freiberger remanufacturing mechatronics electronics

Electronics and Mechatronics

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Automotive Parts Remanufacturers Association

Welcome

www.lup.uni-bayreuth.de

Remanufacturing of Mechatronics and Electronics

Dipl.-Ing. Stefan Freiberger

May 10, 2006


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Structure

Remanufacturing Electronics and Mechatronics

1. Introduction2. Opportunity 3. Demand4. Complexity of the Product5. Process Steps6. Complexity of the Diagnosis7. Conclusion


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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


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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


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Cooperation with the Industry, other Universities and Chairs

Global „Scientific Community“ for RemanufacturingCooperation with the Industry and other Chairs


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1980 1990 2000 2010

Am

ount

of E

lect

roni

cs a

nd M

echa

troni

cs

Year

S. Freiberger

EHPS

EASSteer-by-wire

Opportunity of Remanufacturing Mechatronics

Rack steering

EHPS= Electro-Hydraulic-Power-SteeringEAS= Electrically Assisted Steering


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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


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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 $


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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)


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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


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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

S. Freiberger

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


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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

S. Freiberger


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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


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Thank You -

See You Again !

S. Freiberger

freiberger remanufacturing mechatronics electronics

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