Produktverantwortung des Konstrukteurs - APRA Inverter module, ... Reassembly of the system Initial...

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

M.Sc., Dipl.-Ing. (FH) Alexander Nagel Dipl.-Ing. (FH) Joachim Kleylein-Feuerstein

Chair Manufacturing and Remanufacturing Technology

Bayreuth University

Use of remanufactured parts for

future service processes

Welcome

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 1

APRA Europe Workshop Almelo, 13-14th March 2013

1) Future Developments in Service Processes

2) Light weight design

3) E-Mobility and Remanufacturing

4) Remanufacturing of ECU’s

Table of Contents

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 2


Research Project: Car-Service-Engineering 2020

„Invest 20 minutes of your time to answer 20 questions concerning the Car-Service in 2020“. The questionnaire has been sent to 1254 garages in northern Bavaria.

Our survey in 2011 asked garages. Media coverage (tv, radio, press) approached Car owners . Exciting answers have returned.

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 3


Results of 2520 answers to questionnaire and Media

Garages spend 50% of total repair times for failure diagnosis and faulty part identification.

Only 25% of the customers request “original-new-parts” to repair their car.

47% of the garages would – if available – use remanufactured parts instead of new parts.

Used parts (e.g. ebay) are considered as important by 33%.

97% of the garages wish to use more types of remanufactured parts instead of expensive new parts if available.

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 4


Mechatronics spare parts market in Germany per year

-

200.000

400.000

600.000

800.000

1.000.000

1.200.000

Nu

mb

ers

of

spare

part

s p

er

year

in G

erm

an

y

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 5


Remanufacturing in the future (2020)

Source: „Startschuss SE2020“ Prof. Dr.-Ing. Rolf Steinhilper, July 2012, Bayreuth

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 6


Identified service cases in the research project service engineering 2020

1. Jahr 2. Jahr 3. Jahr 4. Jahr

Projektmanagement durch HWK, Universität Bayreuth und Fraunhofer-Projektgruppe Prozessinnovation:

Projektorganisation, Projektdokumentation, Ergebnispublikation, Ergebnispräsentation, Ergebnisverwertung, Öf fentlichkeitseinbindung, etc.

Finanzielle Projektabwicklung

Erfassung neuer Servicefälle :

Detailaufnahmen in ca. 25 Werkstätten zu 50 Service-Prozessen

Ausarbeitung von innovativen und neuen Kfz-Service-Prozessen

Technisch-wirtschaf tliche Bewertung der Kfz-Service-Prozesse

Auswahl der 10 erfolgversprechendsten Kfz-Service-Prozesse

Wissensmanagement und Ausbildung :

Ermöglichung der Durchgängigkeit und Zugänglichkeit der Informationen zu den 10 neuen Kfz-Service-Prozessen

Anwendungsgerechte Wissensaufbereitung zur Erstellung von 10 neuen Schulungen zu den Kfz-Service-Prozessen

Erstellung von 10 Handlungsanleitungen für die Umsetzung der neuen Kfz-Service-Prozesse in Betrieben

Gestaltung von 10 neuen Kfz-Service-Prozessen :

Neukonzeption der 10 Kfz-Service-Prozesse

Entwicklung von f lexibel einsetzbaren Funktionstestern

Betriebliche Erprobung, Detaillierung und Einführung

der Kfz-Service-Prozesse und Funktionstester

Planung neuer Formen des Kfz-Service:

Vollständige Technologieentwicklung für 5 neue Produkte /Servicefälle

Sicherstellung der Ersatzteilversorgung durch neue Konzepte

Optimierung von Technologien und Abläufen u. a. in der Refabrikation

Planung neuer Kfz-Servicezentren z. B. Motoren-Reparaturzentrum

M1

M2

M3

2012 2013 2014

Phase I

Phase IIPhase I

Collection of 50 service cases in 25 garages in upper franconia

&

Clustering

http://www.kfz-service-engineering-2020.de/

More information on our german website

Government-funded by








BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 7


Service processes derived of collected service cases

Customer claims

Vehicle to garage

Diagnosis

Identification of

malfunction

Replace-ment

New part

Mainten-ance

Fault correction

New service process

Potential for new service processes and Reman

Customer process

Garage process

Legend:

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 8






Table of Contents

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 9


Service case: Light weight constructed automotive parts

Lamborghini... Source: http://www.focus.de/auto/news/lamborghini-kohlenstofffasern-machen-den-neuen-aventador-leicht_aid_602400.html

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 10


Possible Service process:

Accident / damaged autobody

Vehicle to garage

Diagnosis of autobody

Preparation for

maintenance

Thermal repair … ?

New Autobody

Refinish

Repaired damage

Reman-ufactured autobody

Potential for new service processes and REMAN

Customer process

Garage process

Legend:

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 11


Possible parts for remanufacturing

Material Component

Carbon fibre laminate Autobody / E-Mobility

Aluminium Water cooler

Plastics Headlamp

Metal foam (Crash protection)

Monocoque Autobody

Source: http://www.focus.de/auto/news/lamborghini-kohlenstofffasern-machen-den-neuen-aventador-leicht_aid_602400.html, Feb. 2013

http://www.focus.de/auto/news/lamborghini-kohlenstofffasern-machen-den-neuen-aventador-leicht_aid_602400.html













BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 12






Table of Contents

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 13


Service process: E-Mobility automotive parts

Source: „Remanufacturing of Toyota Prius batteries“ M.Sc. Alexander Nagel, June 2011, Bayreuth

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

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Slide 14


Possible Service process: Remanufacturing battery cells

Weak battery

Vehicle to garage

Capacity test of battery

Battery – has reached it‘s end of life

Replace-ment

New part

Charging

Healthy battery

Reman battery cell

Potential for new service processes

Customer process

Garage process

Legend:

Reman company

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 15


Possible parts for remanufacturing

Thermal elements

Battery cells

Gas venting

Contact strip

BMU = battery Management Unit

Monitoring battery modules

Thermal elements connector

Current sensor Relay

Corrosion

AC Inverter module, Generator, …

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 16






Table of Contents

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 17


Automotive parts could not longer be seen isolated

Electronic Control Units (ECUs) are connected to each other via a network e.g. Controller Area Network (CAN)

ECUs share information between each other (e.g. sensor data)

Up to 80 mechatronic and electronic systems are communicating among each other

Overview

Trend towards complex automotive mechatronics

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 18


Remanufacturing of mechatronic assemblies

1

2

3

4

5

Remanufacturing steps

1

2

3

4

5

6

Complete disassembly

Intensive cleaning of all components

Test and diagnostics of components

Remanufacturing of components and/or

replacement by new parts

Reassembly of the system

Initial diagnostics of the system

Quality

Management

Final testing and -

diagnostics

Mechanical

assemblies

Mechatronic

assemblies

Remanufacturing of mechanical and mechatronic assemblies Image source: Prof. Dr.-Ing. Rolf Steinhilper

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 19


Initial diagnosis of the system – Mechanical testing

Problem: sensors and actuators are not tested

Fraunhofer Electric Power Steering (EPS) test bench

Test setup

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 20


Initial diagnosis of the system – Mechatronic and electronic testing

EPS ECU block diagramm

BAYREUTH

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Chair Manufacturing

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Slide 21


EPS CAN Communication

EPS CAN data exchange Image source: Audi SSP 313

Three CAN IDs from the EPS

These IDs content the sensor values

These IDs could be identified by connecting the EPS over a interface to CANoe

EPS pinout

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 22


Initial diagnosis of EPS

Data content of the three IDs from the EPS have to be known for testing

Reverse engineering helps to identify the data

EPS ECU receives values from sensors and other ECUs spread in the whole vehicle

Problem: EPS behavior is dependant on this unknown values

Supporting steering force ABS control Unit

G44 – G47 Speed sensor

(road speed signal)

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 23


WebDCL (WebDistributed–CAN–LIN) - concept

Goal of WebDCL is to develop a simple technology for collecting, analyzing and sharing CAN- or LIN-communication

WebDCL concept

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

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Slide 24


WebDCL application EPS

Recording CAN Traces while field experiment

CAN Traces should be recorded at different speeds

Building test setup with the EPS and replay the recorded traces

CANoe simulation setup for EPS testing

Different speeds could be easily simulated

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 25


Future developments in initial diagnosis

Radio Frequency Communication

Research project “Radio Frequency Communication”

Wireless (service-) interface for ECUs

Analyzing an ECU completely wireless (no separate power supply needed)

Wireless access to error memory and general data (ECU state)

Updating and parameterizing the ECU

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 26


Thank you for your attention!

BAYREUTH

UNIVERSITY

Chair Manufacturing

and Remanufacturing

Technology

UP

Slide 27


Contact

Joachim Kleylein-Feuerstein

Dipl.-Ing. (FH) Universitätsstraße 30

95447 Bayreuth

Phone ++49 (0) 921 / 55 7348

Fax ++49 (0) 921 / 55 7305

[email protected]

www.lup.uni - bayreuth.de/fhg/

Alexander Nagel

M.Sc., Dipl.-Ing. (FH) Universitätsstraße 30

95447 Bayreuth

Phone ++49 (0) 921 / 55 7326

Fax ++49 (0) 921 / 55 7305

[email protected]

www.lup.uni - bayreuth.de/fhg/

Produktverantwortung des Konstrukteurs - APRA Inverter module, ... Reassembly of the system Initial...

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Transcript of Produktverantwortung des Konstrukteurs - APRA Inverter module, ... Reassembly of the system Initial...