重型及越野车型零配件(包括轮胎) 欧洲再制造 Shanghai , China European Remanufacturing of Heavy Duty and Off-Road Vehicle Components (including Tyres) 重型及越野车型零配件(包括轮胎) 欧洲再制造 By Fernand J. Weiland FJW Consulting, Cologne (Germany) Past Chairman & now member of the APRA board Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Definition of Remanufacturing (By European assoc. APRA, CLEPA & FIRM) 再制造的定义 “A remanufactured part fulfils a similar function as the original part . It is restored from an existing part (core), using standardized industrial processes in line with specific technical specifications. “ Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing Process for Automotive components 汽车零配件的再制造过程 Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Heavy Duty Remanufacturing Introduction 欧洲重型车再制造, 概况 The European experts on Remanufacturing tend to focus mainly on the car business and less on the Heavy Duty business That is also what I did in my last Book! This presentation aims now at demonstrating that the Heavy Duty Vehicle Remanufacturing is as important Editor: Fernand J. Weiland European Automotive Remanufacturing Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Light Commercial Vehicles (Are not Heavy Duty!) 轻型商务车(非重型!) Only maximum 3.5 t total weight Only light duty vehicle Components very similar to cars Hydraulic Braking no Air braking 12 Volt not 24 Volt Transmission only 5-6 gears Engine only in average 90 KW Tyres only 15/16 inches Rim diam. Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Heavy Duty Trucks, Trailers and Buses 重型卡车, 拖车及客车 Total weight 3.6 t to 40 t Between 5 and 8 axles Transmissions between 9 and 16 gears Air brakes Electrical equipment 24 Volt Engine from to 150 KW and 400 KW Tyres 17- 24 inches Rim Diameter Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Agriculture vehicles , Tractors, Combined etc 农业机械, 拖拉机, 联合收割机 等等 Special heavy duty vehicles Total weight up to 5 t Engines up to 250 KW – 9 liters Hydraulic brakes Transmission up to 25 gears Tyres diameters up to 215 cm Electrical supply 12 Volt and 24 Volt Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Off Road, Construction,Earth Moving, Mining Vehicles etc 野外, 建筑, 地质工程, 矿山机械 等等 Heavy duty vehicles- Loaders etc Total weight up to 30 t and more Engines up to 250 KW – 12 liters Hydraulic multi disc brakes Hydrostatic Transmission Electrical supply 24 Volt Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Heavy Duty Vehicle in Use in Europe ( West & Central) 重型车在欧洲的使用 (西欧及中欧) Number of vehicles Trucks from 3,6 t to 40 t 5.500.000 Trailors (for above trucks) 1.500.000 Buses 650.000 Agriculture tractors 9.500.000 Off Road, construction, etc 2.100.000 Total 19.250.000 Light Commercial (3,5 t) 27.000.000 Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

For HD Vehicles more product lines are remanufactured 针对重型车型, 再制造被更加广泛地运用 Standard components which are remanufactured for cars/light vehicles are: Starters and alternators, power steering pumps, Fuel injection, electronic control modules, Brake calipers, transmissions, engines and turbochargers But for Heavy Duty additional components are remanufactured such as: Hydraulic Pumps and Cylinders Water &Oil pumps and oil coolers Air compressors and air actuators Radiators & Retarders & Particle Filters Differentials and hydraulics Tyres and Dampers etc Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

HD Vehicles Components Values and Dimensions are much higher 重型车型零配件的价值更高, 适用范围更广 A few examples which clearly demonstrate how much bigger HD components are : Brake caliper of a VW Golf : 2 ,5 kg Brake caliper of a Commercial Truck : 40 kg Engine of a VW Golf : 1.8 l Engine of a Heavy Duty Truck : 12 l Weight of a VW Golf Transmission : 40 kg Weight of Truck Transmissions : 200 kg Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Automotive (Car) Remanufacturing is very big! 汽车行业(乘用车) 再制造前途无限 But how big is Heavy Duty Remanufacturing? The European Automotive (car) Reman business is estimated to be ca. Euro 8 billions A very «broad brush» estimation of HD Remanufacturing can be calculated as follow: In Europe we have 220 million cars in use compared to 20 million HD vehicles in use. Assuming a minimum of 35 % hígher wear (usage) , 25% more product lines and a component value four-five times higher, the end result would be : Euro …………!!! Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing HD Diesel Engines 欧洲重型柴油发动机再制造 OE Manufacturers : Daimler, Volvo, FPT, Scania, Renault, Iveco.Cummins, Caterpillar, Deutz etc Vehicles fitted Trucks 5.000.000 Buses 500.000 Agriculture 9.000.000 Off Road 2.100.000 Vehicle Brand Trucks: Mercedes, Volvo, Daf,Scania,Iveco etc Tractors/Off Road: John Deere, Caterpillar etc Replacement Market Remanufactured ca. 100.000 p.a. Repaired ? Reman Market Share OE Reman : 75 % Independent Reman : 25 % Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing HD Startermotors & Alternators 欧洲重型电子器械再制造 OE Manufacturers Mitsubishi 55 % Bosch 45 % Prestolite, etc. 5 % Vehicles fitted Trucks 5.000.000 Buses 500.000 Agriculture 9.000.000 Vehicle Brand Mercedes, Volvo, DAF, Scania, Iveco, MAN, Renault , John Deere etc. Replacement Market New machines 25 % Reman machines 75 % Reman Market Shares OE Reman : 70 % Independent : 30 % Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing HD Truck Power Steering 欧洲重型转向系统再制造 OE Manufacturers ZF 50 % ZF/Thyssen 25 % TRW 25 % Vehicles fitted Trucks 5.000.000 Buses 500.000 Vehicle Brand Trucks: Mercedes, Volvo, DAF, Scania, Iveco, Renault, Volvo & MAN Replacement Market New units ca. 25 %. Reman & Repair ca. 75 % Reman Market Share OE Reman : 65 % Independent Reman : 35 % Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing HD Air actuated Calipers 欧洲重型空气制动卡钳再制造 OE Manufacturers Knorr Bremse 65 % Wabco 15 % Meritor 10 % Haldex 10% Vehicles fitted Trucks 5.000.000 Trailers 1.500.000 Buses 500.000 Vehicle Brand Trucks : Mercedes, Volvo,Daf,Scania,Iveco etc Axles : BPW, SAF , ZF etc Trailers: Krone, Schmitz Cargo etc Replacement Market New calipers : 75 % Reman calipers: 25 % Reman Market Shares OE Reman : 20 % Independent : 80 % Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing/Retreading Heavy Duty Tyres - The History 历史--- 重型轮胎再制造/新轮廓 Retreading Tyres is a remanufacturing process Which started around WW II at the same time as all other vehicle components In Europe the process is mainly applied to HD and not to car applications In Europe OE Tyre manufacturers and ca. 200 SME companies are retreading/remanufacturing Tyres Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The Process consist of : 重型轮胎再制造过程包括以下: Careful inspection of old Tyre casings (only sound cases/carcasses are reused) Worn tread is buffed (removed) away Small defects are repaired Uncured (soft) rubber is applied on the casing and put for vulcanizing either in a molding machine Or pre-vulcanized treads are put on the casings for vulcanizing in a vacuum autoclave Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The Process 重型轮胎再制造  过程 REIFENDIMENSION: 27.00R49 Gewicht: ca. 900 Kg Photo courtesy of Rösler Tyre Innovators GmbH & Co. KG (Germany)

Remanufacturing HD Tyres 重型轮胎再制造 REIFENDIMENSION:35/65R33 Gewicht: ca.750Kg Photo courtesy of Rössler Tyre Innovators GmbH (Germany)

Remanufacturing HD Tyres The Products are : 重型轮胎再制造   产品 For Trucks from 7,5 tons to over 40 tons, with tyres from 17” to 24” rim diameter and weights of 30 kg to 120 kg For Construction Equipment from 20 tons to 60 tons of overall weight and tyres from 25” to 33” rim diameter and weights of 120 kg to 750 kg For Earth Moving & Mining equipment from 100 tons to 600 tons of overall weight and tyres from 35“ to 63“ rim diameter and weights of 700 kg to 6000 kg Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The Benefits are : 重型轮胎再制造   优势 Retreaded Tyres cost less and reduce the total cost of operating the vehicles New Tyres are produced in highly automated production lines, retreading/remanufacturing uses more labor and creates more jobs The environmental balance of remanufactured Tyres is significantly better, it saves material in the amount of 60% and saves 80% of energy Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The Quality is secured by : 重型轮胎再制造      质量控制 Retreaded Tyres are as good as new Tyres Already the quality starts with accurate inspection of old casings The process must meet the specification UN ECR 108/109 The production facility must be certified by TUV/DEKRA etc The final inspection ensures the required quality The Tyres must be marked with the certified mumber and logo of the retreader NB. Aviation Tyres are often retreaded tyres !!! Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The Markings UN 109R 重型轮胎再制造     UN109R 标识 Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

Remanufacturing HD Tyres The European Market: 重型轮胎再制造    欧洲市场 The European market for replacement of HD Tyres amounts to ca. 10 million units The market share of retreaded/remanufactured HD Tyres is ca. 3.8 million or 38 % Car Tyres which have a low value are not attractive for retreading The Value of Off-Road Tyres for Mining, Construction etc. is high and attractive for remanufacturing Also Aviation Tyres are retreaded and have a high market share vs. new! Aviation tyres can be retreaded up to 5 times!!! Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing, the Trends 欧洲再制造   趋势 Not as for the car business, for Heavy Duty after market sales tend to be controlled by OE players But independent Remanufacturers are ready to fight for their part of the market The life expectancy of components is improving which works against Remanufacturing The components tend to become technically more complex which is in favor of the true specialists Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing, the Trends 欧洲再制造   趋势 But the profit margins for HD & complex components are much better Remanufacturing is in general a growing business (though undermined by new copied units) The recognition as a green industry and the acceptance to service economically vehicles offers the reman industry excellent current and future business opportunities. Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)

European Remanufacturing, 欧洲再制造   Xie Xie Thank you Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing Beijing (China)