4 th Conference on Learning Factories. The η-factory An interdisciplinary learning factory approach to boost the energy performance of production

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1 Stockholm th Conference on Learning Factories The η-factory An interdisciplinary learning factory approach to boost the energy performance of production Prof. Dr.-Ing. Eberhard Abele Christian Eisele Martin Beck

Facts and Figures of energy consumption in industry Electr.

kwh Private Sector 26% Trade & Business 24% Traffic 3% Industry 47% Saving Potential

per year Source:: AG Energiebilanzen und VDI Nachrichten Nr.

of Machines, Buiding and Technical Building services Optimization of Machines and

2 Facts and Figures of energy consumption in industry Electr. Power Demand Germany 2011 Total consumption 540,8 Mrd. kwh Private Sector 26% Trade & Business 24% Traffic 3% Industry 47% Saving Potential 20-40% of the electrical power is lost as heat, this corresponds to 5-10 Mrd. per year Source:: AG Energiebilanzen und VDI Nachrichten Nr.39/2012 Saving Strategies System Design Machines User behaviour Intelligent interaction of Machines, Buiding and Technical Building services Optimization of Machines and research of innovative processes Training of personell and staff Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 1

Waste heat in Manufacturing environments

3 Waste heat in Manufacturing environments Building Insulation Re-Use Process Chain/ Machines Quelle: brb bauen Heat Treatment Cleaning Machine Energetic Interaction Quelle: Bosch Rexroth AG Quelle: Bosch Rexroth AG Machine Components Speed Controller Ball Screw Hydraulik Unit Quelle: Rittal GmbH & Co. KG Quelle: Steinmeyer GmbH & Co. KG Quelle: Bosch Rexroth AG Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 2

The Challenge: Holistic increase of energy efficiency Today:

Subsystem Building Subsystem Technical Infrastructure Subsystem

subsystems High saving potential by realization of energy

Synergies by energy-controlling and recovery measures

4 The Challenge: Holistic increase of energy efficiency Today: Optimization of subsystems within their system boundaries Subsystem Building Subsystem Technical Infrastructure Subsystem Machine Total energy saving potential limited on the Subsystems Quelle: Prof. Dipl.-Ing. J. Eisele Our vision: Holistic factory optimization including all subsystems High saving potential by realization of energy networks Interaction of: Machines Process chains Buildings Synergies by energy-controlling and recovery measures Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 3

The idea behind the model project η-factory Establishing a research and training center in the middle of Campus Developing an interdisciplinary

concept phase Educational integration of energy efficiency, training concepts International notable lighthouse project Source for innovation and

5 The idea behind the model project η-factory Establishing a research and training center in the middle of Campus Developing an interdisciplinary approach for reducing CO 2 emissions (Including research in architecture and civil engineering) Involvement of industry from the beginning of the concept phase Educational integration of energy efficiency, training concepts International notable lighthouse project Source for innovation and technology development Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 4

6 Fields of Innovation in η-factory Energetic interaction Efficient Production source: F. Lang EuB TU Darmstadt Energy exchange between building and machines Energy network between all energy sources and sinks Energy efficient equipment Energy efficient production scheduling Recyclability Changeability source: F. Lang EuB TU Darmstadt single-material cladding construction Modular and flexible Building construction source: F. Lang EuB TU Darmstadt Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 5

7 Logistik Logistik Logistik The η-factory concept: Construction of a real existing process chain for practice-oriented, interdisciplinary research to different topics of energy and resource efficient production Installation of a new research building for the integration of the process chain and the realization of experiments about the interaction between processes and buildings Process 1 Process 2 Process 3 Process 4 Urformprozess Montage Development of a training concept to transfer the research results into practice Technische Universität Darmstadt Forschungsprojekt: η-fabrik Energieeffizienz Technologie- und Anwendungszentrum Sc1 6

Project structure Subproject 1 The virtual energy efficient factory Subproject 2 Energy controlling and energy management Subproject 3 Energy

Flywheel mass battery Subproject 7 Thermal interaction between building, infrastructure and production machines Thermotechnology Subproject 8

8 Project structure Subproject 1 The virtual energy efficient factory Subproject 2 Energy controlling and energy management Subproject 3 Energy efficient part cleaning Subproject 4 Energy resource efficient heat treatment Subproject 5 Energy efficient machining processes Subproject 6 Flywheel mass battery Subproject 7 Thermal interaction between building, infrastructure and production machines Thermotechnology Subproject 8 Energy efficient Building Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 7

9 Energy flows and energy recovery in the η-factory Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 8

10 Realisation of the η-factory at TU Darmstadt Future position of the η-factory Dimensions: 45,80 m x 23,00 m x 12,00 m (length x width x height) shop floor: 650m² office area: 650 m² Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 9

11 ETA-LearningFactory Concept Challenges How to present Energy- Efficiency in a Learning factory? Energy x how to measure Energy? (frequency, sensors, measuring points) x has different forms (electrical, thermal, chemical, etc.) x can be dangerous x is used by many consumers in the factory (machines, peripheral systems) Efficiency x criterias are hard to define x is difficult to quantify x is challenging to visualize Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 10

ETA-LearningFactory - Concept Target Audience Industry Technical

Production Planners Managers Controllers Architecture Heating &

deepen knowledge Politicians Association Members Funding Parties

tab Fachmagazin TGA Technische Universität Darmstadt Research

12 ETA-LearningFactory - Concept Target Audience Industry Technical Planners University Students General Visitors Factory & Production Planners Managers Controllers Architecture Heating & Climatization Energy Networks Bachelor raise enthusiasm Master deepen knowledge Politicians Association Members Funding Parties Energy Managers Pressurized Air Machine Designers picture source: tab Fachmagazin TGA Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 11

Wirkleistung [W] 3500 3000 2500 2000 1500 1000 Zeit [sec] ETA-LearningFactory - Concept Training Modules training module topics 500 0 200 400 600 800 1000 1200 1400 1600 1800 Energy Flows in

duration) Visualization and Monitoring of Energy Flows Interpretation of Energy Measurement Data Methods for Identfying and Quantifiying Energy Efficiency Potentials Key Perfomance Indicators for

13 Wirkleistung [W] Zeit [sec] ETA-LearningFactory - Concept Training Modules training module topics Energy Flows in Factories Assessment of Energy Efficiency Potentials Measuring Equipment and Installation of Sensors for different Energy forms Measuring Strategies (measuring points, accuracy, time resolution, duration) Visualization and Monitoring of Energy Flows Interpretation of Energy Measurement Data Methods for Identfying and Quantifiying Energy Efficiency Potentials Key Perfomance Indicators for Assessing and Tracking the Energy Consumption and Efficiency Levers to Increase Energy Efficiency Technical Levers (Improvement of machines and components, usage of alternative manufacturing technologies) Organizational Levers (establishing organizational structures, influencing user beaviour) Design of Energy Networks Linkage of Energy Sinks and Sources Storage and Re-use of different Energy Forms Conversion of Energy, e.g. heat to cold Control Strategies for Energy Flows Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 12

ETA-LearningFactory - Concept Training Means The Way to Energy Efficiency Lectures Learning Cells Workshops Guides Oral Presentations Posters Brainstormings Handouts Powerpoint

Exhibits Augmented Reality Overlays Interactive Simulations Educational Games Knowledge Quality Function Deployment (QFD) Business Cases Thermographic Analyses Tablet/Smartphone App *

14 ETA-LearningFactory - Concept Training Means The Way to Energy Efficiency Lectures Learning Cells Workshops Guides Oral Presentations Posters Brainstormings Handouts Powerpoint Touchscreen Learning PCs Technology Analyses Books Hearing & Reading Seeing & Feeling Thinking & Speaking Doing Recapitulation Video Clips & Animations Live Data (Machines, Building) Exhibits Augmented Reality Overlays Interactive Simulations Educational Games Knowledge Quality Function Deployment (QFD) Business Cases Thermographic Analyses Tablet/Smartphone App * QR-Code / NFC spots in the factory * Augmented Reality feature Implementation Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 13

ETA-LearningFactory - Outlook Example of presentation techniques Panoramic view from meeting room Explanation of energy efficiency concepts with movie clips & interactive apps Interactive

15 ETA-LearningFactory - Outlook Example of presentation techniques Panoramic view from meeting room Explanation of energy efficiency concepts with movie clips & interactive apps Interactive presentation of specific learning modules Energy Efficiency round tour source: EuB TU Da Technische Universität Darmstadt Research Project: η-factory Energy Efficiency Technology and Application Center Sc1 14

Technische Universität Darmstadt Petersenstr.

16 Thank you for your kind attention! Prof. Dr.-Ing. E. Abele Institut für Produktionsmanagement, Technologie und Werkzeugmaschinen Technische Universität Darmstadt Petersenstr Darmstadt Tel: Fax: info@ptw.tu-darmstadt.de Internet:

Research and Teaching at IAS Prof. Dr.-Ing. Michael Weyrich

Research and Teaching at IAS Prof. Dr.-Ing. Michael Weyrich Institute of Industrial Automation and Software Engineering Research and Teaching at IAS 2017 Prof. Dr.-Ing. Michael Weyrich History since 2013 Institute of Industrial Automation and Software Engineering