Green Factory Bavaria Colloquium 2014

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Authors: Thilo Martens, Eric Unterberger, Christian Gebbe, Gunther Reinhart
Abstract: Life cycle assessment is becoming increasingly important for industry. Like the economic impact the ecological impact is mainly determined in the early stage of development. The challenge in this context is that the impact is difficult to predict, if the product hasn’t been fully designed yet and if the production processes aren’t known. For the economic impact many empirical formulas exist, whereas for the ecological impact such formulas are still missing. Therefore, a life cycle impact assessment tool has been developed which supports the developer during all stages of development.
Authors: Vanessa Schmidt, Markus Graßl, Gunther Reinhart
Abstract: Even though the share of the production machine’s environmental impact might be negligible compared to the product’s own use phase, the environmental impact at the factory site of is potentially significant. Thus, this article presents a contribution for the life cycle oriented evaluation of costs and resource efficiency applied in procurement of a production machine.
Authors: Sven Kreitlein, Tobias Rackow, Jörg Franke
Abstract: 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.
Authors: Tallal Javied, Sven Kreitlein, Alireza Esfandyari, Jörg Franke
Abstract: This paper provides an overview of different types of motor systems and several measurement principals in order to determine the electricity usage of these motors. It focuses on the measurement of electric values of different drive systems. A concept of rough analysis using software or excel based tools is discussed, which shows that it is a lot easier, efficient, and cost effective to first pin point the main electricity consumers and then initiate a fine analysis of these selected systems before a cost and time intensive process of measuring every single drive system is undertaken. To achieve this, a simple and systematic process is described in this paper, which can be used to identify the energy saving potential of drive systems without requiring expensive hardware.
Authors: Eric Unterberger, Florian Karl, Gunther Reinhart
Abstract: Industry is one of the major energy consumers in order to fulfill the social responsibility of the energy turnaround, with the result to involve companies to use their own generated renewable energy. This objective poses sever challenges for industry. The occurring volatile energy can only be handled by an energy flexible production, which allows the adaption of different energy levels. These must be defined already in the planning stages, so that the production can react to the varying energy availability. A harmonized energy supply and energy demand requires a method to plan both systems.
Authors: Tobias Rackow, Tallal Javied, Teresa Geith, Peter Schuderer, Jörg Franke
Abstract: 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.
Authors: Simon Spreng, Johannes Kohl, Jörg Franke
Abstract: The establishment of green products and a sustainable production increasingly affects corporate competitiveness, as an efficient production does not only affect the energy costs, but also improves the company image. As the importance of renewable energy sources increases, mainly providing unsteady energy levels, load management of manufacturing and assembly lines fades into spotlight. For this purpose, proper measuring equipment is required, being able to log and evaluate varying energy loads.This paper entails an approach being able to automatically measure and process electric load profiles. Hereby, all important hardware components with the belonging requirements as well as the software constitution are described.
Authors: Moritz Hamacher, Johannes Boehner, Arnim Reger
Abstract: This paper presents a flexible measuring system to identify energy efficiency potentials in the context of the ISO 50001 standard. On the basis of five essential requirements the flexible measuring system was structured into 4 modules which can be separately extended or modified. As the flexibility was in focus of the development this system it is able to measure the energy consumption on a very detailed level of the components of a machine. In addition it can also acquire measurement data of different other sensor signals like temperatures, flow rates etc. To evaluate the usability of the system in order to identify energy efficiency measures a use case was conducted. Results of the measurement data as well as possible energy savings of the investigated machinery are discussed at the end of this paper.
Authors: Martin Bornschlegl, Paryanto, Michael Spahr, Sven Kreitlein, Markus Bregulla, Jörg Franke
Abstract: Energy costs play a decisive role in the operation costs of automotive production companies. Therefore, energy planning in an early conception and planning stage becomes an important topic. This is because the early conception and planning stage has the greatest potential to influence the energy consumption of manufacturing technologies since about 70-80 % of the energy costs are committed during this stage. However, lifetime cost and specifically energy consumption are currently not a determining factor at this stage. The reason is that the prediction of energy costs for complex manufacturing systems are challenging. Previous research approaches in the area of energy planning are limited to detailed planned production. A standardized approach to determine the energy consumption rates at an early stage does not exist. In this context, the EffiPLAS project has therefore proposed to solve this challenge. The aim of this project is to develop a Methods-Energy Measurement approach with elementary energy elements to support the planning process at an early stage, and to develop a modular simulation model for calculating the energy consumption of industrial robots, which complements the energy prediction. In this paper, the basic concept of elementary energy units and their value determination techniques is presented, and the simulation model is outlined. The developed approach will help to predict the prospective energy consumption of complex production equipment so that energy costs can be accounted for in an improved manner within a life-cycle costing comparative analyses.

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