Abstract
Keywords: LCA, LCC, Design for Sustainability, electrical and electronic system, total life cycle approach
This paper describes the key outcomes of the FP6 EU project "SEES, sustainable Electrical and Electronic System (EES) for the automotive sector". This project aimed to develop processes, guidelines and concepts for sustainable automotive EES. After identifying and grouping the components of the EES, the project team has analysed end of life aspects as well as total life cycle aspects to identify main challenges and opportunities for realising more sustainable automotive EES. Assembly and disassembly studies have been done, as well as specific shredding and recycling studies focussed on different EES components and materials. Furthermore, Life Cycle Analysis (LCA) and Life Cycle Costing (LCC) studies have been conducted to determine the overall life cycle issues. Eco-Design guidelines and tools have been developed to identify and review proposed redesigns.
Two concepts that have been identified and reviewed in the project are: (i) concepts for alternative wire harness systems - focussing on weight reduction (use phase); and (ii) the substitution of glass fibre reinforced polymers by natural fibre reinforced polymers in electronic housing components - focussing on the use of sustainable materials (production phase). The wire harness is one of the heaviest EES components. If the weight of the harness can be reduced, fuel consumption in the use phase is reduced. However, alternative technologies like plastic optical fibres or flat flexible cables require other materials in different quantities, causing different life cycle impacts. In addition most alternative technologies can only substitute part of the traditional harness. One concept analysed the substitution of copper by aluminium. Although some technical problems still have to be solved, aluminium wiring could deliver a significant cost advantage compared to copper. Since aluminium also has a lower density compared to copper, a weight reduction of around 20% can be achieved. However, primary material must be used to guarantee sufficient electrical properties - and production of primary aluminium is very energy intensive. An LCA of this concept has shown that the advantage in the use phase (reduced fuel consumption) is completely diminished by the increased impact in the production phase. The second example that is presented in this paper shows the application of natural fibre reinforced polymers (PP-NF) as a substitution of glass fibre reinforced polymers (PP-GF) for electronic component housings. Several prototypes have been injected and tested. An LCA has shown that this type of material has a better environmental performance than glass fibre reinforced polymers. Production of natural fibres is less energy intensive than production of glass fibres and PP-NF provides a weight as well as a cost benefit compared to PP-GF.
One of the most important outcomes of the project was that major improvements can only be realised if a total life cycle approach is chosen. Although improved recycling technologies can increase the end-of-life value of materials from EES, improvements in the production and use phase of the vehicle are necessary to guarantee a total life cycle improvement.