Shopfloor-Ready 3D Inspection for Engine Maintenance
As part of the ScanExpress project, MTU Aero Engines relies on the HP-FX system from 3D.aero to capture surface defects on engine components directly on the shopfloor with high 3D precision. The objective was to significantly accelerate inspection processes while simultaneously improving the quality of defect assessment.
Time-Consuming Assessment of Microscopic Defects
In engine maintenance, numerous surface anomalies must be evaluated on a daily basis. When potential damage was identified, the analysis was often carried out using manual impressions, which were then examined microscopically in a laboratory environment.
This process was time-consuming and resulted in delays of several days within the maintenance workflow.
Requirement for Precise Measurement in the Production Environment
The goal was to find a measurement method capable of reliably detecting even the smallest defects, easy to operate, and suitable for direct use on the shopfloor without laboratory evaluation. At the same time, the solution needed to deliver reproducible results and integrate seamlessly into existing processes.
Steven Piorun
MTU Specialist for Non-Destructive Testing
We realized that white light interferometry represents the most accurate, most versatile, and most scalable system in multiple directions — and that a solution from our cooperation partner 3D.aero in Hamburg could be a strong fit for the problem and the associated requirements.
Source: © MTU Aero Engines, Aeroreport "ScanExpress: Making 3D scans of defects in engine parts"
HP-FX as a Solution Based on White Light Interferometry
HP-FX is a robot-assisted 3D measurement system based on white light interferometry. The technology enables µm-accurate surface measurements and the generation of high-resolution 3D datasets from real component geometries.
Precise 3D Data Independent of Material Properties
During measurement, the light reflected from the component surface overlaps with light reflected from a reference mirror. These interference effects generate a digital point cloud that accurately represents the real surface.
A key advantage for engine maintenance is the system’s insensitivity to reflective materials, which are commonly found on metallic surfaces.
Flexible Operation with Cobot and Intuitive Software
HP-FX can be operated manually as a collaborative robot or run in automated mode. This allows even larger components to be measured flexibly and independently of fixed measurement stations.
The integrated software controls the measurement process, automatically determines reference surfaces, and enables direct evaluation and documentation of the results.
White Light Interferometry
White light interferometry is an optical measurement technique used for three-dimensional surface inspection. It utilizes interference effects created by the superposition of light reflected from the component surface and light from a reference mirror to generate a digital point cloud of the surface geometry. White light interferometry is highly precise and insensitive to reflective surfaces, making it ideal for engine maintenance applications.
Cobots
Cobots sind Industrieroboter, die zusammen mit Menschen arbeiten. Cobots sind so konstruiert, dass sie in einem gemeinsamen Arbeitsumfeld ohne Käfige bzw. Schutzeinrichtungen arbeiten können und den Menschen bei komplexen Aufgaben assistieren.© MTU Aero Engines
MTU Award for Best New Technology Within the Company
Currently, one HP-FX system is in operation at MTU Maintenance Hannover in the disassembly area, while another is being industrialized in the inspection department. In parallel, MTU is in exchange with its MRO sites worldwide to evaluate additional potential applications. “On average, the company gains one day of turnaround time,” says Walter.Even at this early stage, the new measurement system has set new standards in three-dimensional surface measurement.
For the joint introduction with 3D.aero, the development team received the MTU Award in the category ‘Technology and Future’, an internal innovation award that recognizes outstanding employee achievements.
© MTU Aero Engines
Tomas Domaschke
Founder and Product Expert HP-X
We managed to adapt interferometric measurement to MTU’s specific requirements in a highly agile way, progressing step by step. This level of agility, which is not a given in technical development, quickly led us to a strong result that can now serve as a foundation for further innovations.
Faster Inspections and Reliable Decision-Making
By using HP-FX, surface defects with depths of 20 µm and greater can be detected directly on the shopfloor. Inspection times are significantly reduced, while highly informative 3D data is made available for defect assessment.
Validated Industrial Applicability
As part of the system approval process, HP-FX was metrologically validated and released for the specific application. This ensures that the system delivers reliable and reproducible results.
Added Value for Engine Maintenance
This use case demonstrates how HP-FX accelerates inspection processes, improves documentation quality, and provides a robust basis for decision-making in engine maintenance, with potential for site-wide deployment.