assistedshutdown

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0InternationalLicenseAnApproachtoIncreaseEnergyEiciencyUsingShutdownandStandbyMachineModesApostolosFysikopoulos,GeorgiosPastras,AikateriniVlachou,GeorgeChryssolourisTocitethisversion:ApostolosFysikopoulos,GeorgiosPastras,AikateriniVlachou,GeorgeChryssolouris.
AnApproachtoIncreaseEnergyEiciencyUsingShutdownandStandbyMachineModes.
IFIPInternationalConferenceonAdvancesinProductionManagementSystems(APMS),Sep2014,Ajaccio,France.
pp.
205-212,10.
1007/978-3-662-44736-9_25.
hal-01387868AnApproachtoIncreaseEnergyEfficiencyUsingShutdownandStandbyMachineModesA.
Fysikopoulosa,G.
Pastrasa,A.
Vlachoua,G.
Chryssolourisa*aLaboratoryforManufacturingSystemsandAutomation,DepartmentofMechanicalEngineeringandAeronautics,UniversityofPatras,Patras26500,Greece*Correspondingauthor.
Tel.
:+30-2610-997262;fax:+30-2610-997744.
E-mailaddress:xrisol@lms.
mech.
upatras.
gr.
Abstract.
Energyefficiencyconstitutesaverysignificantfactorthatrequiresitsinclusioninthemanufacturingdecisionmakingattributesdevelopingastrategytoproducemorewithless.
Theidlestateofamachinetoolisaninefficientphase.
Astrategytoincreasetheenergyefficiencyofanalreadybalancedproductionline,usingmachinetoolstand-byorshut-downmodes,duringtheidlephase,isbeingintroduced.
Thisstrategyidentifieswhentheapplicationofsuchmodesisgainfulfromanenergyefficiencypointofview,basedontheavailableidletimeandtheconsumptionofthemachineatthesemodes.
Keywords.
EnergyEfficiency,SustainableManufacturing,MachineTools,Pro-ductionPlanning,Scheduling1IntroductionThemanufacturingindustryisoneofthegreatestenergyconsumersandcarbonemittersintheworld[1].
Themanufacturingsectorisresponsibleforabout28%oftheprimaryenergyuse[3]andfor38%oftheCO2emissionsglobally[2].
Thus,energyandeco-efficiencyhasemergedasoneofthemostsignificantmanufacturingdecisionattributes[4],especiallyincountriesthatarenotenergyindependent[5].
Additionally,energyisanincreasinglyimportantcostfactorduetoitsincreasingprice[6].
Manufac-turingenterpriseshavetoreduceenergyconsumptionforbothcostsavingandenviron-mentalfriendliness,tryingtofindnewwaystoproduce"morewithless"[7]andfur-thermore,evolvefromthestrategy"maximumgainfromminimumcapital"to"maxi-mumgainfromminimumresources"[8].
Severalinitiativesonenergyefficiencyareon-going[9-11].
Energysavingmanage-ment,technologiesandpolicies/regulations[12]areusedtodealwiththeenergyeffi-ciencyissues[13].
Thestudyofenergyefficiencyinmanufacturingsystemscanbedividedintofourmainlevels(Fig.
1)[4].
Thestudyofeachlevelandtheirinter-levelinteractionsareimportantstepstowardstheeffectivestudyofenergyandeco-efficiencyhence,theneedforaholisticapproachisnecessary[4,14].
Fig.
1.
Energyefficiencyanalysisdivision[4]2EnergyEfficiencyatProductionLineLevelDecisionsonplanningandoperatingproductionsystemsaremainlybasedontradi-tionalmetricssuchastime,cost,qualityandflexibility[15].
Intermsofenergycost,alimitednumberofstudiesregardingtime-dependentindustrialplanning,underthepointofviewofelectricitycost,havebeenreported[17-19].
Severalreviewsoncommerciallyavailablemanufacturingsimulationtoolsrevealthattheydonotsupportenergyandeco-efficiencyindicatorsyet[20-22].
Fysikopoulosetal.
[16]haveincorporatedsimpleenergyformulasintoa"reallife"automotiveas-semblyline,withtheuseofdiscreteeventsimulation(DES).
DESincombinationwiththelifecycleassessment(LCA)methodwaspresentedbyJohansonetal.
[23].
Withthehelpofthismodel,theenergyaspectsofthelinealongwithotherperformancemeasures,havebeeninvestigated.
Wohlgemuthetal.
[22]suggestedanapproachfortheintegrationofDESandthematerialflowanalysisintoacomponent-basedframe-work,basedonasinglemodeltowardsacustomizedEnvironmentalManagementIn-formationSystem(EMIS).
Inthisframework,productionprocessesandallkindsofenergyandmaterialflowscanbeanalysedintermsofbotheconomicmeasuresandtheirenvironmentalimpacts.
Herrmannetal.
[20]presentedanenergyorientedsimu-lationmodelfortheplanningofmanufacturingsystems.
Theyreportedupto30%im-provementinenergyefficiencythroughsimulation-assistedprocessplanning.
Mouzonetal.
[24]developedmathematicalmulti-objectivemodelstoinvestigatetheproblemofschedulingjobs,onasingleCNCmachine,towardsthereductionoftimeandenergyconsumption.
Animpressiveoutcomeisthefindingthatwhenanon-bottleneckedmachineisturned-off,theenergyconsumptionsavingsmayreacheven80%.
Additionally,byforecastingtheinter-arrivaltimeoftheorders,significantsav-ingscanbeachievedwiththeuseofproperdispatchingrules.
Otherstudiesfocusonsocialandenvironmentalissuesandnotjustonenergyconsumption[25-28].
Itisevident[4,16,29,30,31]thatthereductionoftheidletimecansignificantlyassisttowardsenergyandeco-efficiency.
Drakeetal.
[32]havereportedsignificantenergyconsumptionduringmachineidletime.
Aspresentedin[30,33],inaproductionmachinetoolandgenerallyinamassproductionenvironment,thepercentageofenergyusedforfunctionsthatarenotdirectlyrelatedtotheactualproductionofparts,maybeashighas85%orevenmore.
However,"correct"orderdistribution(betterbatchandordersorganization)combinedwithearlyorperiodical"machineshutdown"cancon-siderablyreducetheidletime,whichisthemostinefficientstateofasystem[4].
Ad-ditionally,theincorporationofenergyconsumptionmeasuring,peakpowermanage-ment,monitoring,controllingandschedulingmayleadtobetterpredictionofthework-flowandthus,toimprovedenergysavings[4,34,35].
ThankstotheInformationandCommunicationTechnologies(ICT),innovativeproductionmanagementsystemscanbebuilttosupportenergyefficientmanufacturing[36].
3MachineToolsandEnergyEfficiencyThedemandforgreenermachinetoolscreatesnewchallengesforthemachinetoolbuilders.
Thestateoftheartinmachinetoolsistheuseofenergy-efficientcomponentsthatcanreduceenergyconsumptionduringidletimesupto65%[29].
Severalstudiesontheenergyefficiencyofmachinetoolsexist,regardingbothconventionalandnon-conventionalprocesses[30,37,38].
Besidestheprocessvariablesoptimisation,thede-velopmentofenergyandeco-efficientcomponentsisabasictaskformachinetoolbuilders[34].
Thefirststeptowardsimprovingtheenergyefficiencyofmachinetoolsistheiden-tificationofthepowerrequirementsfordifferentmachinetoolactivitiesandthecate-gorizationoftheperipheraldevices.
Fysikopoulosetal.
[4]indicatedthattheactualconsumedenergyrequiredforprocessingisexceededtoagreatextentbytheenergydemandoftherelatedperipheralequipment,especiallyforthelaserbasedprocesses.
Theanalysiscanbecomecomplex,sinceseveralperipheralsmaybesharedamongdif-ferentmachinesinthefactory.
Furthermore,theyconcludedthattheconsumptionofmachineperipheralspermanufacturedpartdependsonprocessvariablesthroughfac-torssuchasprocesstime.
Moreover,theoverallenergyconsumptioncanbesignifi-cantlyreduced,ifduringidletimes,theperipheralsgotoacompleteofforstand-byphase(energy-savingmode)byintegratingsimpletechnologicalfeatures.
Nowadays,machinetoolcontrolsareequippedwiththepossibilitiesofswitchingthemachineintoenergy-savingmodesoreventoshuttingitdowncompletely[39-41].
Thesenewma-chinetoolcapabilitiescanbeusedforthesignificantreductionofaproductionline'senergyconsumption.
4AStrategytoGainEnergyUsingShut-downandStand-by(energy-saving)ModesInpractice,itisnotpossibletoperfectlymatchtheoutputratesofalltheresourcesinaflowlinethus,atleastsomeresourcesremainidleforsometime.
Theissueistoimplementshut-downandstand-bymodesinaproductionlinewhichhasalreadybeingoptimisedintermsofidletime.
Ithastobenotedthattheincorporationofsuchmodesisnotalwaysgainfulandactually,itmaynotevenbepossible,dependingontheidletimeavailable.
Whileamachineisinidlemode,itusuallyconsumesaconstantpower(Pidle).
Thus,theenergywastedintheidlemodeisequaltoEidle=Pidlet,wheretistheidletimeavailable.
Providedthatthemachinewasswitched-off,thisconstantconsumptionwouldhavebeenavoided;however,therewouldbeaperiodofmaximumpowerconsumption,nec-essarytostartupthemachineforitsnexttask.
Itisassumedthatthedurationoftheshut-downandstart-upproceduresisequaltotstartupandthatthecorrespondingenergyconsumptionisequaltoEstartup.
Then,theenergyconsumediftheshut-downmodeisusedequalsEshutdown=Estartupanditispossibleonlyifthetimeavailableislargerthantstartup.
Fromtheabovearguments,itisevidentthattheincorporationoftheshut-downmodeisprofitableonlywhenEshutdowntcr2.
AlltheaboveargumentsaresummarizedinFig.
2.
Fig.
2.
Anindicativediagramfortheenergyconsumptionofamachineduringnon-workingtimeperiodsunderdifferentavailablemodesAccordingtowhatwasanalysedabove,astrategytogainenergyusingtheshut-downandstand-bymodescanbespecified.
Foreverymachine,theidletimedurationspredictedbysuitablesimulationmethodhavetobecomparedwiththecriticaltimestcr1andtcr2andthentheresourcehasto:1.
beshut-down,iftheidletimeislargerthantcr22.
beswitchedtostand-bymode,iftheidletimeliesbetweentcr1andtcr23.
remainidle,iftheidletimeissmallerthantcr1Theprocedurehastoberepeatedforeveryresource.
AlogicaldiagramshowingtheaboveforasystemconsistingofNresourcesisdepictedinFig.
3.
Ithastobenotedthatintheproposedmethod,theshutting-downorswitchingtoastand-bymodeisnotper-formedmanually,butonthecontrary,theseactionsarescheduledduringtheproductionplanningstage.
Fig.
3.
Abasiclogicdiagramdescribingthedecisionprocessforincorporationofshut-downandstand-bymodes5ConclusionsInthisstudy,astrategytoincreasetheenergyefficiencyofanalreadybalancedpro-ductionline,usingthemachine'stoolstand-by(energysaving)orshut-down(com-pletelyturned-off)modes,duringidletime,wasintroduced.
Themainoutcomescanbesummarisedasfollowing:Energyefficiencymetricsshouldbeincludedinthecommerciallyavailablemulti-objectiveoptimizationdecisionsupportsystems.
Applicationoftheshut-downorstand-bymodesisnotalwaysprofitable.
Itdependsontheavailableidletime,theenergyconsumptionforstartingupandwakingup,aswellasthepowerconsumptionduringtheidleandstand-bymodes,asdescribedinSection4anddepictedinFig.
2.
Applicationoftheshut-downorstand-bymodescanbegainfulintermsofenergyandconsequently,intermsoftherelatedenergycosts.
Sincetheinclusionofenergysavingmodesintheproductionschedulecanbegain-ful,themachinetoolbuildersshouldincorporatetherequiredsimpletechnologicalfeaturesintotheirmachines.
Machinetoolbuildersshouldbecarefulwhenincorporatingastand-byfunctionintotheirmachines.
Dependingonthestand-bypowerconsumptionandthenecessarywake-upenergy,theuseofthismodemayneverbepreferableovertheidleorshut-downmode(whentcr1>tcr2).
Futureworkwillfocusonmethodstoarrangethescheduleofaproductionlinesothatthedurationoftheidlestatesisallowingtheuseofenergysavingmodes.
Suchmethodswillleadtomaximumutilisationofthesemodesandthus,oftherelatedenergyandenergycostgains.
Moreover,themethodisgoingtobevalidatedinarealindustrialcasestudy.
6AcknowledgementsTheworkreportedinthispaperwassupportedbythecollaborativeprogramentitled"EnergyEfficientProcessplanningSystem–ENEPLAN",whichisundertheseventhframeworkprogram-FoF.
NMP.
2011-1:TheEco-Factory:cleanerandmoreresource-efficientproductioninmanufacturingProgram.
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