Towards an autonomous maintenance, repair and overhaul process

Denkena, Berend; Nyhuis, Peter; Bergmann, Benjamin; Nübel, Nicolas; Lucht, Torben

doi:10.1016/j.promfg.2020.02.014

Cited by 10 publications

(3 citation statements)

References 9 publications

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“…On the shop floor, these steps are still characterised by lots of manual work. Consequently, the success of repair depends on the training and experience of the individual employee as well as his or her subjective assessment of the component condition [5]. Although automated blade repair has been approached in research (e.g., [6][7][8][9]), it has not been implemented on a large scale yet.…”

Section: Introductionmentioning

confidence: 99%

“…The interaction of production processes with the associated virtual process planning and evaluation processes is investigated in a real manufacturing environment. In order to ensure consistent data management along the process chain and, in particular, to guarantee the exchange of data between the manufacturing and simulation environments, a virtual workpiece twin was developed that carries all the workpiece-related data [5].…”

Section: Introductionmentioning

confidence: 99%

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Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

Denkena

Bergmann

Schumacher

2021

JMMP

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Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. Shape deviations often result from the deflection of tool and workpiece due to process forces. Considering the individuality of repair cases, compensation of those deflections by process force measurement and online tool path adaption is a very suitable method. However, there is one caveat to this reactive approach. Due to causality, a corrective movement, following a force variation, is always delayed by a finite reaction time. At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. To overcome those limitations and to improve compensation beyond the reduction of control delays, this study proposes a novel approach of anticipatory online compensation. Flank-milling experiments with abrupt changes in the tool-workpiece engagement conditions are conducted to investigate the limitations of reactive compensation and to explore the potential of the new anticipatory approach.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

Denkena

Bergmann

Schumacher

2021

JMMP

Self Cite

View full text Add to dashboard Cite

show abstract

“…Hence, these methods are exemplified using the V2500-A1, a mature high-bypass turbofan jet engine operated by the Institute of Jet Propulsion and Turbomachinery (IFAS) (Spuhler et al, 2019). In the CRC 871, the full regeneration process is formed by a real and a virtual repair process (Denkena et al, 2019). Therefore, many sub projects are working together to produce a digital twin of a turbofan jet engine to analyse the impact of deteriorated components on the overall performance, aerodynamics, aeroelastics, and structural dynamics for the virtual repair process (Schwerdt et al, 2019;Goeing et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

Influence of combined compressor and turbine deterioration on the overall performance of a jet engine using RANS simulation and Pseudo Bond Graph approach

Goeing

Seehausen

Pak

et al. 2020

J. Glob. Power Propuls. Soc.

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In this study, numerical models are used to analyse the influence of isolated component deterioration as well as the combination of miscellaneous deteriorated components on the transient performance of a high-bypass jet engine. For this purpose, the aerodynamic impact of major degradation effects in a high-pressure compressor (HPC) and turbine (HPT) is modelled and simulated by using 3D CFD (Computational Fluid Dynamics). The impact on overall jet engine performance is then modelled using an 1D Reduced Order Model (ROM). Initially, the HPC performance is investigated with a typical level of roughness on vanes and blades and the HPT performance with an increasing tip clearance. Subsequently, the overall performance of the jet engines with the isolated and combined deteriorated domains is computed by the in-house 1D performance tool ASTOR (AircraftEngine Simulation for Transient Operation Research). Degradations have a significant influence on the system stability and transient effects. In ASTOR, a system of differential equations including the equations of motion and further ordinary differential equations is solved. Compared to common ROMs, this enables a higher degree of accuracy. The results of temperature downstream of the high-pressure compressor and low-pressure turbine as well as the specific fuel composition and the HP rotational speed are used to estimate the degree and type of engine deterioration. However, the consideration of the system stability is necessary to analyse the characterisation in more detail. Finally, a simplified model which merges two engines with individual deteriorated domains into one combined deteriorated engine, is proposed. The simplified model predicts the performance of an engine which has been simulated with combined deteriorated components.

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Können wir das nicht reparieren? – Entwicklung eines Klassifikationsrahmens für den Einsatz von Additive Repair im Maschinen- und Anlagenbau

Brinker

Bertke

Ganter

et al. 2021

Konstruktion Für Die Additive Fertigung 2020

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Towards an autonomous maintenance, repair and overhaul process

Cited by 10 publications

References 9 publications

Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

Influence of combined compressor and turbine deterioration on the overall performance of a jet engine using RANS simulation and Pseudo Bond Graph approach

Können wir das nicht reparieren? – Entwicklung eines Klassifikationsrahmens für den Einsatz von Additive Repair im Maschinen- und Anlagenbau

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