André Zein

An Investigation into Fixed Energy Consumption of Machine Tools

Improving energy efficiency of manufacturing processes requires knowledge about the energy consumption as a function of the machine tool and cutting process itself. Both theoretical and empirical models of unit process energy consumption have emphasized the relevance of fixed energy consumption which ensures the machine readiness. However, the machine tool behavior during the stand-by mode is lack of thorough study. This paper presented the investigation of fixed energy consumption from definition and description to improvement strategies. Six machine tools covering different manufacturing processes are selected for this investigation in order to evaluate the future savings.

Energy Efficiency Measures for the Design and Operation of Machine Tools: An Axiomatic Approach

Due to environmental legislation and increasing customer demand, the development and deployment of energy-related improvement measures for machine tools has intensified. These measures centre different aspects of machining as integrating energy efficient components or applying start-stop strategies. Although the measures aim for a reduction of energy demand, guidance on the selection and prioritization of efficiency measures is necessary in order to identify adequate methods and create awareness about the effects and interdependencies. Using axiomatic design a matrix is developed that relates functional requirements of improving energy efficiency of machine tools to design parameters.

Framework for Integrated Analysis of Production Systems

Production companies act in increasingly complex and dynamic environments. Facing numerous influencing and closely interconnected factors within production systems, companies are forced to cope with economic and to an increasing degree with ecological objective criteria in order to meet market and legal demands. This leads to complex decision situations regarding planning, operation, and optimization efforts of production systems. This paper presents an integrated framework for production system analysis that allows to analyze the interrelations between economic and ecological factors in the context of production system optimization.

Context-Aware Analysis Approach to Enhance Industrial Smart Metering

With consideration of the increasing relevance of energy consumption and rising energy costs, strategies to improve energy efficiency in manufacturing environments have to be developed. As the energy consumption results from the temporal accumulation of individual power demands of subordinate devices, energy metering enables to capture these demands and display the dynamic behaviour. A fundamental precondition for the identification and implementation of improvement measures is nevertheless transparency about energy demands as well as related couplings and interdependencies. In this paper, the context-aware analysis approach is proposed to provide additional information supporting the understanding of energy consumption in manufacturing environments.

Energy Demand of Machine Tools and Performance Management

This chapter introduces the thematic context as a basis for the elaboration of the research. First, the ecological implications of industrial growth in the economic system are presented, triggering the initiation of the concept of sustainable development. An analysis of energy flows in production systems is then given to identify the origins of energy demand and extended in detail for machine tools. Based on an assessment of energy improvement measures for machine tools according to the availability and barriers, the implications of imperfect information on improving the energy demand are reflected. As a method for promoting efficiency, performance management is introduced and analysed in terms of the feasibility to determine minimum energy requirements and to guide improvement.

Sustainability in Production Engineering – Holistic Thinking in Education –

Considering the environmental as well as the social impact of manufacturing systems besides economic criteria has become a major topic in research and industrial application in the last years. Production processes demand diverse materials and energy for value creation. Considering the increasing economic and environmental relevance of energy and resource consumption, strategies to improve the efficiency and effectiveness of their usage in manufacturing environments need to be fostered in alignment with the premises of a sustainable development. However, focusing only on research and industrial application is a rather shortterm thinking process. While striving towards more sustainability in manufacturing, the integration of this issue into the education of engineering students is a key element on a long-term perspective. Against this background, the paper presents an educational structure and concept of the new TU Braunschweig course Sustainability in Production Engineering.

Life Cycle Innovations in Extended Supply Chain Networks

In today’s business environment enterprises are challenged to rapidly develop successful innovations that have to consider various requirements. Many failures of innovations in different phases of their life cycle can not comprehensively explained by previous theoretical approaches. Against this background, the Life Cycle Innovation framework is proposed in this paper. The integration of the Life Cycle Innovation model within the concept of extended supply chain networks leads to a model that represents the whole life cycle of a product. The approach allows to classify and to describe prior failures and serves as the framework for a simulation approaches.

Handlungsfeld mechanische Bearbeitung

Produktionsmaschinen benotigen zur Erfullung wertschopfender Tatigkeiten neben Rohmaterialien auch Energie und Hilfsstoffe. Ausgangsgrosen des Produktionsprozesses sind neben dem eigentlichen Produkt auch Abluft/Abwarme oder Abfalle bzw. Nebenprodukte (z.B. Spane). Ausgehend von einer ganzheitlichen Fabrikperspektive ist fur die Steigerung der Energie- und Ressourceneffizienz eine Berucksichtigung aller relevanten Energie- und Stoffflusse der verwendeten Betriebsmittel notwendig. Die Analyse der Energie- und Stoffflusse ermoglicht das Aufzeigen von Handlungsfeldern und die Ableitung und Bewertung von Verbesserungsmasnahmen. Im Handlungsfeld der mechanischen Bearbeitung sind neben der Entwicklung von innovativen, neuen Hilfs- und Betriebsstoffen insbesondere auch Methoden fur die allgemeine Berucksichtigung der Energie- und Ressourceneffizienz beim Planen und Betreiben von Maschinen und fur die generelle Bewertung der Oko-Effizienz von Fertigungsprozessen zu entwickeln.

Performance Management Concept to Evaluate and Improve the Energy Efficiency of Machine Tools

With regard to the ensuing need for research, this chapter introduces a comprehensive concept adapting performance management to evaluate and improve the energy efficiency of machine tools. First, the objective and functional requirements of the concept are presented, before an overview about the general concept layout and its structural elements is provided. Each element is then specified in detail illustrating the integrated methodologies and tools to determine an ideal energy performance, observe the actual performance and derive improvement. To guide and support the operation of the concept, the developed elements are coupled in workflow models formalising the processes to evaluate and improve the energy efficiency of machine tools.

Review on the State of the Research in Improving Energy Performance of Machine Tools

This chapter provides a review on the state of the research illustrating the status of current research approaches on improving the energy performance of machine tools. It begins with a short description of relevant approaches classified according to their specific focus within the process of energy performance management. An analysis of the approaches is then conducted evaluating the objectives and constraints in order to obtain a comparative overview about the state of research. In view of the evaluation of approaches, the further need for research is deduced to bridge the energy efficiency gap of machine tools.