© WZL/Fraunhofer IPT Energy Efficiency in Manufacturing Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Fritz Klocke Dipl.-Ing. Dieter Lung Dipl.-Ing. Ralf Schlosser Bilbao, 20.04.2010
Mar 27, 2015
© WZL/Fraunhofer IPT
Energy Efficiency in Manufacturing
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Fritz Klocke
Dipl.-Ing. Dieter Lung
Dipl.-Ing. Ralf Schlosser
Bilbao, 20.04.2010
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Agenda
Introduction1
Fields of Action in Energy- and Ressource-Efficient Manufacturing2
Balancing3
Adapted Process-Design leading to Resource- and Energy-Savings4
Summary5
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Industrial society in strained relations
Environment, climate, recources
Economy growthwelfare
Individual and collective needs
Overall balance
Quelle: Acatech, oct. 2007
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EnvironmentMobilityEnergy
Megatrends
What is the relevance of manufacturing engineering?
Mobilit
CommunicationsHealth Safety
Quelle: Fraunhofer-Gesellschaft
Technical Science and Engineering have to deliver Solutions!
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How will we be able to cope with the polylemma of environment, resources and demography?
Demographical development– 2005: 6,5 billion humans– 2040: 10 billion humans1
Environment and resources– Finite resource availability– Climate change
Change of paradigms
1 Source: United Nations, 2007
Moore Goods with less Resources
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Company: Main target is profit on a long term perspective
Energy consumptionin Germany
~ 10 Porsche Boxster (CO2-emission, 10.000 km)~ 12 living houses (electricity - each 3600 KWh per year)~ 228 fridges (each 198 KWh per year)
Energy efficiency – Saves cost and increases popularity
Challenges
Resource efficiencyEnergy efficiencyRenewable resources
1 state of the art machining center needs about 35.000 kWh electricity per year
Source: German Ferderal Bureau of Statistics, 2007
Traffic20%
Industry18%
Losses for energetic
transformation34%
Private28%
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Energy flow in Petajoule of the Federal Republik of Germany (2008)
12.160 Import4.147 Domestic production
51 Stock removal 2.645 Industry
2.575 Traffic
2.502 Households
1.404 Trade, service, business
2.078 Export and bunkering
519 Non energetic consumption
3.570 Conversion losses
519 Consumption in the energy sectors
35 Statistical differencesSource: Acatech, AGEB, 2009
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Agenda
Introduction1
Fields of Action in Energy- and Ressource-Efficient Manufacturing2
Balancing3
Adapted Process-Design leading to Resource- and Energy-Savings4
Summary5
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Fields of Action and Research Topics
optimisation of process-stability and -quality (zero-error production)
resource-efficiency of mechanical manufacturing processes and systems
energy-efficiency of thermal and chemical manufacturing processes
closed resource-cycles within all process chains and systems
loss-free infrastructural performance of production and manufacturing facilities
development of methods for sustainable resource application
Input-Flow
Pro
zess
Output-Flow
Inp
ut-
Flo
w
Process-steps n
Information
Material
Energy
Ou
tpu
t-Flo
wInformation
Material
Energy
Info
rmatio
n
Mate
rial
En
erg
y
Info
rmatio
n
Mate
rial
En
erg
y
Ressource-Efficiente Production and Sustainable Processes
figure: Ressource-Flows of Production-Systems
Source: EFFPRO Study from the German Federal Ministry of Education and Research
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Agenda
Introduction1
Fields of Action in Energy- and Ressource-Efficient Manufacturing2
Balancing3
Adapted Process-Design leading to Resource- and Energy-Savings4
Summary5
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Energy efficient manufacturingBalance envelopes
How can we balance manufacturing?
– Production site envelope Production site
evaluation
– Machine tool envelope Machine tool
assesment
– Process envelope Assesment models
on a physical process level
Source: Index, Daikin, AL-KO, Boge, Schuch
Process
Machine tool
Production site
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CECIMO ActivitiesSelf Regulatory Initiative
Motivation:– “Our vision as a responsible, sustainable and highly
innovative sector is to cover environmental aspects early in the process from R&D and design through to production, comprising also post-production throughout the whole life cycle of our products.”
Challenge:– Each machine tool should is an individual product with its
own environmental performance improvement potential, a standardisation is not target-orientated
Approach:– The intended goal of the Self Regulatory Initiative (SRI) is to
increase the ecological performance of each machine tool while maintaining the freedom of innovation
– It will not be bound to mandatory requirements. This allows the machine tool industry to define their own rules in the framework of the Ecodesign Directive, while structure, products and customer needs are taken into consideration.
Source: CECIMO, Gildemeister, DST, Heller
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Assessment of a tool changer in machine tools (ECO-Footprint)The life cycle as the balance envelope
Sum
PT
Packaging
PT
Hydraulic/ pneumatic
PT
Machine enclosure
PT
Coolant system
PT
Tool changer
PT
Head
PT
Z-Module
PT
Y-Module
PT
X-Module
PT
45719,3479,23137,0113,82417,1814,815073,03427,09116,711140,7
%
Eco-PointsPT
Eco-IndicatorPT
Inputs/OutputsActivityLife cycle phase
3,730,10,086C45MaterialRaw material manufact.
3,125,20,0241 Truck (24t)Transport (3000km)Logistics
0,75,80,026ElectricityEnergy consumptionManufacturing
91,9748,80,026ElectricityEnergy consumptionUse and maintenance
350 kg 0,6 4,9 0,014C45MaterialDisposal
100 814,8 Sum
350
1050
224
Unit
kg
tkm
kWh
28800 kWh
Amount
Green MachiningGreen Technology
Green FactorySustainable Entrepreneurship
Source: PROLIMA
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Assessment of resource consumption withEnvironmental Product Lifecycle Management
Life cycle phases
Costs categories
Pro
duct
str
uctu
re
Labour costsManufacturing
Machine enclosure Cost element
Source: IEC
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Input power
Chip conveyorElectronicsCompressed air
Ancillary units and losses
25%
75%
Spindle - 30%
Cooling unit - 20%
Cooling - 15%
Drives - 12%
Hydraulics - 11%
88%
100%
Process performance
Performance distribution in maschine tools Today
Source: BMW
Source: Measurements according to VDW, INDEX 2008, EFFPRO, FHG 2008, Gildemeister, DST, Heller
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Power demand in a cutting process Peaks occur due to:
– gaining operating conditions– acceleration of the spindle
Three areas of power demands can be distinguished:
– „Standby-Load“
(constant, only depending on machine tool)
– „Idling-Load“
(variable, depending on machine and process)
– „Process-Load“
(variable, depending on process parameters)
t
Process
IdleStandby
Illumination, Air conditioning, Compressed air,
Cooling lubricants …
Machine
tool
Periphery constant
P
variable
tmain
tcycle
tnon pro
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Agenda
Introduction1
Fields of Action in Energy- and Ressource-Efficient Manufacturing2
Balancing3
Adapted Process-Design leading to Resource- and Energy-Savings4
Summary5
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Power consumption
→ reduce process parameters
Energy per unit
→ increase process parameters
0
2000
4000
6000
8000
4050
6070
8090
0.03
0.06 0.
1
0.15 0.
2
0.25 0.
3
Cut
ting
velo
city
/(m
/min
)
Feed per tooth f / mm
Cut
ting
po
wer
Pe /
W
0
3000
6000
9000
12000
4050
6070
8090
0.03
0.06 0.
1
0.15 0.
2
0.25 0.
3
Cut
ting
velo
city
/(m
/min
)
Feed per tooth f / mm
Spe
cific
cu
ttin
g en
erg
y E
e,s
pe
c. =
Ee/Q
z
Balancing approaches for the electrical energy consumption of manufacturing processes (drilling operation)
For real process evaluation the process result has to be related to the changes on the product. For cutting processes the relation of the specific energy Ec,spec=Ee/Qz is a
workpiece independent relation.
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Energy Efficiency by Short Processing Time: High Requirements for Process Automation
Source: AWK08, Heidelberger Druckmaschinen
Time for tool change
Distribution
primary time
second. time
15s
8,5s
2s
<1,5s
38%
62%
59%
41%25%
75%
13%
87%
0 2 4 6 8 10 12 14 16 18 [s]
n-
n-n+
+ -
+ -
Exemplary Drilling Process:Positioning 200 mmDiameter 12 mmDepth 20 mmDistance of Holes 100
mm
tool change
conventional NC- Machine Tool
conventional NC- Machine Tool, improved cutting parameters
HPC Machine Tool, desired parameters
spindle PositioningProcessing
HPC Machine Tool, parameters implemented100 mm
Zeit
n+
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Resource Saving by Process Modification and –Substitution An example in Bevel Gear Manufacturing
Conventional process chain
Forging
Soft turning, drilling, tapping
with coolinglubricant
Gear cutting with
lubrication Case hardening
Grindingwith
cooling lubricant Gear lapping Screwing
Forging
Soft turning, drilling, tapping
with coolinglubricant
Gear cutting with
lubrication Case hardening
Grindingwith
cooling lubricant Gear lapping Screwing
Optimisation step1.
Hard turning
2. Optimisation step
Gear cutting dry
Wet machining:Cutting material: HSS Coating: TiN
Dry gearcutting
Elimination lubrication/ year ca. 25.000 l
Dry machining:Cutting material: VHMCoating: TiAlN
New process parameters:Feed fCutting speed vc
3. Optimisation step 3.
Soft turning with cooling
lubricant Welding
Soft turning with cooling
lubricant
Elimination cooling lubricant system, consumption/ year Energy: 1,15 Mio. kW/h Medium: 1052 m³ Filter fleece: ca. 45 t
Screwing of crown wheel : - Process drilling and tapping- central cooling lubricant
system
Welding of crown wheel : - Process Elimination of drilling and tapping - Elimination of a central cooling lubricant system
Welding Hard turning
Source: BMW
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Balancing product features in the manufacturing phaseIncreasing product functionality
Goal: – Increase product functionality and duration of usage phase
Functionality is influenced by surface and rim zone properties, which are induced by process chains, however the correlation is more or less unknown
Necessity for research:– Explore correlation between surface and rim zone and
functionality– Identification of process chains which improve functionality– Identification of process parameters which improve
functionality
Process i
Grinding, Hard-turning, ...
Parameters xi,j
Feed vw,Cutting speed vc, ...
Functionality f
Rolling fatigue life, ...
Surface properties yi,k
Roughness, Hardness,Residual stress, microstructure,...
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Development of a methodologyTechnology navigator All relevant characteristics
in a single portfolio
Function footprint defines ideal surface and rim zone
Technology chains may be compared through further economical and ecological characteristics
Technology Footprint process chain T1
Technology Footprint process chain T2
Function Footprint
rel. resource consumption
Energy demand
Resource demand
Material cut-off
Unit cost
Eco- characteristicS
urfa
ce
Technology navigator
Technological characteristicClaim
Roughness Rz
Roughness Ra
Residual stress
...
value .
Function forecast
T1
T2
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Agenda
Introduction1
Fields of Action in Energy- and Ressource-Efficient Manufacturing2
Balancing3
Adapted Process-Design leading to Resource- and Energy-Savings4
Summary5
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Science andinvention Research,
teaching, education
Creativity andenabler
Innovationand market Entrepreneur, Consumer Economy
efficiency and implementation
Government general conditions Freedom degree of regulation Challenge Personal responsibility
Knowledge
Money Money
Social climate Willingness to change Chance utilization Confidence in experts and future
People
People
Boundary Conditions: Circle of Innovation
Source: acatech, Milberg 2007
Sustainable growth by innovation
KnowledgeSustainable growth by innovation