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Energy Consumption Reduction Seminar Report

Manufacturing has been changing with paradigm shifts to support advances in technology and to meet the emerging cultural and societal needs. This has seen the industry move through a number of phases: craft production, mass production, flexible manufacturing and personalised design and manufacture .Today, a new industrial revolution is being conceived that will continue forever in the form of sustainable design and manufacture.

This new revolution is starting to bring together new paradigm shifts from the early phase of energy conscious manufacturing to today’s new vision for energy efficient production.The safety issue of nuclear power generation has affected the whole world, leading to active movements to reduce dependence on nuclear power generation and increase use of renewable energy such as wind power and solar power. However, the technology of renewable energy generation is still in the developing stage; accordingly the energy supply is far behind nuclear power and thermal power. Therefore, energy saving is the most important issue for many industries most of the manufacturing lines consisting of multiple machines at manufacturing sites, especially, for automobile parts are operated for 24 hours, consuming massive amount of electricity.

Therefore, suppressing the energy supply in these manufacturing lines is considered to be significantly effective for energy saving. Although reducing machining time and securing the operation rate are emphasized in these machining lines, the energy consumption is not emphasized.

A commonly accepted energy breakdown by Dahmus and Gutowski divides the power demand of machine tools into three different modes: idle mode, run-time mode, and production mode. In idle mode, the machine is ready for production and components such as the operation panel and fans accumulate to a constant power demand. During run-time mode, further auxiliaries are activated, which, once turned on, have a constant power demand. The production mode represents the power demand while removing material Thus, different approaches aimed to reduce the constant part by either improving specific components or by reducing the overall cycle time .Influences on power demand were identified, such as process parameters , selection of tooling, and workpiece material . Hence, power measurements are highly dependent on a variety of preconditions that directly affect the obtained data and therefore require standardized test procedures.

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