A tool for assessing the energy demand and efficiency of machining systems: Energy benchmarking

Abstract Energy benchmarking has been recognized as an effective analytical methodology and management tool to improve energy efficiency and performance. Many approaches to energy benchmarking have been applied in various fields. Machining systems, which are widely distributed and consume large amounts of energy with low efficiency, possess considerable potential for reductions in energy consumption. However, current research regarding the use of energy benchmarking for machining systems is insufficient due to the complexity and variety of energy consumption processes used in these systems. This paper proposes the use of energy benchmarking to strengthen the evaluation of energy demand and achieve efficiency improvements for machining systems. First, it analyses drivers for energy benchmarking and their characteristics. Next, an energy benchmarking framework for machining systems is presented. Then the concepts of the static, dynamic, single-objective, multi-objective, product-based, and process-based energy benchmarking are discussed from three different perspectives: the motion, object and application level. This lays a theoretical foundation for further energy benchmarking research. Finally, methods for developing energy benchmarking are also addressed including the prediction method, statistical analysis and expert decision. The application of these methods to a real machining plant allows an analysis of the practicability of potentially saving energy through benchmarking.

[1]  Malcolm Powell,et al.  Benchmarking comminution energy consumption for the processing of copper and gold ores , 2014 .

[2]  Liu Shuang,et al.  Multi-period Energy Model of Electro-mechanical Main Driving System during the Service Process of Machine Tools , 2012 .

[3]  Ernst Worrell,et al.  Empirical investigation of energy efficiency barriers in Italian manufacturing SMEs , 2013 .

[4]  Mario Martín-Gamboa,et al.  Environmental benchmarking of wind farms according to their operational performance , 2013 .

[5]  Lee-Ing Tong,et al.  Forecasting nonlinear time series of energy consumption using a hybrid dynamic model , 2012 .

[6]  J Krampe,et al.  Energy benchmarking of South Australian WWTPs. , 2013, Water science and technology : a journal of the International Association on Water Pollution Research.

[7]  Tao Wu,et al.  An energy-responsive optimization method for machine tool selection and operation sequence in flexible machining job shops , 2015 .

[8]  Yanzhong Zhang,et al.  Benchmarking Analysis of Energy Efficiency Indicators in Paper Mill , 2016 .

[9]  Wei Cai,et al.  Fine energy consumption allowance of workpieces in the mechanical manufacturing industry , 2016 .

[10]  Sangkee Min,et al.  Development of an energy consumption monitoring procedure for machine tools , 2012 .

[11]  J. Haider,et al.  Measurement of specific cutting energy for evaluating the efficiency of bandsawing different workpiece materials , 2009 .

[12]  Chen Peng,et al.  Minimising the machining energy consumption of a machine tool by sequencing the features of a part , 2017 .

[13]  Paul Mativenga,et al.  Critical factors in energy demand modelling for CNC milling and impact of toolpath strategy , 2014 .

[14]  P. Sheng,et al.  An analytical approach for determining the environmental impact of machining processes , 1995 .

[15]  Andrew Jarvis,et al.  Strategies for Minimum Energy Operation for Precision Machining , 2009 .

[16]  Lin Li,et al.  Energy requirements evaluation of milling machines based on thermal equilibrium and empirical modelling , 2013 .

[17]  Sami Kara,et al.  Towards Energy and Resource Efficient Manufacturing: A Processes and Systems Approach , 2012 .

[18]  Shilei Lu,et al.  Energy consumption quota of four and five star luxury hotel buildings in Hainan province, China , 2012 .

[19]  Mingqi Liu,et al.  Constructing an energy efficiency benchmarking system for coal production , 2016 .

[20]  Santanu Bandyopadhyay,et al.  Benchmarking energy consumption for dump trucks in mines , 2014 .

[21]  Xiaoling Zhang,et al.  Benchmarking the building energy consumption and solar energy trade-offs of residential neighborhoods on Chongming Eco-Island, China , 2016 .

[22]  Athulan Vijayaraghavan,et al.  Automated energy monitoring of machine tools , 2010 .

[23]  Yanping Liao.  Multi-objective Aerodynamic and Stealthy Performance Optimization Based on Multi-attribute Decision Making , 2012 .

[24]  Marek Balazinski,et al.  An Energy Based Analytical Force Model for Orthogonal Cutting of Metal Matrix Composites , 2004 .

[25]  Mahesh Mani,et al.  Impact of Energy Measurements in Machining Operations , 2010 .

[26]  Jörg Franke,et al.  Methods-Energy Measurement – An approach for sustainable energy planning of manufacturing technologies , 2016 .

[27]  Wei Cai,et al.  Development of dynamic energy benchmark for mass production in machining systems for energy management and energy-efficiency improvement , 2017 .

[28]  G. Rutelli,et al.  Tool wear monitoring based on cutting power measurement , 1990 .

[29]  Ernst Worrell,et al.  Benchmarking energy use in the paper industry: a benchmarking study on process unit level , 2013 .

[30]  Renzhong Tang,et al.  Pareto fronts of machining parameters for trade-off among energy consumption, cutting force and processing time , 2017 .

[31]  Fei Liu,et al.  Multi-objective optimization of machining parameters considering energy consumption , 2013, The International Journal of Advanced Manufacturing Technology.

[32]  Jean-Thomas Bernard,et al.  The measurement of the energy intensity of manufacturing industries: a principal components analysis , 2005 .

[33]  Sung-Hoon Ahn,et al.  Empirical power-consumption model for material removal in three-axis milling , 2014 .

[34]  Sung-Hoon Ahn,et al.  Towards greener machine tools – A review on energy saving strategies and technologies , 2015 .

[35]  Gui-Bing Hong,et al.  Energy efficiency benchmarking of energy-intensive industries in Taiwan , 2014 .

[36]  David Dornfeld,et al.  Energy Consumption Characterization and Reduction Strategies for Milling Machine Tool Use , 2011 .

[37]  Joost Duflou,et al.  Optimization of energy consumption and surface quality in finish turning , 2012 .

[38]  Sung-Hoon Ahn,et al.  Control of machining parameters for energy and cost savings in micro-scale drilling of PCBs , 2013 .

[39]  David Webb,et al.  Predicting Energy Performance of a Net-Zero Energy Building: A Statistical Approach. , 2016, Applied energy.

[40]  U. N. Gaitonde,et al.  Model based energy benchmarking for glass furnace , 2007 .

[41]  Sami Kara,et al.  Energy Monitoring in Manufacturing Companies – Generating Energy Awareness through Feedback , 2012 .

[42]  Fei Liu,et al.  A novel approach for acquiring the real-time energy efficiency of machine tools , 2017 .

[43]  Paul Mativenga,et al.  Specific energy based evaluation of machining efficiency , 2016 .

[44]  Stefan Velchev,et al.  Empirical models for specific energy consumption and optimization of cutting parameters for minimizing energy consumption during turning , 2014 .

[45]  Wei Cai,et al.  An energy management approach for the mechanical manufacturing industry through developing a multi-objective energy benchmark , 2017 .

[46]  Jing Li,et al.  Energy consumption model and energy efficiency of machine tools: a comprehensive literature review , 2016 .

[47]  Hsiao-Tien Pao,et al.  Forecasting energy consumption in Taiwan using hybrid nonlinear models , 2009 .

[48]  Yan He,et al.  Characteristics of Additional Load Losses of Spindle System of Machine Tools , 2010 .

[49]  Christoph Herrmann,et al.  Energy efficiency benchmarking for injection moulding processes , 2015 .

[50]  K. P. Pandey,et al.  Improving energy productivity in paddy production through benchmarking—An application of data envelopment analysis , 2006 .

[51]  Fei Liu.  The Complexity and Strategy for Establishing Product Energy Consumption Allowance in Discrete Manufacturing Industry , 2015 .

[52]  R. Paul Singh,et al.  Energy benchmarking of warehouses for frozen foods , 2008 .

[53]  Karel Berka,et al.  Quantum Chemical Benchmark Energy and Geometry Database for Molecular Clusters and Complex Molecular Systems (www.begdb.com): A Users Manual and Examples , 2008 .

[54]  S. Kara,et al.  Electricity Metering and Monitoring in Manufacturing Systems , 2011 .

[55]  Wei Cai,et al.  An energy-consumption model for establishing energy-consumption allowance of a workpiece in a machining system , 2016 .

[56]  Jeffrey B Dahmus,et al.  Thermodynamic analysis of resources used in manufacturing processes. , 2009, Environmental science & technology.

[57]  Konrad Wegener,et al.  The Total Energy Efficiency Index for machine tools , 2016 .

[58]  Enrique Mateos-Espejel,et al.  Base case process development for energy efficiency improvement, application to a Kraft pulping mill. Part II: Benchmarking analysis , 2011 .

[60]  Xin Yao,et al.  Multi-scale statistical process monitoring in machining , 2005, IEEE Transactions on Industrial Electronics.

[61]  Sami Kara,et al.  Unit process energy consumption models for material removal processes , 2011 .

[62]  End Use.  Annual energy review , 1984 .

[63]  H. Shao,et al.  A cutting power model for tool wear monitoring in milling , 2004 .

[64]  Shun Jia,et al.  Therblig-based energy supply modeling of computer numerical control machine tools , 2014 .

[65]  Congbo Li,et al.  An integrated method for assessing the energy efficiency of machining workshop , 2013 .

[66]  Konrad Wegener,et al.  Methods for evaluation of energy efficiency of machine tools , 2015 .

[67]  Lihui Wang,et al.  Optimization of machining processes from the perspective of energy consumption: A case study , 2012 .

[68]  Janet M. Twomey,et al.  Operational methods for minimization of energy consumption of manufacturing equipment , 2007 .

[69]  Andrea Trianni,et al.  Exploring drivers for energy efficiency within small- and medium-sized enterprises: First evidences from Italian manufacturing enterprises , 2013 .

[70]  Yan He,et al.  An on-line approach for energy efficiency monitoring of machine tools , 2012 .

[71]  Laine Mears,et al.  Energy, economy, and environment analysis and optimization on manufacturing plant energy supply system , 2016 .