In Russia, they were going to establish a rebuilding that gives a second life to car units.
The Russian government has instructed three ministries to consider creating an industry to remanufacture used auto parts. And the process has already begun.
For example, in 2016, the ZF Transmission Industrial Remanufacturing Center was opened under the auspices of ZF itself. Yes, the company has stopped deliveries to Russia, but the center itself, with its equipment and a team of specialists, has not disappeared and is working properly. There are a dozen or two similar centers across the country, but they are scattered, each is responsible for one thing, and the system industry is still very far away.
Restoring parts is beneficial not only in times of crises and shortages, but in general in itself, which is why it has long been practiced in the world. The benefit for car owners is that remanufactured components are close to new in performance, can last for many more years, and are cheaper. For the “restorers” themselves, this is a profitable business. For society as a whole, there is also a benefit – jobs are created and resources are saved. First of all, metals and energy.
Restoration and repair: what is common and what is the difference
A refurbished part is a component in the manufacture of which partially or completely used elements that were in use.
That is, restoration is not the repair of a failed unit with a partial replacement of worn parts, but rather the construction of a new one “in accordance with factory specifications.”
It is not known how this is implemented in our country, but world practice professes a narrow specialization, the use of factory technologies, quality control, branded packaging and a guarantee for a year or six months.
In the international classification, there is also the term “reproduced parts”. They designate units restored at the production facilities of the manufacturer. Many factories have such divisions – including Bosch, Cardone Industries, TRW.
The first approach is usually called rebuilding, the second is remanufacturing, this is the highest form of rebuilding. The first has received the greatest development in the USA, Europe and Japan. But huge rebuilding networks, bringing together hundreds of diversified companies, have recently been created in China (with the approval of the PRC authorities) and Brazil.
Restoration, in the usual Russian sense of it, is most often based on standard kits for the “rebuild” of a particular unit or its individual parts (rebuild kit). In fact, these are rather repair kits, since their use does not at all mean bringing the entire unit into a fully operational condition. And restoration according to science implies exactly full chocolate.
How is rebuilding done?
When repairing, they usually replace or repair a failed component, not really bothering with everything else. During rebuilding, the unit is subject to in-depth diagnostics, disassembly to the screw and troubleshooting of all parts. With the maximum use of specialized equipment. The task is not just to repair, but to radically update and restore the original appearance.
If this is a gearbox, then first it is washed with an alkaline solution in a special “shower room”, then sent to a shot-blasting chamber – it is treated with plastic chips.
Now the box is ready for diagnostics – first the electronic part. Dealer or factory scanner study the readings of the control unit. Then – a complete disassembly and checking everything that may be worn out with a micrometer according to the tolerance tables. All unusable elements are replaced, rubber and plastic elements – by default, regardless of their condition. Those that do not require replacement are thoroughly cleaned, including by ultrasound. If the torque converter (often non-separable) is recognized as serviceable, it is still subject to pressure oil flushing. For repair there is specialized equipment.
The assembled box is checked in a water bath under pressure for tightness. Next – the firmware of all electronics with the current software at the moment with reference to a specific engine. The working fluid is poured into the unit and sent to the stand: performance check in all modes. If everything is fine, the box goes to the finished product warehouse.
Continued on the next page.