"If you look at this engine, only the crankshaft is worn out. Everything else is good. It would be a shame if the 300-plus-kilogram cylinder is scrapped." A few days ago, the reporter went into the key laboratory of China's equipment remanufacturing technology. The staff pointed to one of the engines. Under normal circumstances, these important parts of the car - the engine, transmission just because of local damage, I am afraid it is difficult to escape the destiny of retirement. The automotive industry is often referred to as the "high energy consumption, high consumables" industry.
Is there any way to solve this contradiction? Through advanced technology, these bad parts will be remanufactured, allowing it to avoid the fate of direct retirement after the whole life cycle of design, manufacture, use, and maintenance. It is “regaining new life†to extend the service life and reduce the consumption of resources and energy. In fact, remanufacturing technology has emerged on demand. Remanufacturing is considered an important way for the sustainable development of the automotive industry.
However, in the face of this seemingly unfamiliar concept, people are inevitably wondering whether the quality of remanufactured parts and components is reliable and whether remanufacturing can take into account both social and economic benefits. What benefits do ordinary people buy from remanufactured parts?
Ensure reliable quality
Remanufacturing is not the same as simple maintenance. The key is to use high technology and new materials to repair or even upgrade existing products.
Remanufacturing, in fact, refers to the use of high-tech mechanical and electrical products to professionally repair or upgrade, so that it can be restored to the same or better than new products in the batch manufacturing process. “Remanufacturing is not the same as simple maintenance. Remanufacturing a product is not the same as second-hand goods.†Academician Xu Binshi of the Chinese Academy of Engineering made such an interpretation of the concept of remanufacturing. The key to remanufacturing is the use of high-tech and new materials. There are products to repair or even upgrade.
However, after all, cars are different from other products. Its quality is related to people's travel safety. Can a brand new component-assembled car not guarantee 100% quality and safety, and is it safe to use remanufactured parts?
"After repairing through specialized technologies, remanufactured products must be at least as good as new products in quality and performance, at least not inferior to new products. This is the most important standard." The theme of the two national conferences this year is "Remanufacturing and the automotive industry. In the collective development interview, He Bingguang, inspector of the Central Government Department of National Development and Reform Commission, gave a positive response to the quality of remanufactured products that journalists were very concerned about.
"For example, the use of China's independent innovation of automatic nano-composite brush plating technology, can improve the wear resistance of remanufactured parts 1.5 times. Consumers do not have to worry about the quality of remanufactured parts and components." Xu Binshi said.
He further explained that "the quality of remanufactured products depends to a large extent on the quality of the waste parts themselves. Waste parts whose original materials are not good or whose remaining life span is insufficient will not be used for remanufacturing at all." That is to say, Not all used parts can be used for remanufacturing. “Compared to the various tests to be performed at the initial manufacturing stage of the product, the detection technology in the remanufacturing sector will be more stringent.†At the key laboratory for equipment remanufacturing technology, the reporter saw a Taiwan-based sophisticated testing instrument that can use magnetic materials. Memory and other technologies perform non-destructive testing of worn-out parts, detect internal cracks and fatigue stresses of parts, and assess the remaining life of worn-out parts. Only after screening can remanufacturing be performed.
Xu Binshi introduced that taking the automotive engine as an example, waste parts will be dismantled, cleaned, sorted, tested, and remanufactured using key technologies to repair failed parts, etc., in order to ensure the quality of the remanufactured products. Parts are tested and bench tested. "Consumers can rest assured that they use remanufactured parts."
Efforts to achieve social and economic benefits win-win
The technology of independent innovation can make the remanufacturing industry both cyclical and economic. The future development of the remanufacturing industry must be guided by technological innovation.
Remanufacturing auto parts can achieve great social benefits. "Compared with manufacturing new products, remanufacturing can save 50% in cost, save energy in 60%, save 70% in raw materials, and reduce the adverse impact on the environment compared with manufacturing new products," said Xu Binshi. According to statistics, one ton of remanufactured products can avoid the production of 4 tons of industrial waste and a large amount of fixed waste; the production of 10,000 remanufactured engines can save electricity by 14.5 million kWh and reduce carbon dioxide emissions by 600 tons. Remanufacturing is considered to be a high-level form of “reuse†in the “reduction, reuse, and recycling†principle of the circular economy, which is conducive to the sustainable development of the automotive industry.
However, the fundamental of circular economy is "recycling and economy." If there is only social benefit and economic efficiency cannot be taken into consideration, remanufacturing may lack internal motivation for development. Can remanufacturing parts and components achieve social and economic benefits?
Yu Ping, chairman of Yuchai Machinery Group, said that "at present, the gross profit margin for parts remanufacturing is generally around 20%." According to his forecast, with the expansion of the scale and the soundness of the entire market, the gross profit margin of the remanufacturing industry will be far. Far higher than the current gross margin of new manufacturing.
"Remanufacturing parts and components does not rely on low-tech repairs that are tapped, but rather uses high-tech processes for mass production." Xu Binshi pointed out that the cost of remanufactured products is 50% less than new products, and the profit of remanufactured products will exceed that of new products in the future.
He believes that the key to win-win for both social and economic benefits in parts remanufacturing depends on technological innovation. At present, foreign remanufacturing technologies are mainly based on dimensional repair methods and replacement parts repair methods. If the circular bearing bore of the engine block becomes elliptic due to wear, if the foreign dimensional repair technique is used, the out-of-round bearing bore can be reopened. However, there is a problem that it is difficult to obtain The fittings with bearing holes that change in size are easily inconvenient and resource utilization is not high. China's independent innovation in remanufacturing technology "size recovery and performance improvement method", through the means of automated high-speed arc spraying can be re-manufactured into the same standard size and new parts, all accessories can be used, the utilization of resources Even higher, the cost is only 10% of new products. “The nano-composite brush plating technology and micro-plasma cladding technology that are independently innovated can make the remanufacturing process both cyclical and economic. The future development of the remanufacturing industry must be guided by technological innovation.â€
For ordinary consumers, the price for buying a remanufactured engine is only half the price of new products. Using remanufactured parts means real benefits.
Future development requires multiple parties to work together
The development prospects of the auto parts remanufacturing industry are very broad. At present, China has achieved initial results in terms of technology, policies, and market norms, but it still needs multiple efforts in its future development.
"The development prospects of the auto parts remanufacturing industry are very broad." Xu Binshi judged. In 2005, China listed the engine remanufacturing project as a circular economy pilot project. In 2008, the National Development and Reform Commission selected 14 companies as pilot enterprises to carry out remanufacturing of auto parts, and achieved technology, policies, standards, and market regulations. Initial results. However, at present, China's parts and components remanufacturing industry is still only in its infancy, and future development still needs multiple efforts.
"An obstacle to the development of China's remanufacturing industry is that people's awareness is still relatively low," said He Bingguang. "Remanufacturing" is a brand-new concept for most people. Consumers have not really understood the benefits of remanufactured parts and components products. Even the company's deep-going understanding of the development of the remanufacturing industry is not enough. The enthusiasm has yet to be improved. .
From a technical point of view, Xu Binshi pointed out that there are many differences between remanufacturing technology and traditional manufacturing technology. To improve the utilization rate of discarded parts, it is necessary to strengthen the innovation of remanufacturing technology, establish a competition mechanism, and break through high-tech and key technologies in the field of remanufacturing. Practical technology. "The development of remanufacturing technology requires professionals, so we must also accelerate the development of new talents."
In addition to this, the current unrestricted recycling of used materials for remanufactured waste materials is one of the constraints of the development of the remanufacturing industry. Relevant experts suggest that a system should be established that integrates remanufacturing with manufacturing, recycling, and dismantling, allowing qualified remanufacturers to recycle used parts and remanufacture them. At the same time, it is necessary to strengthen the market access system of the remanufacturing industry, implement qualification management for enterprises engaged in remanufacturing, formulate strict remanufacturing industry standards and quality standards, and standardize the production and sales system of remanufactured products.
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