Testing Environments for Data‑Driven Prediction of Functional Behavior and Reliability in the Circular Factory

In the Circular Factory, used products are reprocessed and recombined into products of a new generation. Choosing which combination of used subsystems to build requires predicting two things: (i) the expected functional behavior of a specific configuration and (ii) its reliability. Each prediction rests on a different kind of model, and the two model types come with their own set of data requirements. A model of functional behavior needs short, tightly controlled measurements that show how a change in embodiment changes a measurable performance quantity. A model of system reliability needs degradation trajectories recorded over long operating times. The problem is that it is unclear how to translate these requirements into dedicated testing environments.
This gap is being addressed by expanding upon the product development process VDI 2221 with a categorization of testing environments along seven dimensions. Applying the methodology to angle grinders results in the development of two testing environments. The first focuses on the variation in functional behavior (deflection of the spindel shaft) due to changes in embodiment (changes in the needle bearing runway on the output shaft). ... mehrThe second testing environment focuses on long-life testing to collect reliability and degradation data.
With these testing environments the data required for the model building can be collected. Providing systematic functional and reliability data enables the Circular Factory to make informed, data‑driven recombination decisions, thereby reducing waste, extending product lifetimes, and advancing scalable circular manufacturing.