reflected pulse width can be determined by determining the times of the heights 152.
In particular, in the event that all of the light directed onto the airfoil 38 would be reflected without being absorbed or otherwise changed, the reflected pulse rate and the reflected pulse width would exactly reflect an actual pulse rate and an actual pulse width, with which the limited laser drill 62 and the limited laser beam 64 operate. However, during the drilling operations, an amount of light absorption by the airfoil 38 based, for example, on a depth of the hole 52, an aspect ratio of the hole 52 (which, as used herein, refers to a ratio of the hole diameter to a hole length) and / or the material into which the limited laser beam is directed (ie the material that is being drilled through) vary. Accordingly, during the drilling operations, the example method 120 may include comparing the values of either the reflected pulse rate and / or the reflected pulse width, as determined at 126, to known operating conditions of the limited laser drill 62 (e.g., the actual pulse rate and / or the actual pulse width of the limited Laser drill 62) included. Such a comparison can reveal an error value. The error value can then be compared to a look-up table that relates such error values to hole depths - taking into account the particular material being drilled into, the hole diameter, hole geometry and any other relevant factors - by a depth of the hole 52, which being drilled in the nearby wall 66 of the airfoil 38 by the limited laser drill 62. The look-up table values can be determined experimentally.
It should be recognized, however, that in other exemplary aspects of the present invention, the exemplary method 120 may additionally or alternatively detect other properties of the light directed along the beam axis at 124 and determine other operating conditions at 126. For example, by continuing to refer to FIG. 5 as well as an exemplary graphical representation 160 of the detected light wavelength values provided in FIG. 7, detecting a light property at 124 may additionally or alternatively include detecting a wavelength along the beam axis light directed away from the airfoil 38 with the sensor 88. In one such exemplary aspect, the one or more operating conditions determined at 126 may include the material into which the limited laser beam of the limited laser drill 62 is directed. Additionally, determining the one or more operating conditions at 126 may include comparing the detected wavelength of light to predetermined values. In particular, different materials absorb and reflect light at different wavelengths. Accordingly, the reflected light directed along the beam axis during drilling operations can define a wavelength that is characteristic of the material into which the limited laser beam is directed. For example, referring specifically to FIG. 7, light directed along the beam axis when drilling into a thermal barrier coating of an airfoil 38 may define a first wavelength 162, while light directed along the beam axis when is drilled into a metal portion of the airfoil 38, can define a second wavelength 164, and light directed along the beam axis after the confined laser beam breaks through the nearby wall 66 of the airfoil 38 can define a third wavelength 166. Accordingly, in one such exemplary aspect, method 120 may determine the layer into which the confined laser beam is drilling based at least in part on the sensed wavelength of light reflected along the beam axis.
However, in other exemplary aspects, the method 120 may include sensing the light at multiple wavelengths. For example, light directed along the beam axis may additionally define a fourth wavelength 163 when drilling through both the thermal barrier coating and the metal part, and light directed along the beam axis when drilling through the metal part and when the nearby wall 66 of the airfoil 38 is at least partially perforated, can additionally define a fifth wavelength 165. Additionally, in other exemplary embodiments, the light may define any other distinct pattern of wavelengths based on a variety of factors, including the material (s) into which the confined laser drill 62 is directed, the depth of the hole 52 that is being drilled, an aspect ratio of the hole 52 that is being drilled, etc. belong. Accordingly, the method 120 may include using fuzzy logic methodology to determine the one or more operating conditions at 126, including, for example, the material into which the confined laser drill 62 will be directed.
However, in still further exemplary aspects of the present invention, the example method 120 may additionally or alternatively detect other properties of the light directed along the beam axis at 124 and determine further operating conditions at 126. Still referring to FIG. 5, as well as an exemplary graphical representation 170 of the detected noise in the light intensity values provided in FIG. 8, the detection of a property of the light at 124 can additionally or alternatively include detecting the noise in the intensity of the Light directed away from the airfoil 38 along the beam axis with the sensor 88. In particular, the exemplary graphic 170 according to FIG. 8 shows a detected noise level in the light intensity with the line 172 and a detected light intensity with the line 174. In such an exemplary aspect, determining one or more operating conditions at 126 may additionally or alternatively include detecting / determining a noise level in the intensity of the light directed away from the airfoil 38 along the beam axis. As used herein, the term “noise level” refers to a variation in the light intensity or other characteristic sensed by the sensor 88. Additionally, in one such exemplary aspect, determining one or more operating conditions at 126 may further include determining a depth of the hole 52 being drilled based on the determined noise level in the intensity of light directed away from the airfoil 38 along the beam axis. In particular, it has been found that during a drilling operation in certain airfoils 38 or other components of gas turbines, an increased noise component in the light intensity detected along the beam axis at 124 caused by factors such as the depth of the drilled hole 52 and an aspect ratio of the drilled hole 52 becomes. Accordingly, by detecting the noise level in the intensity of the light directed along the beam axis away from the nearby wall 66 of the airfoil 38, a depth of the hole 52 can be determined by comparing such noise level with, for example, a look-up table, the hole depths with noise levels in the light intensity taking into account the particular hole 52 being drilled and any other relevant factors. These look-up table values can be determined experimentally.
Still referring to FIG. 5, the example method 120 further includes at 128 determining an indicated breakthrough of the confined laser beam 64 of the confined laser drill 62 through the nearby wall 66 of the airfoil 38 of the gas turbine. The indicated breakthrough at 128 may also be determined based on the property of the light detected along the beam axis with the sensor 88 at 124. Referring again to graph 150 of FIG. 6, if the light intensity is sensed at 124, the sensed light intensity may decrease as the hole 52 is drilled. Accordingly, the example method 120 may determine an indicated breakthrough of the confined laser beam of the confined laser drill 62 through the nearby wall 66 of the airfoil 38 at 128 based on a sensed light intensity falling below a predetermined threshold / breakthrough value. For example, if the predetermined threshold / breakthrough value corresponds to line 156, method 120 may determine a displayed breakthrough at 128 at point 158 on graph 150. This predetermined threshold / breakthrough value can be determined experimentally or based on known values.
The method of Figure 5 further includes determining at 130 a breakthrough of the limited laser beam 64 through the nearby wall 66 of the airfoil 38 based, for example, on the indicated breakthrough determined at 128 and / or the operating conditions determined at 126. For example, the example method 120 of FIG. 5 may determine a breakthrough of the confined laser beam at 130 after determining an indicated breakthrough at 128 and determining one or more operational characteristics at 126. In particular, the exemplary method 120 of FIG. 5 may determine a breakthrough of the limited laser beam at 130 once an indicated breakthrough has been determined at 128, in addition to one or more operating conditions determined at 126 meeting a predetermined criteria - e.g. the depth of the hole 52 is greater than a predetermined value or the material into which the confined laser beam is directed is not the metal part or the thermal barrier coating. A method 120 of drilling a hole 52 in accordance with such an example aspect may enable more accurate breakthrough detection when drilling with the limited laser.
In particular, although some of the confined laser beam may have penetrated the nearby wall 66 of the airfoil 38, the hole 52 may not be completed. More specifically, the hole 52 may not yet define a desired geometry along an entire length of the hole 52. Accordingly, for the illustrated example aspect, the example method 120 of FIG. 5 further includes, at 132, further directing the confined laser beam 64 toward the nearby wall 66 of the airfoil 38 after a breakthrough of the confined laser beam is detected at 130. The method 120 may continue the detection of a light property, such as, for example, a light intensity, a light wavelength or a noise in the intensity of the light directed away from the airfoil 38 along the beam axis with the sensor 88. The method 120 also includes at 134 determining completion of the hole 52 in the nearby wall 66 of the airfoil 38 based on the property of light sensed along the beam axis with the sensor 88. For example, determining the completion of the hole 52 at 134 may include determining an indicated completion based on: the sensed intensity of the reflected light along the beam axis; a reflected pulse rate and / or reflected pulse width of the light reflected along the beam axis; a wavelength of the reflected light on the beam axis; and / or a noise component in the intensity of the light reflected along the one beam axis.
The exemplary method 120 of FIG. 5 further includes, at 136, changing an operating parameter of the limited laser drill 62, such as a power of the limited laser drill 62, a pulse rate of the limited laser drill 62, or a pulse width of the limited laser drill 62, based on the at 126 determined operating condition, based on the indicated breakthrough determined at 128 and / or based on the determination of a breakthrough at 130. For example, the method 120 may include changing an operating parameter at 136 in response to a determination that the limited laser beam 64 of the limited laser drill 62 is directed into the metal portion of the airfoil 38 compared to the thermal barrier coating of the airfoil 38, a detection of an indicated breakthrough at 128 and / or a detection of an incipient breakthrough of the limited laser drill 62 at 130.
Sensor positioned outside the component and directed inside the component
Referring now to Figures 9 and 10, there is provided a system 60 in accordance with another exemplary embodiment of the present invention. In particular, FIG. 9 shows a schematic view of a system 60 in accordance with another exemplary embodiment of the present invention before a confined laser beam 64 from a confined laser drill 62 breaks a nearby wall 66 of an airfoil 38, and FIG. 10 shows a schematic view of the exemplary system 60 9 after the limited laser beam 64 of the limited laser drill 62 has broken the nearby wall 66 of the airfoil 38. Although discussed in the context of an airfoil 38, in other embodiments the system 60 may be used with any other suitable component of a gas turbine.
The example system 60, as illustrated in FIGS. 9 and 10, can be set up in essentially the same manner as the example system 60 according to FIGS. 3 and 4, and the same or Similar reference numbers may refer to the same or similar parts. For example, the system 60 includes a confined laser drill 62 that uses a confined laser beam 64, the confined laser drill 62 being configured to drill one or more holes 52 or cooling passages in a nearby wall 66 of an airfoil 38. Also, as shown, the proximate wall 66 of the airfoil 38 is positioned adjacent a cavity 46 defined by the airfoil 38. In addition, a kickback protection mechanism 82 is also provided that is configured to protect a distal wall 86 of the airfoil 38, the distal wall 86 being positioned on the opposite side of the cavity 46 from the nearby wall 66.
However, for the embodiment according to FIGS. 9 and 10, a sensor 98 is positioned outside the cavity 46 and directed into the cavity 46 in order to detect a property of light within the cavity 46. As discussed in greater detail below, the system 60 is configured to detect breakthrough of the confined laser beam 64 through the nearby wall 66 of the airfoil 38 based on the property of light sensed within the cavity 46 of the airfoil 38. In some exemplary embodiments, the sensor 98 may be, for example, an optical sensor, an oscilloscope sensor, or any other suitable sensor capable of detecting one or more of the following characteristics of light: an amount of light, an intensity of light, and a wavelength of light.
For the illustrated embodiment, the sensor 98 is positioned outside of the airfoil 38 so that the sensor 98 defines a line of sight 100 to the beam axis A of the limited laser beam 64. As used herein, the term "line of sight" means a straight line from one position to another position that is free of any structural obstruction. Accordingly, the sensor 98 can be positioned anywhere outside the cavity 46 of the airfoil 38 that enables the sensor 98 to define the line of sight 100 to the beam axis A within the cavity 46. For example, in the embodiment shown, the sensor 98 is positioned adjacent to the opening 54 (shown schematically) of the airfoil 38 and is directed through the opening 54 of the airfoil 38 into the cavity 46 of the airfoil 38.
Usually, it is difficult to detect light from a laser beam unless such a laser beam is in contact with a surface (for example, when the light is reflected and / or deflected) or unless the sensor 98 is positioned in alignment with an axis of the laser beam is. For the illustrated embodiment, the kickback protection mechanism 82 is configured to interfere with the confined laser beam 64 within the cavity 46 of the airfoil 38 after the confined laser beam 64 has broken through the nearby wall 66 of the airfoil 38. In particular, as noted above, the confined laser beam 64 includes a column of liquid 80 and a laser beam 74 within the column of liquid 80. Referring particularly to FIG. 10, when the confined laser beam 64 has broken through the nearby wall 66 of the airfoil 38, a gas 84, flowed through the cavity 46 by the backlash prevention mechanism 82, the liquid column 80 of the confined laser beam 64 within the cavity 46 of the airfoil 38 in such a way that at least a portion of the liquid from the liquid column 80 intersects the beam axis A and the laser beam 74 . The liquid intersecting the beam axis A may be at least partially irradiated by the laser beam 74 of the limited laser beam 64 within the cavity 46. Accordingly, the sensor 98, which is directed into the cavity 46 of the airfoil 38, can detect a light property, such as a light intensity, from the portion of the liquid irradiated by the laser beam 74.
In some embodiments, the sensor 98 may be positioned outside the cavity 46 and directed into the cavity 46 such that the sensor 98 is configured to detect light from the interior of the cavity 46 of the airfoil 38 at multiple locations. In particular, the sensor 98 can be positioned outside the cavity 46 and directed into the cavity 46 such that the sensor 98 has a line of sight 100 with the beam axis A of the limited laser beam 64 at a first hole location and with a second beam axis A 'of the limited laser beam 64 defined at a second hole location (see. Fig. 10). Such an embodiment can allow time-efficient and more convenient drilling of, for example, cooling holes in an airfoil 38 for a gas turbine.
Referring now to FIG. 11, a block diagram of an exemplary method 200 for drilling a hole 52 in an airfoil 38 of a gas turbine is provided. The example method 200 of FIG. 11 may be used with the example system 60 illustrated in FIGS. 9 and 10 and described above. Accordingly, while the example method 200 is described in the context of drilling a hole 52 in an airfoil 38, it may alternatively be used to drill a hole 52 in any other suitable component of a gas turbine.
As illustrated, the example method 200 includes, at 202, directing a confined laser beam 64 of a confined laser drill 62 toward a first hole location on a nearby wall 66 of the airfoil 38. The proximal wall 66 may be adjacent to one in the airfoil 38 defined cavity 46 be positioned. The method 200 further includes, at 204, sensing a property of light within the cavity 46 defined by the airfoil 38 using a sensor 98 positioned outside the cavity 46 defined by the airfoil 38. In some exemplary aspects, the sensor 98 may be positioned adjacent an opening defined by the airfoil 38 and directed through the opening into the cavity 46. The sensor 98 may thus be positioned at a location that does not intersect a beam axis defined by the limited laser beam 64, but a line of sight to the beam axis defined by the limited laser beam 64, within the cavity 46 of the Airfoil 38 defined.
The method 200 further includes activating a kickback protection mechanism 82 at 206. Activating the kickback protection mechanism 82 at 206 may be, for example, in response to operating the limited laser drill 62 for a predetermined amount of time. Additionally, activating the kickback protection mechanism 82 at 206 may include flowing a gas 84 through the cavity 46 of the airfoil 38 in such a manner that the gas 84 crosses the jet axis within the cavity 46 of the airfoil 38. Accordingly, if the confined laser beam of the confined laser drill 62 breaches the nearby wall 66 of the airfoil 38, the method 200 further includes at 208 interfering with the confined laser beam within the cavity 46 of the airfoil 38 with the kickback protection mechanism 82. In particular, interfering with the confined laser beam contained within cavity 46 at 208 perturbing a liquid column 80 of the confined laser beam in such a manner that liquid from liquid column 80 intersects the beam axis and a laser beam of the confined laser beam. The liquid intersecting the beam axis may be at least partially irradiated by the laser beam of the limited laser beam within the cavity 46 of the airfoil 38.
The exemplary method 200 of FIG. 11 further includes at 210 detecting a first breakthrough of the confined laser beam 64 through the nearby wall 66 of the airfoil 38 at the first hole location based on that with the sensor 98 at 204 from inside the cavity 46 detected light. In some example aspects, sensing a property of light at 204 within the cavity 46 with the sensor 98 may include sensing an intensity of light from the portion of the liquid of the limited laser beam that is irradiated by the laser of the limited laser beam 64. Further, in one such exemplary aspect, determining the first breakthrough of the limited laser beam 64 at 210 may include determining the first breakthrough of the limited laser beam 64 based on the detected light intensity from the portion of the liquid of the limited laser beam 64 that is passed through the laser beam of the limited laser beam 64 is illuminated.
After determining the first breakthrough of the confined laser beam 64 at 210, the example method 200 may include shutting down the confined laser drill 62 and repositioning the confined laser drill 62 to drill a second cooling hole. The example method 200 also includes, at 212, directing the confined laser beam 64 of the confined laser drill 62 toward a second hole location on the nearby wall 66 of the airfoil 38. The method 200 further includes, at 214, sensing a property of light within the airfoil 38 defined cavity 46 using the sensor 98 after directing the limited laser beam toward the second hole position at 212. Further, the method 200 of FIG. 11 includes at 216 detecting a second breakthrough of the limited laser beam 64 through the nearby wall 66 of the airfoil 38 based on the sensed property of light from the interior of cavity 46. The detection of the second breakthrough of the confined laser beam 64 at 216 can be performed in a manner that is substantially similar to the detection of the first breakthrough of the confined laser beam 64 at 210. Also, for the exemplary aspect illustrated, the sensor 98 remains stationary between the detection of the first breakthrough of the limited laser beam 64 at 210 and the detection of the second breakthrough of the limited laser beam 64 at 216. For example, the sensor 98 may be positioned to define a line of sight with the beam axis of the limited laser beam 64 at multiple hole positions (including the first hole position and the second hole position). It should be recognized, however, that in other exemplary aspects, the sensor 98 can be moved, repositioned, or reoriented to maintain or create a line of sight to subsequent hole locations if, for example, the cooling holes being drilled define a non-linear path.
The exemplary method 200 of FIG. 11 may enable a more time-efficient and convenient drilling of multiple holes 52 through the nearby wall 66 of the airfoil 38 using a limited laser drill 62.
Capture the liquid outside the component
Referring now to Figures 12 and 13, a system 60 in accordance with yet another exemplary embodiment of the present invention is provided. In particular, FIG. 12 shows a schematic view of a system 60 in accordance with another exemplary embodiment of the present invention before a confined laser beam 64 from a confined laser drill 62 has penetrated a nearby wall 66 of an airfoil 38. Additionally, FIG. 13 shows a schematic view of the exemplary system 60 of FIG. 12 after the confined laser beam 64 of the confined laser drill 62 has breached the nearby wall 66 of the airfoil 38. It should be recognized that while the exemplary system 60 of FIGS. 12 and 13 is illustrated in the context of an airfoil 38, in other embodiments the system 60 can be used with any other component of a gas turbine.
The example system 60, as illustrated in FIGS. 12 and 13, can be set up in essentially the same manner as the example system 60 according to FIGS. 3 and 4, and the same or Similar reference numbers may refer to the same or similar parts. For example, the exemplary system 60 of FIGS. 12 and 13 includes a limited laser drill 62 (shown schematically in FIGS. 12 and 13 for simplicity) that employs a limited laser beam 64. The limited laser beam 64 includes a liquid column 80 formed from a liquid and a laser beam 74 within the liquid column 80. The constrained laser drill 62 is configured to drill one or more holes 52 or cooling passages through a nearby wall 66 of the airfoil 38. For the illustrated embodiment, the proximate wall 66 of the airfoil 38 is positioned adjacent a cavity 46 defined by the airfoil 38.
However, for the embodiment of FIGS. 12 and 13, the system 60 includes a sensor 102 positioned outside the nearby wall 66 of the airfoil 38 that is configured to detect an amount of liquid from the limited laser beam 64 that is outside the nearby wall 66 of the airfoil 38 Wall 66 of the airfoil 38 is present to determine. A control device 72 is in operative communication with the sensor 102. The control device 72 is configured to detect a breakthrough of the limited laser beam 64 through the nearby wall 66 of the airfoil 38 based on the amount of liquid determined by the sensor 102 to be present. In particular, before the confined laser beam 64 breaks through the nearby wall 66 of the airfoil 38, fluid from the liquid column 80 of the confined laser beam 64 may splash back away from the nearby wall 66 of the airfoil 38 during the drilling operation (i.e., during the operation with the confined laser drill 62) . The liquid from the confined laser beam 64 may form a plume 106 of splash back liquid surrounding the hole 52 just drilled in the nearby wall 66 of the airfoil 38. The flag 106 may be disposed in a splashback area 104 defined by the system 60. Additionally, in some exemplary embodiments, such as the embodiment of FIGS. 12 and 13, the confined laser drill 62 may be positioned within relatively close proximity to the nearby wall 66 of the airfoil 38 such that the confined laser drill 62 is within the Back injection area 104 is positioned. For example, in some embodiments, the limited laser drill 62 may be spaced from the nearby wall 66 of the airfoil 38 between about 5 millimeters () and about 25 mm, for example between about 7 mm and about 20 mm, for example between about 10 mm and about 15 mm , define. However, in other embodiments, the limited laser drill 62 may define any other suitable distance from the nearby wall 66 of the airfoil 38.
In contrast, after the confined laser drill 62 breaks the nearby wall 66 of the airfoil 38 (Fig. 13), fluid from the liquid column 80 of the confined laser beam 64 can pass through the drilled hole 52 and into the airfoil cavity 46 38 flow in. Accordingly, after the confined laser beam 64 penetrates the nearby wall 66 of the airfoil 38, the confined laser drill 62 may not define the plume 106 of splashback liquid in the splashback area 104, or alternatively, the plume 106 may be smaller or otherwise a different shape in comparison to define their size and shape before the confined laser beam 64 breached the nearby wall 66 of the airfoil 38.
For the embodiment according to FIGS. 12 and 13, the sensor 102 can be configured as any sensor that is capable of detecting an amount of liquid from the limited laser beam 64 that is outside the nearby wall 66 of the airfoil 38 is to determine. For example, in some example aspects, sensor 102 may include a camera. If the sensor 102 includes a camera, the camera of the sensor 102 can be aimed at the limited laser beam 62, or alternatively, the camera of the sensor 102 can be aimed at the hole 52 in the nearby wall 66 of the airfoil 38. In each of these embodiments, the sensor 102 can be configured to use an image recognition method to determine whether or not a predetermined amount of liquid is present in the splashback region 104. For example, the sensor 102 may be configured to compare one or more images received by the camera of the sensor 102 with one or more stored images in order to determine the amount of liquid that is present. In particular, the sensor 102 may be configured to match one or more images received by the camera with one or more stored images of the confined laser drill 62 or the hole 52 with an amount of fluid present that is indicative of the confined laser beam 64 the nearby wall 66 of the airfoil 38 has broken through.
However, it should be recognized that in other exemplary embodiments, any other suitable sensor 102 may be provided. For example, in other exemplary embodiments, the sensor 102 may be a motion sensor, a humidity sensor, or any other suitable sensor. For example, if the sensor 102 is a motion sensor, the sensor 102 can determine whether or not a plume 106 of the splashed-back liquid is present in the splashback area 104. A breakthrough can be determined when the plume 106 of the back-sprayed liquid is no longer present in the back-splash area 104.
Referring now to Figures 14 and 15, a system 60 is provided in accordance with yet another exemplary embodiment. The exemplary system 60 according to FIGS. 14 and 15 is set up essentially in the same way as the exemplary system 60 according to FIGS. 12 and 13. However, for the exemplary embodiment of FIGS. 14 and 15, the sensor 102 is configured as an optical sensor, and the system 60 also includes a light source 108 that is separate from the limited laser drill 62. The light source 108 can be any suitable light source. For example, the light source 108 may be one or more LED light bulbs, one or more incandescent lamps, one or more electroluminescent lamps, one or more lasers, or combinations of these.
As noted, the confined laser drill 62 defines a splashback area 104 in which liquid splashes from the confined laser beam 64 before the confined laser beam 64 breaks the nearby wall 66 of the airfoil 38. For the embodiment shown, the light source 108 is positioned outside of the airfoil 38 and is set up to direct a light through at least part of the splashback region 104. In addition, the light source 108 for the embodiment shown is positioned directly on the opposite side of the splashback area 104 to the sensor 102, the light source 108 being directed at the sensor 102 and the sensor 102 being directed at the light source 108. However, in other exemplary embodiments, the light source 108 and the sensor 102 may be offset from one another with respect to the splashback region 104, the light source 108 may not be directed towards the sensor 102 and / or the sensor 102 may not be directed towards the light source 108.
As mentioned, the sensor 102 for the illustrated embodiment is directed at the light source 108, and the light source 108 is directed at the sensor 102 so that an axis of the light source intersects the sensor 102. In such an embodiment, sensing an intensity of light above a predetermined threshold may indicate that there is a decreased amount of fluid from the confined laser beam 64 outside of the airfoil 38 and, thus, that the confined laser beam 64 has breached the nearby wall 66 of the airfoil 38. If liquid is present in the splashback region 104, in particular such a liquid can interfere or deflect light from the light source 108, so that a light intensity detected by the sensor 102 is relatively low. In contrast to this, if there is no liquid or a minimal amount of liquid in the splashback region 104, the degree of interference between the light source 108 and the sensor 102 is limited, so that a relatively high light intensity can be detected by the sensor 102. Accordingly, with such a configuration, sensing a relatively high light intensity may indicate that the confined laser beam 64 has breached the nearby wall 66 of the airfoil 38.
In further exemplary embodiments, if, for example, the light source 108 is not directed at the sensor 102 and the sensor 102 is not directed at the light source 108, however, the detection of a light intensity below a predetermined threshold indicates that a reduced amount of liquid from the limited laser beam 64 is present outside of the airfoil 38. In particular, if the light source 108 is not directed at the sensor 102 and the sensor 102 is not directed at the light source 108, the sensor 102 can detect an increased light intensity if light from the light source is deflected and reflected by the liquid in the splashback area 104. However, if there is no liquid or a minimal amount of liquid in the splash back area 104, light from the light source will not be deflected or reflected by such liquid, and the sensor 102 can consequently detect a relatively low light intensity. Accordingly, in one such exemplary embodiment, sensing an intensity of light below a predetermined threshold may indicate that the confined laser beam 64 has breached the nearby wall 66 of the airfoil 38.
Referring now to FIG. 16, a block diagram of an exemplary method 300 for drilling a hole 52 in an airfoil 38 of a gas turbine is provided. The example method 300 of FIG. 16 can be used with the example system 60 shown in FIGS. 12 and 13 and / or the example system 60 shown in FIGS. 14 and 15, the both described above can be used. Accordingly, while the example method 300 is discussed in the context of drilling a hole 52 in an airfoil 38, it may alternatively be used to drill a hole 52 in any other suitable component of a gas turbine.
As illustrated, the example method 300 includes, at 302, positioning a confined laser drill 62 within a predetermined distance of a nearby wall 66 of an airfoil 38 of a gas turbine. The example method 300 further includes, at 304, directing a confined laser beam 64 of the confined laser drill 62 toward an outer surface of the nearby wall 66 of the airfoil 38. The confined laser beam 64 includes a column of liquid formed from a liquid and a laser beam within the column of liquid is. The example method 300 further includes, at 306, sensing an amount of liquid that is outside the nearby wall 66 of the airfoil 38 from the confined laser beam 64 with a sensor 102. The example method 300 further includes, at 308, determining a breakthrough of the confined laser beam 64 of the confined laser drill 62 through the nearby wall 66 of the airfoil 38 of the gas turbine based on an amount of fluid sensed outside the proximate wall 66 of the airfoil 38 at 306.
In some exemplary aspects where the sensor 102 includes a camera, sensing an amount of fluid present outside the nearby wall 66 of the airfoil 38 at 306 may include a comparison of one or more images received from the camera with one or more contain multiple stored images to determine the amount of fluid that is present. Any suitable pattern recognition software can be used to provide such functionality.
Use of multiple sensors
Referring now to Figure 17, a system 60 in accordance with another exemplary embodiment of the present invention is provided. It should be recognized that while the exemplary system 60 of FIG. 17 is illustrated in the context of an airfoil 38, in other embodiments the system 60 can be used with any other component of a gas turbine.
The example system 60 of FIG. 17 may be implemented in substantially the same manner as the example system 60 of FIGS. 3 and 4, and the same or similar reference numbers may refer to the same or similar parts . For example, the exemplary system 60 of FIG. 17 includes a limited laser drill 62 that employs a limited laser beam 64. The limited laser beam 64 is configured to drill a hole 52 through a nearby wall 66 of the airfoil 38. The nearby wall 66, as illustrated, is positioned adjacent a cavity 46 defined by the airfoil 38. The system 60 also includes a controller 72.
The exemplary system 60 of FIG. 17 further includes a first sensor 110 that is configured to sense a first property of the light from the hole 52 in the nearby wall 66 of the airfoil 38. The exemplary system 60 also includes a second sensor 112 configured to sense a second property of the light from the hole 52 and the nearby wall 66 of the airfoil 38. The second property of light is different from the first property of light. In addition, the controller 72 is operably connected to the first sensor 110 and the second sensor 112 and is configured to determine a progression of the hole 52 drilled with the limited laser drill 62 based on the sensed first light property and the sensed second light property .
For the embodiment illustrated in FIG. 17, the first sensor 110 is positioned outside of the airfoil 38, and is also positioned to detect light reflected and / or deflected by the hole 52 along a beam axis A, ie is directed along the jet axis A away from the nearby wall 66 of the airfoil 38. For example, the first sensor 110 can be set up in essentially the same way as the sensor 88, which is described above with reference to FIGS. 3 and 4. Accordingly, the first sensor 110 can be an oscilloscope sensor or any other suitable optical sensor.
In addition, for the embodiment according to FIG. 17, the second sensor 112 is also positioned outside of the airfoil 38 and directed towards the hole 52 in the nearby wall 66 of the airfoil 38. In particular, the second sensor 112 is positioned such that the second sensor 112 defines a line of sight 114 with the hole 52, the line of sight 114 extending in a direction non-parallel to the beam axis A. In some embodiments, the second sensor 112 may be an optical sensor that is configured to detect one or more of a light intensity, a light wavelength, and an amount of light.
As discussed in greater detail below with reference to FIG. 18, in some exemplary embodiments, the first characteristic of light may be an intensity of light at a first wavelength and the second characteristic of light may be an intensity of light at a second wavelength. Detection of the light at the first wavelength can be indicative of the limited laser beam 64 impinging on a first layer, such as a thermal barrier coating 36, of the nearby wall 66 of the airfoil 38. In contrast, the detection of a light at the second wavelength can be indicative of the limited laser beam 64 impinging on a second layer, such as a metal part 40, of the nearby wall 66 of the airfoil 38. The control device 72 can be configured to compare the light intensity that is detected at the first wavelength by the first sensor 110 with the light intensity that is detected at the second wavelength by the second sensor 112 in order to determine a progression of the hole 52 determine.
It should be recognized, however, that in other exemplary embodiments of the present invention, the first sensor 110 and the second sensor 112 may be positioned in any other suitable location. For example, in other exemplary embodiments, the first sensor 110 and the second sensor 112 may each be positioned to detect light directed along the beam axis A away from the nearby wall 66 of the airfoil 38. Alternatively, the first sensor 110 and second sensor 112 may each be positioned such that each respective sensor 110, 112 defines a line of sight to the hole 52 in the nearby wall 66 of the airfoil 38 that is not parallel to the beam axis A. Alternatively, one or both of the first sensor 110 and the second sensor 112 may be positioned outside the cavity 46 of the airfoil 38 and directed into the cavity 46 of the airfoil 38 (similar, for example, to the sensor 98 described above with reference 9 and 10) or can be positioned within the cavity 46 of the airfoil 38. Alternatively, one or both of the first sensor 110 and the second sensor 112 may be positioned outside of the airfoil 38 and directed at a surrounding surface to detect light reflected from the hole 52 onto the surrounding surface. In yet another alternative, in some exemplary embodiments, the first sensor 110 and the second sensor 112 can both be integrated into a single sensing device at any suitable location.
Referring now to FIG. 18, a block diagram of an exemplary method 400 for drilling a hole 52 in an airfoil 38 of a gas turbine is provided. The example method 400 of FIG. 10 may be used with the example system 60 shown in FIG. 17 and described above. Accordingly, while the example method 400, while discussed in the context of drilling a hole 52 in an airfoil 38, may alternatively be used to drill a hole 52 in any other suitable airfoil 38 of a gas turbine.
The exemplary method 400 of FIG. 18 includes, at 402, directing a confined laser beam 64 of a confined laser drill 62 toward a nearby wall 66 of the airfoil 38. The proximal wall 66 is positioned adjacent a cavity defined in the airfoil 38 , and the limited laser beam 64 defines a beam axis. The example method 400 further includes, at 404, sensing a first characteristic of light from the hole 52 in the airfoil 38 with a first sensor 110. In some example aspects, the first sensor 110 may be positioned outside the airfoil 38 and the first characteristic of light may be a light intensity at a first wavelength. The sensing of the light at the first wavelength may be indicative of the limited laser beam 64 impinging or being directed to a first layer of the nearby wall 66 of the airfoil 38. For example, the detection of the light at the first wavelength may be indicative of the limited laser beam 64 impinging on a thermal barrier coating on the nearby wall 66 of the airfoil 38.
The example method 400 further includes, at 406, sensing a second characteristic of light from the hole 52 in the airfoil 38 with a second sensor 112. The second characteristic of light, sensed with the second sensor 112 at 406, is different from the first characteristic of light that is detected with the first sensor 110 at 404. For example, in some exemplary aspects, the second characteristic of light can be an intensity of light at a second wavelength. The second wavelength may be indicative of the limited laser beam 64 impinging on a second layer of the nearby wall 66 of the airfoil 38. For example, the detection of the light at the second wavelength may be indicative of the limited laser beam 64 impinging on a metal portion 40 of the nearby wall 66 of the airfoil 38.
The method 400 further includes at 408 determining a hole advance based on the first characteristic of light detected at 404 and the second characteristic of light detected at 406. In some example aspects, determining hole advance at 408 based on the first characteristic of light detected at 404 and the second characteristic of light detected at 406 may be a comparison of the light intensity detected at the first wavelength with a Light intensity detected at the second wavelength. For example, a ratio of the light intensity detected at the first wavelength to the light intensity detected at the second wavelength may indicate progress of the hole 52 through the first layer of the nearby wall 66 of the airfoil 38.
In some example aspects, determining the hole advance at 408 based on the first property of light detected at 404 and the second property of light detected at 406 may further include determining that the hole 52 is at least a predetermined amount through the first layer of the nearby Wall 66 of the airfoil 38 is created. For example, the example method 400 may include determining that the hole 52 penetrates at least about 90% through the first layer of the proximal wall 66 of the airfoil 38, such as at least about 95% through the first layer of the proximal wall 66 of the airfoil 38, for example, is created by at least about 98% through the first layer of the adjacent wall 66 of the airfoil 38.
Additionally, depending on certain factors such as the type of material from which the thermal barrier coating is made, it may be desirable to pass through the thermal barrier coating of the nearby wall 66 of the airfoil 38 with less power than the underlying metal portion of the airfoil 38 to drill. Accordingly, in response to determining the hole advance at 408, e.g., in response to a determination that the hole 52 is created through the first layer of the nearby wall 66 of the airfoil 38 by at least a predetermined amount, the method 400 may further adjust at 410 one or more operating parameters of the limited laser drill 62. For example, method 400 may include increasing a power, increasing a pulse rate, and / or increasing a pulse width of the limited laser drill 62.
It will be recognized, however, that in other exemplary aspects, the first characteristic of light and the second characteristic of light may each be any other suitable characteristic of light. For example, in other exemplary aspects, the first sensor 110 can be a suitable optical sensor, and the first light characteristic can be a light intensity. Such an exemplary aspect may further include determining either a reflected pulse region of the limited laser drill 62 and / or a reflected pulse frequency of the limited laser drill 62. Similar to the manner discussed in greater detail above with reference to FIGS. 3-5, the exemplary method 400 of FIG. 18 may be based on the determined reflected pulse width of the limited laser drill 62 and / or the determined pulse rate of the limited laser drill 62 further include determining a depth of the hole 52 drilled with the limited laser drill 62. In addition, in such an exemplary aspect, the second sensor 112 can also be an optical sensor, and the second light property can be a wavelength of the light. As mentioned, the wavelength of the light for the material into which the limited laser beam 64 is directed can be labeled. Accordingly, the example method 400 of FIG. 18 may further include determining a material into which the limited laser beam 64 is directed based on the wavelength of light sensed with the second sensor 112.
In one such example aspect, in response to determining the depth of the hole 52 and determining the material into which the confined laser beam 64 is directed, the example method 400 of FIG. 18 may further adjust one or more operating parameters of the limited laser drill 62 included. In particular, the example method 400 of FIG. 18 may further include determining that the hole 52 has been drilled through the first layer of the nearby wall 66 of the airfoil 38 and increasing a power, increasing a pulse rate, and / or increasing a pulse width limited laser drill 62 to aid in drilling through the metal portion of the nearby wall 66 of the airfoil 38. Alternatively, the example method 400 of FIG. 18 may further include determining that the hole 52 is created through the metal portion of the nearby wall 66 of the airfoil 38 by at least a predetermined amount, and may decrease power, decrease a pulse rate, and / or Reduce the pulse width of the confined laser drill 62 to prevent unnecessary damage to, for example, a remote wall 66 of the airfoil 38.
In any of the foregoing exemplary aspects, it should be recognized that determining hole advance at 408 based on the first property of light detected at 404 and the second property of light detected at 406 may include using any suitable control methodology. For example, determining hole advance at 408 may include using lookup tables taking certain factors into account. These look-up tables can be determined experimentally. Additionally or alternatively, determining the hole advance at 408 may include using a fuzzy logic control methodology to analyze the first and second light properties detected at 404 and 406, respectively.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making, using any devices or systems, and performing the same any included method 400. The patentable scope of the invention is defined by the claims.
[0118] A method 400 of drilling a hole 52 in a component is provided. The method 400 includes directing a confined laser beam 64 of the confined laser drill 62 toward a first hole location on a nearby wall 66 of the component. The method 400 further includes sensing a property of light within a cavity 46 defined by the component. The nearby wall 66 is positioned adjacent to the cavity 46, and the sensor 102 is positioned outside the cavity 46. The method 400 further includes determining a first breakthrough of the confined laser beam 64 through the nearby wall 66 of the component at the first hole location based on the light from the interior of the cavity 46 sensed by the sensor 102. Such a method 400 can enable more convenient and time-efficient drilling in gas turbine components.

权利要求:
Claims (10)
[1]
A method (120, 200, 300, 400) for drilling a hole (52) in a wall (66) of a component, the method (120, 200, 300, 400) comprising:directing a laser beam (64) limited by a light guiding and focusing mechanism of a laser drill (62) towards a first hole position on the wall (66) of the component to penetrate a hole (52) at the first hole position drilling the wall (66) of the component, the wall (66) positioned adjacent a cavity (46) defined in the component;Sensing a property of light within the cavity (46) defined by the component using a sensor (88, 98, 102) positioned outside of the cavity (46) defined by the component; andDetermining a first breakthrough of the limited laser beam (64) through the wall (66) of the component at the first hole position based on the light from the interior of the cavity (46) detected with the sensor (88, 98, 102).
[2]
2. The method (120, 200, 300, 400) of claim 1, wherein the component is an airfoil (38) of a gas turbine; and / or wherein the sensor (88, 98, 102) is an optical sensor.
[3]
The method (120, 200, 300, 400) of claim 1 or 2, wherein the limited laser beam (64) defines a beam axis and wherein the sensor (88, 98, 102) is positioned at a location that does not intersect the beam axis and which defines a line of sight to the beam axis within the cavity (46).
[4]
The method (120, 200, 300, 400) according to any one of the preceding claims, further comprising:Activating a kickback protection mechanism (82) andInterfering with the limited laser beam (64) within the cavity (46) with the kickback protection mechanism (82).
[5]
The method (120, 200, 300, 400) of claim 4, wherein the confined laser beam (64) defines a beam axis, activating a kickback protection mechanism (82) introducing a gas (84) into the cavity (46) of the component in such a way that the gas (84) crosses the beam axis within the cavity (46) of the component.
[6]
The method (120, 200, 300, 400) of claim 4, wherein the confined laser beam (64) defines a beam axis, the confined laser beam (64) comprising a liquid column (80) and a laser, wherein perturbing the confined laser beam (64) within the cavity (46) has perturbing the liquid column (80) of the confined laser beam (64) in such a way that a liquid from the liquid column (80) intersects the beam axis, and wherein the liquid intersecting the beam axis at least partially is irradiated by the laser of the limited laser beam (64) within the cavity (46).
[7]
7. The method (120, 200, 300, 400) of claim 6, wherein detecting a property of light within the cavity (46) is detecting a light intensity from the portion of the liquid of the liquid column (80) of the limited laser beam (64) passing through irradiating the laser of the limited laser beam (64); and wherein determining the first breakthrough of the limited laser beam (64) preferably includes determining the first breakthrough of the limited laser beam (64) based on the detected light intensity from the portion of the liquid of the liquid column (80) of the limited laser beam (64) passing through the laser of the limited laser beam (64) is irradiated.
[8]
8. The method (120, 200, 300, 400) of any one of the preceding claims, wherein the component defines an opening leading to the cavity (46) and wherein the sensor (88, 98, 102) is positioned and through adjacent the opening the opening is directed through as well as into the cavity (46).
[9]
The method (120, 200, 300, 400) of any one of the preceding claims, further comprising:Directing the confined laser beam (64) of the confined laser drill (62) toward a second hole location on the wall (66) of the component;Detecting a property of light within the cavity (46) defined by the component using the sensor (88, 98, 102) after directing the limited laser beam (64) of the limited laser drill (62) towards the second hole position on the wall (66) ) the component; andDetecting a second breakthrough of the limited laser beam (64) through the wall (66) of the component at the second hole position on the basis of the detected light property from the interior of the cavity (46), wherein the sensor (88, 98, 102) between the detection of the first breakthrough and the detection of the second breakthrough remains stationary.
[10]
A system for drilling one or more holes (52) in a wall (66) of a component, the system comprising:a laser drill (62) limited by means of a light guiding and focusing mechanism, which uses a laser beam (64) limited by means of a light guiding and focusing mechanism, the limited laser drill (62) being adapted to produce one or more holes (52) in the Drilling the wall (66) of the component, the wall (66) positioned adjacent a cavity (46) defined by the component;a kickback protection mechanism (82) configured to protect a remote wall (66) of the component, the remote wall (66) being positioned on the opposite side of the cavity (46) from the wall (66); and a sensor (88, 98, 102) positioned outside of the cavity (46) and directed into the cavity (46) to detect a property of a light within the cavity (46), the system being configured to: to determine breach of the confined laser drill (62) through the wall (66) of the component based on the nature of the light detected within the cavity (46) of the component.

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同族专利:

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公开号 | 公开日

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JP2016135506A|2016-07-28|

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DE102015122875A1|2016-07-14|

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CN105772956A|2016-07-20|

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法律状态:
2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |

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2019-05-31| NV| New agent|Representative=s name: FREIGUTPARTNERS IP LAW FIRM DR. ROLF DITTMANN, CH |

优先权:

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申请号 | 申请日 | 专利标题

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US14/592,304|US20160199943A1|2015-01-08|2015-01-08|Method and system for confined laser drilling|

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