Compare Vendors' Claims to Axiam
Repeatable Assembly Processes
Item   Explanation
Repeatable Assembly Processes  

Axiam provides repeatable assembly processes. Repeatable assembly processes require: the use of specially designed hydraulic tooling; highly accurate measurements; specially designed procedures whose goal is repeatability and accuracy; sophisticated application software that does not introduce new variables; and, specially designed gauge tooling. Repeatable processes produce substantial savings and engine performance benefits that more than pay for themselves.

Rotor Hydraulic Assembly Tooling  

Axiam provides specific hydraulic tooling for each rotor module. Hydraulic tooling assures fully seated rotor assemblies and prevents “rotor shift” in the test cell, major sources of vibration. Appropriate hydraulic tooling is essential to achieve repeatable assembly processes.

High Precision Stacking Software  
Axiam's "best fit" rotor stacking software (SmartStack™) utilizes a direct 3-D transformation matrix calculation to build straight rotors from the parts at hand. Thus, replacement or machining of parts is typically required in only 1% of cases. Others use a less accurate and time-consuming “fit-and-try” method for each component. Their methods result in more part replacement and machining.
Predictive Rotor Build using Bolt Holes  
Axiam's SmartStack™ stacking software uses a discreet number of bolt holes to calculate a “best fit” stack. This feature results in a more accurate build. Other stacking software indicates only an angle or orientation. The operator must then choose the appropriate bolt hole – a requirement that introduces variability and inaccuracy.
Full 3-D Predictive Model Output  
Axiam's assembly software produces a predictive model in two planes, which improves accuracy. The first plane is Centerline Deviation™ and the second is Biplane Deviation™ or Perpendicular Plane™.
Reverse Assembly Direction  
Axiam's software allows operators to measure parts in a given attitude while the build model orients the parts in a reciprocal attitude for stacking and assembly. This feature reduces turn time.
"Bow" Reduction Software  
Axiam's software produces straight builds for rotors, bearings, casings and shaft assemblies by establishing one stage as the datum centerline and then mathematically building on this centerline.
"What if" Calculation  
All Axiam software allows the operator to interchange parts in a stack model to perform “what if” calculations. This allows the operator to build to the desired quality level.
Module Mating Software  
Axiam's ShaftMate™ software allows for the optimal mating of modules to each other or to their respective shaft, resulting in lower vibration characteristics in the entire engine.
Bearing Compartment Alignment & Assembly Process  
A bearing compartment’s centerline alignment with the shaft is critical to an engine’s vibration characteristics, performance and time on wing.
Casing Alignment & Assembly Process  
SmartCase™ software generates a predictive model before assembly. It shows assembly straightness and alignment. Significant engine performance, life and time on wing benefits result.
Carbon Seal Assembly   BearingStack™ software compares critical perpendicularity measurements to the shaft centerline to minimize seal wear and oil leakage in engines using carbon seals.
Spline Measurement Data  
Spline data is used in the ShaftMate™ software for the optimal mating of parts, rotor modules and shafts at specific tooth positions. Axiam’s spline gauge head and software allows for easy measurement.
Programmable Output Page  
This software allows an operator to view only the measurements associated with a particular module being assembled.
Reprocess Raw Measurement Data  
The software allows raw data and “what if” analysis of parts data. Measurement datums and filtration can be changed to improve build models.
Output in English or Metric   An operator may choose either English or Metric outputs.
File Management  
An operator can save data on the system hard drive or removable disc. Networking software is available to store data and build models remotely in a database or spreadsheet. The data is stored by directory, part definition, part number, serial number, run number, date and time.
Thermal Measurement Laser Gun  
Parts ready for stacking must be at a specific temperature to achieve proper seating in a rotor stack. Axiam will determine the appropriate parts temperature and maximum time allowed for assembly for proper stacking. Axiam provides a laser thermal gun to confirm part temperature during rotor stacking.
Assembly Manuals  
Axiam provides assembly optimization manuals in ATA format for all its repeatable processes. Manuals contain photo-illustrated procedures that facilitate accurate measurements and assembly.
Parts Measurement
Item   Explanation
Vibration Isolation System  
Measurement gauge vibration isolators prevent shop noise interference with measurement accuracy. Tall parts or assemblies area especially susceptible to shop ambient noise.
High Stiffness Probe Holders  
Axiam's probe-holding arms are designed for high stiffness to promote accuracy. Stiffness is especially critical when measuring tall parts.
Variable Speed Rotary Table  
A probe has the tendency to bounce when measuring measuring parts with interrupted surfaces, resulting in measurement inaccuracy. Axiam's air bearing rotary table can be slowed to measure interrupted surface accurately, preventing bounce.
Automatic-Print Output  
A software feature that allows for the automatic printing of results at the end of each measurement.
Clockwise or Counter-Clockwise Table Rotation  
This feature provides added flexibility, convenience and reduced measurement time for certain engines.
Parts Measurement Tooling  
Axiam provides proprietary precision transfer fixtures and chuck jaws for use in parts measurement with our gauges, resulting in significant part setup time savings and much improved measurement accuracy. This tooling is designed for specific parts of each engine.
Volumetric Accuracy of Measurement Gauges  
Axiam's gauges have an overall volumetric parts measurement accuracy of 10-20 millionths of an inch (data that is loaded into the software) within their parts measurement envelope and rotary table weight capacity. A gauges parts measurement accuracy begins with the accuracy of the rotary table and then progressively deteriorates as part placement on the table, the gauge column, arms, heads, probes, probe placement, software, ambient shop noise and procedures all introduce variables and inaccuracy. An Axiam gauge has an overall volumetric measurement accuracy of 10-20 millionths inch.
Programmable Results Digits  
Axiam's GMS-4000™ & GMS-5000™ software allows the operator to view only the number of data digits desired - especially important metric measurements.
Biplane Deviation™ Measurement  
Biplane Deviation™ is a proprietary measurement within the GMS-4000™ & GMS-5000™ software that mathematically removes "warpage" or distortion from a measured surface, resulting in more accurate stacking models. This measurement uses a face datum.
Perpendicular Plane™ Measurement  
Perpendicular Plane™ is a proprietary measurement within the GMS-4000™ & GMS-5000™ software that mathematically removes "warpage" or distortion from a measured surface, resulting in more accurate stacking models. This measurement uses a diameter as datum.
Miscellaneous Items
Item  
Explanation
Engine Assembly Process Consulting & Analysis  
Axiam provides consulting and analysis of shop engine assembly processes to identify the variables that cause excessive engine vibration and a lack of assembly process repeatability. In the end, new build standards and procedures are established that help bring repeatability.
Turbine Assembly Expertise  
Axiam's engineers possess many years of aero and industrial engine design, testing, overhaul and assembly experience. They draw on this expertise in recommending certain engine shop process changes to achieve repeatability.
3-D Certification Master  
Axiam's 3-D Certification Master is the industry standard, having been approved by the FAA, Pratt & Whitney & GE. It certifies the entire gauge system for accuracy; including probes, rotary table, electronics, software and mathematical algorithms.
NIST Traceable Calibration  
Axiam's gauge system is supplied with NIST traceable masters.
Security Levels (5)  
Axiam's measurement gauges have five security levels to limit access to specific areas such as data transfer, calibration, diagnostics, etc. These security levels help prevent inadvertent changes that might adversely effect gauge results.