CRC 871 – Opening
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00:00
Capital shipCapital shipComputer animation
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Playground slideHot workingComputer animation
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Berlin (carriage)Playground slideEngineSchiffsdampfturbineMaterialCapital shipSpare partMachineFinger protocolPhotographic processingHot workingElectric locomotiveCapital shipSpare partAircraft engineComputer animation
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Playground slideMachineSpare partRail transport operations
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SewingPlayground slideFord FocusGas compressorBladeTurbineFord FocusBladeEngineLastBeschaufelungComputer animation
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Playground slideAir compressorBladeFinger protocolVolumetric flow rateHot workingEngineSpare partDiagram
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Plain bearingPlayground slideFord FocusMechanical watchMarine propulsionAbgasturboaufladungContinuous trackNarrow gauge railwayRail transport operationsGas turbineStrömungsmaschineAircraft engineFord FocusHot workingPlain bearingEnginePhotographic processingCapital shipComputer animation
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Playground slideGamePrinting pressHot isostatic pressingComputer animation
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Capital shipComputer animation
Transcript: English(auto-generated)
00:01
Dear partners from industry and academia, ladies and gentlemen, it is my privilege and honor to open this final symposium of the Collaborative Research Center 871, regeneration of complex capital goods. Dear partners from industry and academia,
00:28
ladies and gentlemen, it is my privilege and honor to open this final symposium of Collaborative Research Center 871, regeneration of capital goods.
00:53
On behalf of my team, I would like to welcome you here for presenting a concise summary
01:02
of what we have been achieving since 2010 throughout three funding periods, which is documented in 287 publications, and the work was done in 27 sub-projects by
01:22
33 principal investigators and so far 43 doctoral students. I would like to take you first through the motivation and objectives of our work. Our motivation
01:44
in a nutshell is that fewer spare parts for complex capital goods save resources. So, they save materials, they save energy, they save capital and labor.
02:02
Therefore, the objectives that we pursued in this research project over the last 12 years was an improvement of repair processes, the development of an ability to assess the functional performance based on the condition we found in the capital good to be regenerated,
02:33
and an increasing scientific understanding of how machinery systems, in short, capital goods
02:46
perform once they have been used. All of this ends up enabling us to make rule-based decisions based on one hand, on the functional assessment,
03:05
for instance, of the performance of the machinery, and on the other hand, an assessment of the production effort. As you see on the left, our sample application was an aircraft engine, and many of the sub-projects that we will be taking you through
03:26
today will show that they go deep into the technology of aircraft engines. However, this served as an example for other capital goods, such as electric train drives,
03:41
as you see on the right, and wind turbines. Our vision for a future regeneration process starts out with the real process of disassembly, as in every regeneration of a machine or
04:05
a system, we disassemble it, we inspect the parts. Then, typically, a decision is made. Can we repair the machinery, or do we have to discard it? In our case, this preliminary decision
04:23
is made as it is in practice right now, based on a virtual snapshot of the machine. If we repair, if we decide for the repair option, then we have to weigh different options. We call
04:44
these options repair paths, or regeneration paths, and in principle there's a large number of paths which are available to us. One path always is discard the component and replace it
05:03
with a new one. Another path always is don't even touch the component, retain it as it is, warn as it may be, and then of course there are different regeneration options. So, between these extremes, replace with a spare part, or leave it as is, we have different levels of
05:27
repair, and these different levels of repair are then simulated. Their repair process is simulated in order to assess the effort that goes into the repair, and a functional simulation
05:43
provides a prediction of what quality, what performance we can expect once the component is repaired. In the end, each of these paths, three paths are shown here, and there may be end paths, each of these paths is evaluated, and in this virtual operation
06:09
shown in blue here, one path is automatically selected. We then return to the real world, and we actually regenerate the component, we reassemble it, and in the end we go through
06:27
an acceptance test, as is done today as well. Over the last three funding periods, which each came in four-year blocks, we migrated, our focus migrated from components
06:49
through modules to the entire engine system. So, initially our focus was on turbine blades. In the second funding period, we looked at a module represented by a compressive
07:04
BLISC, a blade integrated disk, and then in the last funding period, which lasts until now, we looked at the entire system performance. We, that is the four associated institutions,
07:23
the speaker university, as we call it, and literally translated into English and German, is Leibniz Universität Hanover. An associated research center of Leibniz Universität is the center in Hanover. Our colleagues from the Technical University in Braunschweig joined us,
07:45
and one of our colleagues actually ended up migrating to the Technical University of Dresden. So, in the last funding period, that institution was involved as well. The structure of our research consortium consists of four project areas.
08:06
Initially, project area A is dedicated to inspection and diagnostics. Now, when we go from inspection and diagnostics into the repair process, into the regeneration process,
08:20
we face two challenges, and these two challenges are represented by project area B and C. Project area B addresses that there is an interaction of the production, or in this case, repair process, with the functional properties of the product. So, an example may be you mill
08:44
a compressor blade. The compressor blade, due to the milling process, has some roughness, and then that roughness causes some flow losses on the compressor blade, but there are
09:06
two components. We have a large variance of properties. We may have repair blades. We may have spare parts, good as new. We may have blades that were not even repaired, that are left as they were because the performance is sufficiently good. So, this variance requires
09:28
completely new production methods, but also performance assessment methods. And finally, project area D addresses the control of the regeneration process.
09:45
Shown on the right-hand side is that we didn't stop with technology. We did a good bit of public relations from great school children whom we wanted to sensitize
10:08
and claim for our idea of not discarding products, but rather repairing products. So, from these youngsters all the way through engineering congresses
10:26
dedicated to repair of gas turbines, we presented our results. And I dare say that there was a good bit of enthusiasm on the part of both great school children and fellow engineers. In the end, we demonstrated that our concept work in a system demonstrator,
10:49
which we will give you plenty of opportunity to see in the next few two days. Now, when we started this research in 2010, there was not quite as much attention given to
11:08
maintenance of aircraft engines or other capital goods. So, here's a statistic. Of conferences and publications dedicated to aircraft engines and gas turbines,
11:28
and we counted the keyword maintenance in journal publications and conferences. You can see that the number count of the use of maintenance doubled during the period
11:46
during which we performed this research. So, with just a little bit of pride, I would like to say that we had the right idea at the right time and were able to make some contribution to it.
12:00
In the meantime, dedicated conferences, conferences dedicated to this topic developed. There is an advanced manufacturing repair of gas turbines conference by the American Society of Mechanical Engineers, which was presented annually since 2019, and we
12:25
participated in all three conferences since. The main gas turbine conference worldwide, the ASME Turbo Expo has, which has been in existence in 1956,
12:42
dedicated focus tracks, for instance, in 2019 to the maintenance repair and overhaul for turbo machinery. And also here in Germany, we were able to represent our work at the Predictive Maintenance Conference by the TÜV Züt, which is one of the
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organizations in Germany dedicated to safety and operation of technical equipment.
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And we participated there in 2019. But not only in the narrow confines of engineering did this topic of regeneration receive more and more attention, but also in the wider society.
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So right here, you can see examples of the German press addressing this, and also the German federal government dedicated a research program to the circular economy, appreciating value instead of throwing it away,
14:05
or in German, Wirtschätzen Stadtwegverfen, appreciation instead of disposal, has become a major program in the German Ministry of the Environment,
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Nature Conservation, Nuclear Safety and Consumer Protection in 2021, and also in the EU. So I think we were able to make a small contribution to shaping the agenda. With that, I would like to hand over to our conference organizer here for the day.
14:51
And I wish you a pleasant few two days with lots of insights and interesting discussions.
15:01
Thank you very much for your attention.