Selecting a Design-Stage Energy Estimation Approach for Manufacturing Processes

2011 ◽  
Author(s):  
Alexander Weissman ◽  
Satyandra K. Gupta
Keyword(s):  
Energy Consumption ◽  
Point Of View ◽  
Critical Parameters ◽  
Design Stage ◽  
Design Parameters ◽  
Manufacturing Processes ◽  
Design Work ◽  
Energy Estimation ◽  
Energy Consuming ◽  
Facility Level

Manufacturing is an energy-intensive process which could account for significant energy consumption worldwide. Reducing energy consumption on a product level, in addition to a process or facility level, is being seen as a more worthwhile endeavor in light of rising energy costs and environmental concerns. To accomplish this, it is necessary to consider the role of product design in energy consumption. It is possible to design a product such that its manufacture consumes less energy. However, this requires a good model of energy consumption based on the design parameters. A good model must be detailed enough to yield accurate results, but at the same time simple enough such that it can be applied easily and consistently in day-to-day design work. In this paper, we propose an approach for generating such a model by decomposing the manufacturing process into its energy-consuming components. For each component, the relevant design and manufacturing parameters can be elicited by performing sensitivity analysis through analysis and experimentation. Parameters which do not greatly contribute to variance in energy consumption can be held constant, thus simplifying the model. Thus, the simplest possible model can be derived for a specified level of accuracy. We illustrate that critical parameters from energy point of view can differ greatly from process to process by investigating representative manufacturing processes in four general categories: additive, subtractive, forming, and solidification. Finally, we present a case study for injection molding.

Process Planning Strategies to Reduce Energy Consumption in Machining

2018 ◽  
Author(s):  
Arun Unnikrishnan ◽  
P. V. M. Rao
Keyword(s):  
Energy Consumption ◽  
Process Planning ◽  
High Performance ◽  
Cutting Parameters ◽  
High Energy ◽  
Point Of View ◽  
Energy Estimation ◽  
Tool Paths ◽  
Machined Parts ◽  
Selection Of

Continuous need to increase productivity and reliability in machining has led to high-performance machines that are often characterized by high energy demands. As a result, energy minimization is identified as one of the key goals in machining. With the availability of improved predictive models for energy estimation in machining, energy-conscious process planning for machining is now possible. The present work focuses on the assessment of process plans of machined parts from energy consumption point of view. An experimentally validated model for energy estimation is first presented. Using this model two important process planning variables on energy consumption in machining has been studied. Firstly selection of tool paths including curvilinear tool paths has been considered from energy consumption point of view. Secondly, strategies for the selection of cutting parameters for roughing, semi-finishing and finishing from energy consumption perspective are discussed.

scholarly journals A Systematic Methodology for Accurate Design-Stage Estimation of Energy Consumption for Injection Molded Parts

2010 ◽  
Author(s):  
Alexander Weissman ◽  
Arvind Ananthanarayanan ◽  
Satyandra K. Gupta ◽  
Ram D. Sriram
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Product Design ◽  
Flow Simulation ◽  
Setup Time ◽  
Analytical Models ◽  
Design Stage ◽  
Limited Information ◽  
Energy Estimation ◽  
Time Required

Today’s ubiquitous use of plastics in product design and manufacturing presents significant environmental and human health challenges. Injection molding, one of the most commonly used processes for making plastic products, consumes a significant amount of energy. A methodology for accurately estimating the energy consumed to injection-mold a part would enable environmentally conscious decision making during the product design. Unfortunately, only limited information is available at the design stage. Therefore, accurately estimating energy consumption before the part has gone into production can be challenging. In this paper, we describe a methodology for energy estimation that works with the limited amount of data available during the design stage, namely the CAD model of the part, the material name, and the production requirements. The methodology uses this data to estimate the parameters of the runner system and an appropriately sized molding machine. It then uses these estimates to compute the machine setup time and the cycle time required for the injection molding operation. This is done by appropriately abstracting information available from the mold flow simulation tools and analytical models that are traditionally used during the manufacturing stage. These times are then multiplied by the power consumed by the appropriately sized machine during each stage of the molding cycle to compute the estimated energy consumption per part.

scholarly journals The Efficiencies of Single-Stage Centrifugal Compressors for Aircraft Applications

1991 ◽  
Author(s):  
C. Rodgers
Keyword(s):  
Mach Number ◽  
State Of The Art ◽  
Single Stage ◽  
Critical Parameters ◽  
Design Parameters ◽  
Centrifugal Compressors ◽  
Design Work ◽  
Engine Design ◽  
Specific Speed ◽  
System Power

The thrust of most recent advances in single– and two–stage centrifugal compressor technology by the aerospace community has been motivated by interest in increasing airbreathing propulsion system power density, and improving specific fuel consumption with higher stage pressure ratios. Advances in the last decade have made it appropriate to review the major design parameters influencing the efficiency levels of single–stage centrifugal compressors for aircraft applications. A simple efficiency correlation was derived for advanced single–stage centrifugal compressors. It was based upon four critical parameters: • Inlet Specific Speed • Impeller Tip Diameter • Inducer Tip Relative Mach Number • Exit Discharge Mach Number The correlation was shown to predict attainable state–of–the–art efficiencies within a band width of ± 2 % points. This was considered acceptable for preliminary compressor and engine design work.

Relationship Investigation Between Energy Consumption and Parameters in Size Reduction and Pelleting Processes of Biofuel Manufacturing

2014 ◽  
Author(s):  
Zeyi Sun ◽  
Donghai Wang ◽  
Lin Li ◽  
Meng Zhang
Keyword(s):  
Energy Consumption ◽  
Process Parameters ◽  
Critical Role ◽  
Size Reduction ◽  
Critical Parameters ◽  
Manufacturing Processes ◽  
Transportation Fuels ◽  
Energy Consumptions ◽  
Optimal Configurations ◽  
The U.S

Biofuel is considered a sustainable substitute for traditional liquid transportation fuels. The wide adoption of biofuel can effectively reduce the greenhouse gas emissions and secure the energy supply of the U.S. One major concern of the wide adoption of biofuel is the energy consumption during biofuel manufacturing processes, which plays a critical role in successful substitution. In this paper, we focused on the investigations of the relationships between the energy consumption and process parameters of the processes on size reduction and ultrasonic vibration-assisted pelleting. The methodology of design of experiments was used to analyze the experimental results of energy consumptions with different process parameter settings of the two processes. Critical parameters that significantly influence the energy consumption were identified. The optimal configurations of the process parameters were recommended.

Response Comparisons of a Large Floating Structure by Grillage and Shell FE Models

2008 ◽  
Author(s):  
Kazuhiro Iijima ◽  
Junghyun Kim ◽  
Tetsuya Yao
Keyword(s):  
Stress Responses ◽  
Three Dimensional ◽  
Design Stage ◽  
Design Parameters ◽  
Beam Model ◽  
Floating Structure ◽  
Response Level ◽  
Design Work ◽  
Early Design ◽  
Early Design Stage

At the early design stage of a large floating structure, it is firstly important to know the hydroelastic response characteristics in waves. For this purpose, the structure is modeled by three-dimensional grillage, and hydroelastic analysis is performed in order to estimate the overall behaviour. At this stage, main design parameters are: floater shapes, their arrangement and rigidity distributions. They are optimized by referencing to the hydroelastic responses estimated by the analysis. As the design work develops, more detailed modelling is possible. At the final design stage, the design must be confirmed by checking the response against criteria. The structure is re-modeled by shell FE elements for skin structures and beam elements for stiffeners. It is considered that the more correct estimations are performed by employing the refined model. However, there might be significant differences in the modelling and also in the resultant estimations between the first and final stages even when the subject structure is identical. Then, it is necessary to evaluate the differences between the results estimated by using these two models in order to assure the actual response level estimated by using the beam model at the early design stage. In this paper, three-dimensional grillage and shell FE structural models of a large floating structure are prepared. Hydroelastic analyses are performed on the two models. The results are compared in terms of motion, member force and stress responses.

Machine-Specific Estimation of Milling Energy Consumption in Detailed Design

2021 ◽  
pp. 1-24
Author(s):  
Till Boettjer ◽  
Johan Krogshave ◽  
Devarajan Ramanujan
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Design Stage ◽  
Total Energy Consumption ◽  
Estimation Errors ◽  
Workpiece Material ◽  
Detailed Design ◽  
Energy Estimation ◽  
Unit Process

Abstract Manufacturing is a significant contributor to global greenhouse gas emissions and there is an urgent need to reduce the energy consumption of production processes. An important step towards this goal is proactively estimating process energy consumption at the detailed design stage. This is a challenging task as variabilities in factors such as process specifications, machine tool architecture, and workpiece geometry can significantly reduce the accuracy of the estimated energy consumption. This paper discusses a methodology for machine-specific energy estimation in milling processes at the detailed design stage based on the unit process life cycle inventory (UPLCI) model. We develop an adjusted UPLCI model that includes adjustment factors for uncertainties in machine tool specifications and the specific cutting energy of a workpiece material. To validate the adjusted UPLCI model, we conducted a case study that measured the energy consumption for machining three parts made of Aluminum 6082 on two separate three-axis vertical milling machines, a Chevalier QP2040-L and a Leadwell MCV-OP. Results show that the UPLCI model consistently overestimated the total energy consumption for machining the three validation parts across both machine tools. We also found the adjusted UPLCI model significantly reduced the estimation errors for the same tests for both machine tools.

A Novel Pattern for Energy Estimation Framework and Tools to Compute Energy Consumption in Product Life Cycle

2014 ◽  
Vol 14 (1) ◽  
Author(s):  
He Huang ◽  
Gaurav Ameta
Keyword(s):  
Life Cycle ◽  
Energy Consumption ◽  
Product Life Cycle ◽  
Manufacturing Industry ◽  
Design Stage ◽  
Computational Tools ◽  
Energy Estimation ◽  
Product Life ◽  
Domain Specific Knowledge ◽  
Energy Consumptions

Excessive energy consumption has become a worldwide issue in today's design and manufacturing industry. An energy estimation framework that could later be used to integrate with CAD/CAM systems is in demand. This research develops a novel pattern to estimate energy consumptions. The pattern involves a software energy estimation framework and various software energy computational tools. Using this pattern, energy can be calculated by an energy estimation framework which can be attached with diverse energy computational tools. These computational tools can be designed for any purpose to calculate energy consumptions during a product life-cycle and for various manufacturing processes. The framework involved in this pattern features to be domain independent and flexible so that it will be expandable for different manufacturing domains and customizable for users. Details for developing such pattern are presented. Interaction between the framework and its computational tools is also discussed. With help of this pattern, energy estimation framework and energy computational tools can interact smoothly, and the development of computational tools can be extended or expanded for any purpose. Knowledge engineers who exert to integrate knowledge into computer systems can interpret domain-specific knowledge and share their expertise to improve the framework. The framework also assists users who have little knowledge about energy computations to estimate energy consumptions during the design stage, leading to products with reduced energy.

scholarly journals Minimizing Energy Cost in Multi-Legged Walking Machines

2016 ◽  
Vol 85 (3-4) ◽  
pp. 431-447 ◽  
Author(s):  
Teresa Zielinska
Keyword(s):  
Energy Consumption ◽  
Energy Demand ◽  
Body Height ◽  
Step Length ◽  
Point Of View ◽  
Design Stage ◽  
Energy Evaluation ◽  
Walking Machines ◽  
Straight Line ◽  
Difficult Terrain

AbstractDue to their ability to avoid obstacles and to move over difficult terrain, moreover having the ability to adjust their posture, walking machines for many years have been considered as very promising devices for inspection, exploration and surveyance tasks, however still they have not been widely applied. One of the main limitations is the power supply. Six legged walking machines are robust from the point of view of their walking stability in difficult terrain, but their actuators (18 if each leg has active 3 DOF’s) adds to their weight what increases the energy consumption. The higher energy consumption requires more efficient batteries, but usually those are heavier, what again increases the energy demand. Therefore at the design stage a detailed analysis is required of how to decrease the energy consumption. This paper studies energy consumption considering the tripod gait of hexapods. The method used for energy evaluation is presented and the results are discussed. The discussion of energy saving both for the leg transfer phase and during the support phase, which is the most demanding phase, is presented. The energy consumption is expressed in the normalized form, depending on the normalized leg proportions, body height and step length. The straight line forward/backward and side walking are analyzed. The aim of the studies is to provide to the designers the information about favorable leg proportions taking into account the reduction of required energy and to provide the information which leg posture should be selected.

Intertwining E-Learning Technologies and Pedagogies at the System Design Stage

2018 ◽  
pp. 369-406
Author(s):  
Georg Weichhart ◽  
Chris Stary
Keyword(s):  
Individual Learning ◽  
Learning Technologies ◽  
Point Of View ◽  
Design Stage ◽  
Design Parameters ◽  
Interactive System ◽  
Pedagogical Issues ◽  
Learning Support ◽  
Web Based ◽  
E Learning

Although a large number of e-learning systems for individual learning support exist today, many of them still deal with pedagogical issues in an isolated way. In contrast, intertwining interactive system features with educational concepts allows pedagogical designs that may be considered according to their educational rationale. However, pedagogical approaches also do not provide requirements for technologies; they rather consider tools and features as predefined design parameters. Taking an interoperability point of view allows focus on the interaction between the pedagogical and the technological systems. By interpreting technology and didactic approaches as systems and ensuring their interoperability, educators are able to adapt learning experiences and technological features in a way that the overall learning system becomes personalized. A key element of the described work is an architecture that captures the design elements from both progressive education focusing on individual learning support, and the enabling web-based e-learning technologies.

THEORETICAL AND METHODOLOGICAL ASPECTS OF UNDERSTANDING OF THE SYSTEM OBJECT IN DESIGN

2020 ◽  
Vol 1 (4) ◽  
pp. 5-10
Author(s):  
V. Barysheva ◽  
O. Druzhinina
Keyword(s):  
Scientific Research Institute ◽  
Point Of View ◽  
Design Stage ◽  
Comprehensive Understanding ◽  
Design Culture ◽  
Design Program ◽  
Methodological Aspects ◽  
Cultural Experts ◽  
Union Scientific Research Institute ◽  
Separate Product

The article is devoted to the analysis of the system object from the point of view of design from design, sociocultural and philosophical positions. The authors systematize the definitions of a system object of design proposed in the 1960–1980s by theorists and practitioners, art historians, cultural experts and philosophers from different countries, including Russia, which allows a comprehensive understanding of the phenomenon of design culture. This article is devoted to the characteristic properties of the system object in design. They were considered and analyzed on the example of the «Absheron» design-program when designing of agricultural village). This concept was developed at the All-Union Scientific Research Institute of Technical Aesthetics (VNIITE) in 1983. Using the same example, the features of the approach to designing a system object in design was observed not only as a separate product, but as a sociocultural situation that constantly changes at each design stage.

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