The Fraunhofer Institute for Factory Realisation and Automation IFF and Rolls-Royce Solutions Magdeburg GmbH have successfully completed a joint automation project. The aim of the project was to automate a cleaning process for connecting rods so that they can be reused in completely overhauled engines. The project revolving around robot-assisted overhaul of parts is a great example of how technology can contribute to the industry's transformation to a circular economy.
Overhaul
The project revolved around sustainability: connecting rods from used diesel engines are cleaned and prepared for reuse in fully overhauled engines, significantly extending the life cycle of the parts and reducing raw material consumption. The automated cleaning process developed in this partnership ensures that the precision parts meet strict quality standards for their next service life.
Rapid prototyping
The robot-controlled cleaning solution was developed and validated in a short time in Fraunhofer IFF's Use-Case Lab. A particular challenge was to automate the cleaning of large, precision parts of connecting rods while adhering to strict quality standards. The robotic system uses the same tools used in manual overhaul. This is now deployed accurately and reproducibly through robotic control. Controlled, non-destructive machining is also designed to maximise the number of times parts can be reused.
Infrastructure
Fraunhofer IFF has the necessary infrastructure for this in its Use-Case Lab. The project used industrial robotics, force and torque sensors and 3D probe scanners. An experienced interdisciplinary team built and tested a functional proof-of-concept with various component options. The automated process delivered excellent cleaning results with high reproducibility, precisely controlled contact forces and minimal machining. This allows connecting rods to be reused numerous times.
Innovation
"This project is a textbook example of needs-based research," explains Dr José Saenz, team leader at Fraunhofer IFF. "Rolls-Royce Solutions approached us with a specific manufacturing challenge, stemming from their commitment to the principles of the circular economy. We jointly developed a customised solution that meets the real requirements of the industry. This approach ensures that state-of-the-art automated technology actually meets the practical requirements of production, rather than having to look for possible applications afterwards."
Collaboration
The partnership came about on the basis of an intensive dialogue between revision - experts at Rolls-Royce Solutions and researchers at Fraunhofer. Thanks to iterative testing and optimisation cycles in the Use-Case Lab, designs could be quickly validated and the solution could be adapted to the specific requirements in terms of component reuse and quality assurance.
Partnership with the future
The successful proof-of-concept marked the beginning of a growing partnership: both organisations have agreed to continue their cooperation in other phases of optimisation and implementation. "The quick results, professional cooperation 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 makes Fraunhofer IFF an ideal partner for integrating innovative automated solutions into our recycling processes." The next steps consist of preparing the implementation of prototypes on site, based on the designs validated in the Use-Case Lab.
Digitalisation, automation and sustainability
The overhaul -project illustrates Fraunhofer IFF's role as a link between research and industry. It helps companies in the region and beyond to effectively meet the challenges of digitalisation and automation, while promoting sustainability goals through practical, applied research. The Use-Case Lab approach allows companies to quickly test automated designs with manageable risks and low capital expenditure, before committing to full implementation.
Also read: Automated disassembly of electronics
Opening photo: Fraunhofer IFF
