Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Energy Efficiency Optimization using AutomationML modeling and an EnPI methodology
    ( 2019)
    Thiele, Gregor
    ;
    Khorsandi, Niloufar
    ;
    Krüger, Jörg
    Industrial facilities are complex and heterogeneous systems in permanent technological change. The ambitions towards smart factories heighten the requirements for the flexible interconnection of various devices. These industrial entities are controlled, observed and optimized by many services. The tuning of process parameters of several linked components in order to boost the overall energy efficiency is one example of such services. AutomationML (AML) provides a hierarchical description language for industrial systems considering both structure and properties. An extension of the established standard allows for intuitive modeling of energy optimization problems. An approved energy performance indicator (EnPI) methodology was integrated in the libraries of AML in order to simplify and shorten the modeling procedure for the optimization task. The procedure is demonstrated using the example of an industrial cooling system.
  • Publication
    A practical approach to reduce energy consumption in a serial production environment by shutting down subsystems of a machine tool
    ( 2019)
    Can, Alperen
    ;
    Thiele, Gregor
    ;
    Krüger, Jörg
    ;
    Fisch, J.
    ;
    Klemm, C.
    Energy efficiency in production is becoming increasingly important for the automotive industry, motivated by political regulations and competitiveness. Many theoretical approaches to achieve an efficient production via advanced control have only been tested in experimental environments. Important for the transfer into serial production is the proof that all requirements (e.g. quantity and quality) will be met. For ensuring production on demand, machine tools (MT) imitate the real production process to keep themselves at operating temperature. All subsystems of a MT operate at full power in this state, disregarding its necessity. Shutting down these subsystems during non-productive periods is a promising approach for saving energy. This paper will present a method for shutting down components during non-productive periods, while ensuring the ability to produce on demand. Successful tests were already performed during live operation in a plant of a car manufacturer in Berlin, Germany.
  • Publication
    Implementation of an Energy Metering System for Smart Production
    ( 2019)
    Halstenberg, Friedrich A.
    ;
    Lindow, Kai
    ;
    Stark, Rainer
    Digitization is consecutively changing more and more areas of human living. Many products are designed increasingly ""smart"" and connected to their environment. Not only products but also the necessary production facilities and systems are subject to digital change. The goal is to achieve a wide range of improvements and increase the efficiency and flexibility of the interlinked production systems. In Industry 4.0, important production parameters are measured and monitored with the help of sensors. Based on analyses of those data, adjustments and improvements of the production system can be performed. This paper presents the concept and physical implementation of an advanced energy metering system on a factory demonstrator, the so-called SmartFactory 4.0. It produces beverage coasters, which can be designed freely by the customer in shape, material and colour and is produced directly or remotely through a web application. The SmartFactory 4.0 consists of three production modules, which are connected to one another by means of media and information technology. The advanced energy metering system is designed in order to measure and monitor energy consumptions in various production steps. Those data are compared to previous simulations. Steps for the improvement of the energy efficiency of the SmartFactory 4.0 are derived. This paper presents first test results from the application of the system. For different individualized gravures and two different colours (green and orange) with various depths of the produced beverage coaster, energy consumptions of the production have been metered over time. The measured data are analysed and evaluated, and suitable steps for improvement are given. Finally, this research provides suggestions for scaling the energy metering system to larger production systems, and a systematic procedure for implementation is given. This research constitutes one step in the direction of utilizing the concept of the digital factory twin for the improvement of energy efficiency and sustainability of production systems.
  • Publication
    Einsatzverhalten und Leistungsbedarfe unterschiedlicher Kühlungsmethoden beim Außen-Längs-Runddrehen
    (Fraunhofer Verlag, 2018)
    Fürstmann, Paul
    Die Drehbearbeitung hochwarmfester Legierungen stellt produzierende Unternehmen vor wirtschaftliche Herausforderungen. Insbesondere die physikalischen Grenzen verfügbarer Schneidstoff-Beschichtungssysteme limitieren die Schnittparameter und damit potenzielle Produktivitätssteigerungen. Eine wichtige Einflussgröße, welche den Prozesswirkungsgrad und die Produktivität beeinflusst, ist die Wahl einer geeigneten Werkzeugkühlung. Zum besseren Verständnis und mit dem Ziel die Produktivität trotz vorhandener Grenzen zu steigern, wird die Ursache-Wirkungskette des Werkzeugverschleißes bei der Trockenbearbeitung, der Trockenbearbeitung mit einem geschlossen-innengekühlten Drehwerkzeug mit Flüssigstickstoffkühlung und der Überflutungskühlung mit Kühlschmierstoff beim Außen-Längs-Runddrehen von TiAl6V4 analysiert. Ein weiterer Schwerpunkt dieser Arbeit ist die Modellierung der energetischen und wirtschaftlichen Effektivität und Ermittlung der jeweils günstigsten Prozessparameter. Aus den gewonnenen Erkenntnissen lassen sich zukünftige Entwicklungspotenziale ableiten, um die Fertigung hochwarmfester Werkstoffe energetisch effizienter und ökonomischer durchzuführen.
  • Publication
    Objectives and Barriers for the Implementation of Energy Management Systems in Manufacturing Enterprises in Germany: Results of an Empirical Investigation
    ( 2013)
    Jochem, Roland
    ;
    Karcher, Phillip
    ;
    Siemer, Markus
    This paper introduces and examines objectives and barriers that occur during the implementation of an energy management system (EnMS). It thereby presents the results of an empirical investigation regarding manufacturing enterprises in Germany conducted by the Fraunhofer Institute for Production Systems and Design Technology IPK. It further focuses on the context of German legislature and public facilitation made to promote energy efficiency. The results shall give recommendations where promotions made to energy efficiency should be aimed at and what potentials for improvement exist.
  • Publication
    Objectives and Barriers for the Implementation of Energy Management Systems in Manufacturing Enterprises in Germany: Results of an Empirical Investigation
    ( 2013)
    Jochem, Roland
    ;
    Karcher, Phillip
    ;
    Siemer, Markus
    This paper introduces and examines objectives and barriers that occur during the implementation of an energy management system (EnMS). It thereby presents the results of an empirical investigation regarding manufacturing enterprises in Germany conducted by the Fraunhofer Institute for Production Systems and Design Technology IPK. It further focuses on the context of German legislature and public facilitation made to promote energy efficiency. The results shall give recommendations where promotions made to energy efficiency should be aimed at and what potentials for improvement exist.
  • Publication
    Multi-disciplinary strategic research agenda for ICT-enabled energy efficiency
    (School of Civil and Building Engineering, 2012)
    Ellis, Keith
    ;
    Hassan, Tarek
    Das EU-geförderte Projekt REViSITE (Roadmap Enabling Vision and Strategy in ICT-Enabled Energy Efficiency) identifiziert branchenübergreifende Synergien m Verständnis, welche Technologien zur Nachhaltigkeit beitragen. Zudem werden branchenübergreifend Forschungsprioritäten identifiziert aus den Bereichen Stromnetz, Gebäude, Produktion und Beleuchtung.