Checking for Cracks – Safe and Secure

August 14, 2023

Checking for Cracks – Safe and Secure

Secure authentication is the key

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 GmbH as part of their production process.

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 tamper-proof safety solution PITmode fusion from Pilz. The modular operating mode selection and access permission system combines safety with individual configuration options.

Individual permissions increase Industrial Security

Checking for Cracks – Safe and Secure

The crack testing machine is around thirty metres long, fifteen metres wide and up to seven metres 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 safety gate sensors PSENslock, 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.

Benefits at a glance
  • The modular system PITmode fusion is easy to integrate into the design of the extensive plant
  • Permissions are assigned individually, enabling manual intervention in each process step
  • By assigning permissions, safety briefings are restricted to the relevant user groups
  • RFID transponder key combines multiple functions and permissions

Customer statements

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.

Jörg Rhode, Managing Director at Rhode + Wagner Anlagenbau GmbH

The access permission system from Pilz enables us to have individual access permission management and to create various user profiles.

Korbinian Boisserée, Operation Planning – Non-destructive testing procedures at MTU Aero Engines

About Rhode + Wagner Anlagenbau GmbH

Checking for Cracks – Safe and Secure

Rhode + Wagner Anlagenbau GmbH manufactures crack testing machines in Ebersbach-Neugersdorf, east of Dresden. The company was founded in 2009, specialising in conception, planning, design and production to the customer’s exact specifications. This includes complete systems for surface coating and decoating, waste water treatment, water preparation and goods transport systems. With special, automated solutions in the aviation sector, the medium-sized enterprise from Saxony has been listed as a reliable partner for MTU Aero Engines AG, among others, for more than ten years.

About MTU Aero Engines AG

Checking for Cracks – Safe and Secure

MTU Aero Engines AG has its headquarters in Munich and is one of the world’s leading engine manufacturers. The core competencies for MTU are low pressure turbines, high pressure compressors, turbine centre frames, as well as manufacturing and repair processes. In the commercial new engine business, the company plays a key role with the development, manufacture and sale of high-tech components as part of international partnerships. MTU components are used in one third of the world’s commercial aircrafts.


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