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EUC-Saturn is creating digital twins of engine production shops

7.06.2018
Moscow, June 7, 2018
Press-release

UEC-Saturn in Rybinsk (a part of United Engine Corporation, a Rostec State Corporation company) is working at digitizing the production chain for gas turbine engines and their components. The making of digital twins of production shops is in progress. It has been announced within the framework of the conference Digital Industry of Industrial Russia-2018 (CIPR) taking place in Innopolis (Republic of Tatarstan).

UEC-Saturn is a highly innovative enterprise mastering advanced technologies intensively: additive technologies, application of polymer and ceramic composites, supercomputer technologies and others. In cooperation with other companies UEC is implementing a number of large-scale projects in civil and military fields. The SaM146 power plant system for the commercial aircraft Sukhoi Superjet 100 is produced in partnership with Safran Aircraft Engines in Rybinsk. UEC-Saturn is actively developing the line of industrial engines, is involved in the program of building the state-of-the-art commercial engine PD-14 for the airliner MC-21, releases D-30KP engines for the Il-76 aircraft family etc.

“It is already the case that the key competitiveness factor affecting the lead time of market lunch of new products, the cost of development, subsequent series production and ownership of a gas turbine engine is a degree of digital penetration into all product life cycle phases, – says Pavel Bekher, Manager of the Project “Digital Economics”, Economics and Finance Division, UEC-Saturn. – One of the crucial tasks for us is the digitization of the production chain itself. There is to be made a digital twin of a production shop with due account for equipment used, its location in the shop and the peculiarities of automated and manual operations. Such a digital twin allows target values (product plan, capacity, production cycle, expenses) to be monitored on the basis of the actual condition, makes it possible to simulate changes and to estimate their effect close to reality”.

The company is implementing technologies of the industrial Internet of things which provides connection of sensors, pickups and other data acquisition equipment with production control systems and a digital shop twin.

“For almost 20 years now UEC-Saturn has been moving towards the establishment of a digital company. During that time the most actively developing trends were the creation and implementation of control systems for the company’s operation, design and process engineering. As long ago as in 2001 the last drawing table left design stations – all the designing is done in electronic systems. In design engineering we use an integrated product data management system. A significant factor of the company’s success is the application of highly productive engineering calculations. All that has enabled us to reduce the cycle of engine SaM146 entry into market and to cut the expenditure for prototypes. Currently these practices are used extensively for the whole product line of UEC-Saturn. Thus all the modern products of the company are digitized”, – says Pavel Bekher.

Previously UEC-Saturn mastered the through 3D-technology of development and preproduction of aircraft engine parts and components, which has been implemented in the design office and production engineering services. The application of this technology considerably increases effectiveness, reduces the time of introduction into production and mitigates associated risks and expenses.

In the year of the company’s centenary (celebrated in 2016) the supercomputer centre ”Saturn-100” was set up at UEC-Saturn. The centre is a single cluster of the supercomputers AL-100 and SPAK. It is used for complicated, time-consuming and resource-intensive computations. The overall peak performance of the modular data processing centre SPAK (a special-purpose software-hardware system) is 114.5 Tflops, the total RAM is 14.5 TB, the total number of computing processors is 204, the overall number of cores is 2808. The data processing centre AL-100 (the overall peak performance is 14.3 Tflops) put in service earlier was considered the most high-performance supercomputer in the industry of Russia and the Commonwealth of Independent States in 2008.

PJSC "UEC-Saturn" is an engine-manufacturing company specialized in the design and development, production and after-market support of gas turbine engines for military and commercial aviation, power generation and gas compression as well as for ships and vessels. UEC-Saturn is part of United Engine Corporation. It is situated in Rybinsk (Yaroslavl Region). UEC-Saturn is a member of Russia’s Mechanical Engineers Union, an All-Russian industrial association of employers. The Yaroslavl regional division of the All-Russian public organization “Russia’s Mechanical Engineers Union” is headed by Viktor A. Polyakov, Managing Director of PJSC “UEC-Saturn”.

United Engine Corporation (JSC) (a Rostec State Corporation company) is an integrated organization specialized in the design and development, serial production and after-market support of engines for military and commercial aviation, space programs, the Navy as well as for the oil and gas industry and power generation. One of UEC’s prioritized fields of activity is the implementation of comprehensive programs of development of the industry’s companies by introducing new technologies meeting the world-class standards.

Rostec State Corporation is a Russian corporation established in 2007 in order to facilitate the development, manufacturing and export of high-technology industrial products of military and commercial application. The corporation comprises 700 companies, which form 11 defense-industrial and 3 civil industry holdings as well as over 80 direct control companies. The Rostec portfolio spans such renowned brands as AVTOVAZ, KAMAZ, Kalashnikov Concern, Russian Helicopters, VSMPO-AVISMA, Uralvagonzavod and others. Rostec’s subsidiaries are located in 60 regions of Russia and deliver their products to over 70 countries worldwide.  Rostec's consolidated revenue in 2016 reached 1 trillion 266 billion rubles, the consolidated net profit — 88 bln rubles, and EBITDA — 268 bln rubles. The average salary of the Corporation in 2016 amounted to 44 000 rubles. Following Rostec's new strategy, the major objective of the Corporation is to ensure the technological advantage of Russia on competitive world markets. The introduction of a new technological structure and digitalization of Russian economy are among Rostec’s key tasks.

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