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SPARCL Laser Robotic Cell: Turbofan Engine Cleaning Procedure

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This document consolidates engine removal and cleaning steps, integrating a SPARCL.AI Gemini Robotics 2.0 horizontal spin‑platform cell. Each turbofan assembly (fan, compressor, turbine) is mounted on the rotating fixture and cleaned in situ by a robotic FeatherPulse laser head. 

1. Engine Removal & Preparation

  1. Hoisting the Turbofan Assembly

    • Use engine hoist to lift the cowled turbofan module from the pylon (Figure 1).

    • Secure on transport cart; remove inlet and exhaust cowls.

  2. Dismounting Accessory Gearbox & Lines

    • Disconnect fuel, oil, and pneumatic lines.

    • Unbolt accessory gearbox and tag all electrical connections.

  3. Final Demount

    • Lower assembly onto spin‑platform base; align forward (FWD) and inboard (INBD) axes.

 

2. Mounting on Horizontal Spin‑Platform

  1. Platform Fixturing (Figure 2)

    • Engage turbine hub via four‑jaw chuck; tighten to 200 Nm.

    • Engage fan hub similarly; confirm concentricity < 0.1 mm.

  2. Safety Interlocks

    • Close protective enclosure doors; verify door switches and E‑stop circuits.

    • Initialize inert‑gas purge and fume‑extraction systems.

 

3. Robotic Cell & Laser Initialization

  1. Vision Mapping

    • Activate 3D structured‑light scanner; capture blade and rib geometry.

    • Generate laser path: rib channels → platforms → blade surfaces → leading edges.

  2. Laser Parameter Setup

    • Select FP‑500r or FP‑1000r head: 500 W/1,000 W, 100 ns pulses.

    • Load SPARCL.AI recipe: low‑power (20 J/cm²) organics pass; high‑power (60 J/cm²) oxide pass.​

 

3. Spin & Focus Calibration

  • Spin platform at 5 RPM; focus galvo head to mid‑span of blades.

  • Verify spot size: 0.5 mm dia at working distance.

4. Laser Ablation Sequence

  1. Pass 1: Organic & Sealant Removal (Figure 3)

  • Power: 50 W; rep rate: 50 kHz; scan speed: 300 mm/s.

  • Sweep entire circumference for uniform polymer/grease ablation.

  1. Pass 2: Oxide & CMAS Spallation (Figure 4)

  • Power: 500 W; rep rate: 100 kHz; scan speed: 200 mm/s.

  • Target root and tip regions with 50% overlap; assist‑gas Argon at 2 bar.

  1. Pass 3: Surface Finishing

  • Power: 100 W; rep rate: 20 kHz; scan speed: 500 mm/s.

  • Final smoothing to < 1 µm Ra; cool blades with intermittent dwell.

 

5. Post‑Processing & Inspection

  1. Spin‑Stop & Extraction

  • Ramp down platform to zero; purge inert gas off; open enclosure.

  • Remove assembly; reinstall inlet/exhaust cowls.

  1. NDT & Surface Profiling (Figure 5)

  • Perform borescope inspection; use laser profilometry to confirm coating thickness and roughness.

  • Compare to baseline: HAZ < 100 µm; Ra < 1 µm.

  1. Reassembly

  • Reverse removal steps; torque per OEM specs; bleed and functional‑test engine.

Figures reference system schematics in the style of Boeing turbofan hoist graphics.

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