© WZL/Fraunhofer IPT Energy Efficiency in Manufacturing Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Fritz...

© 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

Seite 2© WZL/Fraunhofer IPT

Agenda

Introduction1

Fields of Action in Energy- and Ressource-Efficient Manufacturing2

Balancing3

Adapted Process-Design leading to Resource- and Energy-Savings4

Summary5


Industrial society in strained relations

Environment, climate, recources

Economy growthwelfare

Individual and collective needs

Overall balance

Quelle: Acatech, oct. 2007


EnvironmentMobilityEnergy

Megatrends

What is the relevance of manufacturing engineering?

Mobilit

CommunicationsHealth Safety

Quelle: Fraunhofer-Gesellschaft

Technical Science and Engineering have to deliver Solutions!


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


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%


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


Agenda

Introduction1


Balancing3


Summary5


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


Agenda

Introduction1


Balancing3


Summary5


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


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


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


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


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


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


Agenda

Introduction1


Balancing3


Summary5


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.


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+


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


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,...


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


Agenda

Introduction1


Balancing3


Summary5


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

© WZL/Fraunhofer IPT Energy Efficiency in Manufacturing Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Fritz...

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