ZEISS Power & Energy Solutions

Compressor Unit

Achieving efficiency in engine design

As more advanced blade designs are created and the complexity of airfoil geometry increases, the bar for precision continues to rise.

Any imperfection on the surface or variation in the profile of a compressor blade or vane can adversely affect airflow, impairing blade performance and reducing efficiency. Global production of these components reaches millions annually, with a correspondingly high volume of returns for maintenance, repair and overhaul (MRO). Precise measurement and inspection solutions are therefore essential to ensure a seamless production process.

Enhance power generation: ZEISS Solutions for compressor blades and vanes

Compressor blade and vane quality is a critical aspect of the manufacturing process. The high value of the parts and the time required for production increase the risk of significant non-conformance without careful monitoring. For our customers, ZEISS Power & Energy Solutions are an important asset. They enable the right equipment to be placed on the shop floor at the very point of manufacture. They also provide real-time feedback through related software tools, exactly where it's most useful, ensuring immediate corrective action.

Image illustrating the process steps for quality assurance in the manufacturing of compressor blades and vanes, focusing on critical aspects of the production process.

Forging Airfoil

Forging

In the forging industry, the integration of traditional methods with modern machinery and simulation software significantly enhances the quality and characteristics of the forged parts. Metrology plays a critical role throughout this process by providing accurate measurements and results.

The Challenge

Ensuring that the die and subsequent blades meet specifications is a key challenge in forging. Additionally, maintaining the correct geometry of the parts for further processing is vital for overall product quality and performance.

Our Solution

Advanced optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoil, provide the solution for full surface measurement. They also capture all the surface information of the parts and the tool.

High-precision CMMs are mainly used for die quality control. However, they can also be used to measure relevant cross sections of the airfoil.

Process control of die wear and part quality can be documented along the manufacturing process and over the lifetime of the part using PiWeb Reporting.
Machining

Milling

The blades and vanes can also be manufactured by milling. This requires roughing the socket, airfoil and root dimensions in a first step. In this step, the geometry is formed before the parts are passed on for the final machining process.

The Challenge

Milling is a process that takes place under harsh conditions. Measuring and inspection presents a similar challenge, ensuring geometry and dimensions for further machining and providing offsets for tool correction.

Our Solution

The relevant sections of the airfoil can be measured using high-precision CMM systems. For full-surface measurements, advanced optical measurement systems such as the ZEISS Scan Box and ATOS 5 for Airfoil are the answer, since they also capture the full surface information to be passed on for final machining.

Seamless workflow integration for batch processing within the production environment completes the documentation along the production process by providing live feedback for in-production adjustments using PiWeb Reporting.
Finishing

Final machining

Final machining includes the milling and grinding of the final geometries for blades and their roots, as well for the vanes and their sockets. This is the last machining step before final assembly.

The Challenge

Final machining is a swift process with small tolerances on many critical features and demands on efficiency. Monitoring production quality and also wear and tear of tooling in manufacturing to correct and adjust the offsets.

Our Solution

High-precision CMM Systems like ZEISS PRISMO is the go-to machine to meet the final challenges of of final machined parts. For comprehensive surface measurement, advanced optical systems such as the ZEISS Scan Box and ATOS 5 for Airfoil offer full surface data, ensuring accuracy and detail.

Additionally, seamless workflow integration enables batch processing within the production environment, enhancing documentation throughout the production process. With live feedback provided by PiWeb Reporting, in-production adjustments can be made efficiently, ensuring optimal quality control.
Final inspection

Final inspection and validation

Ensuring conformance to the design and manufacturing requirements is necessary to confirm the parts that are to be assembled into the compressor and that all of the components will fit together.

The Challenge

Part quality control is required to validate geometry, dimensions, and tolerance compliance, as well as to provide final documentation of part quality, gather information for R&D and assembly purposes, and trace parts.

Our Solution

Precise, tactile CMMs such as the ZEISS PRISMO are ideal for final validation of the specifications.

Advanced optical measurement systems such as the ZEISS Scan Box and ATOS 5 for Airfoil can further be used for full-surface measurements to provide the digital twin and gather information for assembly in terms of weight balance and mounting position.

Complete documentation throughout the production process with PiWeb Reporting.