• 专利附录
  • 专利说明
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    • 专利摘要:
    An electrochemical machining system (100) for machining a conductive workpiece (102) is provided. The system includes a drilling tool (112) configured to remove material from the conductive workpiece (102). The boring tool (112) is configured to advance within the conductive workpiece (102) along a tool path to form a borehole (118) that extends through the conductive workpiece (102) in more than one dimension when the material is removed from it. The system also includes an inspection device (122) configured to determine a position of the drilling tool (112) along the tool path and a controller (128) configured to communicate with the inspection device (182). The controller (128) is configured to compare the toolpath to a desired toolpath and to determine a positional error of the drilling tool (112), wherein the positional error is defined by a difference between the toolpath and the desired toolpath.
    公开号:CH711388A2
    申请号:CH00953/16
    申请日:2016-07-22
    公开日:2017-01-31
    发明作者:Lee Trimmer Andrew；Robert Hayashi Steven；James Nieters Edward；Gordon McNamara Jeremy
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    BACKGROUND TO THE INVENTION
    [0001] The present disclosure relates generally to electrochemical machining (ECM) and, more particularly, to systems and methods for producing a continuous, variable geometry wellbore in a conductive workpiece.
    Rotary machines, such as gas turbines, are often used to produce power with electric generators. For example, gas turbines have a gas path that typically includes an air inlet, a compressor, a combustor, a turbine, and a gas outlet in serial flow relationship. The compressor and turbine sections include at least one row of circumferentially spaced rotating blades or blades connected within a housing. At least some known turbine engines are used in combined heat and power plants and power plants. Drives used in such applications can have a large requirement for specific work and power per mass flow unit. In addition, the efficiency of gas turbines is directly proportional to the temperature of the exhaust discharged from the combustion chamber and bypassing the rotating blades or blades of the turbine. As such, the extreme temperatures of the exhaust generally require the static and rotating turbine blades to be made of high temperature resistant materials and having cooling characteristics therein.
    For example, turbine blades are typically cooled by directing compressor exhaust air through a plurality of cooling passages that extend through the turbine blades. At least one known method of forming the cooling channels in the turbine blades is the electrochemical machining of shaped pipes (STEM). STEM is a non-contact electrochemical machining process that uses a conductive workpiece as an anode (that is, the turbine blades) and an elongate drill pipe as a cathode. When the conductive workpiece is flooded with an electrolytic solution, material is oxidized and removed from the conductive workpiece near the leading edge of the drill pipe. STEM is generally effective in forming straight cooling channels that have a large aspect ratio within turbine blades. However, the fixed orientation of an electrode tip positioned at the leading edge of the drill pipe and the rigidity of the elongated drill pipe limits the geometry in which the cooling channels can be formed within the turbine blades.
    BRIEF DESCRIPTION OF THE INVENTION
    In one aspect, an electrochemical machining system for machining a conductive workpiece is provided. The system includes a drilling tool configured to remove material from the conductive workpiece. The drilling tool is configured to advance within the conductive workpiece along a toolpath to form a variable geometry bore hole that extends through the conductive workpiece as the material is removed therefrom. The system also includes an inspection device configured to determine a position of the drilling tool along the tool path and a controller configured to communicate with the inspection device. The controller is further configured to compare the toolpath to a desired toolpath and to determine a positional error of the drilling tool, wherein the positional error is defined by a difference between the toolpath and the desired toolpath.
    [0005] In any embodiment of the system, it may be advantageous for the inspection device to be configured to perform an inspection prior to drilling the conductive workpiece to determine its dimensions, the controller further being configured to implement a modified target toolpath based on To determine variations in the dimensions of the conductive workpiece when compared to dimensions of a virtual conductive workpiece.
    In any embodiment of the system, it may be advantageous for the inspection device to comprise an ultrasound test device and / or an X-ray test device.
    In any embodiment of the system, it may be advantageous for the system to include a flow control device configured to direct a flow of an electrolytic fluid through a central purge passage extending through the drilling tool so as to increase the flow of the electrolytic fluid Fluid is discharged to the conductive workpiece in the wellbore.
    In any embodiment of the system, it may be advantageous that the system further includes an ion sensor configured to measure an ion concentration in the electrolytic fluid dispensed from the wellbore.
    In any embodiment of the system, it may be advantageous that the system further comprises a robotic device connected to the drilling tool, the robotic device configured to advance the drilling tool along the toolpath.
    In any embodiment of the system, it may be advantageous for the robotic device to be configured to communicate with the controller, the robotic device further configured to modify an orientation of the drilling tool within the borehole based on the positional error of the boring tool.
    In another aspect, a method for machining a conductive workpiece is proposed. The method includes advancing a drilling tool within the conductive workpiece along a toolpath to form a variable geometry wellbore extending through the conductive workpiece as the material is removed therefrom. The drilling tool includes a plurality of electrode pads. The method also includes performing an inspection of the conductive workpiece to determine a position of the drilling tool along the tool path and to determine a position error of the drilling tool, the position error being due to a difference between the position of the drilling tool and a theoretical position of the drilling tool Target tool path is defined.
    In any embodiment of the method, it may be advantageous that the method further comprises: performing an inspection prior to drilling the conductive workpiece; Determining variations in dimensions of the conductive workpiece as compared to dimensions of a virtual conductive workpiece; and modifying the desired tool path based on the variations in the conductive workpiece.
    In any embodiment of the method, it may be advantageous that the method further comprises: performing a corrective action to reduce the position error if the position error is greater than a first predetermined threshold.
    [0014] In any embodiment of the method, it may be advantageous that performing a corrective action comprises modifying at least one drilling parameter that includes a height of an electrical current supplied to the plurality of electricians and / or an alignment of the drilling tool within the wellbore and / or or a scavenging pressure of the electrolytic fluid conducted through the wellbore and / or a feed rate of the drilling tool advancing within the wellbore.
    [0015] In any embodiment of the method, it may be advantageous that the method further comprises: performing a small corrective action if the position error is greater than the first predetermined threshold and less than a second predetermined threshold greater than the first predetermined threshold ,
    [0016] In any embodiment of the method, it may be advantageous that the method further comprises: performing an average corrective action when the position error is greater than the second predetermined threshold and less than a third predetermined threshold greater than the second predetermined threshold ,
    In any embodiment of the method, it may be advantageous that the method further comprises: stopping the operation of the drilling tool when the position error is greater than a fourth predetermined threshold, which is greater than the third predetermined threshold.
    In any embodiment of the method, it may be advantageous that the method further comprises: dispensing a flow of the electrolytic fluid to the conductive workpiece within the wellbore, wherein the flow of the electrolytic fluid is directed through a central scavenging passage extending through the drilling tool extends; Measuring an ion concentration in the electrolytic fluid discharged from the wellbore; and determine a chemical composition of the electrolydic fluid based on the ion concentration in the electrolytic fluid.
    In yet another aspect, one or more non-transitory computer-readable storage media is provided with computer-executable instructions contained thereon for use in processing a conductive workpiece. When executed by a controller, the computer-executable instructions cause the controller to direct robotic means to advance a drilling tool within the conductive workpiece along a toolpath to form a variable geometry wellbore extending through the conductive workpiece if material is removed from it. The drilling tool includes a plurality of electrode pads. The computer-executable instructions also cause the controller to direct a robotic device to steer an inspection device to perform an inspection of the conductive workpiece, to determine a position of the drilling tool along the toolpath, and to determine a positional error of the drilling tool, the position error being a difference is defined between the position of the drilling tool compared to a theoretical position of the drilling tool along a desired tool paths.
    [0020] In any embodiment of the storage medium, it may be advantageous for the computer-executable instructions to cause the controller to: steer the inspection device to perform an inspection prior to drilling the conductive workpiece; Determining variations in dimensions of the conductive workpiece as compared to dimensions of a virtual conductive workpiece; and modifying the desired tool path based on the variations in the conductive workpiece.
    [0021] In any embodiment of the storage medium, it may be advantageous for the computer-executable instructions to cause the controller to perform a small correction action if the position error is greater than a first predetermined threshold and less than a second predetermined threshold greater than the first predetermined threshold.
    [0022] In any embodiment of the storage medium, it may be advantageous for the computer-executable instructions to cause the controller to perform an average corrective action if the position error is greater than the second predetermined threshold and less than a third predetermined threshold greater than the second predetermined threshold.
    [0023] In any embodiment of the storage medium, it may be advantageous for the computer readable instructions to cause the controller to terminate operation of the drilling tool when the position error is greater than a fourth predetermined threshold greater than the third predetermined threshold.
    BRIEF DESCRIPTION OF THE DRAWINGS
    These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read in conjunction with the accompanying drawings, in which like reference characters represent like parts throughout the drawings, wherein:<Tb> FIG. 1 <SEP> is a schematic representation of an exemplary electrochemical machining system;<Tb> FIG. FIG. 2 is a perspective view of an exemplary drilling tool that may be used in the electrochemical machining system shown in FIG. 1; FIG.<Tb> FIG. Figure 3 is a cross-sectional view of the drilling tool shown in Figure 2;<Tb> FIG. FIG. 4 is a flowchart of an exemplary method of machining a conductive workpiece that may be used with the electrochemical machining system shown in FIG. 1; FIG.<Tb> FIG. Fig. 5 is a perspective view of an alternative drilling tool that may be used in the electrochemical machining system shown in Fig. 1; and<Tb> FIG. FIG. 6 is a diagram of a portion of the drilling tool shown in FIG. 5 taken along line 6-6. FIG.
    Unless otherwise indicated, the drawings provided herein are intended to illustrate features of embodiments of the disclosure. These features are considered to be applicable in a wide variety of systems, including one or more embodiments of the disclosure. As such, the drawings are not intended to include any conventional features known to those of ordinary skill in the art as necessary to practice the embodiments disclosed herein.
    DETAILED DESCRIPTION OF THE INVENTION
    In the following description and in the claims, reference is made to a number of terms which are to be defined to have the following meanings.
    The singular forms "a," "an," and "the" also include plural refer- ences unless the context clearly dictates otherwise.
    Optional means that the event or circumstance described below may or may not occur, and that the description includes examples in which the event occurs and examples in which it does not.
    Approximate expressions, as used throughout the specification and claims herein, may be employed to modify any quantitative representation that may be allowed to vary without altering the basic function to which it refers , Accordingly, a value modified by an expression or terms such as "about," "about," and "substantially" can not be limited to the specified precise value. In at least some examples, the approximate phraseology may correspond to the precision of an instrument to measure a value. Here and throughout the description and claims, range limits may be combined and / or interchanged. Such areas are identified and contain all subregions contained therein unless the context or wording indicates otherwise.
    As used herein, the term "computer" and related terms, for example, "computing means" are not limited to integrated circuits, which are referred to in the art as a "computer", but are broadly related to a microcontroller , a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein.
    In addition, as used herein, the terms "software" and "firmware" are interchangeable and include any computer program stored in memory for execution by personal computers, workstations, clients, and servers.
    As used herein, the term "non-transitory computer-readable medium" is intended to be representative of any physical computer-based device implemented in any method or technology for the short-term or long-term storage of information that may be computer-readable Commands, data structures, program modules or sub-modules or other data in any device. Therefore, the methods described herein may be encoded as executable instructions embodied in a physical, non-transitory, computer-readable medium, without limitation, including a memory device and / or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least part of the method described herein. Furthermore, the term "non-transitory computer-readable medium" as used herein includes all physical, computer-readable media including, without limitation, non-transitory computer storage devices including, without limitation, volatile and non-volatile media and removable and non-removable media such as firmware, physical and virtual memories, CD-ROMs, DVDs, and any other digital sources such as a network or the Internet, as well as digital means still to be developed with the sole exception that it is a transitory, propagating signal.
    Embodiments of the present disclosure relate to an electrochemical machining system (ECM) and methods of machining a conductive workpiece, such as a turbine blade, blade, or vane. More specifically, the ECM system includes a drilling tool having a body portion and a plurality of electrode pads connected to the body portion in different orientations. Connecting the electrode pads to the body portion at different orientations allows the drill bit to form a continuous, variable geometry wellbore within the conductive workpiece. As used herein, "variable geometry" refers to dimensional changes in more than one plane. The drilling tool may also include a flexible guide member connected to the body portion that facilitates guiding the drilling tool through the continuous, variable geometry wellbore. In addition, the ECM system may include an inspection device for providing real-time feedback on the position of the drilling tool advancing through the conductive workpiece and for orientation of the borehole extending therethrough. As such, real-time feedback in one embodiment is used to determine a positional error of the drilling tool as compared to a desired toolpath, and is used to facilitate proper execution of the toolpath. For example, the real-time feedback is provided as a function of the rate of material removal from the conductive workpiece so that corrective actions can be implemented in a timely manner.
    FIG. 1 is a schematic illustration of an exemplary electrochemical machining (ECM) system 100 for machining a conductive workpiece 102. In the exemplary embodiment, the conductive workpiece 102 is connected to a mounting platform 104 that is positioned within an electrolyte reservoir 106. As will be described in more detail below, a flow control device 108 allows a flow of an electrolytic fluid 109 from the electrolyte container 106 to the conductive workpiece 102 during the machining operation. In the exemplary embodiment, the mounting platform 104 is positioned so that the conductive workpiece 102 is above the electrolytic fluid 109. Alternatively, the mounting platform is positioned so that the workpiece 102 is at least partially immersed in the electrolytic fluid 109 or the electrolytic fluid 109 is supplied from a source remote from the conductive workpiece 102.
    The ECM system 100 includes a power source 110 and a drilling tool 112 that is electrically connected to the power source 110. Specifically, the power source 110 is electrically connected to the conductive workpiece 102, which acts as an anode in the machining process, and to the drilling tool 112, which acts as a cathode in the machining process. The material is removed from the conductive workpiece 102 when the power source 110 supplies electrical power to the drilling tool 112, thereby forming a potential that overlies the conductive workpiece 102 and the drilling tool 112. Material removed from the conductive workpiece 102 by the boring tool 112 is washed away by the flow of the electrolytic fluid 109 discharged to the conductive workpiece 102. More specifically, the flow control device 108 is connected to a pump 114 which allows the supply of electrolytic fluid 109 to the drilling tool 112 via a fluid supply line 116. As such, as will be described in more detail below, the drilling tool 112 moves forward within the conductive workpiece 102 in more than one dimension along a tool path to form a variable geometry wellbore extending through the conductive workpiece 102 when the material is removed from it. More specifically, the drilling tool 112 is capable of advancing within the conductive workpiece 102 in more than one dimension (that is, in a non-linear direction).
    The ECM system 100 also includes a robotic device 120 or any suitable articulating element connected to the boring tool 112 that facilitates advancing the boring tool 112 along the toolpath within the conductive workpiece 102. In the exemplary embodiment, the robotic device 102 is any suitable computer numerically controlled device, such as a robotic gripper, that allows the drilling tool 112 to be advanced along the toolpath in a controlled and automated manner. Specifically, as will be explained in more detail below, the robotic device 120 allows for changing an orientation of the drilling tool 112 within the wellbore 118 such that the wellbore 118 formed within the conductive workpiece 102 has a variable geometry. Alternatively, the alignment of the boring tool 112 within the borehole 118 is changed without the use of a robotic device 120, such as manually by an operator.
    The ECM system 100 may also include an inspection device 122 for performing nondestructive inspection of the conductive workpiece 102. The inspection device 122 may be any nondestructive inspection device that allows the ECM system 100 to operate as described herein. Exemplary nondestructive inspection devices include, but are not limited to, an ultrasound test device, an X-ray test device, and a computed tomography (CT) scanner. As will be described in more detail below, the inspection device 122 operates either continuously or at predetermined intervals to determine the orientation of the borehole 118 formed by the boring tool 112 and / or the position of the boring tool 112 along the tool path. As such, a positional error of the boring tool 112 may be determined when the actual toolpath differs from a desired toolpath of the boring tool 112.
    In some embodiments, the ECM system 100 includes an ion sensor 124 disposed adjacent to an outlet 126 of the wellbore 118. As discussed above, material removed from the conductive workpiece 102 by the drilling tool 112 is swept away by the flow of electrolytic fluid 109 delivered to the conductive workpiece 102. The ion sensor 124 measures an ion concentration in the electrolytic fluid 109 discharged from the outlet 126 of the wellbore 128. As will be described in more detail below, the ion concentration measurement is used to determine a chemical composition of the electrolytic fluid 109, which enables the determination of the health or operating status of the drilling tool 112. Alternatively, a learning algorithm embodied within a memory of a controller 128 is used to determine the health or operating status of the drilling tool 112.
    In an exemplary embodiment, the flow control device 108, the power supply 110, the robotic device 120, the inspection device 122, and the ion sensor 124 are in communication with the controller 128, either wired or wireless. The controller 128 includes a memory 130, that is, a non-transitory computer readable medium) and a processor 132 coupled to the memory 130 for executing programmed instructions. The processor 132 may include one or more processor units (eg, in a multi-core configuration) and / or a cryptographic acceleration unit (not shown). The controller 128 is programmable to perform one or more operations described herein by programming the memory 130 and / or the processor 132. For example, by encoding an operation, the processor 132 may be programmed as executable instructions and provide the executable instructions in the memory 130.
    The processor 132 may include, but are not limited to, a general purpose central processing unit (CPU), a microcontroller, a reduced instruction set processor (RISC processor), an open multimedia application platform (OMAP), an application-dependent integrated circuit (ASIC), a programmable logic circuit (PLC) and / or any other circuit or processor capable of performing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer-readable medium, including, without limitation, a memory device and / or a memory device. Such instructions, when executed by the processor 132, cause the processor 132 to perform at least a portion of the functions described herein. The foregoing examples are exemplary only and are therefore not intended to in any way limit the definition and / or meaning of the term "processor".
    The memory 130 is one or more devices that allow information such as executable instructions and / or other data to be stored and retrieved. The memory 130 may include one or more computer readable media such as, without limitation, dynamic random access memory (DRAM), synchronous dynamic access memory (SDRAM), static random access memory (SRAM), a semiconductor memory disk, and / or a hard disk. The memory 130 may be configured to store, without limitation, executable instructions, operating systems, applications, resources, installation scripts, and / or any other types of data suitable for use with the method and system used herein.
    Operating system and application instructions are arranged in a functional form on the non-transitory memory 130 for execution by the processor 132 to perform one or more of the processes described herein. These instructions may be implemented in different implementations on different physical or physical computer-readable media, such as the memory 130 or other memory such as a computer-readable medium (not shown), which may include, without limitation, a flash drive and / or a memory stick , Furthermore, instructions may be arranged in a functional form on a non-transitory computer readable medium including, without limitation, a smart media (SM) memory, a compact flash (CF) memory, a secure digital (SD) memory, a memory stick (MS), a multimedia card (MMC) memory, an embedded multimedia card (e-MMC) and a micro-disk storage may have. The computer readable medium may optionally be insertable into and / or removable from the controller 128 to facilitate access and / or execution by the processor 132. In an alternative implementation, the computer readable medium is not removable.
    FIG. 1 is a perspective view of a boring tool 112 that may be used with the ECM system 100 (shown in FIG. 1) and FIG. 3 is a cross-sectional view of the boring tool 112. In the exemplary embodiment, the boring tool 112 includes a body portion 132 and a plurality of electrode pads connected thereto. Specifically, a front electrode 136 is connected to a tip 138 of the body portion 134, and at least one side electrode is connected to the body portion 134. For example, a first side electrode 140 is connected to a first side 142 of the body portion 134 and a second side electrode 144 is connected to a second side 146 of the body portion 134. The front electrode 136 is oriented on the body portion 134 such that material oriented in a first direction 148 from the body portion 134 is removed from the conductive workpiece 102 (shown in FIG. 1) when an electrical current is applied to the front body Electrode 136 is supplied. The removal of the material oriented in the first direction 148 from the body portion 134 allows the drilling tool 112 to move in a forward direction along the tool path. In addition, the at least one lateral electrode is oriented on the body portion 134 such that the material oriented in a second direction 150 from the body portion 134 is removed from the conductive workpiece 102 when an electrical current is supplied to the at least one lateral electrode. The removal of material oriented in the second direction 150 from the body portion 134 allows the tool pulling path of the drilling tool 112 to be changed in its direction. As such, the wellbore 118 (shown in FIG. 1) formed by the boring tool 112 advancing within the conductive workpiece 102 has a variable geometry. In addition, it should be understood that any number of side electrodes that allow the boring tool 112 to operate as described herein while shown as having first and second side electrodes 140 and 144 may be used. In addition, the plurality of electrodes may each be connected to an independent power source so that material from each electrode may be removed at different rates. In one embodiment, the power source 110 has a plurality of channels that may be used to independently power the front electrode and the at least one side electrode. The power source 110 is capable of providing a constant current or may pulsate in a one-off-off or a high-current, then-low-current manner.
    The drilling tool 112 also has a plurality of bus lines for connecting the electrode pads to the power source 110 (shown in FIG. 1). More specifically, a first bus line 152 electrically connects the front electrode 136 to the power source 110, a second bus line 154 electrically connects the first side electrode 140 to the power source 110, and a third bus line 156 electrically connects the second side electrode 144 to the power source 110. As such As will be described in more detail below, the front electrode 136 and the first and second side electrodes 140 and 144 are selectively and independently operable to form the wellbore 118 having a variable geometry that extends through the conductive workpiece 102 when Material is removed from it.
    In the exemplary embodiment, the boring tool 112 includes a spacer 158 disposed between the front electrode 136 and the first and second side electrodes 140 and 144. Spacer 158 electrically isolates front electrode 13 from first and second side electrodes 140 and 144. In addition, a gap 160 is formed between adjacent side electrodes when more than one side electrode is connected to body portion 134. As such, the electrode pads are electrically isolated from each other to facilitate limiting the formation of electrical short circuits.
    The drilling tool 112 also includes a non-conductive buffer 162 connected to the body portion 134. The non-conductive buffer 162 may be made of any material that allows the boring tool 112 to operate as described herein. For example, in one embodiment, the non-conductive buffer 162 is made of a non-conductive polymeric material. The non-conductive buffer 162 extends a greater distance from the body portion 134 than the first and second side electrodes 140 and 144. As such, the non-conductive buffer 162 spaces the first and second side electrodes 140 and 144 from the sidewalls of the wellbore 118 to permit the limitation of the formation of electrical short circuits between the first and second side electrodes 140 and 144 and the conductive workpiece 102.
    In addition, the drilling tool 112 includes a flexible guide member 164 which is connected to the body portion 134. The flexible guide member 164 allows the drilling tool 112 to pass through the borehole 118 extending through the conductive workpiece 102. As described above, the electrode pads of the drilling tool 112 are selectively operable such that the bore 118 extends through the conductive workpiece 102 with a variable geometry. As such, forming the flexible guide member 164 from a flexible material allows the boring tool 112 to be maneuvered along a variable geometry toolpath within the conductive workpiece 102. Exemplary flexible materials include, but are not limited to, rubber, silicone, nylon, polyurethane and latex. In addition, in some embodiments, the flexible material is coated with a layer of copper to form an electrical lead along the guide member 164.
    Referring to Fig. 3, a central purge passage 166 extends through the flexible guide member 164 and the body portion 134. The central purge passage 166 is sized to provide a flow of electrolytic fluid 109 (shown in Fig. 1) therethrough for purge lead material removed from the conductive workpiece 102 from the wellbore 118. More specifically, the front electrode 136 includes at least one purging port 168 formed therein. The purge port 168 connects the central purge passage 166 into flow communication with the conductive workpiece 102. As such, electrolytic fluid 109, which is directed through the central purge passage 166, is delivered from the purge port 168 to purge material that has been removed from the conductive workpiece 102 ,
    In operation, the controller 128 directs the inspection device 122 to perform an inspection of the conductive workpiece 102 prior to drilling. The pre-drilling inspection allows the dimensions of the conductive workpiece 102 to be compared to dimensions of a virtual conductive workpiece (that is, a CAD drawing of a nominal conductive workpiece 102). In the exemplary embodiment, the virtual conductive workpiece has a plurality of desired tool paths that correspond to toolpaths for forming the boreholes 118 with the boring tool 112 in the conductive workpiece 102. Inherent dimensional deviations between the conductive workpiece 102 and the virtual conductive workpiece cause the desired toolpath to be changed before being performed by the boring tool 112 to ensure that the boreholes 118 formed in the conductive workpiece 102 are maintained within the dimensional tolerances. As such, the controller 128 determines deviations in the dimensions of the conductive workpiece 102 relative to dimensions of the virtual conductive workpiece and alters the desired toolpath based on the deviations in the conductive workpiece 102. The altered desired toolpaths are then performed by the boring tool 112 ,
    More particularly, in one embodiment, the controller 128 directs the robotic device 120 to advance the drilling tool 112 within the conductive workpiece 102 along a current tool path to form the wellbore 118. The controller 128 then directs the inspection device 122 to perform an inspection of the conductive workpiece 102 to determine a position of the boring tool 112 along the toolpath, compares the toolpath to the corresponding modified target toolpath, and determines a position error of the boring tool 112. The position error is defined by a difference between the position of the drilling tool 112 compared to a theoretical position of the drilling tool 112 along the correspondingly modified target tool path. Alternatively, the controller 128 directs the robotic device 120 to advance the drilling tool 112 along any tool path. In addition, alternatively, the drilling tool 112 is manually advanced along a toolpath.
    In some embodiments, the controller 128 performs a corrective action to reduce the position error by modifying at least one drilling parameter when the position error is greater than a first predetermined threshold. Exemplary drilling parameters include an amount of electric current supplied to the plurality of electrode arrays, an alignment of the drilling tool 112 within the wellbore 118, a scavenging pressure of the electrolytic fluid passing through the central scavenging passage 166 of the drilling tool 112, and a feed rate of the drilling tool 112, which moves forward within the wellbore 118. As such, the controller 128 performs corrective actions by modifying at least one of the drilling parameters for the drilling tool 112 if the position error is greater than the first predetermined threshold.
    In one embodiment, the controller 128 selects which drilling parameter to modify or modifies a drilling parameter by a certain amount based on an amount by which the position error is greater than the first predetermined threshold. For example, the controller 128 performs a small corrective action if the position error is greater than the first predetermined threshold and less than a second predetermined threshold greater than the first predetermined threshold. An exemplary small corrective action includes controlling the power source 110 to supply varying amounts of electrical current to the electrode pads so that the material oriented in the first and second directions 148 and 150 from the conductive workpiece 102 is removed at different rates becomes. An alternative small corrective action includes controlling the power source 110 to supply a first electrical current to the front electrode 136 at a first time and controlling the power source 110 to supply a second electrical current to the at least one side electrode at a second time. which does not overlap with the first time. In an alternative embodiment, the controller controls the power source 110 to supply electrical power to the electrode pads so that cavities or swirls (i.e., a rectangular waveform) are formed in the wellbore 118.
    In addition, for example, the controller 128 performs an average corrective action when the position error is greater than the first predetermined threshold and less than a third predetermined threshold greater than the second predetermined threshold. An exemplary average corrective action includes controlling the power source 110 to stop supplying electrical power to one or more of the electrode pads. An alternative median correction action includes controlling the robotic device 120 to change the orientation of the drilling tool 112 within the wellbore 118.As such, performing average correction actions allows for correcting positional errors of the drilling tool 112 to a greater degree compared to a small corrective action.
    Any combination of small and medium correction actions may be implemented in a coded manner to facilitate advancing the drilling tool 112 along a tool path.
    In some embodiments, the controller 128 terminates operation of the drilling tool 112 if the position error is greater than a fourth predetermined threshold greater than the third predetermined threshold. In such an embodiment, the small and medium correction actions have been unable to return the position error to acceptable tolerances so that terminating the operation of the drilling tool 112 ensures that further deviations from a modified desired tool path are terminated.
    In addition, in some embodiments, the controller 128 receives an ion concentration measurement of the electrolytic fluid dispensed from the wellbore 118, as measured by an ion sensor 124. The controller 128 then determines the chemical composition of the electrolytic fluid based on the ion concentration in the electrolytic fluid. As described above, determining the chemical composition of the electrolytic fluid allows the health or operating status of the drilling tool 112 to be determined. For example, the controller 128 detects when a concentration of ions from the electrode field material measured in the electrolytic fluid has increased. is greater than a threshold. If so, an electrical short may have occurred and the controller 128 stops operating the drilling tool 112.
    FIG. 4 is a flowchart of an exemplary method of processing a conductive workpiece 102 (shown in FIG. 1). As described above, the conductive workpiece 102 is inspected either continuously or at predetermined intervals to detect a positional error of the boring tool 112 (shown in FIG. 1). The controller 128 (shown in FIG. 1) then performs one or more corrective actions to ensure that the toolpath is properly executed. As shown in FIG. 4, this is the process of executing the tool path, inspecting the conductive workpiece 102, determining the position error, and performing corrective actions in a continuous cycle. As such, in one embodiment, the boring tool 112 is advanced along the tool path until it has been completed.
    FIG. 5 is a perspective view of an alternative drilling tool 170 that may be used with the electrochemical machining system 100 (shown in FIG. 1). In the exemplary embodiment, the drilling tool 170 includes a body portion 134 and a plurality of electrode pads connected thereto. Specifically, a front electrode 172 is connected to the body portion 134, and at least one side electrode is connected to the body portion 134. The front electrode 172 has a "cylinder hat" shape with an outer radial portion 174 connected to the body portion 134 and an inner radial portion 176 extending from a front surface 178 of the outer radial portion 174. In addition, purge passage 166 extends through outer and inner radial sections 174 and 176 to facilitate directing fluid to conductive workpiece 102.
    The drilling tool 170 also includes a non-conductive buffer 180 positioned radially outward of the outer radial portion 174 of the front electrode 172. The non-conductive buffer 180 extends circumferentially about the outer radial portion 174 and at least a portion of the non-conductive buffer 180 extends in the first forward direction 148 beyond the front surface 178 of the outer radial portion 174. As such, when an electrical current is supplied to the front electrode 172, an electric field formed thereby is forced to go around the non-conductive buffer before contacting the sidewalls of the wellbore 118 (shown in FIG. 1) Balancing the Abtragsrate of material from the conductive workpiece 102, which is located closest to the outermost portions of the outer radial portion 174 allows.
    In addition, the inner radial portion 176 projecting from the front surface 178 in the direction 184 extends within the range of influence of the electric field generated by the front electrode 172 in the forward direction as compared to a flat electrode having a comparable amount thereof electric current. The stretching in the area of influence of the electric field generated by the front electrode 172 allows increased material removal from the conductive workpiece 102 without having to increase an amount of the electric current supplied to the front electrode 172. In addition, the presence of an outermost portion of the radially inner portion 176 disposed radially inward of the outer radial portion 174 allows the contact between the front electrode 172 and the conductive workpiece 102 to be reduced as the wellbore 118 curves within the conductive workpiece 102 ,
    Fig. 6 is an illustration of a portion of a drilling tool 170 (shown in Fig. 5) taken along line 6-6. In the exemplary implementation, the drilling tool 170 includes a side electrode assembly 182 connected to the body portion 134 (shown in FIG. 5). The side electrode assembly 182 includes a plurality of side electrodes 184 that are spaced apart and circumferentially disposed about the side electrode assembly 182. Specifically, the side electrode assembly 182 also includes a non-conductive spacer 186 extending between adjacent side electrodes 184 that electrically isolates the side electrodes 184 from each other. In addition, the side electrodes 184, like the side electrodes 140, are independently and selectively operable with each other so that the bore 118 formed in the conductive workpiece 102 (shown in FIG. 1, respectively) has a variable geometry.
    The systems and methods described herein are for forming continuous variable geometry holes within a conductive workpiece. The system includes a multi-electrode field drilling tool that is capable of removing material from the conductive workpiece in more than one dimension. The system also includes an inspection device that provides real-time feedback on the position of the drilling tool within the conductive workpiece. The inspection device is connected to a control device which processes the real-time feedback and, in one embodiment, causes the drilling tool to execute a correction action.As such, the systems and methods described herein permit the formation of continuous and variable geometry wellbores within the conductive workpiece in an autonomous, accurate, and time-effective manner.
    As an exemplary technical effect of the electrochemical machining system and methods described herein, at least one of: (a) provides a drilling tool capable of forming bore holes within the variable geometry conductive workpiece; (b) providing real time position data of the drilling tool within the conductive workpiece; and (c) use the real-time position data to facilitate corrective actions for the drilling tool.
    Exemplary embodiments of the electrochemical machining system are described in detail above. The system is not limited to the specific embodiments described herein, but rather components of the systems and / or steps of the methods may be used independently and separately from other components and / or steps described herein. For example, the configuration of components described herein may also be used in combination with other methods, and is not limited to being practiced only with gas turbine components and associated methods as described herein. Rather, the exemplary embodiment may be implemented and used in conjunction with many applications where the image of wellbores within a conductive workpiece is desired.
    Although specific features of various embodiments of the present disclosure are shown in some drawings and not in others, this is for convenience only. In accordance with the principles of embodiments of the present disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of another drawing.
    Some embodiments involve the use of one or more electronic devices or computing devices. Such devices typically include a processor, processing device or controller, such as a Universal Central Processing Unit (CPU), graphics processing unit (GPU), microcontroller, reduced instruction set (RISC) processor, application specific integrated circuit (ASIC), programmable Logic Circuit (PLC), a Field Programmable Gate Array (FPGA), a Digital Signal Processor (DSP), and / or any other circuitry or other processing device capable of performing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium including, without limitation, a memory device and / or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. The foregoing examples are exemplary only and therefore not intended to limit in any way the definition and / or meaning of the term processor and processor device.
    The written description uses examples to disclose the embodiments of the present disclosure, including the preferred embodiment, and also to enable any person skilled in the art to practice the embodiments of the present disclosure, including the manufacture and use of any devices or Systems and performing any procedures involved. The patentable scope of the embodiments described herein is defined by the claims, and may include other examples that will become apparent to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
    An electrochemical machining system 100 for machining a conductive workpiece 102 is provided. The system includes a drilling tool 112 configured to remove material from the conductive workpiece 102. The boring tool 112 is configured to advance within the conductive workpiece 102 along a tool path to form a borehole 118 that extends through the conductive workpiece 102 in more than one dimension as the material is removed therefrom. The system also includes an inspection device 122 configured to determine a position of the drilling tool 112 along the tool path and a controller 128 configured to communicate with the inspection device 182. The controller 128 is configured to compare the toolpath with a desired toolpath and to determine a positional error of the boring tool 112, the positional error being a difference between the toolpath and the desired toolpath.
    LIST OF REFERENCE NUMBERS
    [0069]<Tb> ECM system <September> 100<tb> Conductive Workpiece <SEP> 102<Tb> mounting platform <September> 104<Tb> electrolyte container <September> 106<Tb> flow control device <September> 108<tb> Electrolytic Fluid <SEP> 109<Tb> source of energy <September> 110<Tb> drill <September> 112<Tb> Pump <September> 114<Tb> fluid supply line <September> 116<Tb> hole <September> 118<Tb> robotic device <September> 120<Tb> inspection device <September> 122<Tb> ion sensor <September> 124<Tb> outlet <September> 126<Tb> controller <September> 128<Tb> memory <September> 130<Tb> processor <September> 132<Tb> In the <September> 134<tb> Front Electrode <SEP> 136<Tb> peak <September> 138<tb> First side electrode <SEP> 140<tb> First Page <SEP> 142<tb> Second side electrode <SEP> 144<tb> Second Page <SEP> 146<tb> First Direction <SEP> 148<tb> Second direction <SEP> 150<tb> First bus line <SEP> 152<tb> Second bus line <SEP> 154<tb> Third Bus Line <SEP> 156<Tb> spacer <September> 158<Tb> space <September> 160<tb> Non-conductive buffer <SEP> 162<tb> Flexible Guide <SEP> 164<tb> Central Purge Channel <SEP> 166<Tb> flush port <September> 168<Tb> drill <September> 170<tb> Front Electrode <SEP> 172<tb> Outer radial section <SEP> 174<tb> Inner radial section <SEP> 176<tb> Front surface <SEP> 178<tb> Non-conductive buffer <SEP> 180<Tb> side electrode array <September> 182<tb> Lateral Electrodes <SEP> 184
    权利要求:
    Claims (12)
    [1]
    An electrochemical machining system for machining a conductive workpiece, the system comprising:a drilling tool configured to remove material from a conductive workpiece, wherein the drilling tool is configured to advance within the conductive workpiece along a tool path to form a variable geometry wellbore extending through the conductive workpiece Workpiece extends when the material is removed therefrom;an inspection device configured to determine a position of the drilling tool along the tool path; anda control device which is set up to communicate with the inspection device, wherein the control device is additionally configured to:compare the toolpath with a desired toolpath; anddetermine a position error of the drilling tool, wherein the position error is defined by a difference between the tool path and the target tool path.
    [2]
    2. The system of claim 1, wherein the inspection device is configured to perform an inspection of the conductive workpiece prior to drilling to determine its dimensions, wherein the controller is further configured to provide a modified target toolpath based on dimensional deviations of the conductive workpiece compared to the dimensions of a virtual conductive workpiece.
    [3]
    The system of claim 1 or 2, further comprising a flow control device configured to direct a flow of electrolytic fluid through a central purge passage extending through the drilling tool such that the flow of electrolytic fluid to the conductive workpiece is in is discharged down the borehole.
    [4]
    4. The system of claim 3, further comprising an ion sensor configured to measure an ion concentration in the electrolytic fluid dispensed from the wellbore.
    [5]
    A system according to any one of the preceding claims, further comprising robotic means connected to the drilling tool;wherein the robotic device is configured to advance the drilling tool along the tool path and / or wherein the robotic device is configured to communicate with the control device, the robotic device being further adapted to align the drilling tool within the borehole based on the position error of the boring tool To change the drilling tool.
    [6]
    6. A method of processing a conductive workpiece, the method comprising:Advancing a drilling tool within the conductive workpiece along a tool path to form a variable geometry wellbore extending through the conductive workpiece when the material is removed therefrom, the drilling tool having a plurality of electrode arrays;Performing an inspection of the conductive workpiece to determine a position of the drilling tool along the tool path; andDetermining a positional error of the drilling tool, wherein the position error is defined by a difference between the position of the drilling tool compared to a theoretical position of the drilling tool along a desired tool path.
    [7]
    The method of claim 6, further comprising:Performing an inspection of the conductive workpiece prior to drilling;Determining deviations in the dimensions of the conductive workpiece as compared to dimensions of a virtual conductive workpiece; andModifying the desired toolpath based on the deviations in the conductive workpiece.
    [8]
    The method of claim 6 or 7, further comprising performing a correction operation to reduce the position error when the position error is greater than a first predetermined threshold.
    [9]
    9. The method of claim 8, wherein completing a correction operation comprises modifying at least one drilling parameter, including an amount of electrical current supplied to the plurality of electrode arrays and / or an alignment of the drilling tool within the wellbore and / or a purge pressure of electrolytic fluid passed through the drilling tool and / or includes a feed rate of the drilling tool that moves forward within the wellbore.
    [10]
    The method of claim 8 or 9, further comprising performing a small correction operation if the position error is greater than a first predetermined threshold and less than a second predetermined threshold greater than the first predetermined threshold; orcompleting an average correction operation if the position error is greater than the second predetermined threshold and less than a third predetermined threshold greater than the second predetermined threshold; orterminating the operation of the drilling tool if the position error is greater than a fourth predetermined threshold greater than the third predetermined threshold.
    [11]
    11. The method according to any one of claims 6 to 10, further comprising:Dispensing a flow of electrolytic fluid to the conductive workpiece within the wellbore, the flow of electrolytic fluid being directed through a central irrigation channel extending through the drilling tool;Measuring an ion concentration in the electrolytic fluid discharged from the wellbore; andDetermining a chemical composition of the electrolytic fluid based on the ion concentration in the electrolytic fluid.
    [12]
    12. One or more non-transitory computer-readable storage media having computer-executable instructions embodied thereon for use in processing a conductive workpiece, wherein the computer-executable instructions, when executed by a controller, cause the controller to:Controlling a robotic device to advance a drilling tool within the conductive workpiece along a tool path to form a variable geometry wellbore extending through the conductive workpiece when the material is removed therefrom, the drilling tool having a plurality of electrode arrays;Controlling an inspection device to perform an inspection of the conductive workpiece to determine a position of the drilling tool along the tool path; andDetermining a positional error of the drilling tool, wherein the position error is defined by a difference between the position of the drilling tool compared to a theoretical position of the drilling tool along a desired tool path.
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    同族专利:
    公开号 | 公开日
    DE102016113059A1|2017-02-02|
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    US9943921B2|2018-04-17|
    JP2017030143A|2017-02-09|
    CN106392215A|2017-02-15|
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    2019-11-15| AZW| Rejection (application)|
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    US14/814,259|US9943921B2|2015-07-30|2015-07-30|Electrochemical machining system and method of machining a conductive work piece|
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