The challenge of Fuji Electric Systems Co., Ltd.
Measuring Instruments
3D Case Studies
The challenge of Fuji Electric Systems Co., Ltd.: Achieving faster delivery and improving turbine blade machining quality
Fuji Electric Systems Co.,Ltd.
(Kawasaki, Kanagawa Pref.）
The challenge of achieving the contrary goals of improved quality and shorter lead times
Fuji Electric Group was founded in 1923 with capitalization and technology transfers from Furukawa Electric Works and Siemens AG (Germany), and constantly takes up the challenge of original innovative technology. Within this group, Fuji Electric Systems Co., Ltd. is in charge of the group's electric and power systems.
The Kawasaki Plant, which started operation in 1925, is currently the manufacturing base for generators, producing heavy electric machinery including thermal-power steam turbines/generators, hydraulic turbines/generators, atomic-energy-related equipment, etc. It holds a global top-class share in the geothermal field of clean energy, delivering the world's largest geothermal steam turbines. generators, and plays a role in preserving the global environment.
Market demands and obstacles to overcome
- Three-dimensionallycurved turbine blade
With the current heightening of concern for the global environment, demands for even higher steam turbine performance to achieve reductions in CO2 have been increasing. In order to respond to these demands, steam turbines use three-dimensional blades which are optimally designed to match the flow of steam and have a curve in the circumferential direction.
Since these three-dimensional blades have freeform surfaces, a special gauge for each blade was made to ensure quality in the manufacturing process. However, the measurement results varies according to the experience and skills of the inspector, resulting in major time costs due to remeasurement or confirmation measurement by an expert.
Machining path optimization utilizing scanned shape data
The first process to be tackled was that of centering for machining. A blade is machined from forged or cast material to mill out the final shape. In the past, simple 2D measuring equipment was used to determine shape positional relationships, but this required much work and measurement accuracy was low. Instead, a Konica Minolta RANGE7 is now used to measure shape data, axial alignment with CAD data is performed, and the results are read into a CAM system to determine the optimum machining path, reducing work time. In addition, special gauges are no longer necessary, further reducing costs.
Future activities
- From right: Steam Turbine Dept., Blade Sect.: Hiroyuki Kojima (Manager), Minoru Kozono; Steam Turbine Dept., Construction Design Sect.: Kohei Morita (Assistant Manager); Steam Turbine Dept., Blade Sect.: Nobuhiko Sugahara
Fuji Electric Systems is investigating expanding use of the RANGE7 to upstream and downstream processes. As a first step, they will construct a CAT system to apply it to final finished products to continue meeting challenges by:
- Shortening measurement time
- Increasing utilization of machinery
- Reduce costs by eliminating special cross-section gauges
- Improving measurement quality
Company overview: Kawasaki Plant, Fuji Electric Systems Co., Ltd. Address: 1-1 Tanabeshinden, Kawasaki-ku, Kawasaki Site area: 177,987ｍ2 Employees: 1111 (including related companies, mutual service company) Main products: Thermal power-generation equipment, hydroelectric power equipment, nuclear-power-related machinery, industrial motors/ engines, dust collectors for tunnels, etc.
（As of March 2008）