Patents by Inventor Steven Robert Hayashi
Steven Robert Hayashi has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11702948Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: GrantFiled: November 1, 2021Date of Patent: July 18, 2023Assignee: General Electric CompanyInventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Patent number: 11483002Abstract: A multi-loop controller component for an electric discharge machining (EDM) system includes a plurality of power loop circuits coupled to an output of a power supply of the EDM system and configured to receive DC electric power from the power supply. Each power loop circuits electrically-isolated from other power loop circuits. The multi-loop controller component also includes a plurality of transistors. Each transistor is coupled to a respective power loop circuit and is configured to switch between an ON state and an OFF state to generate a pulse of the DC electric power through the respective power loop circuit. In addition, the multi-loop controller component has a drive controller coupled to the plurality of transistors. The drive controller is configured to transmit at least one control signal to at least one of the transistors to facilitate switching the transistor between the ON state and the OFF state.Type: GrantFiled: February 23, 2017Date of Patent: October 25, 2022Assignee: General Electric CompanyInventors: Yuanfeng Luo, Yuefeng Luo, Dale Robert Lombardo, Steven Robert Hayashi
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Patent number: 11420288Abstract: A laser machining method includes directing, from an F-theta lens having a long focal length of greater than about 250 millimeters, a laser beam at a non-perpendicular beam tilt angle from an optical axis of the lens having a top-hat profile and a narrow beam divergence angle of between about 1 degree and about 3 degrees towards a workpiece on a stage movable in at least an X-direction and a Y-direction, engaging the directed laser beam with the workpiece disposed in the usable field of view, moving the workpiece and the directed laser beam relative to each other, and removing portions of the workpiece with the directed laser beam to define a machined surface.Type: GrantFiled: May 30, 2019Date of Patent: August 23, 2022Assignee: GENERAL ELECTRIC COMPANYInventors: Hongqiang Chen, Steven Robert Hayashi, Xi Zhang
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Publication number: 20220056809Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: ApplicationFiled: November 1, 2021Publication date: February 24, 2022Inventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Patent number: 11161190Abstract: An electroerosion machining system for trepanning and drilling operations is disclosed. The electroerosion machining system includes an electrode assembly configured to machine a desired configuration in a workpiece, a power supply configured to energize the electrode assembly and the workpiece to opposite electrical polarities, an electrolyte supply configured to pass an electrolyte between the electrode assembly and the workpiece, a working apparatus configured to move the electrode assembly relative to the workpiece, and a control system to control the power supply and the working apparatus. The electrode assembly further includes an electrode body in the form of a tube-shaped body, the tube-shaped body defining a hollow interior and one or more replaceable inserts affixed to the electrode body at a working end thereof positioned adjacent the workpiece, the one or more replaceable inserts constructed so as to be selectively attachable and detachable from the working end of the electrode body.Type: GrantFiled: May 28, 2015Date of Patent: November 2, 2021Assignee: General Electric CompanyInventors: Yuanfeng Luo, Steven Robert Hayashi, Andrew Lee Trimmer, Dale Robert Lombardo, John Anthony Vogel
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Patent number: 11014178Abstract: An electrical machining method comprises machining a workpiece by an electrical machining device comprising an electrode; increasing a feedrate of the electrode at a first acceleration if a discharge current passing through the electrode and the workpiece is lower than a discharge current reference; and decreasing the feedrate of the electrode at a second acceleration if the discharge current is higher than the discharge current reference, wherein the second acceleration has an absolute value higher than that of the first acceleration.Type: GrantFiled: July 25, 2017Date of Patent: May 25, 2021Assignee: GENERAL ELECTRIC COMPANYInventors: Dong Liu, Andrew Lee Trimmer, Yuanfeng Luo, Steven Robert Hayashi
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Patent number: 10682715Abstract: A method for electroerosion machining includes providing an electrode assembly comprising an electrode body having a tube-shaped body that defines a hollow interior and one or more inserts affixed to the electrode body to form a cutting surface on the electrode assembly, positioning the electrode assembly adjacent a workpiece to be machined, and providing power to the electrode assembly so as to energize the electrode assembly, with the electrode assembly and the workpiece being at opposite electrical polarities. The method also includes advancing the electrode assembly through the workpiece, with a working gap being maintained between the inserts and the workpiece across which a pulse electric current is passed to remove material from the workpiece, wherein, upon advancing the electrode assembly through the workpiece, a core is formed that is completely separated from a remainder of the workpiece and is contained within the hollow interior of the electrode body.Type: GrantFiled: May 28, 2015Date of Patent: June 16, 2020Assignee: General Electric CompanyInventors: Yuanfeng Luo, Steven Robert Hayashi, Andrew Lee Trimmer, Dale Robert Lombardo, John Anthony Vogel
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Publication number: 20200122255Abstract: An electrode for use in an electromachining system includes a base and an outer rim extending circumferentially about the base. The electrode also includes a body extending between the base and the outer rim. The body defines a concave surface. The electrode is configured to discharge electrical arcs from the concave surface when electrical current is provided to the electrode.Type: ApplicationFiled: February 8, 2017Publication date: April 23, 2020Inventors: Yuanfeng Luo, Dong Liu, Andrew Lee Trimmer, Steven Robert Hayashi
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Patent number: 10603731Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.Type: GrantFiled: November 25, 2015Date of Patent: March 31, 2020Assignee: General Electric CompanyInventors: Yuanfeng Luo, Steven Robert Hayashi, Adegboyega Masud Makinde, Andrew Lee Trimmer
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Publication number: 20190284947Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: ApplicationFiled: March 14, 2018Publication date: September 19, 2019Inventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Publication number: 20190275609Abstract: A laser machining method includes directing, from an F-theta lens having a long focal length of greater than about 250 millimeters, a laser beam at a non-perpendicular beam tilt angle from an optical axis of the lens having a top-hat profile and a narrow beam divergence angle of between about 1 degree and about 3 degrees towards a workpiece on a stage movable in at least an X-direction and a Y-direction, engaging the directed laser beam with the workpiece disposed in the usable field of view, moving the workpiece and the directed laser beam relative to each other, and removing portions of the workpiece with the directed laser beam to define a machined surface.Type: ApplicationFiled: May 30, 2019Publication date: September 12, 2019Inventors: Hongqiang Chen, Steven Robert Hayashi, Xi Zhang
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Patent number: 10376985Abstract: A method for shaping a ceramic matrix composite (CMC) sheet having a first surface and a second surface is presented. The method includes receiving an input signal representative of a predetermined shape and a type of the CMC sheet. Further, the method includes selecting a laser beam based on the received input signal. Also, the method includes projecting the selected laser beam on the CMC sheet to shape the CMC sheet into the predetermined shape.Type: GrantFiled: December 18, 2015Date of Patent: August 13, 2019Assignee: GENERAL ELECTRIC COMPANYInventors: Hongqiang Chen, Steven Robert Hayashi, Martin Kin-Fei Lee, Nitin Garg, Nolan Leander Cousineau, Derrick Wayne Knotts
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Patent number: 10357848Abstract: A laser machining method includes directing, from an F-theta lens having a long focal length of greater than about 250 millimeters, a laser beam at a non-perpendicular beam tilt angle from an optical axis of the lens having a top-hat profile and a narrow beam divergence angle of between about 1 degree and about 3 degrees towards a workpiece on a stage movable in at least an X-direction and a Y-direction, engaging the directed laser beam with the workpiece disposed in the usable field of view, moving the workpiece and the directed laser beam relative to each other, and removing portions of the workpiece with the directed laser beam to define a machined surface.Type: GrantFiled: January 19, 2015Date of Patent: July 23, 2019Assignee: General Electric CompanyInventors: Hongqiang Chen, Steven Robert Hayashi, Xi Zhang
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Patent number: 10222436Abstract: A gradient coil comprises a curved conductor, which is tubular and has a general spiral shape. The curved conductor is formed by a process comprising depositing at least one non-conductive material layer by layer to form a substrate, and coating at least a portion of a surface of the substrate with a conductive material. The substrate has a shape matching with the general spiral shape of the curved conductor. Embodiments of the present disclosure further refer to a method for manufacturing the gradient coil.Type: GrantFiled: August 26, 2016Date of Patent: March 5, 2019Assignee: GENERAL ELECTRIC COMPANYInventors: Yanzhe Yang, Steven Robert Hayashi, Kevin Warner Flanagan, Prabhjot Singh, Jian Lin, Jean-Baptiste Mathieu, Kenneth Paul Zarnock, Thomas Kwok-Fah Foo
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Patent number: 10118792Abstract: Unwinding systems and methods are provided for unwinding a fiber from a bobbin. The unwinding system can include an axle defining a first axis extending an axial direction, a bobbin rotatably mounted around the axle, a pulley positioned to receive the fiber from the bobbin, wherein the pulley is rotatable around a second axis, and a sensor positioned between the bobbin and the pulley. The bobbin is moveable along the axial direction, and wherein the fiber extends tangentially from a surface of the bobbin.Type: GrantFiled: August 3, 2016Date of Patent: November 6, 2018Assignee: General Electric CompanyInventors: Theodore Robert Grossman, Roger Antonio Aparicio, Martin Peter Gill, Steven Robert Hayashi, Andrew William Miller
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Publication number: 20180236579Abstract: A multi-loop controller component for an electric discharge machining (EDM) system includes a plurality of power loop circuits coupled to an output of a power supply of the EDM system and configured to receive DC electric power from the power supply. Each power loop circuitis electrically-isolated from other power loop circuits. The multi-loop controller component also includes a plurality of transistors. Each transistor is coupled to a respective power loop circuit and is configured to switch between an ON state and an OFF state to generate a pulse of the DC electric power through the respective power loop circuit. In addition, the multi-loop controller component has a drive controller coupled to the plurality of transistors. The drive controller is configured to transmit at least one control signal to at least one of the transistors to facilitate switching the transistor between the ON state and the OFF state.Type: ApplicationFiled: February 23, 2017Publication date: August 23, 2018Inventors: Yuanfeng Luo, Yuefeng Luo, Dale Robert Lombardo, Steven Robert Hayashi
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Publication number: 20180230062Abstract: Systems and methods for forming ceramic matrix composite (CMC) components are provided. The CMC component includes a reinforcement material having a plurality of filaments that are at least partially electrically conductive. The plurality of filaments are charged by a charging element with an electric charge of the same sign such that adjacent filaments are in an expanded spatial relationship relative to one another while being coated. While in the expanded spatial relationship, the filaments can also be pulled through a matrix slurry.Type: ApplicationFiled: February 13, 2017Publication date: August 16, 2018Inventors: Theodore Robert Grossman, James Scott Vartuli, Steven Robert Hayashi
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Patent number: 10046382Abstract: A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold.Type: GrantFiled: November 15, 2013Date of Patent: August 14, 2018Assignee: General Electric CompanyInventors: Qi Zhao, Steven Robert Hayashi, Brian Victor Moore, Daniel Tribeni Persaud, Michael Douglas Arnett, Junyoung Park
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Patent number: 10022812Abstract: A method of machining a work-piece formed of titanium-based material, using a machining apparatus, is described. The method includes the steps of providing an electrically-conductive electrode contained within a spindle assembly, in a pre-selected distance and position relative to the titanium-based work-piece; while electrically powering the electrode and the work-piece with a power supply. In the process, fluid electrolyte is circulated through at least two pathways in the machining apparatus—an internal conduit within the spindle assembly; and an external conduit. The charged electrode is moved relative to the work-piece in a plunging motion, to remove material from the work-piece at a relatively high rate, using a high-speed electro-erosion (HSEE) process.Type: GrantFiled: October 9, 2014Date of Patent: July 17, 2018Assignee: GENERAL ELECTRIC COMPANYInventors: Yuanfeng Luo, Steven Robert Hayashi, Andrew Lee Trimmer, Mark James Cintula
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Patent number: 9943921Abstract: An electrochemical machining system for machining a conductive work piece is provided. The system includes a drilling tool configured to remove material from the conductive work piece. The drilling tool is configured to advance within the conductive work piece along a tool path to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom. The system further 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 tool path to a nominal tool path, and determine a position error of said drilling tool, the position error defined by a difference between the tool path and the nominal tool path.Type: GrantFiled: July 30, 2015Date of Patent: April 17, 2018Assignee: GENERAL ELECTRIC COMPANYInventors: Andrew Lee Trimmer, Steven Robert Hayashi, Edward James Nieters, Jeremy Gordon McNamara