Checking for engine component cracks – safe and secure

Even the finest hairline cracks on engine components can lead to failures. That’s why components at MTU Aero Engines pass through an extensive crack testing facility provided by Rhode + Wagner Anlagenbau as part of their production process – a testing system that integrates the tamper-proof PITmode fusion safety solution from Pilz.

Safety and industrial security play a central role, because operating, setup and service personnel must be able to access the plant using various permissions, dependent on their tasks. In order to meet these operating requirements, Rhode + Wagner integrated the PITmode fusion: the modular operating mode selection and access permission system combines safety with individual configuration options.

The crack testing machine is around 30 m long, 15 m wide and up to 7 m high. It consists of several workspaces and process areas, with nine processing booths. That’s why safeguarding of all the infeed and access areas was at the centre of the safety concept.

The components integrated into the safety concept are PSENslock safety gate sensors, to secure the position of the loading carts, and PSENmlock for safe monitoring and guard locking of 14 safety gates.

Not every employee who has access to the machine needs to have all the operating, intervention and change options. The operating mode selection and access permission system PITmode fusion used by Rhode + Wagner enables machine operators such as MTU Aero Engines to have individual operating mode selection and access permission management. Also, it practically excludes operator errors, manipulation, hazards for the operator and damage to the plant.

Jörg Rhode, managing director at Rhode + Wagner Anlagenbau, said: “When Pilz introduced us to PITmode fusion, it was immediately clear to us that this modular operating mode selection and access permission system was ideal for meeting all the safety and industrial security specifications of the customer, MTU Aero Engines, as well as fulfilling our concepts of an efficient, user-friendly plant concept.”

Korbinian Boisserée, head of operation planning for non-destructive testing procedures at MTU Aero Engines, commented: “The access permission system from Pilz enables us to have individual access permission management and to create various user profiles.”