obstacles to and opportunities for growth in the remanufacturing - - PowerPoint PPT Presentation

What are the technological

• bstacles to and opportunities

for growth in the remanufacturing industry?

Todd Wieland, PhD Director of Engineering – New and ReCon Parts Mfg Cummins Inc.

Trends & Drivers

• Internal

– Design optimization includes minimum weight, cost – New materials, coatings & surface treatments – New high value components – Permanent assembly methods, fewer fasteners, joints

• External

– Higher complexity limits local repair options – Greater availability of low cost new part alternatives – More stringent emission laws being adopted globally – Leading emissions markets shift focus to greenhouse gas – Growing environmental sensitivity / stewardship – Growing producer responsibility for end of product life – Global growth and relevance of reman

2

Technology Need – “Additive Manufacturing”

• Remanufacturing traditionally includes re-application
• f new part production processes

– Re-grinding, milling, boring, polishing… – Requires myriad non-standard parts

• Modern analysis and optimization tools

enable removal of “excess” material

– Excess traditional remanufacturers needed

• Thin surface coatings or treatments may prohibit /

limit or require specialized finishing methods

– Nitriding, Nikasil, Alusil

• Wanted: Means to replace worn / corroded mat’l

3

Cylinder Block Early Later

Technology Need – “Additive Manufacturing”

• Thermal Spray

– Twin wire arc – HVOF – Plasma – Cold Spray

• Laser Deposition

4

Sources: http://www.thermalspray.org/index.php?option=com_easyfaq&task=cat&catid=19&Itemid=92 http://www.sulzer.com/en/- /media/Documents/ProductsAndServices/Coating_Services/General/TechnicalArticles/Plasma_Spray_Cylinder_Coatings_in _a_NASCAR_Engine_Expo_2010.pdf http://www.seas.virginia.edu/research/lam/pdfs/speaker%20presentations/Mazumder-NSF-IUCRC%20workshop-2010.pdf

• Environmentally Friendly Cleaning Processes

– Effluent disposition, chemical and water usage, ergonomics – e.g. Laser Cleaning

• “Fit for Market” Processes

– Processes which meet cost requirements in new markets

Technology Need – Improved Processes

5

Sources: http://adapt-laser.com/Technology/Lasertechnology.html Engine remanufacturing technologies and application in China.pdf

It is not cracked today, but what about tomorrow???

Technology Need – New Processes

• Remaining Life Assessment & Damage Reversal

– Electronic components – Electrical insulation systems – Pressurized fluid systems not designed for “infinite life”

• For New Component Types

– Exhaust catalysts and filters – cleaning & reactivation – Hybrid battery systems – rejuvenation, replace cells

6

Design for Service

Technology Need – Integrate into OE Design

• Need “Design for

Remanufacturing”

– Identify WHAT will likely be remanufactured – Develop HOW the product will be reman’d – Make design, materials & assembly decisions to enable this

• Challenges

– Business case not always apparent; may conflict with shorter-term needs

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Design for Assembly Design for Environment Design for Manufacturing Design for Accessibility Design for Logistics