UNIVERSITY OF BIRMINGHAM Mechanical …autoreman.altervista.org/Student_reports/Summer...UNIVERSITY OF BIRMINGHAM Mechanical Engineering DISASSEMBLY FOR REMANUFACTURING AUTOREMAN PROJECT

UNIVERSITY OF BIRMINGHAM

Mechanical Engineering

DISASSEMBLY FOR REMANUFACTURING

AUTOREMAN PROJECT

SHIMING LIU

Student ID Number: 1607155

Summer Internship Project

Tutors: Professor Duc Truong Pham, Dr. Chunqian Ji and Dr. Shizhong Su

28th September 2016

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CONTENTS ABSTRACT ............................................................................................................................................... 3

1. INTRODUCTION .................................................................................................................................. 3

2. IDENTIFICATION OF PATTERNS, ISSUES AND PROBLEMS OF DISASSEMBLY OPERATIONS WITH

HUMAN BEINGS ...................................................................................................................................... 3

2.1 Patterns of disassembly operation carried out by human beings .............................................. 3

2.2 Issues and problems in human disassembly operation ............................................................... 3

2.3 Issues that could be addressed in robotic disassembly .............................................................. 4

2.4 Knowledge required for robotics ................................................................................................. 4

2.5 Challenges for robots .................................................................................................................. 4

3. PRODUCT DISASSEMBLY SEQUENCE CASE-STUDY .............................................................................. 4

3.1 ABS Disassembly Sequence ......................................................................................................... 4

3.2 Carburettor Disassembly Sequence ............................................................................................ 7

3.3 Differential Disassembly Sequence ........................................................................................... 11

3.4 V8 Upper Engine Disassembly Sequence .................................................................................. 15

3.5 V8 Lower Engine Disassembly Sequence ................................................................................. 18

3.6 Induction Motor Disassembly Sequence ................................................................................... 20

3.7 E61 Group Disassembly Sequence ............................................................................................ 24

3.8 Oil Filter Disassembly Sequence ............................................................................................... 27

4. RESULTS AND ANALYSIS .................................................................................................................... 29

5. CONCLUSION ..................................................................................................................................... 30

6. REFERENCES ...................................................................................................................................... 30

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ABSTRACT

For the past decade or so, an increasing number of waste has attracted a tremendous

attention of the world. Remanufacturing is "the process of returning a used product to at

least OEM original performance specification from the customers' perspective, and giving

the resultant product warranty that is at least equal to that of a newly manufactured

equivalent" (Ijomah 2002). Remanufacturing can be more sustainable than manufacturing

de novo because it can be profitable and less harmful to the environment. [1]

AUTOREMAN is a five-year EPSRC-sponsored multi-disciplinary project focussing on

remanufacturing as a means to sustainable manufacturing. This project will develop robotic

technology enabling disassembly to be carried out with minimal human intervention or in a

collaborative fashion by man and machine. [1]

Key words: Disassembly; Remanufacturing; AUTOREMAN;

1. INTRODUCTION

With an increasing emphasis on environmental sustainability, remanufacturing has been

considered a major approach to mitigate problems of materials shortage. And disassembly is

an inevitable procedure which is used to retrieve high value cores in a product for

remanufacturing.

This report presents the identification of patterns, issues and problems of disassembly

operations with human beings as well as several relevant knowledge and challenges for

robotics, 8 subsequent case study for product disassembly sequence planning are also

discussed.

2. IDENTIFICATION OF PATTERNS, ISSUES AND PROBLEMS OF

DISASSEMBLY OPERATIONS WITH HUMAN BEINGS

Figuring out the downside and limitation of disassembly process carried out by human

beings is of great importance to gain a deeper understanding of how to develop a more

suitable and money-saving industrial robotics. Combining with experiences of visiting BMW

and MERITOR, some foundational conclusions are drawn below:

2.1 Patterns of disassembly operation carried out by human beings

The patterns of disassembly operation used by human are based on labor. Operators use various tools (such as hammer, wrench, electric screwdriver, fire sprayer) to disassemble the retired products, the product is semi-fixed on the fixture, different operations are applied on it until it cannot be disassembled further. Although it is flexible during this process, it is much labor-consuming as well as time-consuming, safety and health of operators are also threatened by the hazardous and dusty environment. 2.2 Issues and problems in human disassembly operation

There are many issues that could be encountered through the disassembly process operated by human:

https://pearl.plymouth.ac.uk/handle/10026.1/2829

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a. Human Strength is limited, while the torque needed against the locking and deformation might be huge, operators might not be able to work on it.

b. The products would rotate (sometimes the deformed product could not be well fixed) if unscrewing work was applied on it, which makes the disassembly process even more complex, mere one operator could not handle it, while more operators would cost more money on labor and threaten the safety factor.

c. Anything could happen throughout the process. Careless operation, intensive labor, which might injure the operator and do harm to the company in budget.

d. Non-standard operations by human beings could easily ruin some precise parts, which might cause much more unnecessary waste

2.3 Issues that could be addressed in robotic disassembly

a. Frequent robot maintenance would increase the budget b. Robots might not be as flexible as human beings when they are dealing with hard

disassembly issues c. It might not be easy for robots to change the directions of products in disassembly d. High accuracy is needed to deal with extremely close operations 2.4 Knowledge required for robotics

a. Knowledge of figuring out the product damage condition b. Knowledge of choosing correct tools for disassembly c. Knowledge of coordinating the work cell and positioning the work point d. Knowledge of carrying out the disassembly motions (pulling, gripping, pushing etc.) e. Knowledge of changing tools and altering directions of products f. Knowledge of appropriately applying force to minimise damage g. Knowledge of judging the component damage condition and classifying them 2.5 Challenges for robots

a. Various types of damage and erosion make it difficult for robots to classify products condition

b. Difficulties in judging whether components can be taken out under severe condition

3. PRODUCT DISASSEMBLY SEQUENCE CASE-STUDY

3.1 ABS Disassembly Sequence

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Figure.1: ABS exploded view and isometric view

Code Name

A Pump Motor

B1,B2 Motor Bolt

C1,C2 Nut

D1,D2 Gasket

E1,E2 Rubber

F1,F2 Retaining Bolt

G1,G2 Pump

H1,H2 Pump Washer

I1,I2 Accumulator Seal Ring

J1,J2 Piston

K1,K2 Spring

L1,L2 Accumulator Cover

M Retaining Pin

N1,N2,N3,N4 Cover Bolt

O Electronic Control Unit (ECU)

P1,P2,P3,P4 Inlet Valve

Q1,Q2,Q3,Q4 Outlet Valve

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Code Name

R Housing

Table1: ABS components list

Figure.2: ABS disassembly sequence

DISASSEMBLY OPERATIONS

LEVEL TYPE REPETITIONS CATEGORY TOOL Direction

1 Unscrewing 4 Non-destructive Wrench +Y

2 Separating 1 Non-destructive Blade and Plier +Y

3 Pulling 1 Non-destructive Long Nose Plier -Z

4 Pulling 1 Non-destructive Long Nose Plier -Y

5 Unscrewing 1 Non-destructive Wrench -Y

6 Separating 1 Non-destructive Long Nose Plier -Y

7 Separating 1 Non-destructive Gripper -Y

8 Pulling 1 Non-destructive Long Nose Plier -Y




12 Drilling 4 Semi-destructive Drill Bit +Y

13 Drilling 4 Semi-destructive Drill Bit +Y

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15 Separating 1 Non-destructive Blade and Plier -Y

16 Drilling 1 Semi-destructive Drill Bit +X

17 Separating 1 Non-destructive Long Nose Plier -X

18 Drilling 1 Semi-destructive Drill Bit -X

19 Separating 1 Non-destructive Long Nose Plier +X

20 Drilling 2 Semi-destructive Drill Bit -Z

21 Separating 2 Non-destructive Long Nose Plier -Z

22 Pulling 1 Non-destructive Vacuum Sucker -Z

23 Pulling 1 Non-destructive Hook Tool -Z

24 Pulling 1 Non-destructive Vacuum Sucker -Z

25 Pulling 1 Non-destructive Hook Tool -Z

Table 2: ABS disassembly operations list

Unscrewing: 8 Separating: 10 Pulling: 7 Drilling: 12 Total: 37 Destructive: 0 Semi-destructive: 12 Non-destructive: 25

Figure.3: ABS disassembly operation and type sector

3.2 Carburettor Disassembly Sequence

22%

27%19%

32%

Unscrewing Separating

Pulling Drilling

0%

32%

68%

Destructive Semi-destructive

Non-destructive

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Figure.4: Carburettor exploded view and isometric view

Code Name Code Name

A Rubber Cap R Pilot Jet

B Cable Adjuster S Main Jet Ring

C Locknut, Cable Adj. T Needle Jet

D Mixing Chamber Top U Large Hex Main Jet

E Spring V Washer, Needle Valve Seat

F Seat Plate W Needle Valve Set

G E-Ring X Float

H Jet Needle Y Float Pin

I Throttle Valve Z Float Bowl Gasket

J Starter Plunger Assembly a Float Bowl

K Air Screw b Washer

L O-Ring c Screw

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Code Name Code Name

M Spring d O-Ring

N Idle Adj. Screw e Drain Plug

O O-Ring f Vent Hose

P Spring g Carburettor Housing

Q Vent Hose

Table 3: Carburettor components list

Special requirements: After step 11, the carburettor could be fixed up side down on the fixture.


LEVEL TYPE REPETITIONS CATEGORY TOOL DIRECTION

1 Pulling 2 Non-destructive Plier Y

2 Pulling 1 Non-destructive Plier Z

3 Unscrewing 1 Non-destructive Wrench Z

4 Unscrewing 1 Non-destructive Wrench -Z


6 Separating 1 Non-destructive Gripper Z

7 Separating 1 Non-destructive Long Nose Plier

Z



Z

10 Separating 1 Non-destructive Extractor Z

11 Unscrewing 1 Non-destructive Wrench X


13 Separating 1 Non-destructive Gripper -Z


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18 Pulling 1 Non-destructive Plier X








26 Unscrewing 2 Non-destructive Wrench -P,-Q


-P,-Q


-P,-Q

Table 4: Carburettor operations list

Unscrewing: 16 Pulling: 4 Separating: 18 Total: 38 Destructive: 0 Semi-destructive: 0 Non-destructive: 38

Figure.5: Carburettor disassembly operation and type sector

42%

11%

47%

Unscrewing Pulling Separating

0%0%

100%


Non-destructive

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3.3 Differential Disassembly Sequence

Figure.6: Differential exploded view

Code Name Code Name

A Flange Bolt S Washer

B Pinion Nut T Key

C Companion Flange U Axle Shaft

D Stone Guard V Pinion Gear

E Oil Seal W Gasket

F Bearing Cone Pinion X Differential Cover

G Bearing Cup Y Washer

H Spacer Z Filler Plug

I Housing Differential a Bolt

J Bearing Shim b Shim Diff Bearing Adjustment

K Air Vent c Bearing Cup

L Retainer Bolt d Bearing Cone

M Outer Bearing Retainer e Ring Gear Bolt

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Code Name Code Name

N Spacer Bearing Retainer f Diff Bolt

O Oil Seal g Diff Case L.H.

P Wheel Bearing h Diff Case R.H.

Q Inner Bearing Retainer i Break Cone

R Nut j Shim

k Side Gear q Diff Pinion Gear

m Thrust Plate r Drain Plug

n Helical Springs t Bearing Bolt

o Thrust Washer Diff Pinion u Bearing Cap

p Diff Pinion Cross Shaft y Crown Wheel

Table 5: Differential components list



1 Unscrewing 1 Non-destructive Wrench Y




5 Separating 1 Non-destructive Gripper Y



8 Unscrewing 8 Non-destructive Wrench ±X

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9 Separating 2 Non-destructive Gripper ±X


11 Separating 2 Non-destructive Long Nose Plier ±X

12 Pulling 2 Non-destructive Internal Bearing Extractor

±X


14 Pulling 2 Non-destructive Gripper ±X








22 Pulling 2 Non-destructive Gripper ±X



25 Separating 1 Non-destructive Gripper -X


27 Separating 1 Non-destructive Gripper X


29 Separating 1 Non-destructive Long Nose Plier X





34 Separating 4 Non-destructive Long Nose Plier ±Y,±Z

35 Pulling 4 Non-destructive Gripper ±Y,±Z



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46 Pulling 1 Non-destructive Gripper Y


±Y

48 Separating 2 Non-destructive Long Nose Plier ±Y

49 Separating 2 Non-destructive Long Nose Plier ±Y

Table 6: Differential disassembly operations

Unscrewing: 46 Separating: 46 Pulling: 13 Total: 105 Destructive: 0 Semi-destructive: 0 Non-destructive: 105

Figure.7: Differential disassembly operation and type sector

44%

44%

12%

Unscrewing Separating Pulling

0%0%

100%

Destructive

Semi-destructive

Non-destructive

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3.4 V8 Upper Engine Disassembly Sequence

Figure.8: V8 upper engine exploded view

Code Name

A Spark Plug Cap

B Spark Plug

C Cylinder Head Cover

D Camshaft Bearing Cap

E Bearing Bolt

F Camshaft

G Valve Cap

H Exhaust Manifold Bolt

I Valve Spring

J Exhaust Manifold

K Cylinder Head

L Cylinder Head Bolt

M Valve

N Head Cover Bolt

O Fuel Pressure Regulator

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Code Name

P Fuel Injector

Q Intake Port

R Intake Valve

S Intake Manofold

T Port Bolt

U Manifold Bolt

V Crankcase

Table 7: V8 upper engine components list

Special requirements: During steps 6-9, 11-13, 18-21, 27-30, 32-34, 39-42, extra fixtures are required.




2 Separation 1 Non-destructive Gripper X

3 Unscrewing 4 Non-destructive Wrench P


5 Unscrewing 16 Non-destructive Wrench -X

6 Separation 1 Non-destructive Gripper -X

7 Unscrewing 16 Non-destructive Wrench -X-Y

8 Separation 4 Non-destructive Gripper -X-Y

9 Pulling 8 Non-destructive Long Nose Plier

-X-Y


11 Separation 1 Non-destructive Gripper -Y

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12 Pulling 4 Non-destructive Plier -Y




16 Pulling 2 Non-destructive Gripper -Y




-Y

20 Separation 16 Non-destructive Hook Tool -Y

21 Pushing 16 Non-destructive Hammer Y


23 Separation 1 Non-destructive Gripper Y

24 Unscrewing 4 Non-destructive Wrench -P

25 Unscrewing 8 Non-destructive Wrench -P



28 Unscrewing 16 Non-destructive Wrench -X-Y

29 Separation 4 Non-destructive Gripper -X-Y


-X-Y



33 Pulling 4 Non-destructive Plier -X




37 Pulling 2 Non-destructive Gripper -X




-X

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41 Separation 16 Non-destructive Hook Tool -X

42 Pushing 16 Non-destructive Hammer X

Table 8: V8 upper engine disassembly operations

Unscrewing: 212 Separation: 68 Pulling: 60 Pushing: 32 Total: 372 Destructive: 0 Semi-destructive: 0 Non-destructive: 372

Figure.9: V8 upper engine disassembly operation and type sector

3.5 V8 Lower Engine Disassembly Sequence

Figure.10: V8 lower engine exploded view

Code Name

A Crankshaft

B Shaft Bearing

57%18%

16%

9%

Unscrewing Separation

Pulling Pushing

0%0%

100%


Non-destructive

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Code Name

C Shaft Bearing

D Shaft Bearing

E Shaft Bearing

F Shaft Bearing Cap

G Shaft Bearing Cap

H Bolt

I Crankcase

J Rod Nut

K Rod Bearing Cap

L Connecting Rod

M Rod Bolt

N Gudgeon Pin

O Piston

P Oil Control Piston Ring

Q Second Piston Ring Compression

R Upper Piston Ring Compression

Table 9: V8 lower engine components list

Special requirements: After step 5, the crankcase could be turned upside down Before step 10, the 8 pistons should be placed in a same manner on a fixture(vice) During steps 10 and 11, the pistons could be chucked by vices with connecting rods on the top After step 11, pistons could be turned upside down to proceed the following steps






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4 Unscrewing 16 Non-destructive Wrench -

5 Separating 16 Non-destructive Gripper -

6 Pushing 4 Non-destructive Hammer YZ

7 Pushing 4 Non-destructive Hammer -YZ



10 Pushing 8 Non-destructive Hammer Q

11 Separating 8 Non-destructive Gripper -P


13 Separating 8 Non-destructive Hook Tool P



Table 10: V8 lower engine disassembly operations

Unscrewing: 44 Separating: 64 Pushing: 16 Total: 124 Destructive: 0 Semi-destructive: 0 Non-destructive: 124

Figure.11: V8 lower engine disassembly operation and type sector

3.6 Induction Motor Disassembly Sequence

35%

52%

13%


Pushing

0%0%

100%

Destructive

Semi-destructive

Non-destructive

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Figure.12: Induction motor exploded view and isometric view

Code Name

A Doom Cover Screw

B Spring Washer

C Doom Cover

D Fan

E Back Outer Bearing Cap

F Split Pin

G Back Bearing Cap Screw

H Back Bearing

I Back Cover

J Back Cover Screw

K Back Inner Bearing Cap

L Eye Bolt

M Stator Lock Screw

N Terminal Cover

O Terminal Cover Screw

P Terminal Board Screw

Q Terminal Board

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Code Name

R Body Earth Screw

S Body

T Rotor

U Stator

V Shaft

W Key

X Front Inner Bearing Cap

Y Front Cover

Z Front Bearing

a Front Cover Screw

b Bearing Cap Screw

c Front Outer Bearing Cap

Table 11: Induction motor components list








6 Unscrewing 1 Non-destructive Screwdriver Z

7 Unscrewing 4 Non-destructive Wrench ±X,±Z


±X,±Z


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10 Bending 1 Destructive Plier -





-Y








Y






Table 12: Induction motor disassembly operations

Unscrewing: 28 Separating: 16 Bending: 1 Pulling: 2 Total: 47

Destructive: 1 Semi-destructive: 0 Non-destructive: 46

Figure.13: Induction motor disassembly operation and type sector

60%34%

2%

4%


Bending Pulling

2%0%

98%


Non-destructive

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3.7 E61 Group Disassembly Sequence

Figure.14: E61 group exploded view and isometric view

Code Name Code Name

A Gicleur Cover Nut R Drain Chamber Gasket

B Teflon Seal S Drain Valve

C Gicleur Filter Screen T Drain Valve Spring

D Gicleur 0.7 U Drain Diffuser

E Mushroom V Drain Chamber

F Mushroom Gasket W Cam Stop Screw

G Teflon Gasket X Cam Lever

H Brew Valve Spring Y Cam Chamber

I Brew Valve Z Cam Lever Gasket

J Group Base a Cam Gasket Bushing

K Plug b Cam Gasket Bushing Spring

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Code Name Code Name

L Plug Washer c Cam Chamber Bushing Nut

M Mounting Screw d Handle Base

N Diffuser e Handle Lever

O Pre Infusion Valve f Lock Washer

P Spring Base Support g Handle Base Locking Screw

Q Discharge Chamber

Table 13: E61 group components list





3 Separating 1 Non-destructive Long Nose Plier Z







10 Unscrewing 1 Non-destructive Wrench XZ

11 Separating 1 Non-destructive Gripper XZ



14 Pushing 1 Non-destructive Long Nose Plier Z

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25 Unscrewing 1 Non-destructive Screwdriver Y

26 Separating 1 Non-destructive Long Nose Plier Y







33 Unscrewing 1 Non-destructive Screwdriver Y


Table 14: E61 group disassembly operations

Unscrewing: 12 Separating: 22 Pushing: 1 Total: 35


Figure.15: E61 group disassembly operation and type sector

34%

63%

3%

Unscrewing SeparatingPushing

0%0%

100%

DestructiveSemi-destructiveNon-destructive

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3.8 Oil Filter Disassembly Sequence

Figure.16: Oil filter exploded view

Code Name Code Name

A Stud J Shell

B Washer K Plug, Pipe

C Head Cover L Shell Gasket

D Spring M Plug, Pipe

E Head Gasket N Filter Base

F Element, Filter O Plunger

G Centre Bolt P Spring

H Bolt Q O-Ring, Relief Valve

I Filter Retainer Plate R Plug, Relief Valve

Table 15: Oil filter components list

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15 Pulling 2 Non-destructive Gripper Z



Table 16: Oil filter disassembly operations

Unscrewing: 11 Separating: 17 Pulling: 2 Total: 30


Figure.17: Oil filter disassembly operation and type sector

37%

57%

7%

Unscrewing Separating Pulling

0%0%

100%

Destructive

Semi-destructive

Non-destructive

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4. RESULTS AND ANALYSIS

Figure.18: Types of disassembly operations

As is indicated in the bar chart, it is evident to see that unscrewing is the most popular type

of disassembly operation, accounting for 47.8%. Separating and pulling are also intensively

used in disassembly process, occupying 33.2% and 11.2% respectively. On the contrary,

pushing, drilling and bending are less utilized based on the graph. Therefore, it is reasonable

to conclude that the three main recurrent disassembly operations [3] are: a) Unscrewing; b)

Separating; c) Pulling.

Figure.19: Recurrent disassembly types

47.80%

33.20%

11.20%

6.20%

1.50% 0.10%0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

Unscrewing Separating Pulling Pushing Drilling Bending

TYPES OF DISASSEMBLY OPERATIONS

TYPES OF DISASSEMBLY OPERATIONS

98.40%

1.50% 0.10%0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

Non-destructive Semi-destructive Destructive

RECURRENT DISASSEMBLY TYPES

RECURRENT DISASSEMBLY TYPES

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Figure.19 presents the proportions of three types of recurrent disassembly. It is noticeable

that most disassembly procedures are non-destructive, taking up over 98% from the figure

based on the 8 case-study. However, those irreversible method of disassembly are less used

due to this chart.

5. CONCLUSION

The report presents some basic understanding on Identification of patterns, issues and

problems of disassembly operations with human beings as well as several relevant

knowledge and challenges associated with robotics. Moreover, 8 product disassembly

sequence case studies are also illustrated. As the project was just launched, scientists and

engineers still have a long way to go to figure out both theoretical and practical problems.

From the figures integrated from 8 case studies, it is possible to conclude that the three

main recurrent disassembly operations are Unscrewing, Separating and Pulling. Most

procedures currently are not destructive towards products, while some approaches of

disassembly still pose a great threat on remanufacturing project. As a consequence,

components standards of different products may be integrated into a new specification

which fits both assembly and disassembly process, from which the efficiency and cost-saving

can be benefited as well.

6. REFERENCES

[1] AUTOREMAN Project [WWW Document], 2016. . AUTOREMAN Proj. URL

http://autoreman.altervista.org/index.html

[2] S.L. Soh, S.K. Ong, A.Y.C. Nee. Design for Disassembly for Remanufacturing: Methodology

and Technology. 2014, Elsevier B.V.

[3] TARCÍSIO AUGUSTO SANTOS ALMEIDA. DISASSEMBLY FOR REMANUFACTURING: METHODOLOGY

AND CASE STUDY. 2016.

http://autoreman.altervista.org/index.html

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UNIVERSITY OF BIRMINGHAM Mechanical …autoreman.altervista.org/Student_reports/Summer...UNIVERSITY OF BIRMINGHAM Mechanical Engineering DISASSEMBLY FOR REMANUFACTURING AUTOREMAN PROJECT