circular economy oriented services for re-use and

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 remanufacturingof hybrid and electric vehicles components through smart and movable modules

Date

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

http://www.careserviceproject.eu/

CarE-Service Dissemination Events

July 2021October 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)

Agenda

11:00 Introduction

11:05 Introduction Video of Fraunhofer IWU

11:10 Reforming of sheet metal parts

11:25 De-Soldering of structural parts

11:40 Data management solutions

11:45 SMM - Smart mobile modules - Testing

12:05 Conclusion

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

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

• 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

Concept

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-userDismantlers

Recyclers Logistic providers

Final certified components

ready for delivery

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

Agenda

11:00 Introduction

11:05 Introduction Video of Fraunhofer IWU

11:10 Reforming of sheet metal parts

11:25 De-Soldering of structural parts

11:40 Data management solutions

11:45 SMM - Smart mobile modules - Testing

12:05 Conclusion

Beginn_Dr-Hipke.mp4

20210520_147281_CarE-Service_SheetMetal-ReManufacturing_Technologies_WEBINAR.pptx

Training_Webinar_TP.pptx

Training_Webinar_RS.pptx

CarE-Service_TrainingMetal_SMM2_05_IMA.pptx

Contact

[email protected]

May 25th 2021

Markus Maibaum, M. Sc. | Fraunhofer IWU

Roberto Seyfert, M. Eng. | Fraunhofer IWU

Remanufacturing of metal components:

RFID Data Storage

Marking of materials (Today)

https://www.verbraucherzentrale.de/wissen/lebensmittel/lebensmittelproduktion/recyclingcode-das-bedeuten-die-symbole-auf-verpackungen-11941https://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

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

Intelligent Material Marking

• A novel approach is the marking or saving

of data for :

• ReUse

• Remanufacture or

• Refurbish

• In CarE-Service the aim is:

• collect much more information connected to part or product beside the single material information.

• The focus is to have precise information

which are fitting to special processes for

reuse, remanufacture and refurbish

Full specifics

Main functionality

Base structure

Material

Dispositive effort

Minor

refreshment

Mayor

reforming

Full metal

value chain

A possible Data Chip could be a RFID -Chip

RFID tags can be sorted by :

Frequency

transmission speed

Capacity

prize

Research of data storage hardware and selection

Source: L-mobile.com ; https://www.smart-tec.com/de/auto-id-welt/nfc-technologie

https://www.smart-tec.com/de/auto-id-welt/nfc-technologie

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.

video storage hardware

RFID.mp4

Smart and low cost solution for getting all required data through the live cycle of parts and

assemblies from OEM to remanufacturing companies

documentation for a fitting data storage concept

©

Different RFID Chip Different RFID

Android Open

source software

(write and read)

Source: https://play.google.com/store/search?q=RFID&c=apps&hl=de&gl=US

https://play.google.com/store/search?q=RFID&c=apps&hl=de&gl=US


Joining-Disassembly-Technology

May 25th 2021

Tibor Paizs | Fraunhofer IWU

Car Body Joining Technologies

JoiningDIN 8593 Part 0

Joining by FormingDIN 8593 Part 5

Joining by WeldingDIN 8593 Part 6

Joining by BrazingDIN 8593 Part 7

BondingDIN 8593 Part 8

MAG welding

laserbeam welding

laserbeam brazing

structural adhesive

resistance spot welding

self-pierce riveting

solid riveting

flow drill screwQuelle: Audi AG

Quelle: Audi AG

Quelle: Audi AG

Quelle: Audi AG

Quelle: Audi AG

Quelle: Audi AG

Quelle: https://www.neumaier-industry.com/

Car Body Joining Technologies

steelhigher-strength steelhighest-strength steelhot forming steel

resistance spotweldings

structural adhesive

laserbeam welding

laserbeam brazing

MAG welding

Joining Technologies:

Not detachablyjoining connections!

Quelle: Audi AG

Car Body Recycling

Carcom-

pactionFractio-nation

Melting down and casting

Rolling ofcoils

OEM / Suppliers

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Car Body Recycling

Carcom-

pactionFraction-

ationMelting down

and castingRolling of

coilsOEM /

Suppliers

Remanufacturing by non-destructivedismantling of brazed joint connections

Principle approach of theJoining-Disassembly-Technology:

heat sourcee.g.

laser beam

heat sourcee.g.

laser beam

heat sourcee.g.

laser beam

melted solder

suction

meltingsolder

s ingleparts

s ingleparts

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

Experimental equipment:

Laser processing optic with intelligent temperature control

semitransparent-mirror

Configuration of the laser processing optics with intelligent temperature control:

wave lenght of theprocessing laser: 1050nmwave length of thepyrometer: 1700-2600nm

Experimental equipment: CFX calculation of the gas nozzle

melted solder

suction

heat sourcee.g.

laser beam

CFX calculation of the gas nozzle:

supersonic velocity!

supersonic shocks

configuration of the laser processing optics with intelligent temperatur control:

adapter for the fibreof the pyrometer

DINSE wire feedmodul

pyrometer

high frequency laser beam scanner

observation camera

air cleaner

protection of theoptical 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

blowed out meltedsoldered seam

process of disassembling with

a 1030 nm wavelength laser

processing zone

gas nozzle(high pressure)



process in detail:

the non-destructive desoldering of car-body parts is basically possible with

the technology that has been developed

to increase the process speed, further process optimization are required

a promising approach is the use of a high-speed thermal camera, which is

used for example for laser hardening

further optimizations of the process are not possible within the scope of the

project

summery

Thank you for your attention


reforming of sheet metal blanks

May 25th 2021

Rico Haase, M. Sc. | Fraunhofer IWU

Car Body Recycling

Carcom-



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OEM / Suppliers

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Car Body Recycling

Carcom-



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Concept:Sheet Metal Re-Manufacturing Technology

Principle approach / Value Chain

Aim: Reduce ressource consumption by use of secondary raw material

(SRM) blanks instead of re-melting and roll-milling of recycled material.

Task: Consider mechanical, geometrical and other impacts

on SRM quality which is caused by the previous life cycle.


Principle approach / Value Pyramid

Full specifics

Main functionality

Base structure

Material

Dispositive effort

Minor

refreshment

Mayor

reforming

Full metal

value chain

re-entry level of different recycling routes (WP 3.2)

State of Art

Re-Manu.

Spare parts

[lrp-autorecycling-chemnitz.de]


Process Chain

Low-Tech Approach:

- measurement of sheet metal thickness at single, discrete points

- extraction with handheld sheet metal cutter

trimline depends on operator‘s skills

no defined blank size achievable

re-trim of blank required

- manual marking of blank (thickness/…)

Benefit: lowest fix cost for equipment

Issues: higher labour cost and additional

operations (defined trimming) necessary

Measurement & Analysis of wrecked car

Blank extraction

Application of tracking code

Sheet Metal Forming

operation

Sale / Assembly


Process Chain

High-Tech Approach:

- measurement of sheet metal thickness at several points,

- curvature check by e.g. optical measurement system

- extraction with NC-controlled device:

well-defined, repeatable trimline geometry

direct use for forming operation

- automated marking and traceability of blank

Benefit: detailed information, repeatable quality,

quick processing and low labour cost

Issues: investment in automation required (SMM)

Measurement & Analysis of wrecked car

Blank extraction

Application of tracking code

Sheet Metal Forming

operation

Sale / Assembly


Outlook / Upcoming aspects to consider in process planning of Re-Manufacturing technologies

- Impact of blank curvature

(generalized geometric influence)

- to wrinkling limit and

- to springback behaviour

Establishment of a representative curvature factor

- summarizing the product of a double-curved blank shape

- allowing a separation of convex / concave bowls

- providing a quality parameter for SRM blanks

- Impact of previous forming and heat treatment

(generalized mechanical influence)

- to flow curve and

- to forming limit

Local Strain

Hardening

[Wikipedia:HyperbolischeParaboloidschale]


Forming operation details

Press: Müller-Weingarten CLDZ / 2500 kN

Tooling: deep drawing tool with

press-operated binder

Upper die: 1000 kN

250 mm stroke

Blank holder: 50…100…150 kN

15 mm stroke

delayed return




“Reforming technologies for re-manufacturing of sheet metal parts, metals disassembly and testing in automotive”25 May 2021

This project has received funding from the European Union’s Horizon 2020

research and innovation programme under grant agreement No 776851

Smart Mobile Module – Testing

Matthias Goetze

IMA Dresden

Content

• Where is IMA coming from?

• Role in the concept CarE-Service

• Characteristics in Metal Value Chain

• Smart Mobile Modules

• See you again soon

Where is IMA coming from?

Evaluation of capabilities of products to be alive under service conditions

In laboratories permanently observed state

using Non-destructive Inspections

Eddi current test

Visual inspection

Ult

raso

un

d t

est

Magnetic particleinspection

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

Role in the concept CarE-Service

Goals of future Metal Recovery

Enlarged sustainability by nearly level cycling

Less consumption of process energy

Find high valuable EoL parts dis-

tributed over many locations

High confidence in processing

result for each harvested part

Prosper Second Life Market

Re-soldering

Re-forming

Characteristics in Metal Value Chain

Which metal parts should be considered how?

Large faced sheets without kinkWithout damageMechanical behaviourLimited shapes

Unmountable partsWithout damage

Disconnectable jointsWithout damage


Without damage

• Nondestructive Inspection

• Several kinds of Nondestructive Tests

• Hierarchically by effort, beginning

with visual inspection DIN EN 13018:2016

Findings?!

Rust

Scratch

Dent

Global Visual Inspection at Car Roof

Loca

lVis

ual

In

spec

tio

n


Without damage

• Visual Inspection, standardised

Local Visual Inspection at Car Roof


Limited shapes

• Required minimum radii or maximal curvature respectively

• Shape analysis after reverse design by Digital Image Correlation (DIC)


Limited shapes

• Arrengement of stereoscopic sampling as data base for DIC


Mechanical behaviour

• Required deformation of former plastically formed sheets

• Residual capability of plastification proven by destructive Erichsen-Test

0.538e1

0.000

dz = 12.46mm

DIC measurement Testing machine

TravelerCar Roof


DIN EN ISO 12004-2 Forming Limit Curve

Mechanical behaviour with boundary conditions in circular economy

• Being comprehensive to First Life raw material

• Go easy with material for specimen extracted from a Second Life part

• Quick accessable significant information

AppropiateInappropiate

ε1

ε2

Smart Mobile Modules

Operational process

• Areal situation

• Work sharing

• Logisitic

Dismantler A

Dismantler B

Dismantler D

Dismantler C

Dismantler E

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

Smart Mobile Modules

An approach

• 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

• estimation of the type and content of high value-added

materials for recycling

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 theEnd-of-life of vehicles for producing newparts.

29th June (Demonstration)“Automotive Polyamide Circularity?

Yes, it’s feasible”

In the Techno-polymer Demonstration

event RadiciGroup a project partner will

show the achieved results of recycling

the polyamide components used in the

vehicles through innovative technolo-

gies.

https://www.careserviceproject.eu/news-and-events/




“Reforming technologies for re-manufacturing of sheet metal parts, metals disassembly and testing in automotive”25 May 2021

circular economy oriented services for re-use and

Documents