FLATPACK NEAR-WING ENGINE TURNOVER TOOLING SYSTEM

Challenge

A customer required a near-wing engine turnover system capable of safely rotating a short aircraft engine during repair and inspection. The tool needed to deliver controlled, predictable rotation while preventing deformation of delicate engine structures and maintaining tight positional tolerances throughout the operation.

The system also had to operate within the restricted working envelope found beneath an aircraft wing, where access is limited and spatial constraints are severe. At the same time, it had to be completely flat-packable so it could be transported easily between maintenance sites and assembled quickly in tight bays without specialist lifting or alignment equipment.

Flatpack construction introduced strict limitations on part geometry, joint design and reinforcement. The tool had to support substantial loads, allow precise multi-axis positioning and provide a controlled rotation path, all while being broken down into transportable modules.

In essence: create a rigid, precise turnover tool that behaves like a permanent installation but ships as a compact kit.

How Amtek Tackled It

Amtek began by analysing the forces generated during turnover, paying particular attention to how the centre of mass shifted as engine components were removed or reattached during the repair sequence. The turnover frame needed to maintain stiffness and keep deformation within extremely tight limits to avoid inducing stress into the engine.

Engineering the structural configuration The solution was based on a reinforced A-frame gantry structure capable of supporting approximately six tonnes. The layout was refined through iterative analysis to ensure clean load paths, predictable behaviour and stable rotation even with an offset or changing centre of mass.

Key joints and interfaces were designed to interlock during assembly, giving the structure the rigidity of a permanent fixture despite being modular. These features also ensured repeatable alignment without the need for precision setup equipment.

Developing the turnover mechanism Standard rotary actuators could not deliver the required control or integrate effectively within the flatpack constraints, so Amtek engineered a non-standard actuation system using a precision double-acting hydraulic cylinder. This approach provided:

• controlled motion through the full 90-degree rotational requirement
• consistent movement regardless of engine configuration
• stable behaviour under varying load paths
• smooth and predictable operation for technicians

Stroke length, speed and force characteristics were tuned through modelling and physical trials to achieve the desired performance.

Multi-axis positioning and operator access To ensure the engine could be presented at the correct angle and height for each maintenance step, the system incorporated controlled multi-axis adjustment features in addition to the primary rotation. These adjustments allowed technicians to align the engine safely and ergonomically within the restricted near-wing environment.

Validation through modelling and testing Amtek carried out extensive stress analysis, deformation prediction and joint behaviour modelling, supported by physical testing to confirm stiffness, repeatability and stability under load. This work ensured compliance with aerospace handling expectations and safety requirements.

Every component was assessed not only for strength but also for how it would break down, pack and reassemble on site. Robust alignment features, safe access and operator-focused ergonomics were designed in from the outset.