Produktverantwortung des Konstrukteurs - APRA Inverter module, ... Reassembly of the system Initial...
Transcript of 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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
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 9
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
BAYREUTH
UNIVERSITY
Chair Manufacturing
and Remanufacturing
Technology
UP
Slide 12
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 13
APRA Europe Workshop Almelo, 13-14th March 2013
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
Technology
UP
Slide 14
APRA Europe Workshop Almelo, 13-14th March 2013
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
UP
Slide 15
APRA Europe Workshop Almelo, 13-14th March 2013
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
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 17
APRA Europe Workshop Almelo, 13-14th March 2013
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
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Slide 18
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
Initial diagnosis of the system – Mechatronic and electronic testing
EPS ECU block diagramm
BAYREUTH
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Chair Manufacturing
and Remanufacturing
Technology
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Slide 21
APRA Europe Workshop Almelo, 13-14th March 2013
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
UP
Slide 22
APRA Europe Workshop Almelo, 13-14th March 2013
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
UP
Slide 23
APRA Europe Workshop Almelo, 13-14th March 2013
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
UP
Slide 24
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
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
APRA Europe Workshop Almelo, 13-14th March 2013
Thank you for your attention!
BAYREUTH
UNIVERSITY
Chair Manufacturing
and Remanufacturing
Technology
UP
Slide 27
APRA Europe Workshop Almelo, 13-14th March 2013
Contact
Joachim Kleylein-Feuerstein
Dipl.-Ing. (FH) Universitätsstraße 30
95447 Bayreuth
Phone ++49 (0) 921 / 55 7348
Fax ++49 (0) 921 / 55 7305
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
www.lup.uni - bayreuth.de/fhg/