AROSATEC - Automated Repair and Overhaul System for Aero Turbine Engine Components
Overview
Background & policy context:
The maintenance, repair and overhaul (MRO) of aero engine components consists of a chain of different processes, e.g. inspection, de-coating/coating, welding, milling and polishing. Currently most of these processes are carried out manually. At present the supply industry is developing improved machining equipment to automate the individual process steps.
Nevertheless, the single repair processes remain separate and unconnected. For example, data acquired during the incoming inspection are put down on paper and are not available in electronic form for subsequent repair operations. Therefore, even though the single repair operations may be automated, it is also beneficial to improve the overall process by extending data flow and factory automation throughout the entire MRO chain.
AROSATEC was proposed in the 1st call of the 6th EC framework programme and addresses these issues.
Objectives:
The objectives of the project were:
- To improve existing repair methods by employing adaptive machining technology. The adaptive CNC technologies make use of the information provided by the data management system and compensate for the part-to-part variation of the complex components to be overhauled. The data flow between the adaptive repair steps optimises the single repair technologies as well as the efficiency and the flexibility of the entire chain of repair processes for aeroengine components.
- To develop a data management system which constituted the core of automated overhaul systems for aeroengine components. As part of this innovative data management solution, the single repair process modules are integrated to build an automated repair cell for aero engine components. Furthermore, it is possible to establish 'virtual' MRO workshops. The data management system generates a data set for each individual component and handles the logistics of the components and the accompanying data sets.
As a result, different MRO processes can be carried out at different facilities without loss of information, efficiency or quality. In addition, the approach described supports efficient life cycle monitoring.
Methodology:
The project activities have been grouped into six workpackages:
- Management (WP1), which carried out the general and administrative management of the activities, as well as those concerning the dissemination and exploitation;
- Specification (WP2), which analysed present and future requirements of the system, defined the standardisation of data structure, and tested the compatibility with end user systems;
- Process R&D (WP3), which optimised the necessary technologies (scanning, laser welding, milling, and adding adaptive machining technologies to laser welding and milling);
- Software R&D (WP4), which developed the structure of database, data flow, data distribution, process interfaces and management;
- Integration (WP5), which studied the technology and data integration;
- Testing & Demonstration (WP6), which tested and demonstrated the entire system.
In the first period, the project investigated the end user requirements. The repair processes to be incorporated in AROSATEC was defined, resulting in the detailed requirement specifications. These were analysed by the partners and compared to technologies already available. The gap between contemporary technology and requirements was defined for the development needs and goals for AROSATEC.
While setting up the detailed requirement specification, the improvement of the scanning process and the definition of the data-treatment optimisation was started. In the course of AROSATEC new scanners were tested and optimised, software interfaces were optimised and adapted to each process of the process chain. Additionally, the general layout of the data backbone was set up and the concept tested and verified.
The efforts was then dedicated to optimise the different repair steps, from scanning to laser welding and to adaptive machining. While scanning improvements can be made with the use of new, high accuracy scanners, welding demands sophisticated tooling, especially for complex geometries like on nozzle guide vanes, and intelligent welding strategies. This goal can be reached by adding adaptive technologies to the welding process.
A major problem for the adaptive machining was to fulfil the requirements of the MROs. All parts have to be processed in the given tolerance range although the geometry of each repair part is unique and not equal to the new part description. Additionally, the data backbone was developed and improved and all process steps were equip
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