Aircraft Engine Workshop Overhead Conveyor System
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Solution Overview
Problem
The traditional method of preparing aeroengines for shipping, where engines are supported by transport carts, hinders operator access, prevents parallel tasks, lacks visibility into task progress, relies on printed manuals, and makes inspection difficult, leading to increased costs and time.
Innovation Solution
A workshop layout with fixed stations for fitting, removing, inspecting, and finishing aeroengines, utilizing an overhead conveyor system with hoists and spreaders for easy access and automated movement, and computer terminals for task management and traceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the engine is supported by a transport cart during preparation, then the engine can be moved between locations, but operator access to certain portions of the engine is hindered and safety is compromised
Solution Approach 1:
The preparation process is divided into multiple fixed stations (fitting station, removal station, inspection station, finishing station, shipping station) arranged along a predetermined path. Each station is specialized for a specific task, allowing operators to access the engine from optimal positions without the constraints of a mobile cart.
Solution Approach 2:
The transport cart is replaced by an overhead conveyor system that moves engines through the preparation process in a vertical and horizontal flow path. This dimensional change allows operators to work at fixed stations below the conveyor level, providing unobstructed access to all engine portions without the cart structure interfering with their movements.
2Productivity
If the engine is processed at a fixed station on a transport cart, then tasks can be performed sequentially, but parallel tasks cannot be arranged, lengthening preparation time
Solution Approach 1:
The preparation process is segmented into five distinct fixed stations, each dedicated to a specific task. This segmentation enables multiple engines to be processed simultaneously at different stations, allowing parallel task execution and significantly reducing the total preparation time compared to sequential processing at a single mobile station.
Solution Approach 2:
The overhead conveyor system ensures continuous movement of engines through the preparation process, with no idle time between stations. The control means coordinates the conveyor to maintain optimal flow, ensuring that each station is continuously productive and that engines move seamlessly from one task to the next without interruption.
3Reliability
If tasks are performed at a fixed station with the engine on a cart, then assembly manuals can be referenced, but visibility of task progress and inspection capability are severely limited
Solution Approach 1:
The inspection station is equipped with advanced inspection equipment that provides real-time feedback on task completion and quality. The control means monitors the progress of tasks at each station and provides visibility into the overall preparation status, enabling timely detection and correction of any issues while maintaining a systematic workshop layout.
4Extent of automation
If the engine is moved manually on a transport cart between stations, then flexibility in positioning is achieved, but automation and precision are reduced
Solution Approach 1:
The overhead conveyor system automatically transports engines through all preparation stations without manual intervention. The control means coordinates the conveyor to precisely position each engine at the appropriate location for each task, ensuring both high automation and precise positioning. The system serves itself by automatically picking up engines from the assembly line and delivering them to each station in sequence.
Data Source
AI summary
A workshop for preparing aeroengines for shipping, the workshop including a station for fitting test and measurement mechanism on an engine, a mechanism for transporting the engine to test premises and for returning the engine to the workshop, a station for removing the test and measurement mechanism, a station for endoscopic inspection, a finishing station, and a shipping station. The engines are transported from one station to another by spreaders fastened on the engines and attached to hoists that are movable in translation along an overhead structure arranged in the workshop, each station being fitted with computer terminals for displaying and tracking the tasks to be performed on the engine in the corresponding station.