Progress of remanufacturing engineering and future technology expectation

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Adv.M anuf.f20131 1：8-12D0I 10.1007/s40436-013-0003-8'～ n - · · · ' Progress oirem anutacturing engineering and I-uture technologyexpectationBin.Shi XuReceived：15 September 2012/Accepted：5 November 2012/Published online：14 March 2013◎ Shanghai University and Springer-Verlag Berlin Heidelberg 2013Abstract After development for decades，abroad reman-ufacturing has formed a complete industrial system.Atpresent，the research emphases are on marking logisticsmanagement and market cultivation theory of remanufac-turing products.and so on.The Chinese remanufacturingstarts fairly late.After 1 0 years of development.it formed aremanufacturing mode with Chinese characteristics that issustained by high.tech industries.using the surface engi-neenng technology to restore the size and improve prop-erties，and combining manufacturing，study and researchtogether.The remanufacturing mode is not only circularbut also economic.Wjth the development of science andtechnology，future remanufacturing technology will breakthe previous 1imits.explore and understand the limits ofmicro machining.It will carry out the waste productremanufacturing in the micro-nano scale，and extend theremanufacturing industry to a more broad space。

Keywords Sustainable development·Remanufacturingindustry·Surface engineering·Micro-nano machining1 IntroductionThe development of modem science and technology bringshuman society into industrialization which makes economydevelop rapidly and physical quality of life improvegreatly.However，the more humans enjoy the materialB.-S.Xu(圜 )National Key Laboratory for Remanufacturing，The Academyof Armored Forces Engineering，Beijing 100072，Peoples Republic of Chinae-mail：xubinshi###vip.sina.com垒Springercivilization，the more they feel the environment which theymust rely on gets worse.The environment pollution is severe，and ecological balance has been disrupted.Natural resourcesare wasted seriously，which have resulted in shortage ofresources that support the human society and economic todevelop rapidly[1，2].To protect the environment，build acircular economy to maintain the sustainable economic andsocial development has become a common concem topic ofthe whole world3.Manufacturing industry is not only thepillar industry of the national economy.but also the majorsource of environmental polution，which consumes andwastes a lot of resources.In order to solve the shortage andwaste of resources and to reduce the harm of a lot of failureand discarded products to human.the international has set offa green wave to make fu11 use of resources and reduceenvironment pollution since the 1980s.It proposes the con。

cept ofgreen manufacturing”and new ways of thinking。

Under the situation，the remanufacturing proiect as a newresearch field arises4.It has formed remanufacturingindustry in foreign countries。which is the best method tosolve the waste of resources，the pollution of environmentand the retrofit of used equipments。

2 Development history of the foreign remanufacturingindustryIn the 1950s or earlier，driven by interests.the European andAmerican corporations started recycling used products，andthen the early remanufacturing industry formed5.In thelate 1970s，the Massachusets Institute of Technology beganresearch on the recycling of waste products.In the 1 980s。

the United States officially advocated renovation or regen-eration of waste products，and called itremanufacturing”，while the Japan ese proposed the concept of renewableProgress of remanufacturing engineering and future technology expectation 9plant technology”.In 1992.the Russian scholars proposedthe idea to establishthe committee of repair heat treatmenttechnology”to the International Heat Treatment Commitee6].The W orld Bank funded the final report ofRemanu。

facturing：the experience of the United States and the rev-elation to developing countries”.The final report describedthe United States remanufacturing enterprises and experi-ence，analyzed remanufacturing application prospects ofsome third world countries.It promoted the development ofthe remanufacturing industry.In the United States，Canada。

the European Union and other developed countries，theremanufacturing of used mechanical and electrical productshas several decades of development history.From technicalstandards，production technology，processing equipments，recycling of used products，to the remanufactured productsales and after sales service.the remanufacturing industryhas formed a complete industrial system 7.The remanu-factured product range has covered the auto parts，machinetools，construction machinery，railway equipments，medicalequipments，and some electronic products。

The globa1 remanufacturing output had more than onehundred billion dollars in 2005.Remanufacturing industrvin the United States was the 1argest.and its outic，ut reached75 billion dollars. The automotive and constructionmachinery remanufacturing accounted for more than 2/3，and the outl：ut reached about 50 billion dollars.Japan hadalso strengthened the construction machinery remanufac-turing.Till 2008.58% of the construction machineryremanufacturing was used by the Japanese domestic users，and 34% were exported to foreign countries. Theremaining 8% sold as accessories after dismantling.Til204.Volkswagen had been remanufacturing 7.48 millionautomobile engines and 2.4 milion transmissions.Theratio of the company sold remanufactured engines andaccessories to the new machine was 9：1[8]。

Remanufacturing can not onlv save a huge social wealth。

but also significantly improve the combat effectiveness of themilitary equipments.The United States military absorbs a 1argenumber ofadvanced scientific an d technological achievementsby remanufacaning.thus improves the tactical and technicalperformance of existing weapons and equipments.Remanu-facturing provides excelent application and test opportunitiesto these advanced technologies.Improvement of the equip。

ment performance of the United States military accompanieswith the equipment remanufacturing.The remanufacturingproiect research has attracted the attention of the Americanpolicy-making departments. The defense manufacturingindustry commitee in and after 201 0 which belongs to theUnited States National Research Council，had formulated theframework of the defense industry remanufacturing techno1。

ogy about 2010.It proposed the strategy to achieve the futurerequired manufacturing capabilities，and took perform an ceupgrades，life extension technology and remanufacturingtechnology of the weaDon systems as the important researcharea in current and future defense manufacturing91.Thedefensive weaDons research department of Boston Universityspecializes in cost savings data of remanufacturing products，such as aerospace planes，runner weapons systems and militaryequipment.Longbow AH-64D is a new kind of helicopterwhich is the remanufacturing product of AH 64A.Afterremanufacturing，the battlefield survivability，informationexchange ability.and navigate abilitV of the aircraft increases。

AH-64D can attack 4 times target numbers at the same timethan the AH-64A and its survivability increase by 7.2 timesthan the AH-64A.At present，it has become the strongest andmost advanced helicopter on active duty in the United States。

Target acquisition capability of the remanufacturing M 1A1Dtanks increases 70%.shortens the fire time and improvesaccuracy.Furthermore，the target detection and identificationdistance also increases by 30%.which can provide beterdamage perform ance and reduce the possibility of mis-hits。

The Bradley M2/M 3 chariot of the United States armyupgrades to A3 type after remanufacturing.It integrates carmonitoring，diagnostics/prognostics subsystem the ArmyTechnical Architecture(ATA)command and control softwareprogram group，can fully co-operate with the Abu DonaldM1A1D.type M 1A2SEP.type battle tanks.and otherXⅪ digita1 platform s” military forces.The F-14D fighter isobtained by the remanufacturing of F-14A，and it can simul-taneously track 24 targets and attack six of them，the radarheight ranges from 24 m to 24，000 m.It has monopulse angletracking，digital scan control，target recogn ition，and air strikeevaluation capacity1 01。

3 Overseas research status of remanufacturingindustryForeign remanufacturing model is based on the pieces andsize repair methods to restore the size of the parts。

Research is focused on the analysis 0f fu11 life cycle.theaging of product parts or the changes in the physical andmechanical properties.Inform ation is used in recovery orremanufacturing used products successfuly.To study anddevelop advanced remanufacturing technologies，surfacecleaning technologies and waste minimization technologieswhich have the better economic and environmental effectsare used wel1.The perform ance or aging characteristics ofthe remanufacturing products are measured and theremaining life of the products is predicted using advanceddiagnostic techniques and tools[11].Through the accu-mulation of such basic research works，industrial countrieshave laid a solid foundation for the remanufacturingindustry sustainable development.At the moment.foreignremanufacturing project research has progressed to themacroscopically integra1 research.such as management垒Springer1O B.-S.Xumodel，market cultivation，certification and the socia1 andeconomic benefits。

Margatete[12has studied whether the product recoverysystem and repair industry carl be applied in the automotiveparts remanufacturing，he believes that the remanufacturingproducts recycling has formed a closed loop industrial pro-cessing.Due to the 1ack of knowledge of other industries，theseindustries are not able to remanufacture products of otherindustries.this restricts the development ofthe remanufacturingl3-141.Johan believes that if the remanufacturing productswant to be recognized and purchased by consumers，it mustobtain accurate market inform ation of remanufactured prod-ucts，it must accurately grasp the reverse logistics information151.Theinternalrelationshipsintheory ofthedemandfornewproducts or remanufacturing products are shown in Fig.1 Dueto the insuficient awareness of consumer to remanufacturingproduct，themarketdemandoftheremanufacturingproductsis1ow.andthepriceisanotherimportantfactorwhichaffectstheremanufacturing products.For example，compared with a newproduct，remanufacturing products price is lower，this is due tothe traditional understanding of consumers，the price of an oldproduct certainly cannot be compared with a new product.Butwith the extension of time，consumers reduce interest in newproducts.Due to the lower price，the remanufacturing productshave stronger competition.Lu and Nathalie16]describe aclear remanufacturing system network，the remanufacturingnetwork fRMN)，as is shown in Fig.2.The system assumes thatthere are four kinds of participants：consumers，logistics nodes，remanufacturing centers and producer.As consumers，theyhave two roles：buying new products and using the olds.Therecycling center in the middle iust recycles old products anddoes some necessary processing like cleaning，disassembly，an d inspection.then retum s old products to the remanufacturing. . - - Production distributionfor new products(sales volume). . . . Demand of remanufactured products. Effects ofthe differenceintheFig.1 Internal relationships of the demand of new products orremanufactured products[1 5]Disposed主D Producers/i o Remanufacturing centersjIntermediate centersjDisposal center- Product flow t -Return itemsFig.2 Location problem of a remanufacturing system[16]垒Springercenters.The remanufacturing center receives the productswhich can be remanufactured from the recycling center.Asparts of the product flow line，producers and manufacturingcenter are responsible for the production of the products thatconsumers need.In Fig.2，we can see two processes：one is theinverse process that the old products come from the consumerthrough the recycling center and then flow to the remanufac。

turing center；another is new products from the remanufactur-ing center or producers directly flow to consumers。

Foreign remanufacturing industry has developedmaturely.its technical research also fully expands in the lastcentury.Now，the theoretical studies in foreign remanu-facturing are mainly concentrated on distribution manage-ment and market cultivation。

4 Remanufacturing development in ChinaSince 1 999.we have vigorously publicized and deeply studiedremanufacturingproject[17，18].Duringthelast10 years，theonly existed several remanufacturing companies in Chinaexperienced difficulty in carrying out the work unti1 they gotthe wide recognltion and strong support from the nationa1government agencies，industries and the community.Theremanufacturing companies，such as Sinotruk Jinan FuqiangPower Co.，Ltd.(Sino-British Joint Venture)，the manufac-turing plant of Shanghai Volkswagen(Sino-Germ an JointVenture)，Baike(Changshu)Motor Co.，Ltd.(HongKonginvested).Guangzhou Huadu Worldewide Automatic Trans。

mission Co。，Ltd.(Investments of overseas Chinese1 and soon，are carrying out the remanufacturing processing in theheavy duty truck engines，car engines，vehicle motors as wellas the car gearbox and other areas.respectively.The reman-ufacturing products accord to the intemational standards andmeet the requirements of remanufacturing.It can be said thatthev are the first group of remanufacturing companies inChina.However.their development is extremely difficult dueto various reasons，such as policy，technology and so on191。

Until 2008。the National Development and Reform Com-mission fNDRC1 appointed 14 companies as the first batch ofauto parts remanufacturing industry points，including theabove.mentioned companies， and the remanufacturingindustry in China gets the official nationa1 recognition andpolicy suppof.In the end of 2009，Premier W en madeimponant instructions on remanufacturing and said theremanufacturing industry was very impofant.In 201 0.theNational Development and Reforill Commission and other l1ministries jointly issuedsuggestions on promoting devel-opment of remanufacturing industry”.and bred remanufac-turing industry as new economic growth point.In 201 1.thestate issuedthe 12th Five-Year Plan for National Economicand Social Development”.and it required to promoteremanufacturing industry development；develop and applyProgress of remanufacturing engineering and future technology expectation 11remanufacturing key technology，and promote the circulareconomic mode”in the next 5 years.In 2012，the NationalDevelopment and Reform Commission began to start thesecond batch of national remanufacturing industry pilot。

Above legal provisions as well as the spirit of the instructionsof the Party and state leaders.iniects powerfu1 force to theremanufacturing development.It can be said that China hasentered a new stage that promotes the remanufacturingindustry as the core content of national goals.the reman u-facturing development in China has shown unprecedentedgood momentum.It can be said that China has formed aremanufacturing mode with Chinese characteristics that issustained by high-tech industries.using the surface engi-neering technology to restore the size and improve properties，and combining man ufacturing，study and research together。

The remanufacturing technology in China depends onsurface engineering technology to develop[20].In order torestore or change the material surface morphology，chem-ical composition，stru cture and stress state are applied.Toobtain the required system engineering[2 1]，the surfacecoatings and modification technologies are used to repairthe corrosion，wear and damage parts or materials.Throughseveral years of research and practice，according to thestandard that remanufacturing products characteristics andquality of performance should be not worse than the newproducts.our 1aboratory has innovated a number of inde-pendent remanufacturing technologies with Chinese char-acteristics，such as automated nano-particle compositebrush plating technology，nano less mount intelligent self-repairing additive technology，automated high velocity arcspraying technology，automated micro-plasma claddingtechnology， remanufacturing nondestructive testingassessment techniques and equipments.These technologiesare well adapted to the needs of the development of cir。

cular economy in China.Energy saving，materials saving，reducing pollution play an extremely important role in thehealthy development of the remanufacturing industry。

5 Future prospects of rem anufacturing technologyBased on accumulation of the existing technology，thestudy of the matter structures wil enable mankind to theera of regulating of molecules，atoms，and electrons.Itpromotes machining accuracy from micro-scale to nano-·scale and makes the human understanding of the nature andtransform ation to a new deeper leve1. Nowadays， theworldwide are starting to compete to establish new inte-gration methods and technologies to adapt to nano-scale。

Physical substance of traditional manufacturing andremanufacturing is using connection defects between theatoms，molecules，or crystal for processing，while the nano-processing is taking an atom or molecule on the devicesurface as a direct obiect to be processed.It can be said thatthe physica1 substance of the nano-scale processing is tocut of the bonding between atoms or molecules，remove oradd atoms or molecules.The various material combinationis in the forlTl of covalent bonds.metal bonds.ionic bonds，and so on，and it is difficult to cut the bonding between theatoms，the traditional processing methods are not practical22，231.Thus，countries all over the world are studyingand innovating the nano.scale processing and manufac。

turing technologies，such as a variety of nano cuting andnano welding technologies based on electronics，optics，magnetics and mechanics.The breakthroughs of thesetechnologies wil bring a profound revolution to remanu。

facturing industry，and change the understanding of materand energy structure.By decomposing，regulating andsynthesizing molecules， atom s and other microscopicstructures，it will complete the combination of new mate-rial and energy.At the same time.combining with theexisting macro restructuring technologies，it makes theremanufacturing parts which are mainly used productsreach zero scrap rate，completely realizes the full recyclingof resources.This will open a new application field of theexisting remanufacturing。

Acknowledgm ents Authors are pleased to acknowledge the finan-cial suppo provided by the National Basic Research Program ofChina(Grant Nos.201 1CB013403，2011CB013405，2011CB013401)and the National Natural Science Foundation of China(Grant No。

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