Sven Kreitlein

The Relative Energy Efficiency as Standard for Evaluating the Energy Efficiency of Production Processes Based on the Least Energy Demand

This paper presents a calculation system to evaluate the energy efficiency in the production in general and at the process level more specifically. Its focus lies on the evaluation of the efficiency of the use of electric energy in the manufacturing industry. The basic target is a comparability of the energy efficiency across products through derivation of significant key figures. The basis of a significant evaluation and overarching comparability of the energy efficiency as well as the basis of the derivation of possible saving potentials is the relative energy efficiency (REE). It is determined by the quotient of minimal energy demand and actually measured consumption and requires that the actually measured energy consumption refers to an independent basis of comparison. The step-by-step development of the calculation system is based on the detailed analysis of all influential factors of the energy consumption. The, in this context, developed Least Energy Demand Method enables the determination of energy minima with different bases of comparison as reference values to evaluate the energy efficiency of single parts production.

Holistic Approach to Reducing CO2 Emissions Along the Energy-Chain (E-Chain)

Due to the increasing awareness to reduce CO2 emissions, it is important that car producers (OEM) get transparency about their energy consumption. Especially the production emission is becoming a focus topic in the next years. Hence, it should be started to minimize the energy consumption in a sustainable way. Therefore, this chapter presents a new approach to design a sustainable Energy Chain, which considers all elements beginning from the energy supplier to the end customer. Additionally the energy consumption is assessed, whether it is value-adding or not. This helps to find the levers to reduce energy consumption without reducing the level of quality and quantity. For the implementation of the Energy Chain a suitable software architecture is necessary. This chapter shows possible software modules for energy planning.

Determination of the prospective energy consumption of manufacturing technologies with methods-energy measurement (MEM)

The reduction of energy costs of manufacturing technologies is both an important and current objective for factory operators. But mostly, this idea to reduce the energy consumption is being implemented after the manufacturing technologies are installed. However, it would be more advantageous if efforts were made to save energy during the early planning process. To achieve an estimation of the energy consumption in this early planning stage, a new suitable forecast method is required. Therefore, this paper shows how the prospective energy consumption can be determined by using Methods-Energy Measurement (MEM). Based on the needs of production planners, future challenges and requirements for MEM are listed. Further-more, the concept of basic energy elements and their value determination techniques are introduced, and different possibilities are outlined and assessed. For an easier determination of the energy demands of a complex production cell or manufacturing equipment, standard equipment patterns will be designed. This template supports both planners and decision-makers to create reliable and standardized Resource Performance Indicators (RPI). Subsequently, the architecture of the MEM-calculation model is presented. This approach enables a holistic estimation of the energy consumption of manufacturing technologies and leads to higher levels of transparency. Furthermore, MEM contributes to identify and realize sustainable solutions in advance and as a result, increases the profitability of a factory.

E|Benchmark - Approaches and Methods for Assessing the Energy Efficiency of the Industrial Automated Product Manufacturing

This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production as well as a corporate and cross-industry comparison. Already today, energy-related characteristic value systems are used, which are related to the energy consumption of large electronic household appliances or are focusing on their production facilities. The energy efficiency value is a newly developed indicator and will provide valuable information about the energy efficiency of the production of various products, production operators, and consumers. In the following, the energy efficiency value, which is based on the approach of minimal value calculation, is presented in detail. The basic idea is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. Depending on the analysis of influencing factors, a model highlighting their dependencies could be established. The developed system hinges on a successive calculation of the minimum value. Each of these minimum types can be put in relation to the measured energy consumption. However, depending on the chosen basis, the conclusion and focus of the calculated key figure may vary. By using the real minimum as a basis, the actually existing energy savings become visible. The method will be put to the test through an exemplary application for processes in the fields of cutting technologies. This course of action allows for the validation of the developed energy efficiency value and reveals the potential of this method.

The Least Energy Demand Method as Metric to Evaluate Different Production Levels Based on the Relative Energy Efficiency

This paper presents a calculation system for evaluating the energy efficiency at machine, plant, location, company, and sector level based on the process specific minimum energy demand. The goal is a comparability of the energy efficiency across machines, plants, locations, companies, and sectors through definition of significant key figures. The basis of the derivation of possible saving potentials is the relative energy efficiency (REE). [7] It is determined by the quotient of minimal energy demand and actually measured consumption and requires that the actually measured energy consumption refers to an independent basis of comparison. The step-by-step development of the calculation system, structured in levels, is based on the detailed analysis of all the influential factors of the energy consumption with the help of cause and effect diagrams to calculate the minimally necessary energy demands for the manufacturing process. Furthermore, the described bottom-up approach delivers, ensuing from the process oriented level of perspective, the step-by-step conception of the calculation method. The REE of a level of perspective is calculated on the basis of the REE value of the previous production level as well as according weighting factors. On the basis of the calculation, as well as subsequent measurements within the company, optimization potentials [10] can be clearly described and can lead back to their roots. These optimization potentials are based on exemplary trials presented for a chosen manufacturing chain of the electronics production area.

Efficient near Net-Shape Production of High Energy Rare Earth Magnets by Laser Beam Melting

In this publication we report on our progress in investigating the energy efficient production of rare earth permanent magnets by Laser Beam Melting in the powder bed (LBM). This innovative additive manufacturing process offers the potential to produce magnets of complex geometries without an energy intensive oven sintering step. Another advantage that increases the efficiency of this possible new process route is the high degree of material utilization due to a near net shape production of the magnets. Hence only little material is wasted during a post processing machining step. The main challenge in processing rare earth magnet alloys by means of LBM is the brittle mechanical behavior of the material and the change in microstructure due to the complete remelting of the magnet powder. We therefor expanded the parameter study presented in previous work in order to further increase relative density and magnetic properties of the specimens. In this context process stability and reproducibility could also be increased. This was achieved by investigating the impact of different exposure patterns and varying laser spot sizes. Simultaneously to the experiments the energy consumption of the LBM process was measured and compared with conventional rare earth magnet production routes.

The Least Energy Demand Method as unique tool to evaluate and rate the energy efficiency of the electric drives production

This paper evaluates a method for the assessment and evaluation of energy efficiency of the manufacturing process in the electric drive production as well as a corporate and cross-industry comparison. First, the system for the Least Energy Demand Method will be explained. The basic idea of the calculation is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the measured energy consumption [8]. The Least Energy Demand Method is subsequently extended with the calculation system to evaluate the relative energy efficiency (REE) of higher levels of perspective. The goal is a comparability of the energy efficiency across machines, plants, locations, companies and sectors through definition of significant key figures. The basis of the derivation of possible saving potentials is the relative energy efficiency [6]. The REE of a level of perspective is calculated on the basis of the REE value of the previous production level as well as according to weighting factors. On the basis of the calculation, as well as subsequent measurements within the company, optimization potentials [10] can be clearly described and traced back to their roots. These optimization potentials are based on exemplary trials presented for a chosen manufacturing chain of an electronic production area [5]. The system of the energy efficiency evaluation during the manufacturing process is applied in the production of stators for bike motors.

Economic application of powder resin based groundwall insulation for low voltage electric drives

Powder coating already forms an established variant of groundwall insulation although being used almost exclusively for small, flyer-wound rotors mostly due to the lack of economic application and curing processes for larger drives. However, insulation layers based on powder coatings are able to perform significantly better than common aramid-based slot liners. Regarding recent developments in powder application and curing, efficient application methods regarding energy consumption and process time are able to increase yield significantly. Regarding the altering topological characteristics of modern traction drives e.g. for electric vehicles, powder application and achievable results have to be investigated to assess the value of an industrial implementation. Experiments were performed using an electrostatic coating cell and a fixture simulating various characteristics of modern drives including inner diameter, slot width and -depth. These characteristics as well as available process values were analyzed towards the target figure coating thickness using DoE methods. Results predict a valid application of electrostatic powder coating within certain limits for larger traction drives. Package length should not exceed 80 mm and the diameter to package-length ratio has to be lower than 1.0 in order to achieve consistent, repeatable results. Electrostatic Powder Coating can be a valid alternative regarding groundwall insulation for traction drives, although the regarded process is expected to be best-suited for hybrid applications, due to large diameters and small package lengths of electric drives in this field.

E|Flow - From Production Line Concept to a Physically and Digitally Full-Meshed Production Network

The continuous change of the consumers’ behavior combined with the impact of new technologies to the shop-floor is a challenge for the classic and established line production. Due to the effects of mass-customization there is an increase of the variants of the products combined with a reduction of the number of units per variation. Therefore, it is necessary that the next generations of production lines, especially the assembling devices, have to be designed more adaptable. Regarding to business information systems this trend is realized by a progressive digital integration of the particular units. However, at the physical level of the value stream the sequenced units are linked to each other and arranged flow-orientated since Taylor. Particularly, for mass production the so called “line concept” is well established. This inflexibility of the physical material flow blocks the spread of mass-customization into established industrial sectors where linked manufacturing steps are common use. A product which is very individualized is not, or only with an additional expense, producible on such linked lines. Therefore, it is necessary to resolve the linking of the physical material flow similar to the digital integration of the work flow. The result will be a physically and digitally full-meshed network of production units with a high variability. Especially for a production of goods with a high variant diversity the benefits of a physically meshed production site are obvious. Each part gets its own and individual routing, which depends on the current machine availability, the set-up and other factors. Furthermore, a change of the general conditions during the manufacturing of the part can be considered and lead to an adaption of the routing. One of the most important parts of a flexible physical production network is the transport system, consisting of autonomous and smart entities which are interconnected with business information systems, products and machines.

Ontology-Based Description of Energy Optimization Potentials for Production Environments

Energy efficiency of production systems and of the product itself has grown to a critical competitive factor. Besides the manufacturer’s monetary motivation there are increasing incentives to meet customers’ expectations regarding lifecycle cost and the ecological footprint of products. That neo-ecology, as one megatrend, leads to a new business moral resulting in an energy optimization of the whole product life cycle in terms of resource and energy input. There is a plenty of measures to reduce the energy consumption of a production system and thus to increase its efficiency. To do so companies do not have to develop proprietary solutions for their production sites but can draw on a large pool of measures. However, in practice, many energy optimization measures are unknown to their energy managers. This is mainly owing to the fact that there is no standardized categorization for energy optimization potentials yet. In addition, many efficiency deficits remain undetected as a result of a non-existing efficient methodology for finding energy consumption optimization measures. The domain of information retrieval addresses this issue, as it is able to provide documents matching the user’s information demand. Nevertheless, search queries have to be sufficiently well known in order to gain adequate results. In this paper we show how ontologies can be used to support the user in defining search queries and finding optimization measures efficiently. As formal and explicit specifications of shared conceptualizations, ontologies offer the possibility to represent relevant parts of knowledge in a standardized, machine-readable manner. Therefore, ontologies improve upon data models, which are mainly used for single applications. For the purpose of energy efficiency in production environments, we provide both a methodology to build ontologies for describing energy saving measures and illustrate the application for explicit energy efficiency optimization measures.