Green Electronics/Green Bottom Line: Environmentally Responsible Engineering

597 Pages·1999·36.503 MB·English

by  Lee H Goldberg

Green Electronics
Green Bottom L, ne
Environmentally Responsible
Engineering
Edited by Lee H. Goldberg
and Wendy Middleton
Newnes
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Copyright (cid:14)9 2000 Butterworth-Heinemann
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Library of Congress Cataloging-in-Publication Data
Goldberg, Lee.
Green electronics/green bottom line : environmentally responsible
Engineering / Lee Goldberg.
p. cm.
Includes index.
ISBN 0-7506-9993-0 (alk. paper)
1. Electronic apparatus and appliances-Design and construction-Safety
Measures. 2. Electronics. 3. Electronic industries.
4. Green products. 5. Environmental protection. I. Title.
TK7836.G62 1999
621.381-DC21 99-14522
CIP
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Preface:
About This Book
Hey, there, thanks for picking up this book. I'm pleasantly surprised that you
are taking the time to read this preface, something I didn't start doing regularly until
I made the transition from engineer to writer a few years ago. For both of our sakes,
I'll try to keep this interesting, with only the obligatory paragraph or two of dread-
fully serious, high-minded prose required for all first-time authors of technical
books.
Before we begin in earnest, I want to tell you a bit about how Anwyn, my two-
and-a-half-year-old daughter, got me started writing this book. She's pretty
advanced for her age, so it's no surprise to me that she managed to do this before she
was born.
It began about three years ago, just before Anwyn bounced into our lives. I had
just checked the assignment sheet at the magazine where I worked and saw I had an
editorial due the next day. Since Electronic Design is a hard-core engineering maga-
zine for my fellow travelers of the pocket-protector set, it is heavily technical. Con-
sequently, our editorials are supposed to babble on in glowing tones with expert
opinions about the subtleties of the next generation of electronic technologies, chips,
and widgets.
Unfortunately, it's been five years since I laid down my 'scope probe and
picked up a pen, so some of my knowledge on key topics is not as deep as I'd like.
Because I find it hard to consider myself an expert on the technology I cover, I usu-
ally manage to tap dance around any potentially embarrassing displays of ignorance
by writing funny stuff about it instead. Happily for me (and the guy who writes the
"Dilbert" comic strip), there is no shortage of funny and downright weird aspects to
our profession.
In many of these editorials, I play the straight man for Catherine, my wife,
who gets to say all the intelligent things. By letting her do the preaching, she gets to
look as smart as she really is, and I don't have to take the heat for any opinions that
may really piss off my readers. So, with the arrival of our daughter close at hand, I
figured she was fair game too, and tossed off the following.
xvi Preface:A bout This Book
Death and Children
Wow-there's nothing like the prospect of your first child to make you think
about death! At 40, I have been able to pretty much ignore the warning signs of my
own mortality as I continue to do most of the stuff I did when I was 20. It just hurts
more and takes longer to recover. Even when I married Catherine last year, I was
able to mumble through the "till death do us part" stuff without really having to
acknowledge that this was a closed-term contract. It is only now that I'm facing the
imminent release of Goldberg 2.0 that the concept of having a limited product life
cycle is really dawning on me. Uncomfortable as stating old Mr. Bones in the face
is, it does make me think hard about what kind of legacy I want to give to the little
girl who is waiting for us under the mountain of paperwork that surrounds an adop-
tion.
I hope to leave her a better, more peaceful, and more interesting world than the
one I was born into. This puts me in an ugly double bind, as part of me is seized with
the urge to join every crusade to clean up the planet, while the other part tries to
heed Catherine's wise advice to make more time at home for our family-to-be. I'm
also having to face up to the painful fact that most of the things I've worked on for
the past 20 years had little or no lasting value, other than giving a paycheck to the
folks who made it. I don't get a warm fuzzy feeling when I realize that so many of
the products I devoted my blood, sweat, and tears to ended up as next year's landfill.
I guess it's time I took some responsibility for not wasting the next couple of
decades, too.
For me, acting as a responsible professional breaks down into two separate
issues: what we do and how we do it. Both are equally important. I understand that
most of us end up doing the necessary but unglamorous chores, making the paper
clips, toasters, and the electronic widgets that form the underpinnings of our "civili-
zation," but we can all make a difference by the way we do our jobs. Not all of us get
to do cool, important stuff like finding the cure for cancer, sending people to Mars,
or inventing Spandex, but the choices we make each day down in the trenches can
have just as big an impact on the quality of the world we leave our kids. For exam-
ple, we can, as I have, make the difficult choices to not participate in projects that
undermine, human fights, the environment, and other things that we hold dear to our
hearts.
Although we can't all play starring roles in the slow, painful evolution of our
species, we all can contribute in some way toward a gentler, funnier, and more hope-
ful future. Should our professional duties extend beyond delivering designs on time
and under budget? Should we be worrying about a product's energy efficiency? And
whether it poses an environmental hazard in its manufacture, use, or disposal?
Should we care if it contributes to, or erodes, the social fabric? I think so.
As I look into trading in my sports car for a nice Saturn station wagon and
begin to install a safety parachute on my ultralight aircraft, the idea of making the
world better for all our children begins to look like one of the few things I can do
that has any value past the day the Grim Reaper comes calling. What do you think?
Preface: About This Book xvii
Reflection
Somehow, the editorial made it past our copy editors and hit the street. Shortly
after, my e-mail account began to overflow with letters from engineers who, like
myself, were wrestling with the same dilemmas in their own lives. It was kind of
cool to actually have readers agreeing with me for once and, better yet, to see that
corporate America had not been able to squeeze the paternal instincts out of some of
its hardest working citizens.
Tucked away in the midst of all this was a nice letter from a lady named Jo
Gilmore, at Newnes Press. Somehow, she'd gotten hold of my editorial and decided
I'd be just the kind of quixotic fool who would take on the task of putting together a
book on green engineering. Only half-realizing that our soon-to-arrive child would
soak up every available nano-joule of energy that was not devoted to making a pay-
check, I accepted her offer.
Two and a half years, two editors (Jo moved on to another firm in the interim),
and several thousand diapers later, the book is ready, and my daughter is negotiating
the tricky transition between infanthood and personhood. The journey toward the
book you hold in your hand started out innocently enough but ended up as a major
adventure that consumed a year of nights, weekends, and any remaining bits of san-
ity that my child might have missed. I'm now an author of sorts and a reasonably
competent father.
My hope for this book is much the same as I have for my daughter, I want both
of them to go out into the world, enjoy a long and happy life, and do more good than
harm. What you have in your hands is a small, incomplete map of an exciting terri-
tory I've discovered. While not intended to be a definitive text on the subject, I hope
this book will at least be a good introduction to the relatively new field of green
engineering. Its real goal is to help convince you and others that environmentally
sound practices are not only possible within the electronics industry but, more
important, practical-and profitable.
As technologists, we have an enormous influence on the direction humanity
takes, because we create the tools that shape and propel our cultures and civiliza-
tions forward. Many of the things we have created tend to amplify both our best and
dumbest tendencies, leading us to a dangerous crossroads at the end of the 20th cen-
tury. If we are to keep our grandkids from exhausting the remaining natural
resources and prevent the rest of the critters on the planet from choking on their
waste, we've got to change the way we do business in a big hurry.
Perhaps the most important thing I've learned while working on this book is
that the real trick to inventing a greener future is not simply technological. It lies in
developing ways to integrate environmental factors into the design and management
cultures where we work and into the consumption patterns and behaviors of the
folks who use the stuff we make. I believe that, over the next decade, the high-tech
sector can lead the way in making environmental considerations an integral part of
industry's culture. Whether or not this happens, in good measure, is up to folks like
us. If I've done the job I set out to do, you'll have enough concepts and tools, as well
xviii Preface:A bout This Book
as places to look for more information, to help each one of us begin to clean up his
or her small comer of the world.
Finally, I'd like to ask that, if you find something especially useful that should
have been in this book, please bring it to my attention. Because this field is just start-
ing to approach the knee of a sharp maturity curve, I'm already starting to contem-
plate a second edition. If I don't get back to you right away, please be patient.
Wendy, my assistant editor, and I are suffering from a serious case of toasted brains
from a six-month final push on this book, and I miss being something more than a
shadowy figure to my family. Now that the book is done, I'm going to lie down till
the urge to do "just one more rewrite" subsides and the world stops looking like one
big, mind-sucking computer screen. Once my head clears, my first priority will be to
spend a good chunk of time just hanging out with my wife and daughter.
The second edition can wait a little while, they can't.
Contents
Acknowledgments xi
Preface xv
Section I Design Issues 1
Introduction If You Think Education Is Expensive, Try Ignorance!
----Lee H. Goldberg 3
Part I Designing for Energy Efficiency 13
Chapter 1 Designing Energy-Efficient PCs Using Integrated Power
Management ---Gary Smerdon 15
Chapter 2 Energy Efficient Three-Phase AC Motor Drives for Appliance and
Industrial Applications ~Radim Visinka 29
Chapter 3 A High-Voltage Power Factor Controller Helps Improve Power
Quality ~Ondrej Pauk and Petr Lidik 43
Chapter 4 Designing High-Efficiency DSP-Based Motor Controls for Consumer
Goods ~Aengus Murray 57
Part II Designing for Recyclability 67
Chapter 5 Design for Disassembly, Reuse, and Recycling
~Pitipong Veerakamolmal and Surendra Gupta 69
Chapter 6 Defining Electronics Recycling ----CraigB oswell 83
Chapter 7 Sensor-Based Data Recording for Recycling: A Low-Cost
Technology for Embedded Product Self-Identification and Status
Reporting --Markus Klausner and Wolfgang M. Grimm
and Arpad Horvath 91
vioie
viii Contents
Part III Green Design Automation Tools 103
Chapter 8 A Survey of DfE Software --Joan Williams 105
Chapter 9 Design for Environment: A Printed Circuit Board Assembly
Example --Sudarshan Siddhaye and Paul Sheng 113
Chapter 10 Toward Integrated Product Life-Cycle Design Tools
--Brian Glazebrook 123
Section II Materials and Process Issues 131
Introduction Electronic Manufacturing Processes and the Environment
--Christopher Rhodes 133
Part IV Materials Selection for Electronic Products 135
Chapter 11 Selection of Plastics Using Cost, Structural, and Environmental
Factors --William Trumble 137
Chapter 12 Battery Selection
and ApplicationmEnvironmental Considerations
---George L. Yender 143
Part V Electronic Manufacturing Processes and the
Environment 151
Chapter 1 3 Implementing Green Printed Wiring Board Manufacturing
--Holly Evans and John W. Lott 153
Chapter 14 No-Lead Solder Assembly mWilliam Trumble 161
Chapter 1 5 Chemical Conversion Coatings on Electronic Equipment
mWilliam Trumble 171
Section III Management Issues 177
Introduction Musings Before a New Dawn ~Ted D. Polakowski 179
Part VI DfE for Engineering Managers 183
Chapter 1 6 DfE for Engineering Managers: Making It Count~DfE and the Bottom
Line --Jill Matzke 185
Chapter 1 7 Making It Happen~DfE Implementation --Jill Matzke 193
Chapter 1 8 Getting the Math Right: Accurate Costing Through Product Life
Cycles --Kelly Weinschenk 201
Chapter 1 9 Design for environment~a European Logistics Perspective
--Carsten Nagel 215
Contents ix
Part VII ISO 14001--The Environment Standard for
Industry 225
Chapter 20 Meeting the Letter and Spirit of Environmental Management Using the
ISO 14001 Standard --James Lamprecht 227
Chapter 21 ISO 14001 for the Environment and Your Bottom Line
Jim Hart 245
Chapter 22 Beyond ISO 14000: ST Microelectronics as a Case Study in Environ-
mental Leadership ---Carol Brown 253
Section IV Visions for a New Future 257
Introduction A Day in the Life... Circa 2005 --Lee H. Goldberg 259
Part VIII Wild Ideas and Possible Futures 265
Chapter 23 Designing a Better Tomorrow Today with Self-Disassembling
Electronics --Joseph Chiodo and Eric H. Billett 267
Chapter 24 Ultralight Hybrid Vehicles~Principles and Design
~Timothy C. Moore 281
Chapter 25 The Environment and Nanotechnology
~Vincent F. Di Rodi 297
Part IX Case Studies, Resources, and Contact
Information 303
Appendix A A Case Study: A Printed Circuit Assembly with a No-Lead Solder
Assembly Process ~William Trumble 305
Appendix B Case Study: A Search for Chromate Conversion Coating
Alternatives for Corrosion Protection of Zinc-Plated Electronic
Shelves ~William Trumble and Pat Lawless 311
Appendix C Case Study: "Butterfly," an Application of DfE Principles to a
Telephone ~William Trumble 315
Appendix D Resources 323
Appendix E Author Contact Information 325
Index 331
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