Environmental sustainability through end-of-life recovery has become the main items of contest in the automotive industries. Component reuse as one of the product recovery strategy is now gaining importance in view of its impact on the environment. Disassembly as one of the determinant factors for reuse is a very important and difficult process in life cycle engineering. To enable reuse, a certain level of disassembly of each component is necessary so that parts of the products that have arrived at their end-of life can be easily taken apart. Improvements to the disassembly process of products can be achieved at two levels: in the design phase, making choices that favours the ease of disassembly of the constructional system (design for disassembly) and planning at best and optimising the disassembly sequence (disassembly sequence planning). Hence, finding an optimal disassembly sequence is important to increase the reusability of the product. This paper presents the development work on an optimisation model for disassembly sequence using the genetic algorithms (GA) approach. GA is chosen to solve this optimisation model due to its capability in solving many large and complex optimisation problems compared with other heuristic methods. The fitness function of the GA in this study is dependent on the increment in disassembly time. Comparison of results using different combinatorial operators and tests with different probability factors are shown. This paper will present and discuss the disassembly sequence of an engine block, as a case example which achieves the minimum disassembly time.

Genetically optimised disassembly sequence for automotive component reuse

Problem statement: It is expected that over the next few years type ap proval legislation and public awareness will force vehicle manufacture rs to identify recovery methods during the design process in order to achieve reuse and recycling tar gets. Current vehicle design in Malaysia does not sufficiently aid the economic recovery of parts and materials to reach these targets. Approach: This study aimed to provide a framework for automotive components to be designed for ease of recovery. Disassemblability concept evolved from the life cyc le engineering concept in which design for disassembly is one of the strategies in reducing th e impact of the product to the environment. Results: The proposed methodology that consisted of three distin ct elements namely implementing principles and guidelines of design for disassembly into the desig n, generating optimum disassembly using genetic algorithm approach and evaluating disassemblability of end-of-life products will be discussed. Conclusion/Recommendations: There is a need for effective disassembly in order to enhance the recovery of end-of-life product.The proposed methodology was implemented as a computer-based disassemblability evaluation tool that will enhance disassemblability of the product starting from the design stage.

/pdf/a-design-framework-for-end-of-life-vehicles-recovery-3hwru5guk9.pdf

A Design Framework for End-of-Life Vehicles Recovery: Optimization of Disassembly Sequence Using Genetic Algorithms

Nowadays, automotive manufacturers are facing with impact of the vehicle to the environment. In some European countries, Japan, USA, and Australia, laws require automotive manufacturers to take back their products at the end of their useful life and recycle them. Most of the developed countries also have set new legislation, which is planned to force automotive manufacturers to recover and recycle their products at the end of their life. Disassembly is the first step to recycle automotive components. In general, the designers do not have experience in disassembly and recycling to determine the impact of various design aspects on the disassemblability at the disassembly stage. Based on that, many researchers have proposed several methods in evaluating disassemblability. This paper reviews the evaluation methods of disassemblability which were proposed by the previous researchers and then outlines the functional requirements for a system for evaluating the disassemblabilty of automotive components based on automotive manufacturer and legislation requirements. In particular, the implication of end-of-life vehicle on current product design practice is also explored. The result of the literature review shows that, in order to successfully implement the concept of end-of-life vehicle especially in terms of disassemblability evaluation, the aspects of recycling and disassembly must be considered more rigorously in the product design process.

/pdf/the-evaluation-methods-of-disassemblability-for-automotive-saas9fnc7c.pdf

The evaluation methods of disassemblability for automotive components - a review and agenda for future research

Recent legislative and social pressures have driven manufacturers to consider effective part reuse and material recycling at the end of product life at the design stage. One of the key considerations is to use joints that can disengage with minimum labor, part damage, and material contamination. This paper extends our previous work on the design of high-stiffness reversible locator-snap system that can disengage non-destructively with localized heat [1, 2], to include 1) modeling for tolerance stack-up and 2) lock-and-key concept to ensure that snaps only disengage when the right procedure is followed. The design problem is posed as an optimization problem to find the locations, numbers, and orientations of locators and snaps, and the number, locations and sizes of heating areas, which realize the release of snaps with minimum heat, compliance, and tolerance stack-up. The motion and structural requirements are considered constraints. Screw Theory is utilized to pre-calculate a set of feasible types and orientations of locators and snaps that are examined during optimization. The optimization problem is solved using Multi Objective Genetic Algorithm (MOGA) coupled with structural and thermal FEA. The method is applied on two case studies. The Pareto-optimal solutions present alternative designs with different trade-offs between the design objectives while meeting all the constraints.Copyright © 2008 by ASME

High-Stiffness, Lock-and-Key Heat-Reversible Locator-Snap Systems for the Design for Disassembly

Regarding the high rate of scrap increase in developed and developing countries, governments and unions are issuing legislations to force companies recycling their products after disposal all over the world. This fact is obvious in vehicle and electrical appliances industry. Currently at the end of life of products recyclers think how to take advantage of product end of life. This problem originates from product design and development process. In order to achieve environmentally conscious products, these two elements have to be considered i.e. assembly and disassembly. Consequently, new approaches in design such as design for disassembly are introduced. Through these new approaches, companies are able to take benefit of their product end of life value. But still there is some vague area in design for environment especially when designer wants to combine all aspects at the early stage of design. Tools which are able to consider all design aspects concurrently will decrease total cost in product life cycle and will motivate producers not only to follow legislations, but also get higher benefit of product end of life. This research expects finding methodologies that can combine assembly and disassembly for a less life cycle cost.

Development of a model for integration of assembly and disassembly in life cycle management

Due to the increased responsibility for the end-of-life (EOL) treatments of products by the manufacturers, the ease of disassembly has become a key design issue for mass-produced products. As an extension of the conventional design for disassembly (DFD), this paper presents a computational method for designing assemblies that can be disassembled only in specified sequences. Given an ideal disassembly sequence that maximizes the profit in the absence of geometric constraints, the method simultaneously determines the spatial configurations of components, locaters, and joints, such that disassembly can occur only in the sequence. A multi-objective genetic algorithm is utilized to search for Pareto-optimal designs in terms of the unique realization of the given disassembly sequence, the satisfaction of distance specifications among components, and the efficient use of locators on components. A case study on a simplified laptop computer assembly demonstrates the effectiveness of the method

/pdf/design-for-product-embedded-disassembly-sequence-3l5g8iia05.pdf

Design for product embedded disassembly sequence

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Design for product embedded disassembly sequence