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Design for Recycling Guidelines Most recycling guidelines are divided into three categories:
Fundamental Lessons Learned As part of ongoing efforts in improving vehicle recyclability, a number of fundamental lessons have been learned from the disassembly of vehicles and studies by the Vehicle Recycling Partnership:
The limiting factor in economic recycling of complex, integrated assemblies (such as instrument panels) is the separation into pure material streams. Both manual and mechanical separation have their advantages and disadvantages. Significant value must be retained in a part for manual separation to be economically feasible. Different design techniques should be employed depending on whether one wants to facilitate manual separation or mechanical separation.
These fundamental lessons should be kept in mind when generating design alternatives.
Georgia Institute of Technology Systems Realization Laboratory
Hig h material remo val rate (MRR )? (ap pro x. 10 lb s /min for plastics) No Yes Manu al S ep aration Techn iqu es ap p lied Mid -v alu e b ut imp ro vab le MR R? (ap pro x. 5 lbs /min fo r p las tics ) Yes No Mechanical Sep aratio n Techn iqu es ap p lied Rep eat fo r compo n en ts of ass emb ly
Detached Weight for Cost Neutral Recyling (g/min) The amount of material (in grams) that has to be detached per minute if recycling is to be cost neutral for manual disassembly:
Precious metals: gold palladium sliver Metals: copper aluminium iron Plastics: PEE PC, PM ABS PS PVC Glass 0.05 0.14 5.1 300 700 50,000
Based on West-European hourly rates and material prices in Sept. 1995 (Philips Center for Manufacturing Technology)
End-of-Life Destination Flowchart (from TNO Industry Delft, The Netherlands) General guidelines to determine end-of-life destinations
YES NO
NO
rest fractions
Which parts will be suitable for high and low quality recycling?
Reuse
Incineration
Landfill
Chemical waste
Rule of Thumb:
NOTE: Ideally,
Material Compatibility
Compatibility matrices (or tables) list whether two materials are compatible, that is, they can be processed together. Most tables are for plastics, but some also exist for metal alloys. Most use a (rough) scale of 1-4 or 1-3. Typically, the information regarding compatibility (and especially detailed information) is buried in chemical handbooks.
Matrix material
compatible compatible with limitations compatible only in small amounts not compatible
bottle glass bottle glass window glass drinking glass drinking glass(crystal) TV (screen) TV (cone) TV (neck) LCD (screen) ceramics + + +
TV (cone) 0 0 + -
TV (neck) 0 + + -
0 0 -
0 0 -
Compatibility of Metals In general, metal parts are easily recycled, but the following rules and guidelines apply:
Unplated metals are more recyclable than plated ones. Low alloy metals are more recyclable than high alloy ones. Most cast irons are easily recycled. Aluminum alloys, steel, and magnesium alloys are readily separated and recycled from automotive shredder output. Contamination of iron or steel with copper, tin, zinc, lead, or aluminum reduces recyclability. Contamination of aluminum with iron, steel, chromium, zinc, lead, copper or magnesium reduces recyclability. Contamination of zinc with iron, steel, lead, tin, or cadmium reduces recyclability.
Metal (proce sse d by way of s melting proces s) Copper (Cu) Aluminum (Al) Iron (Fe) Knock -out elements (decre ases value of the fraction to ze ro) Hg, Be, PCB (polychlorobezene) Cu, Fe, polymers Cu Penalty e lements (s eriously decreas e valu e of th e fraction) As, Sb, Ni, Bi, Al Si Sn, Zn
The table shown here is from Ecodesign: A Promising Approach to Sustainable Production and Consumption, UNEP/IE, United Nations.
Look around and you will see a lot of room for improvement.
From:
Green Products by Design Choices for a Cleaner Environment, Office of Technology Assessment, US Congress, Oct. 1992.
Georgia Institute of Technology Systems Realization Laboratory
Material Selection
At the onset of a new program, the Design Office, Platform Engineering, Purchasing and Supply, and the component supplier should discuss recycling issues associated with a concept and determine the best fit materials and processes for specific applications.
Suppliers should be encouraged to demonstrate recyclability and to take materials back for recycling at the end of the vehicles useful life to be recycled in automotive and other applications.
The use of materials which have been recycled, including from old vehicles, is desirable where it is economically viable. (from Chrysler Vehicle Recycling Design Guidelines)
Georgia Institute of Technology Systems Realization Laboratory
Diversity of Plastics There is an incredible variety of plastics in modern vehicles. However, the top 7 used plastics are (in N-America)
Urethane; 1990 - 454 mill. lbs, 1995 - 493 mill. lbs. Polypropylene (PP); 1990 - 437 mill. lbs, 1995 - 522 mill. lbs. Acrylonitrile/Butadiene/Styrene (ABS); 1990 - 281 mill, 1995 - 289 mill. lbs. Polyvinylchloride (PVC); 1990 - 264 mill. lbs, 1995 - 288 mill. lbs. Nylon; 1990 - 208 mill. lbs, 1995 - 246 mill. lbs. Polyethylene (PE); 1990 - 191 mill. lbs, 1995 - 248 mill. lbs. Polyester composite (SMC); 1990 - 173 mill. lbs, 1995 - 261 mill. lbs.
Thus, if you have to choose a plastic, try picking one which is widely used. Minimizing material diversity is beneficial for acquisition, storage, manufacturing, recycling, etc.
Main Material Concerns Meet environment, health, and occupational safety requirements for regulated or restricted substances or processes of concern.
Do not, or limit, the use of materials which pose human or environmental risk.
Mark materials according to standards. Generate minimal home and pre-consumer scrap during manufacturing. Make components of different recyclable materials easily separable, or use materials which can be recycled as a mixture. Standardize material types.
Reduce painting.
Cathode ray tubes (CRTs) pose a major difficulty for recycling. The phosphor-based coating used to provide the necessary luminescence contains heavy metals and other toxins, while the glass itself is loaded with lead and barium. Recycling a specific design of CRT with known constituents is relatively straightforward, but finding a process that will handle very large quantities of CRTs of varying age and specification is not so easy.
Marking of Plastics
SAE J1344 April 1993 contains the standards on marking of plastic parts. Based on standard symbols as published by ISO 1043. Allows for expansion and inclusion of new symbols for new material. (complete appropriate forms). See SAE J1344 for examples and specifics. European legislation will require the marking of all plastic parts with a weight greater than 100 grams.
General:
Avoid regulated and/or restricted materials
These often MUST be recycled, whatever the monetary cost of removal is.
Manual Separation:
Avoid painting parts with incompatible paint
Especially plastics can be contaminated by paint.
Mechanical Separation:
Reduce number of materials as much as possible
Probably two materials can be economically recovered
Choose materials with different properties (e.g., magnetic vs non-magnetic; heavy vs light), thus enabling easy separation. Allow for density separation
Maintain at least 0.03 specific gravity difference between polymers Isolate polymers with largest mass by density
Component Design Apply Design for Manufacturing and Assembly (DFMA) and Serviceability Guidelines as appropriate in component design.
Facilitate ease of assembly removal and material separation. (There is a close correspondence between DFA, DFD, and Design for Service)
Difficult to remove
Minimize the number of components within an assembly. Minimize material types within an assembly. Build in planes of easy separation where this does not affect part function.
Look under a hood for good and bad examples.
Question: What other (non-DFR) reasons exist for minimizing part and material count?
Georgia Institute of Technology Systems Realization Laboratory
a)
b)
a) Traditional design of springs in a doorlock: different materials, e.g., steel, aluminum b) Injection molded s pring sys tem made from POM (single material product)
Springs and their support systems are always classical examples of component integration. Note the reduction in part and material count.
Georgia Institute of Technology Systems Realization Laboratory
Examples:
Dashboard cover: Old design: PVC top foil, PUR foam core, steel support plate New design: PP top foil, PP foam core, support layer of PP Bumper: Old design: PC skin, PUR foam core, steel support New design: Integral foam of PC, PP, support frame of PC, PP
General:
Integrate parts
Reduce disassembly time
Mechanical separation:
Avoid using incompatible materials
E.g., stiffen sections rather than adding foam for noise-vibration-heat areas
Manual:
Use Design for Manufacturability/Assembly and Serviceability guidelines Reduce number of steps to remove a recyclable part Reduce chance of contamination Route wiring to facilitate removal
Separate at bulkheads/interface areas
Georgia Institute of Technology Systems Realization Laboratory
Fasteners Guidelines
About 32.5% of all activities in the disassembly process consist of the loosening of screws. These activities consume 54% of the entire disassembly process time.
According to VDI 2243, this is a typical example. The separation of staple, glue, press joints or joints made by deformation not only require more specialized equipment, but also embody a higher risk of damaging the component, if it is to be reused.
Additional problems occur when contaminations such as oil, dirt and corrosion are present.
Commonize fasteners
Try to design with minimum screw head types and sizes. (remember the Volkswagen Bugs 13 mm wrench standardization)
Select Proper Coatings Corroded fasteners cause severe problems for fast removal of parts Select coatings which minimize corrosion.
This may drive up the cost. Phospate & oil coatings have low corrosion resistance Better (but more costly) coatings may be warranted for recyclability (and servicability).
Cadmium coatings should not be used because of potential health and environmental hazard.
Snap fits
Use snap fits wherever possible to reduce the use of additional fasteners.
Adhesives Joining or bonding materials of the same type with compatible adhesives enhances recycling. But, non-compatible adhesives may cause contaminants to enter the material waste stream. Therefore, adhesive selection and the effect on part recyclability should be discussed with Materials Engineering as part of the development process at the onset of a program.
principle of connection
Material Connection
Frictional Connection
Positive Connection
characteristics of connection Static Strength Fatigue Strength Joining Expenditure Guidance Expenditure Detaching Expenditure Destructive Detaching Expenditure Product Recycling Material Recycling
welding
magnetic connection
Velcro fastener
plastic
spring connection
snap joint
bent-lever connection
1/4-turn fastener
Recyclability
Detaching Behaviour
Joining Behaviour
Carrying Capacity
good
average
bad
This table gives an overview of a German rating of fasteners. It will give you an idea of how different fasteners compare against each other.
Trade-offs Design for Recycling can negatively affect performance and cost issues.
For example, required material substitution is not always possible or will cost more.
However, in most cases, the trade-offs can be resolved and often converted in win-win situations. Often cited and studied and questioned are the trade-offs between design for disassembly and design for assembly. Take a look at the DFA guidelines and compare them not just with DFD, but also with DFR in general.
Remember, a shredder does not care much about geometry and fasteners
Georgia Institute of Technology Systems Realization Laboratory
10) Design components for end-to-end symmetry when possible. 11) Design components for symmetry about their axes of insertion. 12) Design components that are not symmetric about their axes of insertion to be clearly asymmetric. 13) Make use of chamfers, leads, and compliance to facilitate insertion.
Limiting Factors Identify the limiting factors and address these first! Look at a combination of the following component aspects:
Weight If recyclability and recycled content are defined by weight, it makes sense to look at the heaviest components first. Improving a 10 pound components recyclability rating from 4 to 3 has a larger impact on the overall system recyclability than improving a 1 pound component. Distance from target ratings Components with recyclability ratings of 4 and lower should be improved. Pay special attention to components with a recyclability rating of 4 because they can often relatively easily be changed to obtain a (good) rating of 3. The same applies for material separation ratings, i.e., first focus on those components with a separability rating of 4. Risk Those components with a high risk are also prime candidates for improvement. Violation of Design for Recycling guidelines A component which clearly violates some of the Design for Recycling guidelines may also be a limiting factor and a prime candidate for improvement. Pay special attention to WHY one or more guidelines have been violated; it may have been done intentionally to, say, increase functionality or manufacturability.
Often, upon careful inspection, the material or combination of materials is the limiting factor in most parts.
Georgia Institute of Technology Systems Realization Laboratory
Risk Assessments Some basic simple risk assessments with respect to achieving targets can be done
Risk
Recyclabilit y
Low
% Recyclability identified an d meets in it ial t arget s. P lanned ch anges will n ot degrade it .
Medium
% Recyclability do es n ot meet initial target s, but plan ned changes provide impro vement s.
High
1) % Recy clabilit y do es n ot meet initial target s an d/or p lanned ch anges do no t provide impro vement s. 2) % Recy clabilit y meets in it ial t arget s, but plan ned changes degrade it below t arget level. 1) % Recy cled co nt ent does no t meet initial target s an d/or p lanned ch anges do no t provide impro vement s. 2) % Recy cled co nt ent meet s initial target s, but plan ned changes degrade it below t arget level.
Recycled Co ntent
Recycled co nt ent identified an d meets in it ial t arget s. P lanned ch anges will n ot degrade it .
Recycled co nt ent do es n ot meet initial target s, but plan ned changes provide impro vement s.
Management Issue: Recyclability Target Setting Goal of designer: Improve vehicle recyclability
85% (by weight) required recyclability in 15 years
Current recyclability (first revision) 75% Four (yearly) revisions of vehicle expected Data available on:
expected production for each year estimated reliability of vehicles
Aim: Aid designer in setting appropriate targets for the recyclability of each revision of the vehicle
Target Setting: Parameters Production Uncertainty: Normal, = 5,000 Recyclability: Triangular, 3% Reliability, Weibull distribution Monte Carlo simulation used to explore effects of a given set of targets
Iteration 1 2 3 4 5 Mean Estimated Production 100,000 95,000 95,000 90,000 90,000 Mean Estimated Recyclability 75% TBD TBD TBD TBD Estimated Reliability =7, =11 =7, =11 =7, =11 =7, =11 =7, =11
0.850
90%
0.800
0.750
5%
0.700
5 89%
0.850
90%
0.800
0.750
5%
0.700
Inclusion of Uncertainty How will changes in technology and legislation affect the target definition and prioritization of limiting factors?
Y Iteration 5 legislative mean Range of Expected Regulatory Limits at Iteration 5 (one-sided distribution) Iteration 4 Reduction of m ean environm ental im pact and variance over several iterations Iteration 3 Iteration 2 productsmean environmental impact
Initial Product
compliance
legislative limit
Environmental Impact
high
Computer-Based Tools
Design System
Assembly Mo deling CAD Features Parametrics Geo metry Ro b ustn ess Graph ics Man ufacturin g Serv ice
Produ ct Mo deling
Process Mo deling
Pr ocess Synthesis & Selection Imp rov emen t Mo dels Co mp arison Mo dels
Co mp arison Mo dels
Ev aluation Modules
Disassembly
Facilities DB Features, Components, & Mating Relationships DB Database of P roduct Representations Geo metry Parametric Assemb ly Mo del Life-Cycle Info rmatio n Materials DB
Process DB
Given are the geometric (solid) and assembly models of a center console design generated using a modern CAD package.
Solid Model
Bezel
Ashtray
Latch
Armrest
Coverplate Hinge
Endcap
Rightbase
Front bracket
Bin
Virtual Disassembly Disassembly in a Virtual Reality environment facilitates design for recycling as well as design for serviceability.
Other assessments are also being added (e.g., demanufacture process cost assessments)
The key is to use the existing product models and add functionality in existing and (for a designer) familiar software systems.
NSF grants: Virtual Design Studio for Servicing and Demanufacture (Rosen, Bras, Mistree, Goel, Baker) DMI9420405 CAD for De- and Remanufacturing (Bras and Rosen) DMI9414715 Enhancing Reusability by Design (Bras) DMI9410005 Integrated Product and De- and Remanufacture Process Design (Bras) DMI9624787 Georgia Institute of Technology Systems Realization Laboratory
Virtual disassembly allows tracking of basic disassembly path based on user/designer experience. This path can be finetuned using other tools.
Camera component s
Disassembly paths are simulated and tested. Different robots can be simulated and programmed Detailed information about the kinematic and dynamic behavior of the robot can be obtained
Georgia Institute of Technology Systems Realization Laboratory