| Research project: | GreenMES – Green Mobile Engine Services Development of a novel kinematic system for minimally invasive blade edge machining, suitable referencing, and machining strategies |  |
| Research area: | Kinematic development, automation, MRO | |
| Funded by: | Federal Ministry for Economics Affairs and Climate Action | |
| Collaboration with: | Lufthansa Technik AG, DLR Institut für Instandhaltung und Modifikation, IT Concepts GmbH | |
Association leader: | Lufthansa Technik AG | |
| Start of the project: | January 2025 | |
| End of the project: | December 2027 | |
| Contact person at the institute: | M.Sc. Vincent Ahrens |
Description:
The aim of the GreenMES project is to develop an automated, minimally invasive machining system to increase the efficiency of aircraft engines. Compressor blades are exposed to severe environments during operation. Even the smallest foreign objects in the airflow erode the leading edges of the blades, blunting them and thus reducing the efficiency of the engine. Larger particles also leave nicks that weaken the structure of the blades. As a result, fuel consumption and emissions increase, while the service life of the engine decreases. Until now, repairing these defects has required the time-consuming and costly disassembly of the entire engine. Only once the compressor blades have been removed can the complex mechanical processing required to restore the original contour and round off notches be carried out.
This is precisely where GreenMES comes in. To be able to remedy efficiency losses more frequently and at the same time more cost-effectively, the blades will in the future be machined directly inside the engine while still installed. This so-called on-wing repair is particularly challenging from a technological perspective, as access to the high-pressure compressor when installed is only possible through small openings.
In the project, the IFPT is therefore developing an innovative repair process and miniaturized kinematics that carry out this process deep inside the engine. With this approach, GreenMES is helping to maintain the long-term efficiency of engines, conserve resources, and sustainably reduce emissions in air traffic.
Contact person at the institute: M.Sc. Vincent Ahrens