CLeo

Motivation

Due to the current EU Urban Wastewater Directive, up to 71,000 wastewater treatment plants across the EU will need to be equipped with an additional fourth treatment stage in the medium term to remove micropollutants, microplastics, and pathogens. Micro- and ultrafiltration systems enable this efficiently and reliably. The production of these filtration systems is largely automated. However, quality assurance for detecting defects and leaks is still carried out manually using the bubble test in a water bath. After moistening, the filter systems must be stabilized in another immersion bath for transport to prevent damage to the membrane system. Scaling up production to a competitive level requires the digitalization of leak detection and the automated repair of filter modules.

Project Description

The CLeo joint project aims to develop an inline quality inspection system for filter membrane modules. For this purpose, a prototype test chamber is being designed, in which filter modules with edge lengths over 1 meter are exposed to a test gas, and potential leaks are detected and pinpointed via spectroscopy. Initially, the mechanical and optical basic design of the test chamber will be created, and possible components – such as for the automatic handling of the modules – will be selected. The correlation between leak flow and detection signal will be determined, and AI-based image processing will be implemented.

Objectives

The goal of the CLeo KMU-innovative project is to develop an inline quality inspection system that detects leaks without affecting the structure of the membrane. Automated leak detection contributes to a significantly more ecological and cost-efficient production of filter modules. Additionally, the precise localization of leaks enables the automated repair of the modules. This allows production to be cost-effectively scaled to meet future demand without compromising the quality of the modules. The testing system is generally suitable for all types of filter modules, such as those used in the food industry or the chemical industry.

Subprojects

• DBI Gas- und Umwelttechnik GmbH (DBI): Project coordination and development of gas application
• WTA UNISOL GmbH: Preparation of the requirements specification, integration of the individual components, development of a filter module with defined defects for evaluating the automated quality inspection
• ibl Maschinenbau GmbH: Development of the robotic system for automated quality inspection
• Fraunhofer Institute for Material and Laser Technology IWS: Development of a novel laser-based leak detection process with AI data processing
• Westsächsische Hochschule Zwickau (WHZ): Development of a protective textile to cover the measurement area in order to shield external factors during testing