More information
Description
For 10 years we have specialized in the regeneration of turbocompressors for passenger cars, trucks, construction and agricultural machinery. The need for this project arises from the trends that are radically changing the turbocompressor regeneration market: miniaturization of elements (downsizing), increasing their speed, decreasing engine capacity, use of turbines for petrol engines, use of electronics to control the operation of turbocompressors and ever more common use of turbines with variable geometry. In the case of industrial components, repair is even more complicated. As a result, the existing repair methods are imperfect and often fail to maintain factory parameters.
By combining the modern technological line, original diagnostic software, and development work, Turbolmet will offer new quality regenerated devices with longer service life, as well as regeneration services of new types of turbocompressors.
The project objective is also a better waste management (reduction of the amount of generated waste by nearly 3 tons per year) and reduction of pollutant emissions to the atmosphere (by over 10 tons per year). The project also covers installation of a photovoltaic system to increase productivity and energy efficiency of the regeneration process.
Summary of project results
The project addressed the issue of modern, environmentally friendly remanufacturing of turbochargers and DPF filters. For proper remanufacturing, in addition to knowledge, specialized machinery was needed to remanufacture and test turbines/filters.
The challenge for the Beneficiary was the radically changing turbocharger remanufacturing market: the miniaturization of components and the increase in their rotational speeds, associated with downsizing, i.e. the reduction of engine capacity, the use of turbines for gasoline engines, the use of electronics to control the operation of the turbocharger, the increasingly common use of variable geometry turbines. Changes in the automotive market made previous repair methods imperfect, as they did not ensure that the factory performance of turbines was maintained. In addition, the company wanted to work with green technologies.
It was also a challenge to create an optimal storage area for turbocharger/filter remanufacturing materials.
Challenges to customers:
- repairing the turbocharger using modern technological solutions, allowing the repair of the latest types of turbochargers and allowing precise cleaning and balancing of the equipment, which has an impact on the service life of the remanufactured component;
- diagnosis of the cause of damage to the turbocharger, so that the problem of the need for a new repair does not return;
- short repair time, while maintaining high quality service;
- reduction of exhaust emissions into the atmosphere;
- guarantee and reliability of the remanufactured equipment.
Activities and results produced by the project:
- Purchase of a new process line and retrofitting of new employees (3 persons) with necessary equipment/tools;
- Reconstruction of the production and storage hall;
- Purchase of functional specifications from an IT company, on the basis of which proprietary, innovative software was developed;
- Purchase of software licenses for comprehensive turbocharger/filter diagnostics;
- Obtaining results and recommendations for optimizing the process line;
- Conducting tests of the software for conducting diagnostics of turbochargers/filters, purchased under the project;
-Conducting tests of turbochargers remanufactured by Turborolmet using the technology line acquired under the project.
The results of the project are:
1. A new technological line designed for future remanufacturing and changing types of turbochargers/filters.
2. A proprietary IT system that allows verification and diagnostics of the damage with analysis of the cause of the damage and the ability to send the verification results directly to the customer, who will be able to eliminate the problem;
3. A new efficient process line calibrated and optimized in terms of parameters and deployment, enabling faster remanufacturing, while state-of-the-art machines ensure measurement accuracy and high quality service.
4. the ability to achieve manufacturer''s parameters, and even higher than recommended by the manufacturer, of the remanufactured equipment (turbochargers/filters), due to individual, not serial processing of the turbine and the possibility of individual setting of parameters, e.g. balancing - this allows to achieve up to 3 times lower underweight than recommended by the manufacturer.
5. providing services that meet the highest quality and environmental standards - thanks to a modern line and photovoltaic installation.
Services for the regeneration of turbochargers and DPF filters are addressed to individual customers and car services, authorized garages, car dealers.
Summary of bilateral results
-