Freiberger Remanufacturing Mechatronics Electronics
Transcript of Freiberger Remanufacturing Mechatronics Electronics
Electronics and Mechatronics
Division
Automotive Parts Remanufacturers Association
Welcome
www.lup.uni-bayreuth.de
Remanufacturing of Mechatronics and Electronics
Dipl.-Ing. Stefan Freiberger
May 10, 2006
Electronics and Mechatronics
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Automotive Parts Remanufacturers Association
Structure
Remanufacturing Electronics and Mechatronics
1. Introduction2. Opportunity 3. Demand4. Complexity of the Product5. Process Steps6. Complexity of the Diagnosis7. Conclusion
Electronics and Mechatronics
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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!
Europe
.Bayreuth
Electronics and Mechatronics
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DemontageMontage
Diagnose
Aufarbeitung
UP
Reinigung
The Remanufacturing Industries R&D Partner in Bayreuth
DisassemblyAssembly
Cleaning
Testing
Reconditioning
UPEuropean Remanufacturing Technology Center
Electronics and Mechatronics
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Cooperation with the Industry, other Universities and Chairs
Global „Scientific Community“ for RemanufacturingCooperation with the Industry and other Chairs
Electronics and Mechatronics
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1980 1990 2000 2010
Am
ount
of E
lect
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nd M
echa
troni
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Year
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EHPS
EASSteer-by-wire
Opportunity of Remanufacturing Mechatronics
Rack steering
EHPS= Electro-Hydraulic-Power-SteeringEAS= Electrically Assisted Steering
Electronics and Mechatronics
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Mechatronics and Electronics in Most of all Products1. Automotive Components
2. Electrical Apparatus
3. Machinery
4. Office Furniture
5. Toner Cartridges
6. Others
Electronics and Mechatronics
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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!
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Opportunity of Remanufacturing - High Value Products
Mechatronic System Sales Price in US $
Antilock Brake System (ABS) 1620 $
Dynamic Drive >1480 $
Electro Hydraulic Brake (EHB) > 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 > 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 $
Electronics and Mechatronics
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Systems in Remanufacturing – Now and in the Future ClassicRemanufactured -
• Starters
• Alternators
• Turbo chargers
Future
• Control Units
• Electro hydraulic power steerings (EHPS)
• Electronic Stability Program (ESP)
• Engines
• Brake calipers
• Air conditioning compressors
• Electrically assisted steerings (EAS)
• Air flow meter
• ...
Remanufactured-
S. Freiberger
(more and more)
Electronics and Mechatronics
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Mechatronisches System
Complexity of the Products – Analyzed for a Industry Partner S. Freiberger
Electrically Assisted Steering Electro-Hydraulic-Power-Steering
Mechanic & Energy Converter
Control
ECU
Actuator Sensor
Information / Energy
Actual ValueGiven Value
Energy / SubstancesEnergy / Substances
Electronics and Mechatronics
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Process steps in Mechatronics- und Electronics-Remanufacturing
Quality Assurance
Final Testing
2 Disassembly of the System
3 Thorough Cleaning
4 Diagnosis and Sorting
Reconditioning of Parts or Subsystems and/or Replenishment
6 Product Reassembly
5
1 Entrance Diagnosis of the System
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Final Testing(Climate Chamber)
2 Opening the System
3 Diagnosis and Sorting
4 Replenishment of Parts
Closing the System5
1 Entrance Diagnosis of the System
Quality Assurance
Mechatronics-Remanufacturing Electronics-Remanufacturing
Electronics and Mechatronics
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Diagnosis for Mechatronics - Entrance and Final Test S. Freiberger
Methods for Diagnosis of Mechatronics
Signal Based Methods• Absolute Value Control
• Value Trend Control
• Calculation of the Characteristic Curves
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
Test Bench in Computer Aided Design
Test Benchin Reality
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Diagnosis for Electronics – Failure Detection and Isolation
X-Ray Diagnose
Thermography Diagnose
Methods for Diagnosis of Electronics
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
Signal Model Based Methods• Stochastic Signal Model
• Spectral Analyse
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Electronics and Mechatronics
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Diagnosis with Real Road Tests – Analyzed for an Industrial Partner S. Freiberger
Place: Test-territory of the German federal force in Bayreuth
(Oschenberg)
Vehicle: Borrowed from the Chamber of Crafts
Reason for real road test:
• Find the operating points in reality.
• Compare the test bench results with the reality.
• Find out the specifications.
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Conclusions
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.
S. Freiberger
Electronics and Mechatronics
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Thank You -
See You Again !
S. Freiberger