Metrology-Driven Automation Enables Circular Engine Remanufacturing
The Fraunhofer Institute for Factory Operation and Automation (IFF) and Rolls-Royce Solutions Magdeburg GmbH have successfully completed a joint automation project. The objective of the project was to automate a process of cleaning connecting rods for reuse in fully overhauled engines. The project is a prime example of needs-driven technology transfer against the backdrop of industry’s transformation into a circular economy.
The project revolved around sustainability: Connecting rods from used diesel engines are cleaned and readied for reuse in fully overhauled engines, prolonging components’ life cycle substantially and reducing resource consumption. The automated cleaning process developed in this collaborative partnership ensures that the precision components meet strict quality standards for their next lifetime.
Reproducibly Through Robot Guidance
The robotic cleaning solution was developed and validated in the Use-Case Lab at Fraunhofer IFF. One particular challenge was to automate the cleaning of large, precision connecting rod components, while complying with strict quality standards. The robotic system uses the same tool used in the manual process. It is now used precisely and reproducibly through robotic guidance. Controlled nondestructive machining is additionally intended to maximize the number of times the parts can be reused.
Fraunhofer IFF has the infrastructure needed for this in its Use-Case Lab. Industrial robotics, force/torque sensors and 3D touch probe scanners were used in the project. An experienced interdisciplinary team built and tested a functional proof-of-concept with a number of component options. The automated process achieved excellent cleaning results with high reproducibility, precisely controlled contact forces and minimal machining. This makes it possible to reuse connecting rods numerous times.
Industry-Driven Innovation
“This project is a prime example of needs-driven research,” explains Dr. José Saenz, team manager at Fraunhofer IFF. “Rolls-Royce Solutions approached us with a specific manufacturing challenge based on their commitment to circular economy principles. We jointly developed a custom solution that meets industry’s real requirements. This approach ensures that state-of-the-art automated technology really meets the practical requirements of manufacturing, instead of having to look for potential uses afterward.”
The collaborative partnership was built upon intensive dialogue between Rolls-Royce Solutions’ refurbishment experts and Fraunhofer research scientists. Iterative testing and optimization cycles in the Use-Case Lab made it possible to validate designs quickly and modify the solution for the specific requirements of component reuse and quality assurance.
Partnership With a Future
The successful proof-of-concept marked the beginning of a growing partnership: Both organizations have agreed to continue their collaboration in other phases of optimization and implementation. “The quick results, professional collaboration and flexible approach impressed us,” explains Peter Killus, Senior Manager Engineering for Service at Rolls-Royce Solutions Magdeburg. “The combination of research expertise, practical experience and state-of-the-art infrastructure make the Fraunhofer IFF an ideal partner for the introduction of innovative automated solutions into our recycling processes.”
The next steps will involve preparing prototype implementation on site, based on the designs validated in the Use-Case Lab.
Digitalization, Automation and Sustainability
The project is illustrative of Fraunhofer IFF’s role as an interface between research and industry. It helps companies effectively meet the challenges of digitalization and automation, while advancing sustainability targets through practical, applied research. The Use-Case Lab approach enables companies to test automated designs quickly with manageable risk and low capital expenditures before they commit to full implementation.
For more information: www.iff.fraunhofer.de
