Circular Handheld Machines from an Environmental and Human Perspective

Background and Challenge

Vibration injuries are a major occupational health issue across Europe. On May 22, 2023, the EU adopted a new Machinery Regulation that introduces a revised approach to the mechanisms behind vibration injuries, including a requirement to report high-frequency shock vibrations. This has led to a stronger focus on handheld machines and the potential for well-designed models to reduce vibration-related injuries.

Circular business models rely on long product lifespans and high utilization of products with low environmental and climate impact. Through robust, flexible, and upgradable product design, it is possible to reduce vibrations while also promoting environmental sustainability.

However, today’s products are rarely adapted for circular business models. Instead, they are often designed in ways that risk making them unattractive, outdated, or prone to premature wear and failure.

Purpose and Goals

The project aims to apply future-adaptive design principles to both existing and new machines to support climate, environmental, and social sustainability. It focuses on developing circular machines that comply with the EU’s new regulations, featuring interchangeable components and modules that simplify repair and upgrading. The objective is to reduce environmental impact while minimizing the risk of vibration-related injuries.

Solution

The key to designing future-adaptive products is a "future-proof" product architecture. This means creating a product that is inherently designed for easy repair and upgrades over time, as new needs emerge. This includes not only components and hardware but also new software integrated into the machines as part of a circular business model. For example, sensors and software that monitor and record vibration exposure.

Intense vibrations not only raise the risk of vibration injuries but also hinder automation. Vibration can cause robotic machines to malfunction. By developing low-vibration machines, the level of automation and robotics in manufacturing can be increased.

A longer product lifespan also leads to significant improvements in the product’s environmental and climate performance.

The innovative aspect of the project is applying this approach to a range of handheld machines in the manufacturing sector, including impact wrenches, chisel machines for cast scrap removal and grinding/cutting machines.

The prototypes will demonstrate how the choice of materials and manufacturing techniques impact the lifespan and environmental burden. This contributes to building competence among manufacturers and companies that repair and upgrade machines. The project will also apply environmental analyses (life cycle assessment) to identify which parts of the manufacturing process have the greatest environmental impact and need to be addressed.

The measures are relevant in industries other than the automotive sector, such as the construction and building sector, as well as the stone industry, which are large users of handheld machines.

Expected short-term impact

• Increased knowledge and experience among participating companies in designing products tailored for circular business models.
• Low-vibration machines for both humans and robots are available on the market. Increased potential for automation.
• Upgraded existing machinery that meets new regulations – occupational health and safety.
• New business opportunities for existing machinery; e.g., modular solutions that can be machine- and individual-customized.
• Dissemination of results to other industries; e.g., the construction and building sector, as well as the stone industry.

Expected long-term impact

• Handheld machines designed for a circular business model.
• Reduced climate impact during the use and manufacturing of handheld machines.
• Increased competitiveness for the manufacturing industry with a healthier workforce (fewer work-related injuries).
• Compliance with the EU's new Machinery Regulation 2023/1230 and subsequent regulations for machine manufacturers.
• Safe and attractive workplaces for both women and men.
• Internationalization of results and the project.