Time consuming checking of torque levels of each individual bolt involved in a manufacturing process can be eliminated by a new intelligent connectivity based solution, described here by Design Engineer Jonathan Beaumel of JPB Système. Tasks that took two engineers two days are being undertaken now by one engineer in two hours.
Regardless of their size or the industry segment in which they operate, manufacturing companies are constantly striving to increase efficiencies within the various processes they employ. With many maintenance operations still planned and performed manually, often by experienced operators performing sometimes basic yet time-consuming tasks, it is easy to see how manufacturers are sometimes swimming against the tide when it comes to achieving efficiency goals.
In an effort to improve in this area, more companies are turning to innovative and disruptive technologies to streamline processes and reduce the time and costs involved within their maintenance operations. One laborious, yet highly important, task is the need for maintenance engineers to manually check the torque level of every single bolt that might be in place within a particular piece of machinery, engine, or countless other structures or vehicles.
This has led to the emergence of certain solutions that are designed to eradicate the high level of time demanded in such instances. However, despite solutions such as ultra-sonic waves enabling accurate measurements, there are certain fundamental limitations, including physical access to the bolt and information (such as the length of the bolt), which might not be known or be readily to hand.
As a go-to supplier and solutions provider in aerospace, solving key challenges for manufacturers within this space – as well as other industries – we began looking at ways to address this fundamental issue a couple of years ago. It was apparent that maintenance engineers needed something that would meet head on the fundamental challenges within processes themselves, while also overcoming the shortcomings of existing solutions.
This has seen us develop a proof-of-concept solution called Smart Washer, a next-generation sealing technology that enables touchless and wireless measurement of bolt axial load.
Importantly, this means that instead of having to manually verify the torque level of every single traditional bolt, maintenance engineers are notified about those specific fasteners that are either too tight or too loose so they can attend to them accordingly in just a few seconds.
Designed to improve efficiencies within MRO, the technology performs the fundamental role of a standard washer but uses intelligent connectivity to provide maintenance and service engineers with a clear picture of axial loads. This has been achieved by incorporating a proprietary strain gauge, as well as a transmission system into the washer, which via an accompanying reading device (Smart Reader), relays the information to maintenance engineers.
Our customer Airbus Helicopters has noticed quantifiable efficiency gains across helicopter engine maintenance. In this instance, a helicopter can require a periodic check that necessitates removal of its engines and interior trim even before maintenance engineers can gain access and check the bolts. Once examined, the engine needs to be re-installed and a ground-run undertaken to ensure correct installation of the engines. This is a very labour-intensive, heavy-maintenance operation that would typically take around two days and require two engineers. Using Smart Washer, Airbus has reported that they are able to perform the same task in about two hours and with one engineer.
We also see opportunities in the energy and renewable resources markets. For example, manufacturers of wind engine turbines for power generation could leverage the benefits of Smart Washer in conjunction with a drone, saving time (and ultimately costs), as well as overcoming safety issues inherent with hard-to-access wind turbine blades.
Ultimately, most manufacturers or companies that are required to perform maintenance checks on machinery or other infrastructures set themselves clear goals when it comes to reducing time and cost across such processes. Thanks to innovative providers that commit to addressing and solving these fundamental challenges with smart technology solutions, such manufacturers will be well equipped in their constant quest to continually improve efficiencies.
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