Abstract: To accelerate the remanufacturing process of electronic waste products, this study designs a partial disassembly line with the multi-robotic station to effectively dispose of excessive wastes. The multi-robotic partial disassembly line is a technical upgrade to the existing manual disassembly line. Balancing optimization can make the disassembly line smoother and more efficient. For partial disassembly line balancing with the multi-robotic station (PDLBMRS), a mixed-integer programming model (MIPM) considering the robotic efficiency differences is established to minimize cycle time, energy consumption and hazard index and to calculate their optimal global values. Besides, an enhanced NSGA-II algorithm (HNSGA-II) is proposed to optimize PDLBMRS efficiently. Finally, MIPM and HNSGA-II are applied to an actual mixed disassembly case of two types of computers, the comparison of the results solved by GUROBI and HNSGA-II verifies the correctness of the model and excellent performance of the algorithm, and the obtained Pareto solution set provides multiple options for decision-makers.
Abstract: Electric cars with their fast innovation cycles and their disruptive character offer a high degree of freedom regarding innovative design for remanufacturing. Remanufacturing increases not only the resource but also the economic efficiency by a prolonged product life time. The reduced power train wear of electric cars combined with high manufacturing costs for batteries allow new business models and even second life applications. Modular and intermountable designed battery packs enable the replacement of defective or outdated battery cells, allow additional cost savings and a prolongation of life time. This paper discusses opportunities for future remanufacturing value chains of electric cars and their battery components and how to address their potentials with elaborate designs. Based on a brief overview of implemented remanufacturing structures in different industries, opportunities of transferability are evaluated. In addition to an analysis of current and upcoming challenges, promising perspectives for a sustainable electric car circular economy enabled by design for remanufacturing are deduced. Two mathematical models describe the feasibility of pursuing a circular economy of lithium ion batteries and evaluate remanufacturing in terms of sustainability and economic efficiency. Taking into consideration not only labor and material cost but also capital costs for equipment and factory facilities to support the remanufacturing process, cost benefit analysis prognosticate that a remanufacturing battery can be produced more cost-efficiently. The ecological benefits were calculated on a broad database from different research projects which focus on the recycling, the second use and the assembly of lithium ion batteries. The results of this calculations show a significant improvement by remanufacturing in all relevant factors especially in the consumption of resources and greenhouse warming potential. Exemplarily suitable design guidelines for future remanufacturing lithium ion batteries, which consider modularity, interfaces and disassembly, are used to illustrate the findings. For one guideline, potential cost improvements were calculated and upcoming challenges are pointed out.
Abstract: The paper presented a sustainable design model for integrated evaluation of the design and supply chain of a product for the sustainable objectives. To design a product, there can be alternative ways to assign the detailed specifications to fulfill the same design objectives. In the design alternative cases, different material and manufacturing processes with various supply chain activities may be required for the production. Therefore, it is required to evaluate the different design cases based on the sustainable objectives. In this research, a closed-loop design model is developed by integrating the forward design model and reverse design model. From the supply chain point of view, the decisions in the forward design model are connected with the forward supply chain. The decisions in the reverse design model are connected with the reverse supply chain considering the sustainable objectives. The purpose of this research is to develop a mathematical model for analyzing the design cases by integrated evaluating the criteria in the closed-loop design and the closed-loop supply chain. The decision variables are built to represent the design cases of the forward design and reverse design. The cost parameters in a forward design include the costs of material and manufacturing processes. The cost parameters in a reverse design include the costs of recycling, disassembly, reusing, remanufacturing, and disposing. The mathematical model is formulated to minimize the total cost under the design constraints. In practical applications, the decisions of the mathematical model can be used for selecting a design case for the purpose of sustainable design of a product. An example product is demonstrated in the paper. The test result shows that the sustainable design model is useful for integrated evaluation of the design and the supply chain to achieve the sustainable objectives.
Abstract: The main purpose of this article is to provide a comprehensive review of various physical and chemical processes for electronic waste (e-waste) recycling, their advantages and shortfalls towards achieving a cleaner process of waste utilization, with especial attention towards extraction of metallic values. Current status and future perspectives of waste printed circuit boards (PCBs) recycling are described. E-waste characterization, dismantling/ disassembly methods, liberation and classification processes, composition determination techniques are covered. Manual selective dismantling and metal-nonmetal liberation at – 150 µm at two step crushing are found to be the best. After size reduction, mainly physical separation/concentration processes employing gravity, electrostatic, magnetic separators, froth floatation etc., which are commonly used in mineral processing, have been critically reviewed here for separation of metals and non-metals, along with useful utilizations of the non-metallic materials. The recovery of metals from e-waste material after physical separation through pyrometallurgical, hydrometallurgical or biohydrometallurgical routes is also discussed along with purification and refining and some suitable flowsheets are also given. It seems that hydrometallurgical route will be a key player in the base and precious metals recoveries from e-waste. E-waste recycling will be a very important sector in the near future from economic and environmental perspectives.
Abstract: Excessive fretting wear at the taper-trunnion junction
(trunnionosis) apparently contributes to the high failure rates of hip
implants. Implant wear and corrosion lead to the release of metal
particulate debris and subsequent release of metal ions at the tapertrunnion
surface. This results in a type of metal poisoning referred to
as metallosis. The consequences of metal poisoning include;
osteolysis (bone loss), osteoarthritis (pain), aseptic loosening of the
prosthesis and revision surgery. Follow up after revision surgery,
metal debris particles are commonly found in numerous locations. Background: A stable connection between the femoral ball head
(taper) and stem (trunnion) is necessary to prevent relative motions
and corrosion at the taper junction. Hence, the importance of
component assembly cannot be over-emphasized. Therefore, the aim
of this study is to determine the influence of head-stem junction
assembly by press fitting and the subsequent
disengagement/disassembly on the connection strength between the
taper ball head and stem. Methods: CoCr femoral heads were assembled with High stainless
hydrogen steel stem (trunnion) by Push-in i.e. press fit; and
disengaged by pull-out test. The strength and stability of the two
connections were evaluated by measuring the head pull-out forces
according to ISO 7206-10 standards. Findings: The head-stem junction strength linearly increases with
assembly forces.
Abstract: In this paper is described a new conception of the
Cartesian robot for automated assembly and also disassembly
process. The advantage of this conception is the utilization the
Cartesian assembly robot with its all peripheral automated devices for
assembly of the assembled product. The assembly product in the end
of the lifecycle can be disassembled with the same Cartesian
disassembly robot with the use of the same peripheral automated
devices and equipment. It is a new approach to problematic solving
and development of the automated assembly systems with respect to
lifecycle management of the assembly product and also assembly
system with Cartesian robot. It is also important to develop the
methodical process for design of automated assembly and
disassembly system with Cartesian robot. Assembly and disassembly
system use the same Cartesian robot input and output devices,
assembly and disassembly units in one workplace with different
application. Result of design methodology is the verification and
proposition of real automated assembly and disassembly workplace
with Cartesian robot for known verified model of assembled actuator.
Abstract: A green design for assembly model is presented to
integrate design evaluation and assembly and disassembly sequence
planning by evaluating the three activities in one integrated model. For
an assembled product, an assembly sequence planning model is
required for assembling the product at the start of the product life cycle.
A disassembly sequence planning model is needed for disassembling
the product at the end. In a green product life cycle, it is important to
plan how a product can be disassembled, reused, or recycled, before
the product is actually assembled and produced. Given a product
requirement, there may be several design alternative cases to design
the same product. In the different design cases, the assembly and
disassembly sequences for producing the product can be different. In
this research, a new model is presented to concurrently evaluate the
design and plan the assembly and disassembly sequences. First, the
components are represented by using graph based models. Next, a
particle swarm optimization (PSO) method with a new encoding
scheme is developed. In the new PSO encoding scheme, a particle is
represented by a position matrix defining an assembly sequence and a
disassembly sequence. The assembly and disassembly sequences can
be simultaneously planned with an objective of minimizing the total of
assembly costs and disassembly costs. The test results show that the
presented method is feasible and efficient for solving the integrated
design evaluation and assembly and disassembly sequence planning
problem. An example product is implemented and illustrated in this
paper.
Abstract: This paper deals with a novel approach of power
transformers diagnostics. This approach identifies the exact location
and the range of a fault in the transformer and helps to reduce
operation costs related to handling of the faulty transformer, its
disassembly and repair. The advantage of the approach is a
possibility to simulate healthy transformer and also all faults, which
can occur in transformer during its operation without its
disassembling, which is very expensive in practice. The approach is
based on creating frequency dependent impedance of the transformer
by sweep frequency response analysis measurements and by 3D FE
parametrical modeling of the fault in the transformer. The parameters
of the 3D FE model are the position and the range of the axial short
circuit. Then, by comparing the frequency dependent impedances of
the parametrical models with the measured ones, the location and the
range of the fault is identified. The approach was tested on a real
transformer and showed high coincidence between the real fault and
the simulated one.
Abstract: In the past years, the world has witnessed significant work in the field of Manufacturing. Special efforts have been made in the implementation of new technologies, management and control systems, among many others which have all evolved the field. Closely following all this, due to the scope of new projects and the need of turning the existing flexible ideas into more autonomous and intelligent ones, i.e.: moving toward a more intelligent manufacturing, the present paper emerges with the main aim of contributing to the analysis and a few customization issues of a new iCIM 3000 system at the IPSAM. In this process, special emphasis in made on the material flow problem. For this, besides offering a description and analysis of the system and its main parts, also some tips on how to define other possible alternative material flow scenarios and a partial analysis of the combinatorial nature of the problem are offered as well. All this is done with the intentions of relating it with the use of simulation tools, for which these have been briefly addressed with a special focus on the Witness simulation package. For a better comprehension, the previous elements are supported by a few figures and expressions which would help obtaining necessary data. Such data and others will be used in the future, when simulating the scenarios in the search of the best material flow configurations.
Abstract: Design for Disassembly (DfD) aims to reuse the
structural components instead of demolition followed by recycling of
the demolition debris. This concept preserves the invested embodied
energy of materials, thus reducing inputs of new embodied energy
during materials reprocessing or remanufacturing. Both analytical and
experimental research on a proposed DfD beam-column connection
for use in residential apartments is currently investigated at the
National University of Singapore in collaboration with the Housing
and Development Board of Singapore. The present study reports on
the results of a numerical analysis of the proposed connection utilizing
finite element analysis. The numerical model was calibrated and
validated by comparison against experimental results. Results of a
parametric study will also be presented and discussed.