MAY 2023 AFTERMARKET 47 Significant reductions According to Tom Wright, Product Manager at Melett, there has never been a better time to offer remanufactured turbochargers: “The entire UK economy is being gripped by the cost-of-living crisis, and the garage and automotive sector is no exception. With service providers and customers concerned about spending, it’s important to consider the benefits in cost offered by remanufactured components, with significant reductions in price when compared to original equipment products. “Cost savings aside, we’re reminding the industry that there’s no compromise on safety and part quality. The use of high-quality components in remanufacture ensures a long-term, sustainable approach on vehicle repair and servicing.” He added: “Automotive Parts Remanufacturers Association (APRA) Europe recently reported that remanufacturing saves millions of tons of carbon equivalent emissions, 85% of raw materials and 55% of energy compared with new production, meaning remanufacturing is sustainable and resource friendly. Remanufacturing provides additional benefits on a wider scale, with the environment benefitting from carbon savings and reduced emissions from not having to extract raw materials in the manufacturing process of a new turbocharger.” For more information, visit: https://www.melett.com/ Automation Meanwhile, ACtronics has opened a new remanufacturing line, which will fully automate the process. “This has a hugely positive effect on quality and lead time,” said Operations Manager Dean Bartram, “and we are therefore very proud of it.” He went on to say: “During the optimization phase, the ATE Teves MK60E, a popular ABS system, was used as a pilot part and now that the remanufacturing line is functioning as desired, it is also being prepared for the remanufacture of other ABS systems. In addition to the MK60E, the other types will also be remanufactured automatically in the near future. We will briefly explain (and show) how the revision process works within this new line. “It all starts with opening the ABS system and removing the components to be replaced. A pre-programmed CNC machine opens the ECU (or parts of the HCU in some cases) and removes material where it is needed to properly access the internal components. The solder is then heated in specific places and extracted: the electronic components that are replaced can now be removed from the printed circuit board. What follows next is an extensive circuit board cleaning process. “The assembly starts with the placement of new electronic components. A pre-programmed pick-and-place machine places these components in the correct position with extreme precision. Because these components are already provided with the correct amount of solder in advance, the printed circuit board only needs to be sustainably heated in specific places. The steps after that are a bit too extensive to name and/or discuss briefly, but the process will in any case end with a new cover, made in-house. “The ABS system should now be functioning correctly again, but this does not mean that the remanufacture process ends here. Before the remanufactured part is packed, it first undergoes an extensive End Of Line test. This test checks not only the electronics, but also uses an advanced fluid circuit with which the pump motor and the various valves within the HCU can also be thoroughly tested. If it eventually turns out that the ABS system is fully in working order, the part is neatly packed, of course provided with installation instructions.” Dean added: “The remanufacturing line for ABS systems has already more than proven its added value. For ACtronics there was only one conclusion: This is the future. A second remanufacture line for instrument clusters has therefore already been taken into use. the development of a third remanufacture line, for TCUs, is also in full swing. To be continued.” www.aftermarketonline.net
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