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TechView


A Retrofit at Lufthansa


Te Luſthansa Technik group of com- panies (LHT Group) is one of the few service companies allowed to overhaul aircraſt and engines from a wide variety of manufacturers. Indeed, for certain procedures and manufacturers, the Luſthansa Technik site in Hamburg, Germany, is the only qualified repair location in the world. Repairs to engine housings represent


a particularly difficult challenge. Engine housings are complex, heavily stressed components made of materials that are expensive to buy and process. In sched- uled maintenance, it is sometimes pos- sible to replace only those sections that show signs of mechanical and thermal stress—an alternative that is technically challenging, but financially, extremely interesting compared with using new parts. To do this, the component to be overhauled is first precisely measured and a CAD model of its actual shape is created. Next, the worn sections from the engine components are replaced with new material, which is then reworked so that it exactly matches the previous structure in terms of shape, size, and accuracy of fit. Te repair technology requires machining centers of a particu- lar size and quality, as Andreas Tölle, project engineer at Luſthansa Technik in Hamburg, explained: “Our large vertical turning and grinding machines from Jungenthal, with their solid and reliable mechanics, are completely indispensable for this type of work.” Tey are regularly overhauled to reflect the state-of-the-art in terms of both electrical engineering and CNC technology. Luſthansa Technik in Hamburg


recently turned to Siemens to retrofit


the drive technology and control system on its Jungenthal vertical turning and grinding machining center. “Everything we produce is a one-off


and needs to be individually pro- grammed and processed,” said Tölle. “Our staff also needs to be able to operate all of the machines easily. Tat’s why we are gradually converting all our machining centers to use CNCs with shop-floor soſtware from Siemens.”


“We are gradually converting all our machining centers to use CNCs with shop-floor software.”


Te electrical engineering part of the


retrofit included all of the axis drives and the CNC system. Te Sinumerik 840D sl, with its Sinumerik Operate graphical user interface and integrated ShopTurn shop-floor soſtware, made it possible to combine the turning and grinding processes that previously required two CNCs into a single control system, thus saving one entire control panel. Tis means that there is now more space around the machine and users can move around freely as they operate the grinding functions from an MP8 mobile control panel. With the turning and grinding


processes now combined in a single control system, programming and program management have also been considerably simplified. Te old CL800 cycles have been translated one-to-one into ISO cycles for the new control system. On the OP 015 control panel, more information can be visualized in a clear and transparent manner than ever before.


Matthias Wunderlich


Lufthansa Account Manager Siemens


Munich, Germany


For example, it is now already


obvious during the simulation phase whether a tool can be used at a par- ticular angle of approach. In ShopTurn, which is also integrated into Sinumerik Operate, contour sections can be easily cut out and inserted, using the copy- and-paste function. Te panel is also extremely useful when operating in manual mode. To fully exploit the capabilities of the


Sinumerik tool management system, Luſthansa Technik retrofitted the tool turret with Capto toolholders. Tis allows the Jungenthal machine to be specifically fitted with ready-made tools, simplifying in-process tool changes, eliminating the need for time-consum- ing scratching and allowing entire pro- duction sequences to be combined into cycles and programmed processes. “More efficient tool and program


management has increased our process- ing speeds on average between 10 and 20%,” explained Tölle. Equipped with the new Sinumerik


CNC, Simotics S-1FK7 servomotors and the Sinamics S120 drive system, including actively regulated infeed, the Jungenthal machine now has the flex- ibility to deliver the efficient produc- tion processes required for aircraft maintenance. The retrofit proved par- ticularly economical when compared to the cost of buying a new machine, even without counting the work saved on foundations and infrastructure. This resilient machine will probably also last longer than a newer model built today, says Tölle, who is already thinking ahead to the next retrofit with Siemens as its partner. ✈


Aerospace & Defense Manufacturing 2013 61


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