In response to the imperative of sustainability and resource efficiency, this article introduces an innovative framework for the remanufacture of hydraulic drive system components, firmly rooted in the tenets of the circular economy. This method mixes cutting-edge additive manufacturing technologies, meticulous 3D scanning techniques, and the rigorous discipline of reverse engineering to rebuild active elements within hydraulic drive systems. Fundamental to this framework is a resolute commitment to the repurposing of non-defective components, fostering a closed-loop system that systematically curtails waste generation and significantly diminishes the environmental footprint associated with hydraulic drive system maintenance. This article presents a meticulous examination of the remanufacturing process for a flowmeter, elucidating the intricate integration of additive manufacturing technology and the precision of 3D scanning to restore a previously damaged rotor. Through this interdisciplinary approach, we aim to elucidate the manner in which contemporary engineering practices can be harnessed to catalyze circularity, enhance resource efficiency, and increase sustainability within industrial operations. By demonstrating the efficacy of additive manufacturing and reverse engineering in hydraulic system remanufacturing, this article contributes significantly to the discourse on sustainable engineering methodologies, underlining their pivotal role in shaping a more environmentally conscientious, circular economy.

In most situations, for the proper design of a gerotor pump, numerous parameters must be taken into account: the pump geometry, the properties of the materials from which the pumps are made (Young’s modulus, Poisson’s coefficient, friction coefficients, etc.), the hydraulic characteristics of the circulated fluids (fluid density, kinematic viscosity, etc.), the working performance of the pump (speed ranges, pressure, flow rate, etc.), with greater or lesser influence on volumetric efficiency, work capacity, or energy consumption. The paper presents a study regarding the inspection of the reciprocally enwrapping surfaces of the gerotor pumps using a three-dimensional measurement technique specific to reverse engineering, which involves 3D scanning of the pump components in gearing movement. The components were measured by means of a specific software (GOM Inspect) and compared, by overlap, with the CAD models made with the help of CATIA software (CATIA V5R21). At the same time, an analytical calculation algorithm was developed for the complementarity of virtual representations. Finally, the advantages of the reverse engineering technique compared to the developed theoretical algorithm and traditional CAD design are presented.

The article presents several current methods of remanufacturing hydraulic components, a trend that is encouraged, on the one hand, by concerns about reducing material consumption in the context of the circular economy - some of these materials being expensive or in short supply. On the other hand, remanufacturing by modern methods can lead to a decrease in energy consumption in the devices concerned, due to obtaining shapes that are difficult to achieve by classical procedures. Among the remanufacturing processes considered there are additive manufacturing, metal coating, reverse engineering, etc. An important step in the remanufacturing process is testing of components, which certifies the achievement of performances at least equivalent to those of the original products. To this end, the article presents a test bench solution with the help of which tests can be carried out on hydraulic devices such as hydraulic pumps and (linear or rotary) motors, hydraulic directional control valves or other types of valves.