Produceer met minder energie energy and ressource efficiency in production- ralf schlosser

© WZL/Fraunhofer IPT

Energy and Ressource Efficiency in Production

Seminar “Produceer met minder energie”

Dipl.-Ing. Ralf Schlosser,

Sirris Zwijnaarde, 08.11.11

Seite 2© WZL/Fraunhofer IPT

Summary5

Industrial Case Studies and Application of Sustainable Manufacturing4

Assessment of energy- and resource consumption within the BEAT Project3

Motivation2

Presentation WZL1

Agenda

Page 3© WZL/Fraunhofer IPT

RWTH Aachen and Fraunhofer-Gesellschaft

RWTH Aachen University Founded in 1870 33,000 students

Faculty of Mechanical Engineering 8,700 students

(incl. 1,800 first year students) 54 professors 2,600 employees 140 graduates per year

Fraunhofer-GesellschaftMore than 80 institutes und facilities

at 40 locations in Germany 18,000 employees approx. € 1.65 billion research funds

per year, € 1.4 billion through research contracts 3 institutes in Aachen


Production Technology in AachenLaboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University institute Founded in 1906 720 employees 16,000 m² offices and laboratories

Fraunhofer Institute for Production Technology IPT Fraunhofer-Gesellschaft institute Founded in 1980 365 employees 3,000 m² offices and laboratories Certified to DIN EN ISO 9001:2000 Partner in Boston/USA:

Fraunhofer Center for Manufacturing Innovation CMI


Grinding and forming

Solid forming,sheet metal forming, hard smooth rolling, tribology

Turning,milling,drilling,broaching

Cutting technology

CAD/CAMtechnologies

CAx technologies

Process and Manufacturing Technology

Process and productmonitoring

Materialremovalprocesses

Process moni-toring systems and strategies

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. mult. Fritz Klocke

Laser machining

Rapid Manufacturing

Laser surfacetreatment

Joining,cutting,forming

Tool and die making

Precision and micro technology

Optics and optical systems

Plant engineering and construction

Automotive, aerospace, turbine construction

Grinding,lapping,polishing,honing


Prof. Dr.-Ing. Dr.-Ing. E.h.Fritz Klocke

Dipl.-Ing. Dieter Lung Chiefengineer

Chair of Manufacturing Technology − Cutting Technology Department

Basics of Cutting

Dr.-Ing. KlausGerschwiler

Process and Process strategy development

Machinability investigations

Lubricoolant Supply Strategies

Dipl.-Ing.Ralf Schlosser

Modeling and Evaluationof

Cutting Processes

Process model development Cutting Simulation Calculation of the influence on

the work piece Micro cutting

6 Phd Students 1 Post Doc

4 Phd Students

1 Post Doc

7 Technicians

Tribology Processanalysis Tooldevelopment Microtechnology

Cutting durability tests

MetallographicInvestigations

Technology-Research Circle

Energy-/Ressourceefficiency Energetical Evaluation of

cutting processes Ecological

Lifecycle Management

2 Programmer 1 Apprentice

Prof. Dr.-Ing. Dr.-Ing. E.h.Dr. h.c. Dr. h.c. Fritz Klocke


Summary5



Motivation2

Presentation WZL1

Agenda


Motivation: Social and ecological boundary conditions

Source: J.Jeswiet, Bundesanstalt für Geowissenschaften und Rohstoffe 2000

1 200015001000500

Wor

ld p

opul

atio

n /b

il.

Population growth

4 bilions in 50 years

2 bilions in 45 years

1 bilion in 80 year500 Mio. in 200 years

0

1

2

3

4

5

6

7

8

Year

2025

1975

1930

18501650

For the future demand of the growing world population more products have to be manufactured with less energy and resources.

2000

Coal

Crude oil

Natural gas

Uranium

Iron

Copper

Zinc

Years 50 100 150 200

Resource availability


Higher body strength leads to weight reduction and to

a positive carbon footprint

Press hardened steelsConventional, high-strength and ultrahigh-strength steels

Press hardened steel provides higher strength in comparison to cold-formable steels and multilayer applications

Improved crash characteristics

Car body weight reduction of 9 kg

Press hardening of car bodies shown on the example of an Audi A4

-19

-60

-40

-20

0

20

Cha

nge

on th

e C

O2

-equ

ival

ent /

kg/

car

-53

15

-57

Positive carbon footprint already during product manufacturing – environment-friendly before roll-out

Material-production

ProductionUsage

Total

Source: AUDI AG


Life Cycle Assessment along the product life cycle Determination of material and energy

flows for all life cycle phases (according to DIN EN ISO 14040)

Calculation of environmental impacts (scientifically based characterisation factors)

Potential reduction of energy and material consumption in 2 ways:

– Identification of „hot spots“ → saving options can be deduced

– Better understanding and comparability of material and energy consumption for different machining processesRecycling/

Disposal

Energy

Resource

Waste

Emissions

Energy

Resource

Waste

Emission

Energy

Resource

Waste

Emissions

Energy

Resource

Waste

Emissions

Production

Use

Raw material extraction


Energy and tool costs in a cylinder head production

0

50

100

150

200

250

2000 2001 2002 2003 2004 2005 2006 2007

Costs for electrical energy Tool costs

Cos

ts /

%

Costs

24,2%

18,5%57,3%

Cooling lubricantCleaningMachining

Energy

Source: Volkswagen


Summary5



Motivation2

Presentation WZL1

Agenda


BMBF-Project BEAT: Assessment of energy efficiency of alternative processes and technology chains

Aims

Classification of manufacturing processes

Identification of inefficient processes

Holistic life cycle assessment of alternative processes and process chains

Our proceeding

Identification of the relevant balance shell

Detection of material and energy flows in manufacturing processes

Definition of criteria to evaluate the energy and resource efficiency of manufacturing processes

Pictures: FhG, WZL, Daimler, Bosch


Chart of the energy and resource flows within gear manufacturing Machine tools as the relevant balance shell for

the evaluation

Detection of all input and output quantities along the whole process chain

Multiple energy and material flows

Detection of central installations for process media supply


Section of the energy and material flow chart

Direct layerIndirect layer


Average power consumption Energy per part

Evaluation of the direct electrical energy flows in valve injectors

Turning

Washing

Heat treatment

Eroding

Rounding

Laser marking

Grinding

Deburring

Flow rate check

Optimisation of the highest power consumers doesn’t necessarily bring the best benefit.


Intermediate Summary The energy per functional unit (per part) is not only dependent from the average power

consumption of a process

Main influencing factors are also the manufacturing time and amount of parallel processed workpieces

Further investigation in the Projects BEAT will also discuss the topics:– Energy efficiency map of cutting processes– The effect of indirect energy by peripheral units as air conditioning, central lubricoolant supply,

central compressed air units– Holistic Life Cycle Assessment of all material and energy flows in the single processes and the

complete process chains within the GABI Software

www.beat-bmbf.de


Summary5



Motivation2

Presentation WZL1

Agenda


Short process chains reduce work in progress inventory, the processingtime, energy consumption per part and increase the process safety

Coil production

Gap partshearing

Die forgingI

Die forgingIII

Die forgingII

Blankshearing

Integratedheating

Gap part

Energy efficiency by process substitution

Coil production

Routeshearing Die forging Blade

shearing

Local heating and

compressing

RouteFinished part

Forged bolster

Punch scrap

Source: Zwilling J.A Henckels AG


Optimized machining strategy for the manufacturing of lubricating bores in cylinder heads

Lubricating bore: borehole depth: l = 520mm

bore diameter: d = 7mm

aspect ratio: l/d = 74

Essential approach: expanding the application of

solid carbide drills!

Conclusion: process time reduction

leads to essential energy saving

Source: MAN Diesel & Turbo

Old tool concept:HSS - Single-lip drill

cutting parametersf = 0.035 mm

New tool concept: Spiral solid carbide drill

cutting parametersf = 0.23 mm

1,74

0

5

10

-80%

NewOld

8.71

Mac

hini

ng ti

me

t/min

Tool concept

1.74


Increase in productivity by dry machining

status 2006

HSS-PMAlCrN 90 4 0.24

Cutting materialcoatingcutting speed. vc / m/minfeed fa / mmmax. chip thickness / mm

yesterday

HSS-PMAlCrN 150 4 0.24

today

HMAlCrN240 3 0.18

01234567

1999 2002 2005 2006 yesterday today

Tim

e pe

r par

t /m

in

Continuous improvement

Dry machiningWet machining

tomorrow

tomorrow

?

Leap in technology

Source: Daimler AG


Exhaust gas heat recovery

960° C process temperature

60m³ natural gas/ h → 120 kg CO2/ h

Technical heat generation only by gas

Heat exchanger installation on burner exhaust gas line, furnace cooling not yet used

Approx. 60 KW can be continuously fed back into the energy network

Source: Daimler AG

Ring hearth furnace Ring hearth furnace with heat recovery

Transparency creates simple optimization potentials

Technical heat network

heat reflow

heat input

consumer i

consumer …


Necessary ventilation power is predefined by machine manufacturer

Oversized and not adaptable plant ventilation

Regulation of machine and plant ventilation is not considered in the design

50% energy reduction for machine and plant ventilation through flexible installations

Integration of flexible machine and plant ventilation into the requirements

Plant ventilation

Machine ventilation

Energy saving potentials in machines and plants

Status before Status after

Inflexible machine und plant ventilation

Adaptable machine- und plant ventilation

Adaptable and flexible central installations

>30 Nm³/(m².h)

720 m³/h1800 m³/h

17 Nm³/(m².h)

Source: Daimler Trucks


Use of water in the automobile productionWater consumption within the BMW Group 2009: 3.2 Mio m³

Source: BMW Group 2011

Drinking water

Ground WaterProcess waste water

Evaporation

Sanitary waste water


Use of water in the automobile productionReduction of consumption of sanitary water

Source: BMW Group 2011

02468

10

86 100 2 124 14 16 18 20 22

Flow

rate

/(l/m

in)

24Time /s

Water consumption of a conventional tap:4 l water, 24 s runtime

Water consumption of a sensoral tap:2.2 l water, 15 s runtime

02468

10

18 20 2422Time /s

168 10 12 1460 2 4Fl

ow ra

te /(

l/min

)

Sensors within taps reduce the average water consumption during hand washing

about 45%

Picture: bau-web.de


Resource saving by reconditioning instead of recycling

Distributor pump Fuel-injector-mount combination

Fuel injection/ignitionStarter and generators

Serial reconditioning of starters and generators

Annual savings compared to production of new components:

– 85.000 MWh energy = 88% savings compared to new production 200.000 kg

350.000 kg

1.600.000 kg

58.000 kg

800.000 kg

4.300 kg

Copper

Aluminium

Steel

CO

CO2

SO2

“Back in Box”Disassembling

+Cleaning

Replacementof wear parts

Assembly +

Final check

Exchangeproduct

Source: Bosch


Summary5



Motivation2

Presentation WZL1

Agenda


Acknowledgements

We kindly acknowledge the support of the Project BEAT by