Tobias Rackow

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.

Green Controlling – Ressourcenorientierte Steuerung von Unternehmen

Kurzfassung Der erste Schritt zur Hebung von Energieeinsparpotenzialen ist das Aufdecken unnötiger Verbräuche. Folglich ist es notwendig, den Unternehmen ein Werkzeug an die Hand zu geben, mittels dessen die Energieströme im Produktionsprozess transparent gemacht und visualisiert werden können. Hierzu bietet die Green Controlling-Methodik einen ganzheitlichen Lösungsansatz, indem sie Energie als vierte Hauptzielgröße – neben Zeit, Kosten und Qualität – in die Unternehmensführung aufnimmt und so dem gewichtigen Stellenwert dieser Größe gerecht wird.

Energieverbräuche in der Kosten- und Leistungsrechnung

Kurzfassung Steigende Energiepreise führen insbesondere in preissensitiven und energieintensiven Branchen zu einem differenzierteren Umgang mit Energieverbräuchen. Durch den Einsatz von Energiemanagementsystemen gewinnen Unternehmen immer mehr Transparenz über ihre Energieverbräuche. Der vorliegende Beitrag beschreibt Potenziale, wie diese Transparenz auch im Rahmen der Kosten- und Leistungsrechnung genutzt und dadurch die Bewertung der Wirtschaftlichkeit der hergestellten Produkte präziser gestaltet werden kann.

Simulation-Based Optimization of the Energy Consumption in the Hardening Process for Calcium Silicate Masonry Units

Owing to a high cost pressure and the need for a reduction of carbon dioxide emissions for manufacturing calcium silicate masonry units (CS), the CS-industry strives to cut the energy consumption. The most energy consuming process step is the autoclaving. About 87% of the energy is required for this particular process step, where the green bodies are steam-hardened at 200°C.For reducing the energy consumption, most of the alternatives aim at optimizing the complete manufacturing process. In this paper, the focus is put on an optimized loading process for the autoclaves, in consideration of preceding and subsequent process steps. For this purpose, a simulation model is developed, where different strategies of loading are implemented and tested. This model can be used to find optimally scheduled assignments of production orders to the available autoclaves, based on the volume of each manufactured product.The analysis of the tested strategies shows, that it is possible to save up to almost 9 % of the required energy for autoclaving by an optimized assignment of the available autoclaves.

Energy Controlling - Analysis and Evaluation of Energy Measuring Equipment for the Purpose of Energy Transparency in Production Plants

This paper addresses the analysis and evaluation of energy measuring devices for the operation in the manufacturing industry. The focus lies on the comparison and scoring of energy meters regarding their performance spectrum against the backdrop of an energy controlling. Based on the fundamentals of electro technical metrology, the main measurement parameters were identified which are necessary for the purpose in the manufacturing industry. Further, capability characteristics for the differentiation of electricity meters were defined. With this, a classification of meters into a basic, a standard, an advanced and a premium class was undertaken. It is shown, that the advanced class is sufficient for the permanent monitoring of electricity consumption in the lights of energy controlling.

Logistical Integration of Smart Homes for Automated Consumer Goods Supply Based on Smart Refrigerators

Supply with daily consumer goods is a time consuming and quite inefficient task. Furthermore, some people may be dependent on caregivers resulting in additional costs. Hence, it offers opportunities for developing e-commerce solutions in order to enable customers to use otherwise wasted time for replenishment of their private food stocks more efficiently. Although, some digital stores for consumer goods have evolved recently, still only a small part of total sales, especially in food retail, is realized online. Due to inappropriate packaging there still are problems with the quality of fresh products. Also, current solutions for depositing parcels if the customer is absent are not suitable for fresh or cooled goods. Therefore, we show state of the art and developments necessary to establish the logistical integration and thereby enabling automated consumer goods supply in smart home environments. As smart appliances are playing an important role for enabling the automation, our focus is set on such hardware. To demonstrate customer acceptance of smart stocks in their private households, market research has been performed on smart refrigerators in place for every conceivable appliance capable of capturing consumer goods. Our results prove that especially younger generations are very interested in and willing to pay for intelligent appliances.

Integrated Energy-Controlling in Industrial Value Chains

The energy efficient production of goods can only be used as a unique selling proposition, if reliable values for the energy consumption, caused by production and transportation, are determinable. Furthermore, the customer must be able to compare these values for different products. Using a consistent and standardized methodology for calculating these values along the value chain, this comparability can be achieved. Providing this information, as potentially required by the end customer or by law, the penetration of this methodology could be achieved, while obviously the comparably more energy efficiently produced goods would be more attractive for the (end) customer. Consequently, an incentive system would emerge, which motivates the companies to improve their energy efficiency throughout the complete value chain. The following paper presents the above-mentioned methodology along with a unified scheme for allocating the energy consumption of the production to products.