Researchers at the Fraunhofer Institute for Manufacturing Engineering and Automation (Fraunhofer IPA) have been working on how defective parts of e-bikes can be industrially refurbished so that they can be used again. In a study, they showed that new life can be breathed into e-bike motors.
If a component of an e-bike is defective, it is usually completely replaced with a new one. The old one ends up in the garbage because repairing it is not economical and often also not technically feasible. In the study “Adaptive Remanufacturing in the Electric Bicycle Industry”, researchers at Fraunhofer IPA have now examined whether an industrial-style refurbishment is possible. And whether it is not economically worthwhile replacing individual components. The study was carried out in the framework of the project “AddRE-Mo”which is funded by the Federal Ministry of Education and Research (BMBF) and can be requested free of charge.
New parts through additive manufacturing processes
First, the scientists examined the e-bike motors with regard to their probability of failure. They then checked to what extent defective or worn parts can be additively manufactured so that they can be easily replaced. Through 3D modeling or digitizing, they obtained data to 3D print these parts and selected the necessary materials and additive processes to be able to manufacture them. The parts were manufactured together with the company cirp, which specializes in additive processes, and Electric Bike Solutions.
120 different components made of 20 different materials were produced using the 3D printing process. The scientists tested the components for service life, noise development and temperature resistance on specially developed test benches under real conditions. Transmission gears, which were manufactured using the high-speed sintering process, for example, proved to be particularly reliable.
The scientists were able to prove that it is possible to rebuild an e-bike motor by remanufacturing it so that it is in no way inferior to a new motor. Depending on the number of units, the savings potential for these and similar components is around 30 to 40 percent. It is already worthwhile for the manufacturers of bicycle electric motors to use such additive manufacturing processes.
Environmentally friendly remanufacturing
This would also benefit the environment. “Additive manufacturing offers the potential to increase circularity in the electric bicycle industry and reduce the waste of resources. 90 percent of the impact on the climate, calculated in kilogram CO₂ equivalents, can be saved compared to new production,” explains Jan Koller, project and group leader at Fraunhofer IPA.
The results of the project will be shown in the new learning factory for remanufacturing, the RemanLab, at the Fraunhofer IPA in Bayreuth, which is scheduled to open on May 23. All processes for disassembly, cleaning, refurbishment and testing of the parts can be experienced. “Until now, remanufacturing has been characterized by costly and labor-intensive processes. In the RemanLab, we show how digital technologies and automation can revolutionize the remanufacturing not only of electric motors, but also of small electrical appliances and other products in the future,” says Koller.
(olb)
