
“Silent Machine” project increases working comfort.
Gurten, Linz, June 2025 - It is a literally unmistakable side effect in many production lines that has been triggered by electromobility: From motor housings to battery trays to chassis parts, more and more and ever larger components are being manufactured from ever thinner-walled aluminum parts. If these are drilled and milled in metalworking machines - so-called “machining centers” - this inevitably increases vibrations and noise emissions at the same time. The machine engineering company Fill from Gurten (district of Ried im Innkreis) and the Linz Center of Mechatronics (LCM) have now put a stop to this phenomenon, which affects the entire industry. Thanks to state-of-the-art measurement technology and signal processing, extensive tests on an “acoustic box” and intensive simulations, a significant improvement in quality has been achieved for machine operators. Noise emissions have been reduced by seven decibels (dB). As a result, Fill's machining centers, which are used to manufacture components for the automotive industry, can now operate reliably below the required limit value.
"In our highly competitive industry, new developments must be incorporated into the product quickly. Because the automotive supply industry is also very price-sensitive, the product price must not increase significantly," says Roman Binder, outlining Fill's requirements for development partner LCM. As deputy head of the “Research and Development” team, the mechanical engineering graduate initiated and supported the joint development process to reduce noise emissions. It became clear that LCM was the right partner for this shortly after the start of the project in spring 2023. "The team led by LCM project manager Lukas Grasböck intensively analyzed a machining center at our site in Gurten. They recorded its acoustics and vibrations using state-of-the-art measurement technology and processed the data using advanced signal processing." In addition to an acoustic camera, a vibration exciter, a vibrometer, sound intensity probes, acceleration sensors and free-field microphones were also used. The LCM experts naturally focused on the loudest milling process. Once all other transmission paths for the sound had been ruled out, the four-person team set their sights on the machine housing. “This offered the most promising opportunities to achieve a rapid and efficient reduction in noise emissions,” explains Grasböck.
Real implementation confirms simulation
Fill has tackled twelve suggestions for adjustments to the design of the machine housing from this catalog. The LCM team at Fill spent two days measuring the specific effects of the adapted machine housing on the noise emissions of the machining centers. "Our simulation results were confirmed. We were able to determine a reduction in noise emissions of 7 dB," explains Lukas Grasböck. Almost two years after the start of the project, Fill has already implemented some of these improvements in the SYNCROMILL machining centers. "The housings of these machines protect the operators from injuries, milled chips or cooling lubricants. We have now been able to improve the noise protection and thus significantly strengthen a very important safety component," says LCM Managing Director Johann Hoffelner, pleased with the rapid and concrete implementation of the development results in the Fill machining centers.
High development speed, improved working comfort
Roman Binder is highly satisfied with the speed of the development work and the feasibility of the results. "The LCM team suggested measures for design adjustments that we can implement quickly and easily ourselves. Above all, LCM helped to significantly increase working comfort for all operators at Fill machining centers." For example, all openings on the machine housing were sealed with customized sound insulation and the gap dimensions of the housing elements were reduced to reduce noise emissions. Fill customers who have recently purchased a SYNCROMILL machining center are already benefiting from some aspects of the “Silent Machine” project. Some of the measures can be seen on the Fill stand at the EMO trade fair in September.
Written by Haslinger, Keck. PR
Translated with DeepL
About Linz Center of Mechatronics GmbH
LCM is a reliable and experienced partner for research and development. The company offers a partnership right through to the finished product, commissioning and support with certification. LCM serves around 450 customers with its focus on drive technology, sensor technology and electronics, IIOT and mechanics. Digital product development and AI methods are used in applications such as predictive maintenance and condition monitoring. With its technical know-how, LCM supports its customers in the implementation of requirements for resource optimization, circular economy or renewable energies.
Contact
Linz Center of Mechatronics GmbH
Altenberger Str. 69, 4040 Linz
T 0732/2468-6002
E office@lcm.at
W https://www.lcm.at
Legend:
Photo 1: (from left) Roman Binder (Fill), Lukas Grasböck (LCM) and Alexander Reininger (LCM) inspect the inner workings of a Fill Silent Machine.
Photo 2: Following design modifications to the acoustic box, a robot in the LCM laboratory scans the new acoustic characteristics. The measurement results are shown in color in the overlay.
