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Automated Repair and Overhaul System for Aero Turbine Engine Components
Project no.: 502937, FP6, STREP, Priority: aeronautics and space
Project public website: www.arosatec.com

Project summary description and project objectives
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. Today 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, the data which are acquired during the incoming inspection are put down on paper and are not available in electronic form for subsequent repair operations. Even though the single repair operations may be automated, therefore, this does not improve the overall process by promoting data flow and factory automation throughout the entire MRO chain.

The first objective of the proposed project is 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 aero engine components.

The second objective of the proposed project is to develop a data management system which will constitute the core of automated overhaul systems for aero engine 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 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.

Contractors
1: BCT, Germany, Industry, SME
2: Alround, Germany, Other, Non-profit organisation
3: ISQ, Portugal, Other, Non-profit RTD organisation
4: Metris, Belgium, Industry, SME
5: MTU, Germany, Industry, Turbine maintenance industry
6: Sifco, Ireland, Industry, Turbine maintenance industry
7: Skytek, Ireland, Industry, SME

Coordinator contact details
Dr. Claus Bremer
BCT GmbH
Martin Schmeisser Weg 9
44227 Dortmund
Germany
Phone: +49-231-97 50 10-0
Fax: +49-231-97 50 10-99
Mobile: +49-172-231 8814
E-Mail: c.bremer@bct-online.de
Internet: www.bct-online.de

Project Duration
Start: 01.11.2003
End: 31.07.2006
Duration: 33 months