Pulmonary drug delivery system M.pharm -2nd sem P'ceutics
New solutions for disassembly, remanufacturing and testing automotive metal parts
1. This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules
Date
2. Please mute your microphone and open it only to ask questions in
the dedicated discussion slots at the end of each presentaion and in
the closing session
Use the chat to ask questions and submit comments during the
entire workshop
Raise your virtual hand if you want to ask a question in the
dedicated discussion slots
Presentations will be available for dowload in the CarE-Service
project website (www.careserviceproject.eu)
Connection recommendations
3. CarE-Service Dissemination Events
July 2021
October 2021
13th May (Training)
“Polyamides today:
from polymerization to recycling”
25th May (Training)
“Reforming technologies for re-manufacturing
of sheet metal parts, metals disassembly and
testing in automotive”
May 2021
June 2021
4th June (Demonstration)
"Innovative community platform for the reuse,
remanufacturing and recycling of metals,
techno-polymers and batteries in automotive”
29th June (Demonstration)
“Automotive Polyamide Circularity?
Yes, it’s feasible”
5th July (Training)
"Mobile Solutions and Flexible lines for vehicles
battery dismantling”
21st July (Demonstration)
“New solutions for disassembly, remanufacturing
and testing automotive metal parts”
September 2021
20th September (Training)
“Battery Circular Economy approaches for
redesign, reuse and regulation”:
• Battery re-design: a sustainable
solution for the transition to Circular
Economy
• Second life battery applications:
challenges, solutions and case studies
• New Battery Regulation: implications
for the European battery value-chain”
18th October (Demonstration)
“Circular Economy holistic approach for
used batteries of electric and hybrid-electric
vehicles”
19th October (Demonstration)
“Circular economy-based mobility services”
October 2021
November 2021
25th November
(Final Exploitation Event)
The CarE-Service project will celebrate the
final event with a holistic discussion of
demonstrated results:
“Circular economy in the future automotive
market: new products and services generated
by the CarE- Service project"
(hosted by Fiat Chrysler Automobiles)
4. Agenda
10:00 Introduction
10:05 Introduction Video of Fraunhofer IWU
10:10 Reforming of sheet metal parts
10:30 De-Soldering of structural parts
10:50 Data management solutions
11:00 SMM - Smart mobile modules - Testing
11:25 Conclusion
5. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Project introduction
Dr. Thomas Hipke
Fraunhofer-Institute
for Machine Tools and Forming Technologies
6. Project figures
No Name Country
1 CONSIGLIO NAZIONALE DELLE RICERCHE* - Coordinator Italy
2 LINKOPINGS UNIVERSITET Sweden
3 ENVIROBAT ESPANA SL Spain
4 PRODIGENTIA - TECNOLOGIAS DE INFORMACAO SA Portugal
5 AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS Spain
6 CIRCULAR ECONOMY SOLUTIONS GMBH Germany
7 COBAT SERVIZI Italy
8 FIAT CHRYSLER AUTOMOBILES ITALY SPA Italy
9 RADICI NOVACIPS SPA Italy
10 IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK GMBH Germany
11 FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V Germany
12 AVICENNE DEVELOPPEMENT France
13 CIA AUTOMATION AND ROBOTICS SRL Italy
14 E-VAI SRL Italy
15 JRC -JOINT RESEARCH CENTREEUROPEAN COMMISSION Belgium
7. • Redesign E&HEVs for circular economy
• Develop EU leadership in advanced
technologies for re-use of E&HEVs
• Reduce TCO of E&HEVs
• Create new value chains and businesses in
EU around Circular Economy of E&HEVs
The concept of CarE-Service
Innovative
mobility
services for
citizens
based on
E&HEVs
• Increase citizens’ quality of life through
circular economy of E&HEVs
• Increase market acceptance and change
consumers’ behavior
• Guarantee return-flow of E&HEVs
• Increase market of innovative services
• New mobility services with upgrade
remanufactured parts
• Create a suitable regulatory framework
9. Mobile units bringing advanced technology for on-site disassembly and
testing/certification where is the demand
Disassembly Module
CarE-Service ICT Platform and Smart Mobile Modules (SMMs)
ICT Platform connecting demand and supply of re-usable parts and allowing the
coordination and optimization of the re-use value chain
Cloud-based CarE-
Service Platform
Testing Module
Manufacturer
End-user
Dismantlers
Recyclers Logistic
providers
Final certified
components
ready for
delivery
10. Demonstration
• Technical solutions in 3 re-use
value chains
• Re-use applications
• Mobility services
(multiple locations, customers
involvement)
• Overall business sustainability
• Social impact
Expected results
Exploitation
• Open industrial training
workshops
• Exploitation meetings
• First market replicators
• Regional Authorities involved
• White paper for regulation
• Community of customers
Stakeholders’ Group
Consumers’ Committee
Social Community
11.
12.
13. Agenda
10:00 Introduction
10:05 Introduction Video of Fraunhofer IWU
10:10 Reforming of sheet metal parts
10:30 De-Soldering of structural parts
10:50 Data management solutions
11:00 SMM - Smart mobile modules - Testing
11:25 Conclusion
14. ▪ Recap: Recent developments of secondary raw material
▪ Process Design for further lifecycle based on pre-used material
▪ Challenges for use of SRM
▪ Typical properties of secondary raw materials (SRM)
▪ SRM material market
▪ Re-Manufacturing of SRM material
Sheet metal remanufacturing - Agenda
15. ▪ State of the art is recycling of metals on very basic raw material level
▪ Significant resource consumption for re-melting and subsequent milling
process: 9.54 MWh/t [InnoCaT: Green Carbody Technologies]
▪ environmentally friendly alternative:
re-introduction of material on a higher level of the metal working
value chain ➔ characteristic sheet shape is preserved
Recap: Recent developments of
secondary raw material (SRM)
State of the Art
Innovation Potential
16. Process Design for further lifecycle
based on pre-used material
pre-used
component
(1st life)
blank
extraction
from rooftop
cut of blank
for further
processing
deep draw
operation
springback &
mech.
properties
blank: 1485x785 mm²
round blanks Ø ~320 mm
final component
remanufacturing tool
17. ▪ The use of secondary raw materials (SRM) in a conventional forming
process is challenging in terms of:
▪ mechanical properties
▪ forming limit curve FLC
▪ initial strength of the material
▪ geometric appearance
of the SRM blank
▪ single- / double-curved shape
▪ varying sheet metal gauges
across the SRM blank
➔ The re-manufacturing process need to be robust towards those impacts
➔ Establishment of SRM material categories is proposed to qualify material
Challenges for the use of SRM
18. ▪ The use of secondary raw materials (SRM) in a conventional forming
process is challenging in terms of:
▪ mechanical properties (scaled for better visibility)
▪ forming limit curve FLC ➔ lowered - Tests ongoing, pending project
▪ initial strength of the material ➔ increased - Tests completed.
Challenges for the use of SRM
[AutoForm Material DB, edited]
[AutoForm Material DB, edited]
19. ▪ due to previous lifecycle, a part of the formability is consumed already
▪ to limit the individual characterization effort,
global degradation of material properties is assumed
➔ increased initial strength while lowered elongation
Typical properties of secondary raw materials (SRM)
HC180B
Virgin material
(typ. value)
after
work hardening
after
bake hardening
Yield Strength (205 ± 25) MPa
~ 220 MPa
➔ 15 MPa
increase
~ 255 MPa
➔ 35MPa*
increase
Elongation to
fracture
> 34%
~ 25%
➔ 9% decrease
* Impact of bake hardening quantified in InnoCaT (Green Carbody Technologies)
20. ▪ The use of secondary raw materials (SRM) in a conventional forming
process is challenging in terms of:
▪ geometric appearance of the SRM blank
▪ varying sheet metal gauges across the SRM blank ➔ tolerance
▪ single- / double-curved shape: radii and orientation
▪ Categorization of blanks: Largest curvature value does decide.
➔ Scalar value
Challenges for the use of SRM
[Wikipedia:
Hyperbolische
Paraboloidschale]
21. ▪ SRM blanks can be harvested easily from the outer shell of wrecked cars.
Both, mechanical and flexible laser cutting technology can be applied.
➔ Shown by Tibor Paizs.
▪ Different blanks can be nested into a single raw blank for improved
material and economic efficiency.
▪ SRM blank material is offered through the CarE-Service portal:
https://www.careserviceproject.eu/technologies/ict-platform/
SRM material market
Surface Inspection &
Curvature Measurement
22. ▪ shaped blanks are cut from SRM raw blank by means of flexible metal
working technologies - several blanks can be nested for material efficiency
Re-Manufacturing of SRM material - blank cutting
23. ▪ shaped blanks are cut from SRM raw blank by means of flexible metal
working technologies - several blanks can be nested for material efficiency
Re-Manufacturing of SRM material - blank cutting
24. ▪ Formability of a brake disk cover part has been validated.
▪ The replacement of virgin material by SRM blanks can be accessed by
means of a FEA validation and material properties supplied by the SRM
provider.
Re-Manufacturing of SRM material - forming
final component
remanufacturing tool
25. ▪ Formability of a brake disk cover part has been validated.
▪ The replacement of virgin material by SRM blanks can be accessed by
means of a FEA validation and material properties supplied by the SRM
provider.
Re-Manufacturing of SRM material - forming
1st attempt:
Circular blank
➔ Trimming
necessarily
required.
26. ▪ Formability of a brake disk cover part has been validated.
▪ The replacement of virgin material by SRM blanks can be accessed by
means of a FEA validation and material properties supplied by the SRM
provider.
Re-Manufacturing of SRM material - forming
2nd attempt:
Shaped blank
➔ Developed
length of trim
➔ No further
cutting required.
28. Remanufacturing of metal components:
Joining-Disassembly-Technology
July 21 2021
Tibor Paizs | Fraunhofer IWU
29. Principle approach of the
Joining-Disassembly-Technology:
heat source
e.g.
laser beam
heat source
e.g.
laser beam
heat source
e.g.
laser beam
melted
solder
suction
meltingso
lder
single
parts
single
parts
final
product
brazing
Joining Disassembly
Brazed seam of CuSi3, CuAl8---
melting temperatur: 1040 °C
sheet steel (DC04, HX360, o.ä.)
melting temperatur: 1600°C
processing window:
1200°C…1500°C
30. configuration of the laser processing optics with intelligent temperatur control:
adapter for the fibre
of the pyrometer
DINSE wire feed
modul
pyrometer
high frequency laser
beam scanner
observation camera
air cleaner
protection of the
optical components
collimating lens
semitransparent-
mirror
focusing lens
adjustable gas
nozzle
position table for x
direction
Position table for z
direction
Experimental equipment:
complete processing Optics
31. blowed out melted
soldered seam
process of disassembling with
a 1030 nm wavelength laser
processing zone
34. adjustable parameters of the test stand:
Joining-Disassembly-Technology:
construction and assembling of the test stand
1. Influence of nozzle
distance
35. 1. Influence of nozzle distance:
Joining-Disassembly-Technology:
construction and assembling of the test stand
good nozzle distance!
36. adjustable parameters of the test stand:
Joining-Disassembly-Technology:
construction and assembling of the test stand
1. Influence of nozzle
distance
2. Influence of the laser
power
37. 2. Influence of the laser power:
Joining-Disassembly-Technology:
construction and assembling of the test stand
good laser power!
38. adjustable parameters of the test stand:
Joining-Disassembly-Technology:
construction and assembling of the test stand
1. Influence of nozzle
distance
2. Influence of the laser
power
3. Influence of the spot
diameter
39. 3. Influence of the spot diameter:
Joining-Disassembly-Technology:
construction and assembling of the test stand
good laser spot diameter!
40. adjustable parameters of the test stand:
Joining-Disassembly-Technology:
construction and assembling of the test stand
1. Influence of nozzle
distance
2. Influence of the laser
power
3. Influence of the spot
diameter
4. Influence of the laser
beam oscillation
41. 3. Influence of the laser beam oscillation:
Joining-Disassembly-Technology:
construction and assembling of the test stand
Disassembling works better
without laser beam oscillation
43. May 25th 2021
Markus Maibaum, M. Sc. | Fraunhofer IWU
Roberto Seyfert, M. Eng. | Fraunhofer IWU
Remanufacturing of metal components:
RFID Data Storage
44. Marking of materials (Today)
https://www.verbraucherzentrale.de/wissen/lebensmittel/lebensmittelproduktion/recyclingcode-das-bedeuten-die-symbole-auf-verpackungen-11941
https://www.derwesten.de/panorama/kaum-jemand-weiss-es-das-bedeutet-der-geheimnisvolle-code-auf-plastikflaschen-id221114365.html
Sources:
metals
polymers
iron, steal
aluminium
• material marking is only a standard for purely material recycling of raw material
• There are many different chains and recycling routes
46. Intelligent car component data
• the novel approach is to get data directly
from the part without a network or cloud
solution
• The data should fit very good to the special
processes
• ReUse
• Remanufacture (e.g. reforming) or
• Refurbish
• Also it is necessary to have much more
data besides the material class itself:
• Thickness
• Curvage
• Alloy
Full specifics
Main functionality
Base structure
Material
Dispositive effort
Minor
refreshment
Mayor
reforming
Full metal
value chain
48. ▪ RFID tags can be sorted by :
▪ Frequency
▪ transmission speed
▪ Capacity
▪ Prize
▪ Communication range
▪ The RFID transfer standard NFC
▪ High storage capacity
▪ Low communication range
Research of data storage hardware and selection
Source: L-mobile.com ; https://www.smart-tec.com/de/auto-id-welt/nfc-technologie
49. Type Parameter Mandatory /
optional
Derived
from
Description
general Vehicle name mandatory OEM car name depending on OEM
general Part ID mandatory OEM unique part ID
general Year of
manufacture
mandatory OEM YYYY(.MM.DD)
general Part type mandatory OEM profile, structural part, deep
drawn part, etc.
general Material class mandatory OEM e.g. steel
general Material ident
number
mandatory OEM e.g. 1.0922
general Material norm mandatory OEM e.g. DIN EN 10268
general Material name mandatory OEM e.g. HC180Y+ZE
general Surface status mandatory OEM e.g. +AZ 150
▪ Writing Informations
data storage Hardware & Software in focus
▪ Put the written Chip on a
fitting place
▪ Reading Informations
▪ Example of potential useful
data for remanufacturing
processes.
53. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Operational Demonstration
Smart Mobile Module – Testing
Matthias Goetze
IMA Dresden
54. Role in the concept CarE-Service
CarE-Service Project an integrating Business Model
• Network of highly
specialized contributors
• Multinational in EU
Technopolymer Value Chain
… one of three
55. Role in the concept CarE-Service
Focus of the Value Chain of Technopolymers
• Material recovery on level (structural components) Radici Group
• Reliable quality of End of Life parts (post customer) CIA & IMA
• Revaluation of parts by approved attributes on the CarE-Service Marketplace
• Advanced procedure or technology on site
Typical parts made from Technopolymer
https://demo.ev.care/en/13-techno-polymers
C-Eco & Prodigentia
56. Role in the concept CarE-Service
Where is IMA coming from? – Evaluation of capabilities of products
to be alive under service conditions
Permanently observed state (laboratory)
Eddi current test
Visual inspection
Ultrasound
test
Magnetic particle
inspection
57. Role in the concept CarE-Service
Premise of Recovery
• Appropriate End of Life parts
• Proven characteristics
• Successfully passed
inspections
Challenge concerning
EV&HEVs
• Limited number of post-use
cars in this ramp-up phase
• Old fashioned car design
58. Disassembly Module
• DSS suggesting which components to disassemble
based on car sensors data, manufacturer product
data and market
• Disassembly guidelines
• Robotics cooperative disassembly
• Mechatronics tools
Inside the Business Models
Smart Mobile Modules – Why?
• Mobile services tailor made for sophisticated recovery
• Advanced technologies for on-site disassembly and testing
• Operation on demand
Testing Module
Functional, geometric, mechanical and electric
testing methods and technologies for:
• Evaluation of re-usable parts
• Testing of components and parts for remanufacturing
• Type / content of value-added materials for recycling
59. Inside the Business Models
Connected with ICT Platform
• Mobile services intermidiately affects the data base
Public domain
(non-associated trade)
Internal order and logistic
(part-/material flow)
Evaluation
(edit attributes)
SMM Testing
61. Inside the Business Models
Outcome for the Technoploymer Value Chain
• Boxes of parts allowed for production of structural parts
• Selected in Catagory 3 – Level-Cycling
Rubbish or undifferentiated flow of automotive waste
• that is recycled after the removal of hazardous
thorough shredding and chemical processes
EV&HEVs circular economy perspective
62. Techniques for Technopolymers
Purpose: Material Identification
Proven Conditions
• Nondestructive Inspection
• Several kinds of Nondestructive Tests
• Hierarchically by effort, beginning
with visual inspection DIN EN 13018:2016
63. Techniques for Technopolymers
Visual Inspection, standardised
• Precise defined task
• Limited time consumption
Local Visual Inspection
Qualification to reproducely
realize inspection tasks
65. Techniques for Technopolymers
Global Visual Inspection
• Process control by JobCards, e.g. wheel cover
• Description, options of decision and time
66. Techniques for Technopolymers
Infrared Spectroscopy
• Mobile solutions
• Preconfigured analysis
• Material libraries
Laser
activated
LED
activated
Laser
activated
(production is
going to be
terminated)
67. Techniques for Technopolymers
Near Infrared reflective Spectroscopy
• Range 1400nm … 2500nm
• Less than 3s per capture
• Operation temperature 0°C ... 40°C
• Relative humidity up to 80%
Preconfigured espcecially for Technopolymeres
71. Techniques for Technopolymers
When the job is done
• Parts successfuly passed keep members of lot
• Expectable change of amount of parts inside a lot
73. See You Again Soon
21st July (Demonstration)
“New solutions for disassembly,
remanufacturing and testing automotive
metal parts”
In the Metal demonstration event,
Fraunhofer IWU will show the technolo-
gies for disassembling and remanu-
facturing the metal components at the
End-of-life of vehicles for producing new
parts.
https://www.careserviceproject.eu/news-and-events/
