from research. to market

Transcription

1 from research. to market A Pilot Plant for De-Manufacturing of mechatronics in Lombardy RIM Plus Workshop Giacomo Copani (ITIA-CNR) Kick-off Meeting 8 July 2015, Brussels, Belgium

2 SUMMARY Why a De-manufacturing Pilot Plant of mechatronics in Lombardy What it is How it was designed and built Difficulties and success factors Future developments 2

3 ITIA Research and Innovation DOMAINS Dynamic Analysis and Simulation of Machinery Machine Tools; Mechatronics; Cutting Process; Energy Efficiency; Virtual Prototyping Micro Enabled Devices and Systems Micro Manufacturing; Micro Robotics; Micro Assembly; Micro EDM; Micro Injection Moulding Intelligent and Autonomous Robot Systems Human-Robot Interaction Control; Environment-Robot Interaction Control; Robot Design, Dynamics and Control; Multi Robot Cooperation Machine and Manufacturing Control Systems Advanced Machine Control; Adaptive Factory Automation; Energy Efficient and Green Production; Consumer Centred Manufacturing Enterprise Engineering and Virtual Applications Augmented & Virtual Reality; Virtual Factory; Semantic Web and Ontology; Human Factors Manufacturing Business Models Business Models; Industrial Product Service Systems; Manufacturing Strategy; Life Cycle Management; Sustainability. 3

4 From research domains to pilot factories MBM Manufacturing Business Models Macro Factory Factory for personalized products, Vigevano Lab ITIA RTD&I DOMAINS EVA 2MACS IRAS MEDIS DASM Products/Processes Design Life Cycle Assessment Enterprise Engineering and Virtual Applications Supply Chain and Integrated Logistics Machine and Manufacturing Energy Analysis and Optimization Machine and Manufacturing Control Systems Dynamic Analysis and Simulation of Machinery Manufacturing Technologies Robot Systems Micro Enabled Devices and Systems Innovative Mechanical Components Micro Factory Factory for micro production, Milano and Bari Labs De-Production Factory Re/De Manufacturing Pilot Plant, Milano Lab ITIA PILOT FACTORIES Digital Factory VFF - Virtual Factory Framework, FP7 Project, coordinated by ITIA-CNR 4

5 Why a De-manufacturing Pilot Plant of mechatronics in Lombardy Strategic reasons Regional contextual reasons Internal reasons Sustainability is in the first places of European agenda Lombardy is the first Italian manufacturing Region ITIA is the Institute of CNR dealing with Manufacturing Europe struggles to bring research results in the market The infrastructure for innovation is fragmented and not often accessible to companies Lombardy promoted programs for the development of Regional innovation infrastructure Lombardy identified Regional smart specializations The mission of ITIA is doing both research and innovation 5

6 What happened ü In 2009 Lombardy Region launched a program to fund research and innovation avtivities in cooperation with regional CNR institutes ü The program entailed investments in innovation infrastructures ü ITIA applied to the call and the proposal was funded (2mio costs, 50% by Lombardy Region and 50% by CNR) ü The proposal was targeting applications in advanced manufacturing but was living room to precisely define such applications during the project ü A multi-disciplinary task force was created to define a target application considering Lombardy vocation and ITIA competences 6

7 The work of the task force Strategic analysis (roadmaps and foresight studies) Market and technology analysis contextualized to the Region/Country Internal analysis (competences to face the challenge) Sustainability in an important priority in the European agenda Manufacturing can significantly contribute to achieve sustainability Efficient End-Of-Life processes represent an important enabler of sustainability Mechatronics products are in constant diffusion and there are many open issues related to their End-Of-Life Mechatronics products and their manufacturing is at the core of ITIA activities and ITIA owns multi-disciplinary competences to address the challenge Lombardy Region has a high tradition in manufacturing technologies and can use it to develop leadership in Demanufacturing technologies De-Manufacturing of mechatronics 7

8 What it is: addressed processes Materials Energy Materials Energy Materials Energy Materials Energy Materials Energy Materials Energy Raw material acquisition Material processing Manufacture and assembly Use and service Retirement and recovery Treatment Disposal Waste Waste Waste Waste Waste Waste Re-use Repair Remanufacturing Recycle (closed loop) Recycle (open loop) ITIA-CNR 8

9 What it is: goals Reuse product as a whole Highest level Reuse subassemblies and components Remanufacturing Materials recycling Incineration Disposal as waste Lowest level Source: Adapted from Kopacek,

10 What it is: products focus MECHATRONIC PRODUCT MECHANICAL PART ELECTRONIC PART EOL mechanicals EOL electronics 10

11 Conceptual approach Multi-disciplinary and integrated approach for EOL value maximization Flexible automation to cope with variability Valorization of humans Intelligent mechanical pre-treatments to avoid pyrolysis Economic and environmental sustainability 11

12 Layout Cell 1: Robotic Disassembly. Cell 2: PCB testing, repair and component disassembly. Cell 3: PCB shredding and separation. 12

13 Cell 1: Disassembly and re-assembly technologies Challenges and limitations: High variability and uncertainty on the status of the product. High cost and rigidity of automated solutions ( Sony Minidisc, Fuji single-use camera ). Objective: To disassemble the mechanical part from the electronic part of the mechatronic component by exploiting man-machine cooperation. To re-assemble the component after the treatment. Key Issue: man-machine cooperation. 13

14 Cell 2: Remanufacturing technologies Requirements: Need to automatically treat heterogeneous PCBs and components. Strong requirements on cycle times. Features: Gantry architecture, based on linear motors. Vision system, for X-Y automatic compensation. Force control in Z, to prevent damages on PCBs. Automatic tool change. Automatic pallet load/unload. Automatic flux and soldering paste dispenser

15 Cell 3: Pre-treatment technologies Challenges: Rigid processes, the process parameters remain unchanged independently on the product properties. As a result, mechanical processes are poorly adopted for complex products (e.g. PCBs). Objective: To develop flexible mechanical recycling processes and systems for optimal pre-treatment of complex material mixtures. Hyperspectral imaging to perform the on-line In-line optimization of the process parameters classification of product conditions and mixtures. to adapt to the material characteristics. 15

16 Digital Factory 16

17 New business models Hazardous parts Re-usable parts Consumer WEEEs Industrial WEEEs National Collective Systems (NCS s) Collection Macro disassembly Multi- Treatment Facilities (MTF s) Macro shredding Macro separation Metals scrap market Non-metals scrap market PCBs Traders PCBs Testing Micro disassembly Micro shredding Re-usable components market Trading Micro separation Non-metal powders market Industrial PCBs Base metals powders market Smelting Leaching Refining Authorized Recovery Centers (ARC s) Precious metals market 17

18 Funding history First project Regione Lombardia-CNR ( ) Project Zero Waste PCBs National Program La Fabbrica del Futuro ( ) Project Sustainable Manufacturing Italian Intelligent Cluster Factory ( ) Project Fideas - Intelligent Factory for efficient advanced de-manufacturing Second project Regione Lombardia-CNR ( ) 5 mio total investment Project WEEEReflex-Highly Evolvable E-waste Recycling Technologies and Systems, National Program La Fabbrica del Futuro ( ) 18

19 The use of pilot plant UNTIL NOW IN THE FUTURE Support R&I in the funded projects Enable technology services (on demand) for companies Offer infrastructure and competences for master and PhD theses Create a Regional community around Demanufacturing of mechatronics Become an infrastructure open to companies with a clear business modes Implement the teaching factory concept MISSION Support companies innovation for establishing industrial De-manufacturing processes Support the increase of knowledge around mechatronics Demanufacturing processes Increase competences and technology capability in Demanufacturing of mechatronics 19

20 The Lombardy De-manufacturing community Manufacturer/+ Demanufacturer+ Technology+ Provider+ University/+ Research+Center+ Composites) +)Tex-le) Rivierasca) Xnext,)LOT,) Holonix) UNIBG,)POLI) (Chimici)) Electronics) Italtel)) Relight,)A2A,) Xnext,)LOT,) Holonix) ITIAGCNR,) IREAGCNR,) RSE) White)Goods) Candy) Xnext,)LOT,) Holonix) ITIAGCNR,) IREAGCNR,) POLI))(Amb.)) Automo-ve) components) Magne-) Marelli,) Cannon) Xnext,)LOT,) Holonix) ITIAGCNR,) IREAGCNR) Medical) Technology) ENKI) 20

21 Success factors Address Institute strategy towards a strategic goals common to all research groups Multi-funding and multi-objective strategy Involve companies in projects and continuous discussions: work with industrial cases Create a permanent committee on Pilot Plant management and development Target coherently Regional, National and European level Promote De-manufacturing as a strategic topic among policy makers at EU, National and Regional level Pursue industrial and scientific growth at the same time 21

22 Difficulties Align the interests of different research groups and stakeholders Keep the momentum Continue guaranteeing funding to the strategic project Establish a stable business model for the offer of services to companies 22

23 23 The vision for the future Tampere Norte Saxony Tampere Scotland Norte Basque Country Saxony Lombardy Tampere Scotland Norte Basque Country Saxony Lombardy Vanguard(Pilot(Network(on(De3(and(Remanufacturing( Laser&based) remanufacturing)of#the# mechanical#parts#in# large#machinery.# Re&use)of)composites) by#thermal)processes) from#aeronau5c#sector# and#wind#energy# system.#recovery)and# re8use#of#metal)scrap)by# plasma)process.# Robo9cs)handling) systems#suppor5ng# disassembly#and# reassembly#opera5ons# in#the#automo5ve# industry# Mechanical) remanufacturing)and# in&use)product) monitoring)in#the# automo5ve#industry.# Re&produc9on)of) steel)sheets)by) Hydroforming)and# CNC8bulk#metal# forming.# Sustainable# demanufacturing) processes)and#systems# for#the#recovery)of)key& metals,)technology) plas9cs,)rare)earths)and# composite)materials) #

24 Thank you for attention 24