Research
System Demonstrator

Subproject S System Demonstrator

The system demonstrator summarizes the researched technologies in a real process chain. Aim is to demonstrate the feasibility of condition-based regeneration of complex capital goods. Furthermore, the system serves as a platform for the application-oriented transfer of the technologies into the industry.

MOTIVATION AND OBJECTIVES

Vision of the system demonstrator

Within the Collaborative Research Centre (CRC) 871 a novel approach for the regeneration of complex capital goods was developed. A combination of virtual and real repair process was designed based on the example of the aircraft engine and in particular the turbine blade, in order to make rule-based decisions about the type and necessity of a repair based on a condition-based function quantification. The functional analysis in the virtual process enables an assessment of the service life of the component on the one hand and its influence on the performance on the other. On the basis of this information, the best possible path is then virtually evaluated, taking into account special customer requirements, and then executed using newly developed repair technologies. This innovative approach uses methods (e.g. numerical simulations of components and manufacturing processes) that are traditionally only used in product and manufacturing development and transfers them to the regeneration of complex capital goods for a model- or fact-based decision. In order to experience the benefits of linking virtual and real repair processes in their complexity as examples, guests from industry and research will be able to personally experience this from November 2020.

Animated preview of the system demonstrator

RESULTS

In order to consider the feasibility of an automated repair process for turbine blades not only theoretically, a system demonstrator will be set up in this subproject. In this demonstrator, all technologies for regeneration will be combined as a "proof-of-concept" and then presented to interested parties from industry and research. The regeneration process begins with the dismantling, followed by the condition assessment, the technical simulation and the economic evaluation up to the execution of the repair and the subsequent quality assurance. In addition to demonstrating the research content of the repair process, the focus is on investigating the interactions of the individual repair steps by implementing a consistent data and material flow. The aim is to further coordinate and develop the individual processes and networking. The findings and processes are not only limited to turbine blades, but can also be transferred to other complex capital goods such as stationary gas turbines or wind turbines.

Automatic damage characterization as basis for the selection of the regeneration path

CURRENT RESEARCH AND OUTLOOK

 

The system demonstrator is currently being set up at the LUH's Technical Production Centre. Current work steps are the elaboration and implementation of the consistent data flow as well as the detailed planning of the plant concept. From 2019, the construction of the individual process cells, including the commissioning of subsystems, will begin. The entire plant will be operational at the beginning of 2020 so that the continuous regeneration process can be set up. To experience the system in person, be our guest at the demonstrations from November 2020. In the meantime, Mr. Nicolas Nübel will be happy to answer any further questions you may have.

Example of four possible regeneration paths

SUBPROJECT LEADER

Prof. Dr.-Ing. Berend Denkena
Address
An der Universität 2
30823 Garbsen
Building
Room
113
Address
An der Universität 2
30823 Garbsen
Building
Room
113
Prof. Dr.-Ing. Jörg Seume
Address
Appelstraße 9
30167 Hannover
Address
Appelstraße 9
30167 Hannover

STAFF

M. Sc. Nicolas Nübel