Energy-Flow Methodology for Thermodynamic Analysis of Manufacturing Processes: A Case Study of Welding Processes

2012 ◽  
Vol 326-328 ◽  
pp. 366-371 ◽  
Author(s):  
D. Zambrana ◽  
A. Aranda ◽  
G. Ferreira ◽  
F. Barrio
Keyword(s):  
Energy Consumption ◽  
Production Line ◽  
Energy Flow ◽  
Manufacturing Industry ◽  
High Energy ◽  
Manufacturing Processes ◽  
High Quality ◽  
Energy Unit ◽  
Welding Processes

Manufacturing processes involve the input of high quality energy and/or dissipation of low quality energy to manipulate a material; similarly the input of high quality material usually leads to the generation of low quality materials. A useful output involves the operation of conventional processes including a wide variety of functions such as lubrication, air compression, cooling, heating, pumping, etc., which have, on the one hand, high energy and material consumption and, on the other hand, losses due to an inherent departure from reversible processes. This paper presents an energy-flow methodology to determine the ratio between the additional energy required per useful energy unit for the manufacturing processes. As an application of the method proposed in this work, an assembly and welding production line is shown as a case study. This process is a common technique used in the manufacturing industry and its energy consumption depends on several parameters e.g. heat and electrical input. As a result of this study, the energy consumption of the production line has been reduced by approximately 30% from the 645.94 Wh of total energy consumption, where the consumption of real useful energy is 4% of this total.

scholarly journals Implementation of Digital Twin for Engine Block Manufacturing Processes

2020 ◽  
Vol 10 (18) ◽  
pp. 6578
Author(s):  
Roman Bambura ◽  
Marek Šolc ◽  
Miroslav Dado ◽  
Luboš Kotek
Keyword(s):  
Real Time ◽  
Production Line ◽  
Manufacturing Industry ◽  
Real Life ◽  
Engine Block ◽  
Manufacturing Processes ◽  
Production Plant ◽  
Implementation Framework ◽  
Digital Twin ◽  
Programmable Logic Control

The digital twin (DT) is undergoing an increase in interest from both an academic and industrial perspective. Although many authors proposed and described various frameworks for DT implementation in the manufacturing industry context, there is an absence of real-life implementation studies reported in the available literature. The main aim of this paper is to demonstrate feasibility of the DT implementation under real conditions of a production plant that is specializing in manufacturing of the aluminum components for the automotive industry. The implementation framework of the DT for engine block manufacturing processes consists of three layers: physical layer, virtual layer and information-processing layer. A simulation model was created using the Tecnomatix Plant Simulation (TPS) software. In order to obtain real-time status data of the production line, programmable logic control (PLC) sensors were used for raw data acquisition. To increase production line productivity, the algorithm for bottlenecks detection was developed and implemented into the DT. Despite the fact that the implementation process is still under development and only partial results are presented in this paper, the DT seems to be a prospective real-time optimization tool for the industrial partner.

scholarly journals Performance Evaluation Using Multivariate Non-Normal Process Capability

Processes ◽  
2019 ◽  
Vol 7 (11) ◽  
pp. 833 ◽  
Author(s):  
Alatefi ◽  
Ahmad ◽  
Alkahtani
Keyword(s):  
Manufacturing Industry ◽  
Process Capability ◽  
Quality Characteristic ◽  
Process Capability Indices ◽  
Manufacturing Processes ◽  
Capability Indices ◽  
Skewness Reduction ◽  
Quality Of Products

Process capability indices (PCIs) have always been used to improve the quality of products and services. Traditional PCIs are based on the assumption that the data obtained from the quality characteristic (QC) under consideration are normally distributed. However, most data on manufacturing processes violate this assumption. Furthermore, the products and services of the manufacturing industry usually have more than one QC; these QCs are functionally correlated and, thus, should be evaluated together to evaluate the overall quality of a product. This study investigates and extends the existing multivariate non-normal PCIs. First, a multivariate non-normal PCI model from the literature is modeled and validated. An algorithm to generate non-normal multivariate data with the desired correlations is also modeled. Then, this model is extended using two different approaches that depend on the well-known Box–Cox and Johnson transformations. The skewness reduction is further improved by applying heuristics algorithms. These two approaches outperform the investigated model from the literature because they can provide more precise results regardless of the skewness type. The comparison is made based on the generated data and a case study from the literature.

Overview of Energy Consumption Model for Manufacturing Processes

2011 ◽  
Vol 130-134 ◽  
pp. 2288-2293 ◽  
Author(s):  
Bing Bing Li ◽  
Hong Chao Zhang ◽  
Qing Di Ke ◽  
Li Ding ◽  
Lei Zhang
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Energy Flow ◽  
Flow Analysis ◽  
Manufacturing Processes ◽  
Comprehensive Overview ◽  
Improve Energy Efficiency ◽  
Energy Consumption Model ◽  
Whole Life Cycle ◽  
Collection Methods

The energy consumption for manufacturing processes is the largest impact contributor in various characterization categories, based on the assessment of environmental effects during the whole life cycle. It is necessary to investigate the manufacturing processes in depth to find out mechanism that can improve energy efficiency. This paper presents a comprehensive overview on two important aspects of energy consumption models for manufacturing processes: 1) two data collection methods: top-down and bottom-up; 2) two process-based analytical methods: thermodynamic model (including energy flow analysis and exergy analysis), and mechanical model. These models can improve energy efficiency.

Comparison of Different Scenarios Using Computer Simulation to Improve the Manufacturing System Productivity: Case Study

2013 ◽  
Vol 845 ◽  
pp. 770-774 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Milad Hatami ◽  
J.M. Rohani ◽  
H. Mihanzadeh ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Waiting Times ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Resource

In the manufacturing industry, managers and engineers are seeking to find methods in order to eliminate the common problems in manufacturing systems such as bottlenecks and waiting times. This is because that all of these kinds of problems impose extra cost to the companies. In addition, manufacturing companies are striving to sustain their competitiveness by improving productivity, efficiency and quality of manufacturing industry for instance high throughput and high resource utilization. The paper concentrates on the application of computer simulation to analysis manufacturing system in order to improve the productivity. Therefore, this study introduces a color manufacturing line as a case study and the basic application of arena 13.9 software. The goal of this paper is to improve the productivity and efficiency of the production line by using computer simulation. To achieve this goal, first the basic model of the current situation of production line was simulated. Second, three different alternatives were simulated and modified to find the best scenario based on the maximum productivity and minimum total cost.

scholarly journals Research on the channels for creation and development of high-quality “green manufacturing” brands — a case study of Xiamen

2021 ◽  
Vol 257 ◽  
pp. 03081
Author(s):  
Xiujuan Zhang ◽  
Pingyuan Zhao
Keyword(s):  
Manufacturing Industry ◽  
Rapid Development ◽  
Green Manufacturing ◽  
Design Guidelines ◽  
Ecological Impacts ◽  
High Quality ◽  
The World ◽  
Global Vision ◽  
Further Development

as the manufacturing industry gains momentum around the world, the conflicts between its rapid development and the accompanying consumption of materials, discharge of wastes and ecological impacts spiral. Governments around the world have explored measures and made achievements in alleviating the dual pressures from economic growth and environmental degradation. As for the overall trend of the manufacturing industry, creating and developing “green manufacturing” brands is the only way for the manufacturing industry to achieve further development. It is of great significance to design guidelines for green manufacturing from the angle of branding, the green notion provides more profundity and the soul to brands, ensuring sustainable development of brands. The development of green brands in Xiamen has adopted a global vision and related to the local realities, which would provide lessons for high-quality development of green manufacturing brands in other places.

scholarly journals EVALUATION OF ENERGY-EFFICIENT RETROFIT POTENTIAL FOR GOVERNMENT OFFICES IN INDIA

2021 ◽  
Vol 6 (2) ◽  
pp. 03-17
Author(s):  
Gazal Dandia ◽  
◽  
Pratheek Sudhakaran ◽  
Chaitali Basu ◽  
◽  
...  
Keyword(s):  
Energy Consumption ◽  
Total Energy ◽  
Energy Efficient ◽  
Energy Demand ◽  
Energy Savings ◽  
High Energy ◽  
Payback Period ◽  
Total Energy Consumption ◽  
The Cost

Introduction: High energy consumption by buildings is a great threat to the environment and one of the major causes of climate change. With a population of 1.4 billion people and one of the fastest-growing economies in the world, India is extremely vital for the future of global energy markets. The energy demand for construction activities continues to rise and it is responsible for over one-third of global final energy consumption. Currently, buildings in India account for 35% of total energy consumption and the value is growing by 8% annually. Around 11% of total energy consumption are attributed to the commercial sector. Energy-efficient retrofitting of the built environments created in recent decades is a pressing urban challenge. Presently, most energy-efficient retrofit projects focus mainly on the engineering aspects. In this paper, we evaluate various retrofitting options, such as passive architectural interventions, active technological interventions, or a combination of both, to create the optimum result for the selected building. Methods: Based on a literature study and case examples, we identified various energy-efficient retrofit measures, and then examined and evaluated those as applied to the case study of Awas Bhawan (Rajasthan Housing Board Headquarters), Jaipur, India. For the evaluation, we developed a simulation model using EQuest for each energy measure and calculated the resultant energy savings. Then, based on the cost of implementation and the cost of energy saved, we calculated the payback period. Finally, an optimum retrofit solution was formulated with account for the payback period and ease of installation. Results and discussion: The detailed analysis of various energy-efficient retrofit measures as applied to the case study indicates that the most feasible options for retrofit resulting in optimum energy savings with short payback periods include passive architecture measures and equipment upgrades.

scholarly journals Integration of FMECA and statistical snalysis for predictive maintenance

2021 ◽  
Vol 2 (1) ◽  
pp. 33
Author(s):  
Rabia Ghani
Keyword(s):  
Production Line ◽  
Manufacturing Industry ◽  
Failure Modes ◽  
Remaining Useful Life ◽  
Predictive Maintenance ◽  
Time To Failure ◽  
Failure Data ◽  
Criticality Analysis

<p>The estimation of time-to-failure of machines is of utmost importance in the Manufacturing Industry. As the world is moving towards Industry 4.0, it is high time that we progress from the traditional methods, where we wait for a breakdown to occur, to the prognostics based methods. It is the need of the era to be aware of any incident before it occurs. This study provides application of Statistical-based Predictive maintenance. A BOPP Production line has been considered as a case study for this research. Since the inception of the line in 2013, it is evident that 60% of breakdowns are due to lack of maintenance and timely replacement of bearings. Therefore, the research is based on the application of FMECA (Failure Modes, Effects and Criticality Analysis) to determine which bearing in the production line is most prone to failure and determination of which statistical model best fits the failure data of the most critical bearing. The result provides the best distribution fit for the failure data and the fit can be utilized for further study on RUL (Remaining Useful Life) of the bearing through Bayesian Inference.</p>

scholarly journals A Novel Reconstruction Approach to Elevator Energy Conservation Based on a DC Micro-Grid in High-Rise Buildings

Energies ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 33 ◽  
Author(s):  
Yongming Zhang ◽  
Zhe Yan ◽  
Feng Yuan ◽  
Jiawei Yao ◽  
Bao Ding
Keyword(s):  
Energy Consumption ◽  
Energy Conservation ◽  
High Energy ◽  
Energy Storage Devices ◽  
Storage Devices ◽  
High Rise ◽  
Field Data Collection ◽  
Micro Grid ◽  
Save Energy

Elevators were reported to cause an important part of building energy consumption. In general, each elevator has two operation states: The load state and power regeneration state. During operation, it has the potential to save energy by using regeneration power efficiently. In existing research, a set of energy storage devices are installed for every elevator, which is highly costly. In this paper, an energy conservation approach for elevators based on a direct current (DC) micro-grid is proposed, which has better economy. Then, an innovative energy-efficient device for the elevator group is designed based on a supercapacitor with similar characteristics and lifetimes. In a high-rise building case study, the experimental test and field data collection show that the innovative approach could result in a high energy efficiency within 15.87–23.1% and 24.1–54.5%, respectively. It is expected that the proposed method and designed device could be employed practically, saving energy consumption for elevator reconstruction.

Dynamic Balancing Analysis of the Armature in an Automobile Starting Motor: An Industrial Case Study

2011 ◽  
Author(s):  
Hugo I. Medelli´n Castillo ◽  
Edgar A. Mendoza Lo´pez
Keyword(s):  
Manufacturing Process ◽  
Production Line ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Dynamic Balancing ◽  
Industrial Case Study ◽  
Design Changes ◽  
Electrical Motors ◽  
Design And Manufacture

It is a common design practice to balance all rotating members of a machine. Rotating parts can be designed to be inherently balanced by their geometry. However, due to production tolerances there will be some small unbalance in each part. Therefore a balancing operation may be required for each part after manufacture. In the case of electrical motors the major source of vibration and noise is unbalance in the armature. In the motor manufacturing industry, this problem is generally corrected by removing material from the armature. However, the number of unbalance armatures is generally high and therefore the balance operation is usually a bottleneck in the production line. As a result, the manufacturing process becomes inefficient and costly. Based on the fact that a motor manufacturing company is facing balancing problems in its production line, this paper presents a dynamic balancing analysis of the armature in an automobile starting motor. A theoretical balancing analysis is carried out using the design and manufacture information. Balancing is also experimentally studied at the assembly line by measuring the unbalance through the whole manufacturing process. Both analysis, theoretical and experimental, and then compared. From this comparison several external factors that affect the unbalance in the real assembly process are identified. As a result, design changes and production process modifications are proposed to reduce the armature unbalance.

scholarly journals Innovative heat-technology of processing phytoestrogenic raw materials into functional powders

2020 ◽  
Vol 84 (1) ◽  
pp. 16-21
Author(s):  
Zhanna Petrova ◽  
Kateryna Slobodianiuk
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Energy Saving ◽  
Raw Materials ◽  
High Energy ◽  
Drying Methods ◽  
Energy Costs ◽  
High Quality ◽  
Heat Technology ◽  
Vegetable Raw Materials

Outdated technologies in drying processes can lead to iПеrrational use of energy, as a consequence, high energy consumption and increased energy consumption. Therefore, the issues of energy saving and energy efficiency are the most important tasks to be solved. Nowadays, energy saving and energy efficiency are also part of the environmental problem. Ukraine, which has a unique geographical position for Europe, is fully supplied with natural resources, - one of the countries where there is inefficient use of energy resources. One of the energy-consuming areas of vegetable processing is drying. In the modern world, the issue of energy efficiency of drying methods is one of the most relevant areas of research. Convective drying of vegetable raw materials requires a rational use of regime parameters of the process corresponding to the biochemical properties of the processed object. The primary objectives of this area of processing of vegetable raw materials are to reduce energy costs and ensure high quality characteristics of the final product. This article presents the developed heat-technology for obtaining phytoestrogenic powder from soybeans and spinach. Which includes 3 stages: preliminary preparation of raw materials for drying; drying of thermolabile vegetable raw materials; dispersion and packaging of the obtained phytoestrogenic powder. As a result of previously conducted comprehensive research, it was found that the use of heat technology reduces energy costs at the stage of preparation of raw materials through the improvement of existing hydrothermal treatment of soybeans, as well as energy savings of 21% through the use of developed step modes. Studies of the qualitative characteristics of the obtained phytoestrogenic powder confirm the high quality of the final product.

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