Energy Efficiency in Strategy of Sustainable Production

Energy Efficiency in Strategy of Sustainable Production Jörg Franke and Sven Kreitlein

ISBN-13: 978-3-03835-646-2 Applied Mechanics and Materials Vol. 805 Electronically available at http://www.scientific.net

Energy Efficiency in Strategy of Sustainable Production

Edited by

Jörg Franke and Sven Kreitlein TRANS TECH PUBLICATIONS

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Applied Mechanics and Materials ISSN: 1660-9336, ISSN/ISO: Applied Mechanics and Materials Editor: Xi Peng Xu, Huaqiao University, Ministry of Education Engineering Research Center for Brittle Materials Machining, Xiamen, 361021, China, [email protected] Editorial Board: see back inside cover.

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Editorial Board: Cadoni, E., University of Applied Sciences of Southern Switzerland, Switzerland

Koukolová, L., Technical University of Kosice, Slovakia

Cheng, Y.S., Harbin Institute of Technology, School of Materials Science and Technology, China

Krenický, T., Technical University of Košice, Department of Technical Devices Design, Slovakia

Chinakhov, D.A., Yurga Institute of Technology of National Research Tomsk Polytechnic University, Russia

Lucas, M., University of Glasgow, Department of Mechanical Engineering, UK Meor, Y. M.S., Malaysian Nuclear Agency Bangi, Materials Technology Group (MTEC), Malaysia

Delgado Sobrino, D.R., Slovak University of Technology in Bratislava, Slovakia

Olaru, A., Politehnica University of Bucharest, Romania

Dodun, O., Gheorghe Asachi Technical University of Iaşi, Romania

Semanco, P., TU Kosice, Faculty of Manufacturing Technologies, Slovakia

Gogu, G., Clermont Université, Pascal Institute, France

Syed-Khaja, A., Friedrich-Alexander-Universität Erlangen-Nürnberg, Germany

Hajduk, M., Technical University of Kosice, Department of Production Systems and Robotics, Slovakia

Uhl, T., AGH University of Science and Technology, Department of Robotics and Mechatronics, Poland

Karama, M., Université de Toulouse, INPT Ecole Nationale d’Ingénieurs de Tarbes (ENIT), France

Zulkifli, R., Friedrich-Alexander-Universität Erlangen-Nürnberg, Germany

Also published in these series: 776 (2015) Recent Decisions in Technologies for Sustainable Development 775 (2015) Engineering Solutions for Industrial Production 773-774 (2015) International Integrated Engineering Summit 2014 772 (2015) Advanced Research in Aerospace, Robotics, Manufacturing Systems, Mechanical Engineering and Bioengineering 771 (2015) Instrumentation and Measurement Systems 770 (2015) Urgent Problems of Up-to-Date Mechanical Engineering 769 (2015) Trends in Statics and Dynamics of Constructions 768 (2015) Selected Proceedings of the Ninth International Conference on Waste Management and Technology 766-767 (2015) Advances in Materials and Manufacturing 764-765 (2015) Modern Design Technologies and Experiment for Advanced Manufacture and Industry 763 (2015) Mechanical Engineering, Industrial Materials and Industrial Technologies 762 (2015) Mechatronics and Robotics 761 (2015) Recent Technologies in Design, Management and Manufacturing 760 (2015) Advanced Technologies in Designing and Progressive Development of Manufacturing Systems

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Selected, peer reviewed papers from the 2 Green Factory Bavaria Colloquium 2015, September 30 - October 1, 2015, Nuremberg, Germany nd

Edited by

Jörg Franke and Sven Kreitlein

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Preface Processing trade and industry consume more than half of the electric energy in Germany. Producing enterprises expend up to and sometimes even more than 10% of their total cost on energy. The steadily increasing energy demand with limited fossil resources and the tendencial cost and investment intensive renewable energy will inevitably lead to further increases in expenditures on energy in manufacturing companies. Together with the strong perception of an environmentally friendly behavior among customers, employees and society energy is developing into the most important strategic competitive factor. Therefore, companies increasingly consider the economical use of energy. The potential savings are enormous: up to 30% or about 10 billion euro in Germany annually. The model factories for energy efficiency in production of the Fraunhofer Institutes in Augsburg and Bayreuth and of the Universities in Erlangen-Nuremberg and in Munich, as well as the Universities of Applied Sciences Amberg/Weiden, Ansbach, Coburg, Deggendorf, Hof, Ingolstadt, Nuremberg and Schweinfurt/Wuerzburg are targeting together the long-term objective of energy self-sufficient production plants. These research factories develop technologies to optimize energy consumption and to minimize the wastage of resources in production and laboratory. Further, strategies for adapting the energy consumption to the offer and procedures for decentralized renewable energy are developed and implemented in the Green Factories. The Green Factories in Bavaria combine up the research skills of all relevant fields for energy efficient production processes, e.g. mechanical engineering/ manufacturing technology, electrical engineering, information technology, process engineering, materials science and economic science. They also consider all major types of energy, e.g. for motion, illumination, information processing, manufacturing processes and thermal control. Furthermore, the Green Factories address the use of energy in production, logistics and administration in more than 35 research projects. With clear focus on energy efficiency in production, the Green Factories are aiming to expand into an international research network, which currently consists of more than 50 companies and 20 research institutes in named universities with more than 40 active scientists. In the model factories for energy-efficient production, innovative industrial partners have the opportunity to present and to develop advanced techniques and technologies for energy-efficient production together with scientists from the participating research institutions in the available laboratories and production areas. They also allow for intensive networking and to pass on knowledge effectively to users and students. This unique concept of collaborative research between industry and universities guarantees an efficient research and a fast and more efficient transfer of the results into the economy. The project partners would like to express their sincere thanks to the Freistaat Bayern for funding the project “Green Factory Bavaria” in the framework of the “future initiative Aufbruch Bayern”.

Joerg Franke Sven Kreitlein Institute for Factory Automation and Production Systems (FAPS) Friedrich-Alexander University Erlangen-Nürnberg

Table of Contents Preface

Chapter 1: Energy Efficiency as an Element of a Strategy for Sustainable Production The Least Energy Demand Method as Metric to Evaluate Different Production Levels Based on the Relative Energy Efficiency S. Kreitlein, I. Kupfer, M. Brandmeier and J. Franke The Relative Energy Efficiency as Standard for Evaluating the Energy Efficiency of Production Processes Based on the Least Energy Demand S. Kreitlein, I. Kupfer, M. Mühlbauer and J. Franke The Least Energy Demand Method as Metric to Describe the Relative Energy Efficiency of a Product Based on its Manufacturing S. Kreitlein, I. Kupfer, M. Scholz and J. Franke Smart Factory Meets Smart Grid: Cyber-Physical Compressed Air Systems Enable Demand Side Management in Industrial Environments R. Boehm, J. Buerner and J. Franke Multi Criteria Decision Making Enhancing Sustainable Energy Management J. Boehner Green Energy Management Portal – Knowledge and Project Management for Energy Efficiency Projects M. Brandmeier, K. Rummler, M. Brossog and J. Franke Scenario Based Method to Increase the Flexibility of Energy Use in Production Systems E. Unterberger, J. Glasschröder and G. Reinhart Ontology-Based Description of Energy Optimization Potentials for Production Environments M. Brandmeier, F. Schäfer, S. Kreitlein and J. Franke A Conformity Check and Optimization of the Energy Management System Based on ISO 50001 T. Javied, F. Dlugosch, T. Maul and J. Franke Simulation Based Evaluation of Energy Saving Potentials in the Field of Electric Drives Manufacturing S. Spreng, J. Kohl, P. Proshkovsky and J. Franke Intelligent Energy Profiling for Decentralized Fault Diagnosis of Automated Production Systems J. Kohl, H. Fleischmann and J. Franke Approaches for Monitoring the Energy Consumption with Machine Learning Methods C. Gebbe, J. Glasschröder and G. Reinhart Integrated Energy-Controlling in Industrial Value Chains T. Rackow, T. Donhauser, P. Schuderer and J. Franke E|Flow - From Production Line Concept to a Physically and Digitally Full-Meshed Production Network M. Scholz, M. Hußnätter, S. Kreitlein and J. Franke

3 11 19 25 32 38 46 53 61 67 73 79 86 94

Chapter 2: Equipments and Technologies of Sustainable Production Research on the Influence of Geometry and Positioning on Laser Sintered Parts M. Launhardt, C. Fischer and D. Drummer Influence of Pre-Strain and Simulated Paint-Bake on Mechanical Properties of High Strength Aluminum Alloy AA7020 M. Merklein and J. Degner A System Embracing Observation of Different PTFE-Compounds in the Sealing Application of Rotary Manifolds J. Müller, R. Illek, G. Michos, K. Faust, M. Hubert and J. Franke

105 115 123

b


Influence of Processing Parameters in Reaction Injection Foam Molding for Multi-Layer Parts on Foam Structure and Mechanical Properties M. Löhner and D. Drummer Functional Printing of Silver Nano Ink on Injection Molded Polymeric Substrates J. Bahr, J. Schirmer and M. Reichenberger GreenBearings – Friction Behaviour of DLC-Coated Dry Running Deep Groove Ball Bearings J. Kröner, S. Tremmel, S. Kursawe, Y. Musayev, T. Hosenfeldt and S. Wartzack Numerical Investigations on the Influence of Process Parameters on the Forming of Gears in Forward Extrusion M. Merklein, C. Kiener and A. Reiss Energy Efficient Laser Beam Welding of Metals with a Ultra-High Brightness Direct-Diode Laser System A. Laukart, M. Dobler, S. Kohl, H. Fritsche, A. Grohe, B. Kruschke and M. Schmidt Influence of Surface Structured Filler Wires on Laser Beam Welding of Copper Alloys V. Mann, F. Gärtner, F. Hugger, K. Hofmann, F. Tenner and S. Roth Automated Pattern Recognition in Load Profiles of Milling Operations A. Reger, H.H. Westermann and A.P. Aires Energy Demand Simulation of Machine Tools with Improved Chatter Stability Achieved by Active Damping R. Kleinwort, R.S.H. Popp, B. Cavalié and M.F. Zaeh Energy Efficiency Analysis of Vapor Phase Soldering Technology through Exergy-Based Metric A. Esfandyari, A. Syed-Khaja, M. Horvath and J. Franke Measurement of the Resource Consumption of a Selective Laser Melting Process C. Gebbe, M. Lutter-Günther, B. Greiff, J. Glasschröder and G. Reinhart Economic and Ecological Evaluation of Hybrid Additive Manufacturing Technologies Based on the Combination of Laser Metal Deposition and CNC Machining M. Lutter-Günther, S. Wagner, C. Seidel and G. Reinhart A Dynamic Simulation Model of Industrial Robots for Energy Examination Purpose Paryanto, A. Hetzner, M. Brossog and J. Franke Evaluation of Model Based Predictive Control Algorithms for Fractional Horse Power Drives M. Blank, S. Wendel, P. Loehdefink and A. Dietz Energetic Simulation of Complex Mechatronic Drive Systems over Complete Drive Cycles S. Hörlin, A. Dietz, M. Hubert and J. Franke Simulation-Based Optimization of the Energy Consumption in the Hardening Process for Calcium Silicate Masonry Units T. Donhauser, J. Ehrhardt, T. Rackow, J. Franke and P. Schuderer Improving Resource and Energy Efficiency of Packaging Machines: Contribution of an Increasing Format Flexibility G. Götz, P. Stich, S. Thunig, J. Glasschröder and G. Reinhart Energy Efficiency and Productivity Optimization of Industrial Cleaning Equipment F. Kübler, T.H.J. Uhlemann, J. Dill and R. Steinhilper

131 139 147 154 162 171 180 187 196 205 213 223 231 241 249 257 265