Energy 2030

Organizing Committee

Final Program

Poster Exhibition Venue 2006 Proceedings


Proceedings of the Second International Energy 2030 Conference,
November 4-5, 2008, Abu Dhabi, U.A.E.

A Framework to Collect, Assess and Reduce Energy Consumption of Manufacturing Equipment

Mehmet Bayram Yildirim

Wichita State University, USA

Lawrence Whitman

Wichita State University, USA

Haitao Liao

Wichita State University, USA

Jamal Ahmad

The Petroleum Institute, UAE

Worldwide industry consumes about half of the world’s energy [1], and energy costs U.S. manufacturers $100 billion annually. Nowadays, energy use has become a major concern especially considering the depletion of non-renewable resources [2]. In addition to reducing manufacturing cost, energy reduction also positively impacts greenhouse gases as one kilowatt-hour of electricity reduces two pounds of carbon dioxide from being released into the atmosphere [3].

For the reduction of energy consumption many solutions have been proposed, but such reduction is difficult to achieve as it appears that consumption is not managed in a structured way. Gutowski et al. [4] notes that in the Toyota Motor Corporation 85.2% of the energy is used in non-machining operations which are not directly related to production of parts. Kordonowy [5] characterizes the power consumption of manufacturing equipment by analyzing the background runtime operations of machining (i.e., spindle, jog, coolant pump, computers and fans, etc.). It is found that over 30% of the energy input into the system during machining is consumed by these background processes. However, these calculations consider the whole system as opposed to a developed model for each process. Dahmus and Gutowski [6] observe that the total energy requirement for the active removal of material can be quite small compared to the background processes needed for operating a machine. In all of the above references, energy consumption calculations point out the magnitude of energy expenditure in non-process related activities and the potential for energy savings. In order to wisely utilize energy at the sub-cellular operation level and eventually extend the methodology to the enterprise level, it is necessary to look into and quantify the components of energy consumption in each process. This paper reports on a framework for energy collection and operational models at the machine level. The framework gives detailed energy profiles of industrial equipment. That detailed profile not only provides an accurate assessment of energy consumed for a given material, machine, and part geometry, but also provides significant information for prescribing energy reduction strategies at the machine level. The intent will be then to integrate those models into energy consumption models at the facility level and ultimately into models at the enterprise level.


Copyright © 2006 - 2013 | The Petroleum Institute | Abu Dhabi | United Arab Emirates