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0.1.1.1.1
Use stage
0.1.1.1.1.1 Geographical coverageThe
hydraulic motor is sold almost exclusively in Eastern and Western Europe, Asia
and USA, but the largest market is in a few countries close to Denmark (Western
Europe). The distributed data is reported in appendix C, table (C1.1). The
figure (3.14) should be seen as an expression of where and how many
hydraulic motors OMV/W-800 in percentage are sold at the time of data
collection. Please note that the figure changes with respect to markets every
time. As evident from figure
(3.14), 76% of the hydraulic motors OMV/W-800 are sold in the Western
Europe. 1% of the hydraulic motors are sold in Denmark, 13% exported to America
and 8% are sold to Asian countries. 2% of the motors are sold in other markets
e.g. the Middle Eastern and African markets. All transport is by lorry, and
ship. 0.1.1.1.1.2 Introduction
Figure
(3.14): Geographic
distribution of semi-products. ¨
Many of the machines (applications) used for agriculture run double
shifts, e.g. Harvester combine and tractors in the harvest season. ¨
The forestry machines (applications) also runs double time during
harvest season - in Europe from May to September. ¨ Use in lorry cranes varies in time, depends on the lorry location to location transport and load. ¨ Machines used in the laying of asphalt run in double shifts except during very rainy weather or snowstorms. Ten main applications (Combine Harvesters, Mini excavators, Forklift trucks, Lawn mowers, Skid-steer loaders, Carnes, Road Rollers, Man-lifts, Tractors and Wheeled loaders) are assumed to be used to estimate data for the use stage for the hydraulic motor OMV/W-800. Detailed data on ten main applications is illustrated in Appendix C, chapter 2, section (C.2.1). On the basis of available data on working time, workload and working capacity, working situation and locations, the age and replacement of the hydraulic motor is estimated as follows: 0.1.1.1.1.3
Age of the
Hydraulic motor:
The
performance and life of the motors, however, depend on the type and condition of
the fluid, workload, application and working stability. The
workload means, how much load is on the motor in working position. Working
stability means the load on the motor is stable or varied during working
position. Fluid condition means condition and type of fluid. However, to ensure satisfactory function and operating life it is
necessary to match the operating conditions to the properties of the fluid and
all other recommended materials in the use stage. The
age of the hydraulic motor is different in all applications as mentioned in the
previous section. The working time (age) in the different applications is
estimated and on the basis of average estimated values, the
lifetime of the hydraulic motor is set at 8.31 years (see in detailed,
appendix C, chapter 2, section (C.2.2)).
The product is used
on various loads and various operation times in the different applications. The
average operation time is set at 8 hours a day for 5 days a week in the
different applications. With respect to potential impacts on the environment and
resource consumptions, the above assumptions are found to be most significant (see
sensitivity analysis results in appendix C, chapter 7, section (7.4)), and
are the main focus points in the environmental diagnosis and discussion in the
later sections 0.1.1.1.1.4
Parts replacement
The parts replacement data is
estimated on the basis of used-age, workload and working capacity in the
different applications. Detailed data on replacement in each of the ten main
applications are reported in appendix C, chapter 4. The all replacement
assumptions mentioned below do not contribute to potential impacts
significantly, and therefore not discussed in the later sections.
0.1.1.1.1.4.1
O-Ring,
Dust and Shaft Seal
The O-rings set (5 pieces) and
seals are often changed in motor service and in other part replacements.
O-rings, shaft seal and dust seal replacement data are estimated from motor age
and reported in detail in appendix C, chapter 4, section (C.4.1). 8 sets
of O-Rings, 7 pieces of dust seal and shaft seal are estimated. 0.1.1.1.1.4.2
Cardan
Shaft and output shaft
The
cardan shaft is installed between the output shaft and gear set. The gear set
rotates the cardan shaft and then the cardan shaft rotates the output shaft. It
can break with a varied load, but this rarely happens. It is assumed that 0,1%
of the cardan and output shafts are replaced in use stage (see in detailed
appendix C, chapter 4, section (C.4.2). Tapered
roller bearings are installed
on the output shaft. The function of the bearing is to make a flexible rotation
of the output shaft, which can break with varied loads on the output shaft, but
this rarely happens. In order to complete this study, 0,1% of the bearing set is
assumed to be replaced in the product (see in detailed appendix C, chapter 4,
section (C.4.3). 0.1.1.1.1.4.4
Other
replacements The
motor’s other installed parts can break with technical problems. For example,
the front cover can break in an accident when the output shaft breaks.
Distributor valves can lose its efficiency if user does not change hydraulic oil
regularly. The other replaced parts are assumed to be 0.1% replaced in the
entire life span of the hydraulic motor (see appendix C, chapter 4, section
(C.4.4). 0.1.1.1.1.5
Re-used material
The
hydraulic motor parts are re-installed in second-hand products. It is assumed
that the material is screened during shredding and useable material is
re-assembled in the second-hand motors, (company information). Data is
missing on the percentage of material used to re-assemble second-hand motors. In
order to complete the study 8% material (Tom Tychsen estimation) of the
hydraulic motor is assumed to be re-used. Furthermore all replacements in the
reassembled hydraulic motor are also included in this study. The hydraulic oil
and energy consumption on 8% part of the hydraulic motor (double age) is
significant in the hydraulic product system, but these two parameters are
already included in the ‘environmental diagnosis’ section, therefore this
assumption is not discussed separately (see appendix C, chapter 4, section
(C.4.5).
0.1.1.1.1.6
Returned motors replacement
6%
of the hydraulic motors are returned with technical fault problems for repair
and for parts replacement (distributors information). Furthermore data (%) is
not available on repaired, on re-used (some motors are sold as a second-hand
product to other distribution companies, that can repair and re-install
second-hand parts used for low capacity load) or on disposed (un-repairable)
retuned motors. In order to achieve the target, 2% of the motors are assumed to
be repaired and returned to the end user, 2% are assumed to be sold as
second-hand material (but these motors are also used again, so these are also
added in repaired data) and 2% of the motors are disposed when returned from the
end user. This assumption is part of the above assumption, therefore is not
discussed separately (see appendix C, chapter 4, section (C.4.6).
It
should be noted that 2% of the motors, which are routed directly to the disposal
location, are not recorded in the database. On the other hand 8% of the motor
material is re-used in the form of second-hand material. Electricity consumption
and replacement on 8% (total) –2% (direct disposed without use) = 6% motors is
recorded in the database. 0.1.1.1.1.7
Hydraulic Oil
Hydraulic oil
is used to convert fluid energy into mechanical energy in the system. The
advantage of hydraulic oil is to lubricate the system and protect the parts
against corrosion, and lead dirt particles and heat off the system. There is no
special oil recommended by Sauer-Danfoss. The company recommends those minerals
hydraulic oils, which contain anti-wear additives. The
amount of the used hydraulic oil in applications is also different. The total
amount of hydraulic oil is estimated on the basis of ten main application
storage capacities and replacement, and reported in detail in appendix C,
chapter 5. A total
of 365.47 + 21.9 (re-used motor) litres of oil is used in the entire lifespan of
the hydraulic motor (see detailed data in appendix C, chapter 5, table (5.1)).
The
oil can leak out from the application during replacement and create pollution to
air, water and soil. Another uncertainty is that the oil can reduce in the
application when the system is over heated or with others errors. In this study
leaking and other fractions are neglected by assuming no leakage and no
reduction in the use stage. 100% of the oil is collected from the application
and burned. Hydraulic
oil contributes to resource consumptions in the use stage. In order to estimate
the resource consumptions in the use stage, the Tellus S oil data is recorded in
the EDIP database system found from the manufacturing company (see appendix
C, chapter 5, section (5.1)). The
hydraulic oil assumptions mentioned above are significant and contribute to
potential impacts, including environmental impact potentials in the disposal
stage by incarnation and resource consumptions (crude oil) in the use stage, and
are therefore included in the environmental diagnosis and later discussion
sections. 0.1.1.1.1.8
Energy Consumption:
The
motor works on different torque, oil pressure and outputs. As shown in figure
(3.3) above, the motor has output from 2kWh (unloaded) to around 43kWh (full
load). The energy consumption varies in different applications. For example, the motor installed in the harvester combine works on high torque and consumes more energy than the man-lifts. It is assumed that the motor is working on medium load for the entire lifespan in the references applications, because in some applications the motor has a very high torque and in others a very low torque. The average output of the hydraulic motor is assumed to be 21.75 kWh. Furthermore the energy consumption is calculated on the basis of the functional unit illustrated in the previous section (3.1.2) and total energy consumption in the entire life span of the hydraulic motor is found to be 1542875MJ. 100% gasoline oil (diesel) energy is assumed to be used in the use stage. Total gasoline oil is calculated to be 36345.720 liters (see detailed calculation in appendix C, chapter 3). The above assumptions on energy consumption are most significant in the hydraulic product system with respect to environmental potential impacts and resource consumptions (see sensitivity analysis results in appendix C, chapter (7), section (7.4)), and are the main focus points in the environmental diagnosis and discussion in the later sections |
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