CONnected Flexible dIGital hybrid additive manufacturing Unit designed for REpair (CONFIGURE)

如今，越来越复杂的高价值工程部件一旦损坏，就太有价值了，不能丢弃。不幸的是，目前的维修方法，往往基于一系列复杂的人工操作，很难控制，以确保高性能，往往安全至关重要，零件具有所需的完整性水平。当零件在偏远、往往不适宜居住和危险的地方进行维修时，很难提供所需的维修技能水平，这一问题就会加剧。迫切需要一种灵活、高效和自动化的方法来修复高价值金属零件，接近使用点。混合增材制造（AM）工艺将定向能沉积（DED） AM工艺与传统的5轴加工相结合，已经投入生产。虽然非常有效，但这种解决方案仅限于相对较小的部分。在CONFIGURE中，将开发并演示一个灵活的自动维修单元，包括维修操作的每个阶段（损坏评估、维修、整理和最终检查）。使用具有可互换检测、沉积和加工头的机器人平台，它将允许几乎无限尺寸的零件在无缝操作中进行修复。新装置可以提供便携式甚至移动配置，使其能够在任何需要的地方定位。数字化制造技术是该项目的一个关键方面。一组传感器将被纳入维修单元，以提供过程和零件质量数据。该信息用于使设备在自主模式下运行，也将被记录，以便进行详细分析并提供可追溯性。配置单元将在两个最终用途部门进行演示，即损坏的铁路轨道的修复和高价值的采矿设备，但有广泛的潜在跨部门应用，包括新零件的生产。

Today's increasingly complex high value engineering parts are too valuable to discard whenthey are damaged. Unfortunately, current repair methods, often based on a series of complexmanual operations, are difficult to control to ensure that high performance, often safetycritical, parts have the required level of integrity. This problem is exacerbated when parts arerepaired in remote, often inhospitable and hazardous locations, where it is difficult to providethe required level of repair skill.There is an urgent need for a flexible, efficient and automated method of repairing high valuemetallic parts, close to the point of use. Hybrid Additive Manufacturing (AM) processes,combining Directed Energy Deposition (DED) AM processes, with conventional 5 axesmachining are already in production. Although very effective, this solution is limited torelatively small parts.In CONFIGURE a flexible automated repair unit, encompassing every stage of the repairoperation (damage assessment, repair, finishing and final inspection) will be developed anddemonstrated. Using a robotic platform with interchangeable inspection, deposition andmachining heads it will allow parts of almost unlimited size to be repaired in a seamlessoperation. The new unit can be provided in portable and even mobile configuration, enabling itto be positioned wherever required.Digital manufacturing technology is a key aspect of the project. An array of sensors will beincorporated into the repair unit to provide both process and part quality data. Thisinformation, used to enable the unit to operate in an autonomous mode, will also be logged toallow detailed analysis to be performed and provide traceability. The CONFIGURE unit will bedemonstrated in two end-use sectors, repair of damaged rail track and high value miningequipment but there are a wide range of potential cross-sector applications, including new partproduction.