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1、 WORLDWIDE ENGINEERING STANDARDS Material Specification General GMW3116 Recyclability/Recoverability Guidelines Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Originating Department: North American Engineering Standards Page 1 of 13 1 Scope The purpose of this specification
2、 is to aid the GM design community in designing more recyclable/recoverable vehicles that have maximum end of life value. This design guide is written for current technology. As technology progresses the design guide will be updated. 2 References Note: Only the latest approved standards are applicab
3、le unless otherwise specified. 2.1 External Standards/Specifications. ISO 1043-1 ISO 11469 ISO 1043-2 ISO 22628:2002 ISO 1629 2.2 GM Standards/Specifications. GMW3059 2.3 Additional References. GM1738 GME NOA # 13 3 General Recycling Design Guidelines 3.1 Material Selection. 3.1.1 Standardize Materi
4、al Selection. If possible, use the same material type(s) used on specific components or subsystems across product lines. 3.1.2 Select Recyclable Materials. Select materials for which recycling technologies are currently practiced refer to EUCAR list of proven technologies, contact GM Materials Engin
5、eering for more information. 3.1.3 Minimize the Use of Multi-Material Parts. 3.1.4 Limit Material Types Used within Part Assemblies. 3.1.5 Reduce or Eliminate Coatings. Uncoated materials are easier and less costly to recycle than coated materials. 3.1.6 Restricted and Reportable Substances for Part
6、s (GMW3059). All materials supplied to GM must comply with GMW3059, Restricted and Reportable Substances for Parts, latest version. 3.1.7 Marking of Polymeric Parts. Marking of polymeric parts is required to make it easier to identify the type of material(s). 3.1.7.1 Marking of Plastic Parts. For th
7、e marking and identification of vehicle components and materials having a weight of more than 100 g, the following standards shall apply: ISO 1043-1 Plastics - Symbols-Part 1: Basic polymers ISO 1043-2 Plastics - Symbols- Part 2: Fillers and Reinforcing Materials ISO 11469 Plastics - Generic Identif
8、ication and Marking of Plastic Products. 3.1.7.1 Marking of Rubber Parts. For the marking and identification of vehicle components and materials having a weight of more than 200 g, the following standards shall apply: ISO 1629 Rubber - Rubbers and Lattices Nomenclature. 3.2 Design for Pre-Treatment.
9、 3.2.1 Operating Fluids. Provisions shall be made in the part, system and vehicle design for fast and efficient removal of operating fluids from: Fuel Tank Engine Oil Pan Gearbox/Transmission Brake System Air Conditioning System Shock Absorbers Engine Cooling System/Radiator Power Steering System Wi
10、ndshield Washer Fluid LPG Tank CNG Tank Note: Draining of fluids may be made by pressure, vacuum or gravity. Fluid containers should have only one low point that is easy to locate. 3.2.2 Parts and Components. Provisions shall be made in the part, system and vehicle design for GMW3116 GM WORLDWIDE EN
11、GINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 2 of 13 April 2006 fast removal of the battery, oil filter, glass, LPG- tanks and CNG-tanks during the pre-treatment phase. 3.2.3 Pyrotechnics. Provisions shall be made in the part, system and vehicle design for f
12、ast and simultaneous deployment of the pyrotechnic seat belt pretensioners and all of the airbags during the pre-treatment phase. 4 Recyclability/Recoverability 4.1 Vehicle Recyclability/Recoverability. The entire vehicle recyclability/recoverability calculation shall be carried out per ISO 22628, R
13、oad vehicles - Recyclability and recoverability Calculation method. 4.2 System and Part Recyclabiity/Recoverability Calculations only fro Parts Developed for Korean Market. For parts listed in Appendix A Table A1 intended for Korean market supplier must upon request provide Recyclability/Recoverabil
14、ity information to GM. Supplier shall use the Part Recyclability/Recoverability report form in Appendix A Table A4. These parts must fulfill 85% recyclability / 95% recoverability. 4.2.1 Recycling Technology. Supplier shall provide recycling technology referred to on the Recyclability/Recoverability
15、 report form. 4.2.2 Part Percentage Recyclability Calculation. The calculation sheet in Appendix A, Table A4 can be used to calculate the % Recyclability of a part. 4.2.3 Part Percentage Recoverability Calculation. The calculation sheet in Appendix A, Table A4 can also be used to calculate the % Rec
16、overable of a part. This is done by taking the recyclability and adding in the percent of the part that is not recyclable but would be available for energy recovery. 4.2.4 System Percentage Recyclability Calcula- tion. To calculate the % Recyclability for a system, sum the masses of M, D1, and D2 fo
17、r each component and divide by the system mass. 4.2.5 System Percentage Recoverability Calculation. To calculate the % Recoverability for a system, sum the masses of M, D1, D2 and D3 organic for each component and divide by the system mass. 5 Recycled Content 5.1 Guidelines. 5.1.1 Use Recycled Mater
18、ials. Recycled content material shall be used where technically feasible and economically viable. Select materials that have post-consumer or post-industrial recycled content. Consider validating equivalent virgin material as a back up. Examples of recycled content use are given in Appendix B. 5.1.2
19、 Carry Over Parts. Part releases with recycled content materials have to be carried over from the predecessor model if possible (see GME NOA # 13). 5.1.3 Maximize Use of Black or Natural Compo- nents. Design and select plastic and textile materials and trim assemblies that use black or heather color
20、ed materials to enhance the use of recycled materials. Using natural (not colored) resins increases the applications the material can be recycled into. 5.1.3.1 Recompounded resin must contain 25% minimum recycled content. 6 Packaging 6.1 Minimize Packaging and Packaging Offal. Select packaging for p
21、arts and materials that is reusable, has recycled content, and/or is recyclable. Where possible design parts/assemblies that minimize packaging needs. Reference GM Packaging Specification, GM1738. 6.2 Eliminate wherever possible the use of plugs, caps, and covers. Some of the plugs, covers, caps wer
22、e originally intended to protect parts during shipment in bulk loaded containers. The assemblies may now be shipped in layered returnable trays, to protect them. 6.3 Use a common recyclable material for all necessary plugs, caps, and covers such as low density polyethylene (LDPE) whenever possible.
23、6.4 Use a natural color resin if possible for all plugs, caps, and covers. Natural resin is easier to sell on the recycle market than colored resin. 6.5 Mark all polymeric plugs, covers, and caps. Identify the type of polymer by marking each part according to 3.1.7 in this specification or with the
24、appropriate SPI symbol for packaging materials. 7 Notes 7.1 Glossary. 7.1.1 General Terms. End-of-Life vehicle: “End-of-life vehicle“ shall mean a vehicle, which the holder/owner discards or intends or is required to discard. ELV is understood as a vehicle intended to be scrapped. Recovery: Reproces
25、sing in a production process of the waste materials for the original purpose or for other purposes, together with processing as a means of generating energy. GM WORLDWIDE ENGINEERING STANDARDS GMW3116 Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Page 3 of 13 Re-use: Any o
26、peration by which components of end-of-life vehicles are used for the same purpose for which they were conceived (example: starter, transmission, engine, etc.). Recycling: Reprocessing in a production process of the waste materials for the original purpose or for other purposes but excluding energy
27、recovery. Mechanical Recycling: Material processing of used materials by physical means into products. Examples: Aluminum cylinder block made from secondary aluminum Boot coverings made from recycled bumper material Feedstock Recycling: Material processing of used materials by chemical or thermal me
28、ans into basic chemicals or monomers for plastics or hydrocarbon materials feed stock. Examples: Pyrolysis, Hydrogenation Energy Recovery: Use of combustible waste as a means to generate energy through direct incineration with or without other waste but with recovery of the heat. Example: Generating
29、 heat from shredder fluff in heating stations instead of using fossil fuels Dismantling: Removal of parts and materials from the vehicle. For recycling purposes, destructive methods may be used. 7.1.2 Recycled Material Content Terms. Recycled Material Content: Proportion, by mass, of recycled materi
30、al in a product or packaging. Only post-industrial and post-consumer material shall be considered recycled content. Industrial scrap is not considered recycled content. Industrial Scrap: Industrial scrap is product or material that has been generated as a by-product of a given process, which has pro
31、perties allowing it to be recycled back through the same general process. Industrial scrap, sometimes referred to as home scrap or regrind, is not considered recycled. Post Industrial Waste: Post industrial waste is product or material that has been generated as a by-product of a given process which
32、 has properties significantly different than those of the original material and therefore in its current form cannot be recycled back through the same general process. Example: Process scrap, off spec/wide spec/excess fiber, molding trial offal, trim offal, wide spec material, and unused resin from
33、molders. Post Consumer Waste: Post consumer waste is product that has been discarded by an individual, commercial enterprise or other public or private entity after having fulfilled its intended application or use. Example: Nylon carpet, polypropylene cotton bails, polypropylene battery cases, polyc
34、arbonate water jugs, polycarbonate CDs/DVDs, and PET bottles. 7.1.3 Plastics Recycling Terms. Regrind: Irregularly shaped and sized materials that result from grinding parts, sprues, runners, etc. The material receives no further treatment, heat histories, or additives. Depending on the source and e
35、nd use, regrind can fall into any of the three recycled content categories (home scrap, post- industrial, and post-consumer). Home Scrap Regrind: Regrind which is used in the same part. For example, blue polypropylene door trim scrap used in the same blue door trim manufacturing process. Post-Indust
36、rial Regrind: Regrind which is diverted from the original part production process and used into a different part. For example, blue polypropylene door trim scrap used in the substrate of an A-pillar. Post-Consumer Regrind: Regrind which is recovered from consumers and used to make new parts. For exa
37、mple, ABS post-consumer telephone housings that are ground and made into console bins. Repelletized: Uniformly shaped and sized pellets that result from taking ground parts, sprues, runners, etc. and running them through an extruder. The material receives an additional heat history and some contamin
38、ants can be removed with a screen but there are no additives. This material will either be post-industrial or post- consumer depending on whether the source is industrial scrap or consumer waste. Recompounded: Uniformly shaped and sized pellets that result from taking ground parts, sprues, runners,
39、wide spec resin, fiber etc. and blending them in an extruder with virgin material and/or additives. The material receives an additional heat history; some type of added material to improve properties and some contaminants can be removed with a screen. This material will either be post-industrial or
40、post-consumer depending on the source. 7.2 Acronyms, Abbreviations, and Symbols. CNG Compressed Natural Gas ELV End-of-Life Vehicle LDPE low density polyethylene LPG Liquid Petroleum Gas SPI Society of Plastics Industry GMW3116 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corpora
41、tion All Rights Reserved Page 4 of 13 April 2006 8 Coding System This standard shall be referenced in other documents, drawings, VTS, CTS, etc. as follows: Example: GMW3116 Where: GMW GM Worldwide 3116 Sequential Number 9 Release and Revisions 9.1 Release. This material specification originated in M
42、ay 1998. It was first approved in December 2000. It was first published in December 2000. This standard replaces EDS-M-0103 (GMDAT), GM502M (GMNA), and TKLE-97-0097 (Saab). 9.2 Revisions. Rev Approval Date Description (Organization) C JAN 2005 General Revision (GMNA) D APR 2006 Minimized restriction
43、s on material selections and design for disassembly sections, Updated to current template (Global Recyling Team) GM WORLDWIDE ENGINEERING STANDARDS GMW3116 Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Page 5 of 13 Appendix A: System and Part Recyclability/Recoverability C
44、alculation Table A1. Parts list to fulfill 85% recyclability / 95% recoverability only valid for parts for Korean market Front Bumper (including additional parts) Rear Bumper (including additional parts) Fender liners Wheel guards Deflector water Air cleaner cover and frame Glove box A Molding A, Ro
45、cker panel Cover A-Inner Rocker panel Cover A-Pillar Cover B-Pillar, upper Cover B-Pillar, lower Cover C/D-Pillar Battery tray Engine/Beauty cover Protection molding Side Wheel cover Grille Radiator Washer fluid reservoir Steering column cover Surge tank A, coolant Cowl/Hood cover Spoiler Radiator f
46、an/fan shrouds Tailgate trim GMW3116 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 6 of 13 April 2006 Is the part on the pre- treatment list? (See Table A6) Enter into pretreatment section of worksheet. Is the part on the exception list? (See T
47、able A7) Enter into the section of the worksheet noted in the exception list. Does the part contain metal that can be physically separated from the part? Recycling Recycling and Recovery determined by the exception list Is the part all metal? Enter mass into the metal section of the worksheet. Recyc
48、ling partial metal mass Other material portion of the part Does the other material portion of the part weigh less than 0.1 kg? Use the suitability matrix to determine dismantlability Is the material organic? Enter into D3- Organic on the Worksheet. Enter into D3-In- Organic on the Worksheet. Landfil
49、l Recovery Recycling Recovery or Landfill yes no yes yes yes no yes yes no Figure A1: Process Flow Diagram for Recyclability/ Recoverability only valid for parts for Korean market GM WORLDWIDE ENGINEERING STANDARDS GMW3116 Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Page 7 of 13 Table A2: Part Dismantling for Recycling Suitability Matrix only valid for parts for Korean market 1 2 3 4 5 6 Category Mass Recycling Technology (See Table A8 all thermoplastics; PUR-composites Electro-static separation: Mechanica
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