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We are transforming how we inspect our engines | Rolls-Royce

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We are transforming how we inspect our engines - by combining automation, data, and human expertise for smarter, more efficient and safer operations.

Historically, engine inspections required colleagues to take hundreds of photographs of each engine from multiple angles. Inspectors often needed to work from elevated platforms to capture the necessary views, before reviewing and stitching together images. This process was time-consuming and could make it harder to maintain fully standardised inspection records.

High-tech drones for safe and fast operation and excellent images

But now, using advanced drone technology, a full 360-degree inspection of the engine exterior can be done in just minutes. A Rolls-Royce Pearl engine can be scanned in around four and a half minutes, while a Rolls-Royce Trent engine takes approximately nine and a half minutes.

Built for the aerospace industry, these drones are fully automated systems, that don't need GPS or manual piloting. Instead, they use laser-based LiDAR positioning and advanced obstacle-avoidance navigation with millimetre precision to capture high-resolution images of the engine exterior. The drone also has built-in emergency landing programming and backup battery storage to ensure it always lands smoothly and safely.

A 360° scan replaces hundreds of photographs

The drone produces a digital model so detailed that engineers can zoom in on serial numbers or instantly identify scratches or other external defects with 0.5 mm precision +/- 3% of the distance.

Strong partnerships

Our external technology partner for drone scanning has a decade of experience in automated aircraft inspection and already collaborates with several aerospace and MRO businesses. Working with such an experienced partner enables us to bring our shop floor closer to Industry 4.0 standard, where automation, data, and human expertise complement each other.

The result? Faster, safer, and more traceable inspections, with less room for human error. Although we are still in the early stages of deployment, the technology has already proven its worth in several of our facilities by consistently producing high-quality images and easily accessible digital data, thereby strengthening productivity and increasing people safety and product quality.

Drones are helping our Quality Control Teams to work more safely, efficiently, and precisely than ever before. The future of inspection is not about replacing people with machines or AI; it’s about equipping our skilled Inspection Teams with the technology that enables them to further excel in their job.

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