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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
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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
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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.
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MBM
EVA
2MACS
IRAS
MEDIS
DASM
ITIA
RTD
&I D
OM
AIN
S
Manufacturing Business Models
Supply Chain and Integrated Logistics
Enterprise Engineering and Virtual Applications
Life Cycle Assessment
Dynamic Analysis and Simulation of Machinery
Machine and Manufacturing Energy Analysis and Optimization
Manufacturing Technologies
Products/Processes Design
Machine and Manufacturing Control Systems
Robot Systems
Micro Enabled Devices and Systems
Innovative Mechanical Components
ITIA PILOT FA
CTO
RIES
Macro Factory Factory for personalized products, Vigevano Lab
Micro Factory Factory for micro production, Milano and Bari Labs
De-Production Factory Re/De Manufacturing Pilot Plant, Milano Lab
Digital Factory VFF - Virtual Factory Framework, FP7 Project , coordinated by ITIA-CNR
From research domains to pilot factories
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Why a De-manufacturing Pilot Plant of mechatronics in Lombardy
• Sustainability is in the first places of European agenda
• Europe struggles to bring research results in the market
• The infrastructure for innovation is fragmented and not often accessible to companies
• Lombardy is the first Italian manufacturing Region
• Lombardy promoted programs for the development of Regional innovation infrastructure
• Lombardy identified Regional smart specializations
• ITIA is the Institute of CNR dealing with Manufacturing
• The mission of ITIA is doing both research and innovation
Strategic reasons Regional contextual reasons Internal reasons
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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
What happened
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• 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 De-manufacturing technologies
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)
De-Manufacturing of mechatronics
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Recycle (open loop)
© ITIA-CNR
Raw material
acquisition
Material processing
Manufacture and
assembly
Use and service
Retirement and
recovery
Treatment Disposal
Materials Energy
Materials Energy
Materials Energy
Materials Energy
Materials Energy
Materials Energy
Waste Waste Waste Waste Waste Waste
Re-use
Repair
Remanufacturing
Recycle (closed loop)
What it is: addressed processes
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Source: Adapted from Kopacek, 2008
Disposal as waste
Incineration
Materials recycling
Remanufacturing
Reuse subassemblies and components
Reuse product as a whole Highest level
Lowest level
What it is: goals
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MECHANICAL PART
ELECTRONIC PART
MECHATRONIC PRODUCT
EOL mechanicals
EOL electronics
What it is: products focus
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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
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Cell 1: Robotic Disassembly.
Cell 2: PCB testing, repair and component disassembly.
Cell 3: PCB shredding and separation.
Layout
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Cell 1: Disassembly and re-assembly technologies
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.
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”).
Key Issue: man-machine cooperation.
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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.
Requirements:
§ Need to automatically treat heterogeneous PCBs and components.
§ Strong requirements on cycle times.
Cell 2: Remanufacturing technologies
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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).
In-line optimization of the process parameters to adapt to the material characteristics.
Hyperspectral imaging to perform the on-line classification of product conditions and mixtures.
Objective: To develop flexible mechanical recycling processes and systems for optimal pre-treatment of complex material mixtures.
Cell 3: Pre-treatment technologies
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Digital Factory
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Macro disassembly
Macro shredding
Macro separation
Re-usable parts
Hazardous parts
Multi- Treatment Facilities
(MTF’s)
Authorized Recovery Centers
(ARC’s)
Micro disassembly
Micro shredding
Micro separation
Testing
Smelting
Leaching
Refining Precious metals market
Non-metal powders market
Metals scrap market
Non-metals scrap market
National Collective Systems (NCS’s)
Collection Consumer WEEEs
Industrial WEEEs
PCBs Traders
Trading
Re-usable components market
Base metals powders market Industrial PCBs
PCBs
New business models
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Funding history
• First project Regione Lombardia-CNR (2010-2012)
• Project “Zero Waste PCBs” – National Program “La Fabbrica del Futuro” (2013-2015)
• Project “Sustainable Manufacturing” – Italian Intelligent Cluster Factory (2013-2015)
• Project “Fideas - Intelligent Factory for efficient advanced de-manufacturing” – Second project Regione Lombardia-CNR (2013-2015)
• Project “WEEEReflex-Highly Evolvable E-waste Recycling Technologies and Systems”, National Program “La Fabbrica del Futuro” (2014-2016)
≈ 5 mio€
total investment
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The use of pilot plant
• 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 De-manufacturing 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 De-manufacturing processes
• Increase competences and technology capability in De-manufacturing of mechatronics
UN
TIL
NO
W
IN T
HE
FU
TU
RE
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The Lombardy De-manufacturing community
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)
Manufacturer/+Demanufacturer+
Technology+Provider+
University/+Research+Center+
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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
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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
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The vision for the future
Tampere
Norte
Saxony
Tampere
Scotland
Norte
Basque Country
Saxony
Lombardy
Tampere
Scotland
Norte
Basque Country
Saxony
Lombardy
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