Produktverantwortung des Konstrukteurs

1
Welcome
Remanufacturing of Mechatronics and
Electronics Dipl.-Ing. Stefan
Freiberger May 10, 2006
www.lup.uni-bayreuth.de
2
Structure

• Remanufacturing Electronics and Mechatronics
• Introduction
• Opportunity
• Demand
• Complexity of the Product
• Process Steps
• Complexity of the Diagnosis
• Conclusion

3
University of Bayreuth, Germany

• Located in the South of Germany (approx. 250 km
  north of Munich)
• Chair of Manufacturing and Remanufacturing
  Technology
• Chairman Prof. Dr.-Ing. Steinhilper
• Europe's Only University Institute for
  Remanufacturing!

4
The Remanufacturing Industries RD Partner in
Bayreuth
UP
European Remanufacturing Technology Center
Assembly
Disassembly
UP
Cleaning
Montage
Demontage
Reconditioning
Reinigung
Testing
Aufarbeitung
Diagnose
5
Cooperation with the Industry, other Universities
and Chairs
Global Scientific Community for Remanufacturing
Cooperation with the Industry and other Chairs
6
Opportunity of Remanufacturing Mechatronics
S. Freiberger
Steer-by-wire
EAS
Amount of Electronics and Mechatronics
EHPS
Rack steering
1980 1990 2000
2010
Year
EHPS Electro-Hydraulic-Power-Steering EAS Electr
ically Assisted Steering
7
Mechatronics and Electronics in Most of all
Products

1. Automotive Components
2. Electrical Apparatus
3. Machinery
4. Office Furniture
5. Toner Cartridges

8
Opportunity of Remanufacturing Electronics

• In today's vehicles up to 60 ECUs are built in!
• Not all last for 100.000 miles!
• 5 years after the serial production most of, no
  new ECU will be produced!

9
Opportunity of Remanufacturing - High Value
Products
Mechatronic System Sales Price in US
Antilock Brake System (ABS) 1620
Dynamic Drive gt1480
Electro Hydraulic Brake (EHB) gt 1680
Electrically Assisted Steering (EAS) 800
Electro Hydraulic Power Steering (EHPS) 500
Electronic Stability Program (ESP) 3520
Window Lift 300
Air Conditioning System 2000
Electrical Seat Adjustment 670
Valvetronic gt 1680
Hydro Unit of ABS 960
Extra Charge for Hydro Unit for ESP 240
4x Wheel Rotation Speed Sensor 4x 160
Angle Sensor 220
Cross Acceleration Sensor 270
Rotation Speed Sensor (Vertical Axis) 1190
Total Costs for ESP 3520
10
Systems in Remanufacturing Now and in the
Future
S. Freiberger

• Classic
• Remanufactured -
• Starters
• Alternators
• Turbo chargers

• Engines
• Brake calipers
• Air conditioning compressors

• Future
• Control Units
• Electro hydraulic power steerings (EHPS)
• Electronic Stability Program (ESP)

(more and more)
Remanufactured-

• Electrically assisted steerings (EAS)
• Air flow meter
• ...

11
Complexity of the Products Analyzed for a
Industry Partner
S. Freiberger
Control
Information / Energy
Given Value
Mechatronisches System
Actual Value
ECU
Mechanic Energy Converter
Energy / Substances
Actuator
Sensor
Energy / Substances
Electro-Hydraulic-Power-Steering
Electrically Assisted Steering
12
Process steps in Mechatronics- und
Electronics-Remanufacturing
S. Freiberger
Mechatronics-Remanufacturing
Electronics-Remanufacturing
Quality Assurance
Quality Assurance
1 Entrance Diagnosis of the System
1 Entrance Diagnosis of the System
2 Disassembly of the System
2 Opening the System
3 Thorough Cleaning
3 Diagnosis and Sorting
4 Diagnosis and Sorting
4 Replenishment of Parts
Reconditioning of Parts or Subsystems
and/or Replenishment
5
Closing the System
5
6 Product Reassembly
Final Testing (Climate Chamber)
Final Testing
13
Diagnosis for Mechatronics - Entrance and Final
Test
S. Freiberger
Test Bench in Computer Aided Design
Methods for Diagnosis of Mechatronics

• Model Based Methods
• Parameter Estimation
• State Conditioning
• Parity Space
• Artificial Neuronal Networks
• Fuzzy-Models
• Neuro-Fuzzy-Models

• Signal Model Based Methods
• Stochastic Signal Model
• Spectral Analyze

• Signal Based Methods
• Absolute Value Control
• Value Trend Control
• Calculation of the Characteristic Curves

Test Bench in Reality
14
Diagnosis for Electronics Failure Detection and
Isolation
S. Freiberger
Methods for Diagnosis of Electronics

• Signal Model Based Methods
• Stochastic Signal Model
• Spectral Analyse

• Signal Based Methods
• Logistic Test
• In-circuit-test

• Model Based Methods
• Artificial Neuronal Networks
• Fuzzy-Models
• Neuro-Fuzzy-Models

• Emission and Absorption Based Methods
• Direct Visual Diagnoses
• Microscopic Diagnoses
• Acoustic-microscopic Diagnoses
• X-Ray Diagnoses
• Thermography Diagnoses

X-Ray Diagnose
Thermography Diagnose
15
Diagnosis with Real Road Tests Analyzed for an
Industrial Partner
S. Freiberger

• Reason for real road test
• Find the operating points in reality.
• Compare the test bench results with the reality.
  
• Find out the specifications.

Place Test-territory of the German federal
force in Bayreuth (Oschenberg) Vehicle
Borrowed from the Chamber of Crafts
16
Conclusions
S. Freiberger

• Facts
• Electronics and mechatronics are involved in
  vehicles and other applications in very high
  numbers.
• The systems have a high value, also
  remanufactured units.
• Systems fail.
• Garage could only diagnose failures but can not
  repair the units.
• Electronics and mechatronics have a very high
  potential for remanufacturing.
• Remarks
• Electronic and mechatronic systems are very
  complex.
• The diagnosis of failures for the systems is also
  challenging.
• There are very much different applications which
  look similar or the same (different programs in
  the electronics).
• It is essential to built up knowledge before
  starting the remanufacturing process.

17
S. Freiberger
Thank You -
See You Again !