Unified Embodiment Description for functional evaluation of used components in circular manufacturing systems

Abstract: Circular manufacturing systems require functional evaluation of used components based on their physical state. Existing approaches describe this state from separate perspectives, such as design, manufacturing, and degradation, resulting in fragmented and incompatible representations. As a consequence, the physical state cannot be reliably linked to the functional behavior of the corresponding subsystem, which is a prerequisite for informed R-strategy decisions. This paper introduces the Unified Embodiment Description (UED), a state-dependent representation of mechanical components structured into two coupled layers. The first layer is a unified characteristic space, which adapts and extends as new lifecycle effects emerge. The second layer consists of functionally derived tolerance regions that link these embodiment characteristics to the functional behavior of the surrounding subsystem. A supporting UED method guides the model-building process of both layers. The UED is demonstrated in a case study on the spindle shaft of an angle grinder, in which manufacturing variations and degradation patterns such as polishing wear and scratches are quantified. These embodiment changes are embedded into the unified characteristic space and translated into functionally derived tolerance regions through experimental testing of the spindle-bearing subsystem. The results show that embodiment changes induced over the lifecycle can be consistently integrated within the unified characteristic space and that the relations between embodiment and functional behavior can be quantified to support end of life decisions. Overall, the UED provides a foundation for embodiment modeling that adapts to component state and enables decision-making based on functional evaluation for used components in circular manufacturing systems.