iMAP round view
- For components with a diameter of up to 3'500mm
- Maximum load capacity: up to 30'000kg
- High precision air bearing rotary spindle
- Multiple gauge configuration with 2,4 or 8 channel measurement software
- IntelliStack predictive rotor stacking software
- Included parameters: Roundness, runout, flatness, parallelism and concentricity
For the measurement and assembly of mechanical assemblies such as aircraft engines, industrial gas turbines and steam turbines.
The ultimate system for improving productivity in turbine rotor assembly
Having an accurate idea of component geometry prior to assembly is extremely important in the face of ever-increasing environmental pressures and rising fuel prices. The much more reliable measurement data collected by iMAP enables precise handling of component parts by rotor stacking software, which in turn enables precise alignment of rotor assemblies. iMAP has been independently verified and proven to provide our customers with significant operational improvements over their traditional measurement methods.
Trends and challenges in the aerospace industry indicate that significant long-term investment by leading manufacturers and operators will be required to meet the rapidly increasing global demand for these engines, with some of the major changes already underway.
These new challenges in the aerospace industry mean that the global engine fleet will need to grow by more than 20,000 net new engines by 2025.
- In 2015, the number of engines was 50,478; in 2025, the number of engines is expected to be 70,563.
- The global engine fleet is growing at 3.4% per year.
- Next-generation engines account for a 30% share in 2025.
- Combined engine sales are expected to grow to $1 trillion over the next 20 years.
- Boeing and Airbus delivered a combined 1300 in 2015, and their backlog of work was 10,000.
Source: Clearwater International, CAVOK
This increased demand for new engines has the direct consequence that the mro market is growing at a similar pace to meet the demand. mro (maintenance, repair and overhaul) by definition involves repair work on the dismantled engine (off-wing repair) and the replacement of parts to return the engine to its intended operating condition. The engine is disassembled and inspected, and damaged parts are repaired or replaced as necessary.
- Engine overhaul interval: every 3,500 to 7,000 hours
- Typical overhaul cost: $200,000 to $800,000
- Market value $27.9 billion in 2015
- Annual growth of 5.3% leads to $46.8 billion in 2025
Source: AeroStrategy, ARSA
IMap's capabilities set new standards for precision, flexibility, and performance in a wide variety of calibration and testing applications.
IntelliProbe corrects extreme setup errors
Software algorithms correct profile deviations due to misalignment of parts. The ?intelligent inspection' function corrects deviations of an uncentered part up to 2% of the radius of the part with negligible error.Easy sharing of results
Inspection templates and inspection data files can be quickly and easily shared for analysis purposes via email or as PDF reports or CSV files using a free downloadable viewer.Advanced Stacking Software for Predictive Modeling
IntelliStack™ is software for solving the mathematical problem of how best to assemble a multi-stage rotor assembly. The rotor stacking program can be used to assemble rotors of industrial gas turbines, steam turbines, and aircraft engines.Sub-micron performance
iMAP provides an extremely high level of accuracy, supporting sub-micron measurements and precise repeatability.Reduces inspection times by up to 90%
AccuScan's ability to measure 3,600 data points per revolution on up to 8 surfaces simultaneously significantly reduces your process times compared to other available methods.
Unlimited number of surfaces
Up to 8 surfaces can be measured simultaneously, with an unlimited total number of surfaces that can be measured.High load capacity
The sophisticated design of iMAP's bearing options guarantees not only the highest possible precision, but also a very high loading capacity.Compatible with virtually all production environments
iMAP is specifically designed for use in production environments and features a B89.3.1 standard profile filter to eliminate all background noise.Measurement of circular geometries
The system is designed to collect and analyze circular geometry test data such as roundness, eccentricity, diametrical runout, planar runout, flatness of circular surfaces, and parallelism.Probe Types
AccuScan™ can be equipped with probes such as lvdt, half-bridge, laser, wireless laser, eddy current, and capacitive probes that are best suited for your application.Process Reference Standard
Sub-micron circular geometry reduces process measurement inaccuracies to a level that allows the iMAP system to be considered your measurement reference standard.
Key Operational Improvements
iMAP Gauge rundr (runout and runout)
Manual data collection compared to iMAP data collection
A gauge system analysis, also called Gage rundr (Gage Repeatability and Reproducibility), is a statistical tool for measuring the amount of gauge system variation (scatter) caused by the gauge system itself and by the operators of the instrument making the measurement.
- 10-fold improvement in repeatability and reproducibility for concentricity measurements compared to manual systems
- 3.5 times improvement in repeatability and reproducibility for axial runout measurements compared to manual systems
- 90% faster than conventional methods
AccuScan test procedure
Perform the inspection procedure in three simple steps
- Step 1 Select an inspection template and assign color-coded probes to surfaces.
- Step 2 Start the inspection.
- Step 3 View the results, print a report, or save the results to a PDF or geometry data file.
The iMAP features are designed to help you get the job done.
Quick and easy
Using simple, intuitive, full-featured Windows software, operators can quickly and easily control the types of complex parts typically found in gas turbines.Programming can be done offline, instantaneously or both.
Inspection templates can be generated using AccuScan™ on the unit, using AccuScan ife™ independently on any computer anywhere in the world, or a combination of both.Results are dynamically recalculated
Unprocessed test data is collected and stored so that fixed points, surface definitions and units of measure can be changed at any time. The results are then dynamically recalculated.Setting markers when tolerance limits are exceeded
Marking out of tolerance is a quick way for the operator to identify non-conforming parts.Integrated help
Clicking the ?Help" button in the upper right corner of any screen gives the operator immediate access to comprehensive user instructions.Internal Probe Calibration
Probes are calibrated using the ?Probe Calibration Wizard' accessed from the ?Tools' menu. Calibration is a multi-step process and instructions are displayed at each step.
Centering and leveling plates
The centering and leveling plates allow operators to quickly and easily position the part and make radial adjustments of +/-12 mm and tilt adjustments of +/- 1 degree.High precision air bearings
The iMAP uses high-precision hydrostatic air bearings to provide exceptional motion geometry.Vibration dampening base
The vibration damping granite base assembly helps ensure accuracy by isolating the measurement process from disturbances in the production environment.Probe Alignment
Lasers help align probes with each other or with a component or process fixed point. The lasers project a green line along the component under test.Rigid Column Units
Column units provide a rigid platform on which to mount probes and can be moved by balance arms and locked in any position by a mechanical clamping system.
Advanced stacking software for predictive modeling
IntelliStack™ is software for solving the mathematical problem of how best to mount a multi-stage rotor assembly.
IntelliStack™ software can be used to assemble industrial gas turbine, steam turbine, and aircraft engine rotors, is fully compatible with all AccuScan test systems, and significantly improves rotor unit assembly by iteratively calculating the optimal position of each part, taking into account adjacent parts and its effect on overall rotor quality.
The user can configure stacking parameters such as the number of parts per unit and the number of allowed positions for each part (both without theoretical maximum), the stacking methodology (e.g. concentricity or balance oriented), etc. The stacking parameters for each part can be configured by the user.
The stacking parameters for each part can be pre-programmed at the same time as the inspection parameters with AccuScan ife. The inspection results can then be used in stacking if they were generated with AccuScan™.
Reusable stacking templates can also be created and used in recurring assembly scenarios. By pre-programming stacking parameters and using stacking templates, only a list of part identifiers is needed to perform the stacking.
Sub-assembly stacking, part stacking, stacking at a known or locked position, and part replacement stacking are all scenarios that can be implemented using IntelliStack™ software. Reduced assembly time, elimination of costly rotor disassembly, reduced runout and imbalance problems, and better visibility into machining process functions and their impact on the rotor assembly are some of the benefits.