EAS3000 P04 with Optional Probe Bracket
EAS3000 P04 with Optional Probe Bracket
Genspect Software - Setup Screen
Genspect Software - Setup Screen
Genspect USB Controller
Genspect USB Controller

EAS3000

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(GE Tooling #9471M13PO4)

(Max Part Size 50″ dia. x 90″ tall, Max Part & Fixture Weight: 3,000 lbs)

Ultra-precision, Fully Integrated Stack Prediction Systems

Engine Assembly Systems (EAS) provide engine stack projection capabilities for high pressure compressor and turbine (HPCR and HPTR) builds. Also referred to as stack prediction, these system allow operators to quickly and accurately measure individual turbine engine parts and precisely align component stacks the first time, ensuring the least amount of runout.

This process results in lower vibration, less engine wear, a streamlined production process, and improved financial performance. Maintenance and overhaul procedures are also optimized. And the value of your critical engine assets is increased through extended engine life.

Our EAS technology has been deployed worldwide within the aviation, marine transportation, and power generation industries. We are proud to have been selected by General Electric to play an integral role in the launch of the LEAP engine. We are also supporting GE’s Gen9X engine development and production ramp up. This close collaboration has resulted in ABTech becoming a fully licensed supplier of GE Aviation’s Genspect Stack Projection Software System.

As precision motion and measurement experts we work closely with you to configure our rotary motion solutions to meet your exact needs, including developing custom solutions for the most unique applications.

The EAS 3000 is designed for applications that include the largest commercial and private aircraft as well as land and marine propulsion, and power generation turbines. The Genspect GE tooling number is #9471M13PO4. Variations are available to meet other OEM engine models.

System form parameters include roundness, concentricity, perpendicularity, parallelism, and flatness. Overall system accuracy is under 5.0 millionths of an inch (5.0 µ” or 0.125 micron).

Features & Benefits

Sub-micron Accuracy Air Bearing Rotary Table

The foundation of each Engine Assembly System is an ultra-precision air bearing rotary table that is designed and built by ABTech.

  • Frictionless and maintenance-free rotary table
  • Ultra-precision sub-micron accuracy
  • Nearly absolute repeatability
  • Highly robust stainless steel materials that minimize touchdown and gall damage
  • Requires standard compressed shop air (60 psi)

For maximum durability and stability, and to ensure the highest accuracy and repeatability, each rotary table is mounted to a natural granite base.

Maximum Efficiency and Ease-of-Use

An often overlooked capability with stack prediction systems is ease of use and its production and training efficiency. What separates our system from competitive products is the attention to detail. We listen to our customers to ensure our designs offer the most efficient path to project completion.

Our heavy-duty adjustable tilt and center worktables allow engine part to be easily and precisely aligned to the air bearing’s rotational axis. The tilt and center worktable’s spherical seat design ensures that the part’s center point is maintained when leveling, saving valuable set up time for both measurement and assembly.

To provide quick access when loading parts or unloading a finished assembly, systems can be configured with either a swing-away dual gage stand or a tall counterbalanced gage tower. And to further shorten setup and measurement times, every gage configuration is capable of mounting up to eight electronic indicators connected to a state-of-the-art USB controller.

Configurations to Meet Your Specific Needs

EAS configurations range from portable systems that maximize production floor “on-machine” flexibility to models that can handle load capacities from 500 to 3,000 lbs. Parts sizes can range up to 50” in diameter and 90” tall. See our specifications tab for detailed functionality of each of our models.

Fully Licensed Supplier of GE Aviation’s Genspect Systems

ABTech has collaborated closely with General Electric on numerous engine projects including the recent launch of the LEAP engine. As part of this partnership, ABTech has become a fully licensed supplier of GE Aviation’s Genspect Stack Projection Software System.

Genspect Systems include a USB controller and stack projection software. The controller has inputs for up to eight LVDT gages, the air bearing table’s rotary encoder, and a USB interface for PCs. Genspect systems purchased from ABTech are turnkey solutions for assembling jet engines and turbines and come complete with the following:

  • Air bearing platform
  • Controller
  • All required lever and plunger type probes
  • Genspect software preloaded on a Windows based computer
  • A large color monitor
  • A fixed base floor rack to house the PC and other electronics

Software

Stack Projection Increases Productivity, Improves Turbine Performance, and Reduces Engine Wear Prolonging Engine Life

ABTech has collaborated closely with General Electric on numerous engine projects including the recent launch of the highly successful LEAP engine. As part of this partnership, ABTech has become a fully licensed supplier of GE Aviation’s Genspect Stack Projection Software System.

While the hardware platform is critical to ensure accuracy and durability, the stack projection software plays a central role in delivering a range of functionality. The software included with our Genspect Engine Assembly Systems (EAS) allows operators to quickly and accurately measure individual turbine engine parts to ensure the least amount of runout, and properly align component stacks the first time.

The end result is lower vibration, less engine wear, a streamlined production process, and improved financial performance. Maintenance and overhaul productivity are also optimized. And the value of your critical engine assets is increased through extended engine life.

To meet your particular needs, the software has built-in customizable display and output options. User selectable scale resolutions and SAE or metric units offer full flexibility for all of your part requirements. For consistency in each new measurement, part parameter files – with defined surfaces and corresponding gages and orientations – are organized and saved by engine type. Individual results are also stored by engine and can be called up as necessary for input in the stack projection module.

The software is also designed to simplify and accelerate the initial training process. On screen “step-by-step” instructions are presented in a way that assists the novice operator through each measurement without reducing the efficiency of experienced users. And “refreshers” are available as needed.

To speed the measurement process, all Genspect Engine Assembly Systems offer multiple gage head options to measure several surfaces in a single step. Roundness, flatness, concentricity, parallelism and perpendicularity results are output for each individual surface simultaneous with the datum results, and the stack projection value and angle are reported.

Our EAS technology has been deployed worldwide within the aviation, marine transportation, and power generation industries. We are proud to have been selected by General Electric to play an integral role in the launch of the LEAP engine as well as to support GE’s Gen9X engine development and production ramp up.

The experience and expertise we have garnered in collaborating with the world’s premier developer and manufacturer of jet engines has positioned us to deliver industry-leading engine assembly platforms to the aviation, aerospace, power generation, and land and marine propulsion industries. If you manufacture or maintain turbine engines we can assist you to increase your engine’s efficiencies and value, while simultaneously enhancing your productivity while minimizing your maintenance costs.

Specifications:

Working envelope:

  • Axial load capacity (max centered and balanced): 3,000 lbs (1,361 Kg)
  • Max part diameter (swing): 50″ (1,270 mm)
  • Max part height (OD probe access): 90″ (2,286 mm)
  • Height to worktable: 28″ (711 mm)

Specifications:

  • Heavy duty rotary air bearing (Model HDRT600)
    • 1000 line count rotary encoder assembly
    • Air consumption: 4.50 CFM @ 60 psi
  • Spherical seat type tilt and center worktable assembly (Model HDTC4)
    • 24″ (610 mm) diameter worktable
    • Four screw type knobs (2 centering, 2 leveling at 90⁰) for tilt and center adjustments
    • 1/4-28 tapped holes in worktable for fixture mounting
    • 3/8-16 UNC holes in worktable for fixture mounting
  • Rotary table anti-rotation kit
  • Dual element air filter/regulator for air bearing supply (Model #00938A)
    • 5.0 micron pre-filter w/ regulator (0 – 150 PSI)
    • 0.3 micron second stage filter, oil/water removing (coalescing)
  • Granite surface plate and low profile welded steel base frame
      • 32″ x 60″ x 8″ grade A black natural granite surface plate
    • Welded steel base with elastomer type passive vibration isolation mounts
  • Counterbalanced tower style gage stand with single gage arm
    • Vertical travel: 90″ (2.3 meters)
    • Horizontal travel: 28″ (711 mm)
    • Coarse manual height and arm adjustments
    • Position locks with fine gage head adjustments
  • Fixed probe support stand and slide plate mounted to granite between towers and rotary table
  • Two lever-type and two plunger-type probes with 5M extension cables and fine adjust probe mounts
  • Three calibration gage blocks
  • USB Genspect controller box
  • Windows 7 PC with keyboard and mouse
  • 27″ wide format flat screen color monitor
  • Fixed base electronics rack with monitor mount and keyboard shelf with tilt and swivel adjustments and adjustable heights
  • GE’s proprietary Genspect software, includes:
    • Measures runout, roundness, concentricity and perpendicularity
    • Step-by-step probe calibration program
    • Tilt and center assist feature for easy part alignment
    • WinSPS stack projection module

Options

  • Gage towers with customized heights and horizontal arm lengths
  • MicroTIR+ for capturing indicator readings at angular increments with LVDT probes, controller, PC, and software (replaces GE Genspect specific software and electronics)

Accessories

  • Lever and plunger type electronic gage heads and extension cables
  • Fine adjust probe mounts
  • Magnetic base portable gage stands
  • Additional gage holder fixtures
  • Mobile electronics cart with heavy-duty casters and articulating “swing-arm” monitor mount
  • Certified master artifact

Consult with one of our highly trained representatives to determine the best EAS model and configuration for your specific needs.

Applications

  • Aerospace
    • Large commercial aircraft
    • Large private aircraft
    • Large military jet engines
    • Defense/military
  • Marine and land transportation
  • Power generation
    • Gas-powered plants
    • Renewable

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Thank you for your interest in ABTech’s ultra-precision measurement tools and services.
Please tell us a little about what you need to accomplish and we will be in touch to discuss any of the additional details that will help you choose your best option.

Thanks a lot for your help. Your rapid, informative correspondence was invaluable. Hopefully I won't be bothering you with any further questions, but it's good to know you're willing. (following remote technical support provided for system installed at the South Pole) Morgan HedgesPost-doctoral Research Associate
Princeton University
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Every product we sell exemplifies our company-wide commitment to "Pride in Precision" craftsmanship. To that end, all of our products are designed, manufactured, and tested exclusively by ABTech at our New Hampshire facility.

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