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Equipment Availability and
Energy Efficiency – a
Contradiction?
Verfügbarkeit und Energieeffizienz im
Widerspruch?
Dr. Patrick Reichen
March 5, 2015
2 | © Bühler |
Energy Efficiency vs. Availability
Energy consumption 12.9 kWh/100km
Energy efficiency label A
Empty weight 1270 kg
Power 125 PS
Acceleration 7.2 s
Availability ?
Energy consumption ~207 kWh/100km
Energy efficiency label ?
Empty weight 2903 kg
Power 300 PS
Acceleration 11.0 s
Availability ?
Source: Hummer, H2
Higher dynamics, stiffness, faster movements require more energy!
Source: BMW, i3
15th International Die Casting Conference | Bad Homburg | March 5, 2015
3 | © Bühler |
Energy Efficiency Becomes Important
Financial and political drives favor energy efficient processes
Trend to higher energy cost
Commitment of Bühler to decrease energy consumption by 25% until 2020
Gas
0
0.02
0.04
0.06
0.08
0.1
0.12
€/kWh
EU Average Germany France
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0.05
€/kWh
EU Average Germany France
Gas price increased by 86% since 2004 Electricity increased by 45% since 2004
Source: Price development for industrial consumers, Eurostat
15th International Die Casting Conference | Bad Homburg | March 5, 2015
4 | © Bühler |
Agenda
1
2
3
Effective Energy Consumption of DC Cells
Cost Impact: Availability vs. Energy Efficiency
Standardized Energy Consumption of DCM
15th International Die Casting Conference | Bad Homburg | March 5, 2015
source: IHK source: Fotolia source: Autoweek NL
5 | © Bühler |
Principles of the VDMA Cycle
Part and die independent measure of a die casting machine
Measure for a DCM and NOT a DC Cell
Energy consumption of peripheral components (die tempering, dosing,
spraying, etc.) are not considered
Represents a process near cycle!
Applicable to hot and cold chamber DCM
15th International Die Casting Conference | Bad Homburg | March 5, 2015
“The VDMA-Specification was elaborated by a working group of the Foundry
Machinery Association within VDMA, because manufacturers of pressure metal
diecasting machines were increasingly asked for energy efficiency and power
consumption. This VDMA-Specification describes a standardized procedure to
measure energy, whose boundary conditions and the documentation of the results
considering in equal measure the interests of both manufacturer and equipment-
user.” according to VDMA24499
6 | © Bühler |
Standardized Reference Cycle
Process steps 1 2 3 4 5 6 7 8 9 10 11 1
Die Closing
Dosing Time1)
Plunger Forward
Solidification Time1)
Die Opening
Ejector Forward
Extracting Time1)
Ejector Backward
Spraying Time1)
Plunger Backward
Waiting Time2)
Cycle 1 Cycle 2
1) Process-related times defined according
to machine size
2) Time for the DCM to reach status “ready
for next cycle”
for cold chamber DCM only
15th International Die Casting Conference | Bad Homburg | March 5, 2015
7 | © Bühler |
VDMA Standard Cycle for a DCM
Dosing time Plunger Forward
Solidification time
Die Opening/Ejector
Extraction Time
Ejector Backward
Spraying Time
Plunger Backward
VDMA Reference Cycle
Die Closing
15th International Die Casting Conference | Bad Homburg | March 5, 2015
8 | © Bühler |
VDMA Test Report for DCM
“Energy Certificate” for DCM
Disclosure of key information
Machine size: Carat 320c
Energy consumption:1.615 kWh/cycle
Cycle Time: 84.7 s
Represents a process near cycle
NOT a dry cycle!
15th International Die Casting Conference | Bad Homburg | March 5, 2015
9 | © Bühler |
Agenda
1
2
3
Effective Energy Consumption of DC Cells
Cost Impact: Availability vs. Energy Efficiency
Standardized Energy Consumption of DCM
15th International Die Casting Conference | Bad Homburg | March 5, 2015
10 | © Bühler |
Confidential
Goal: in depth evaluation of the total energy consumption
Focus on electrical energy, compressed gas and cooling water
Results measured in specific energy consumption (related to part weight)
Effective Energy Consumption How to benchmark energy consumption in a real production environment?
Energy Consumption (complete factory 100%)
Al Preparation
DC Cell
DC Machine
50%
12%
1-3%
Definition Boundary
Conditions Definition of Parts
15th International Die Casting Conference | Bad Homburg | March 5, 2015
11 | © Bühler |
Confidential
Results Energy Measurement Protocol
Document to show the current energy
consumption of a specific process
Equipment and product dependent
protocol
15th International Die Casting Conference | Bad Homburg | March 5, 2015
12 | © Bühler |
Confidential
Results For oil pan, bedplate, shock tower
Approx. Machine Size ~800t ~1800t ~2800-4000t
Values for 1 part Oil pan Bedplate Shock Tower
Electrical [kWhelec/cycle] 1.542 3.879 3.870
Air [Nm3/cycle] 3.407 0.378 6.972 0.774 4.479 0.497
Cooling Water [kWhth/cycle] 0.893 0.013 2.183 0.033 2.159 0.033
Total Energy [kWh/cycle] 1.934 4.685 4.400
Specific Energy [kWh/kg]* 0.921 0.509 0.969
25.0%
13.5%
36.6%
14.0%
2.0% 1.3%
7.7%
31.3%
15.0% 39.8%
4.9% 0.3%
2.8% 5.9%
41.7%
10.5%
32.9%
5.6%
1.1% 2.0% 6.2%
Oil Pan Bedplate Shock Tower
DCM
Spraying
Die Tempering
Press
Extraction
Robot
Part Cooling Dosing Furnace
* part weight
15th International Die Casting Conference | Bad Homburg | March 5, 2015
13 | © Bühler |
Confidential
Agenda
1
2
3
Effective Energy Consumption of DC Cells
Cost Impact: Availability vs. Energy Efficiency
Standardized Energy Consumption of DCM
15th International Die Casting Conference | Bad Homburg | March 5, 2015
14 | © Bühler |
Confidential
Availability Known as OEE Calculation of OEE Downtime: 93.2 min Planned Production: 660 min
𝑂𝐸𝐸 =567 𝑚𝑖𝑛
660 𝑚𝑖𝑛×
405𝑝
410.7𝑝×
391 𝑝
405 𝑝 = 0.818
Theoretical cycle time: 82.8 s
# of produced parts: 405 parts
# of parts out of spec: 14 parts
Required Information of planned
production time:
0.859 0.986 0.965
**Results based on measurements on Carat180 – 7.7.2014
# of parts that should have been produced in the
available time (uptime/theo. cycle time)
5 automatic
4 semi-automatic
3 manual
2 setup
1 off
0 emergency off
15th International Die Casting Conference | Bad Homburg | March 5, 2015
15 | © Bühler |
Impact on Cost and Energy Savings Based on energy measurement of a standard die casting cell
1) Personal and structural, maintenance, capital, consumables, die
Impact of OEE improvement much bigger on the costs per part
15th International Die Casting Conference | Bad Homburg | March 5, 2015
18.9%
1.5%
10x higher impact!
15%
e.g. OEE from 0.6 0.75; Energy reduction by 15%
A) Cost for machine utilization1) 150.- €/h f(OEE)
B) Energy costs 0.09 €/kWh f(OEE, Energy)
Production: 7.728 kWh/cycle, Stand-by: 4.694 kWh/cycle
16 | © Bühler |
Summary
15th International Die Casting Conference | Bad Homburg | March 5, 2015
Improvement of OEE with higher impact on cost savings
Effective energy consumption as specific value
Quality requirements
Availability of an installation
Hardware configuration
Comparison of different systems only by standardized procedures
e.g. VDMA 24499 for DCM
Equipment Availability and Energy Efficiency – a Contradiction? – No!!
17 | © Bühler |
www.buhlergroup.com
18 | © Bühler |
For further questions – Please contact:
15th International Die Casting Conference | Bad Homburg | March 5, 2015
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