beyond 3d printing – new demand on electric infrastructure

Mark Stephens, PE, CEM, CP EnMS Senior Project Manager

Advanced Manufacturing Workshop:

Challenges for Tomorrow, Solutions Today June 4, 2014

Beyond 3D printing – new demand on electric infrastructure

2 © 2014 Electric Power Research Institute, Inc. All rights reserved.

Why Focus on 3D Printing?

•  3D Printing (Additive Manufacturing) is the most commonly recognizable piece of technology constituting advanced manufacturing.

•  10 Years ago, digital smart metering was recognized as smart grid itself (which was not true and often misleading).

• Similarly, we need to understand Additive Manufacturing as one of the first bricks of in which we will build and operate the smart factory.

Recent Collaboration with America Makes


Previous Successful Collaborative Efforts • EPRI has traditionally led research to

understand the customer end-use equipment for the utility sector: –  Base line Power Quality Requirements –  Power Requirements, and Energy

Intensity •  This work as has led End-Users, OEMs, and

Consultants need to better understand the PQ environment and utilize robust equipment and power system designs.

•  This research has also led to new Industry Standards (i.e. SEMI F47), improved equipment designs through collaboration, and important insights for everyone involved along the way.

Semiconductor Processing Equipment

CNC Machine

Tools

Chiller Systems

Food Processing

Plastic Extrusion


SEMI F47-0706


Research Questions

• Power Quality & Reliability – How will these loads be different

from a PQ Standpoint? – What will PQ Sensitivities and

Contributions be? – What mitigation strategies will be

required?

•  Power & Energy – What will these loads look like from a

power standpoint? – What is the energy intensity of

additive manufacturing in comparison with traditional methods?

3D Printing Mfr Site(s)

Collaborators in Answering These Questions

EPRI Member Utilities


Injection Molding & Fused Deposition Modeling • Part cycle time in seconds or minutes • Hydraulic and Electronic motor drives (AC or DC) • Resistive SCR Heaters for Melt Pipe and Mold • Requires Cooling Water from local chiller or plant system •  PQ Performance Understood •  Power Profile and Energy Intensity Understood

• Part cycle time in minutes, hours, or days • Stepper Motor Drives • Resistive SCR Heaters for chamber • Requires compressed air & vacuum

(from Plant air or via internal pumps) •  PQ Performance Not Well Understood •  Power Profile and Energy Intensity Not Well understood

Injection Molding

FDM


CNC (Subtractive) & Selective Laser Sintering (Additive)

• Part cycle time in seconds or minutes •  Multi-Axis Servo Drive •  Spindle Drive •  Requires Compressed Air •  PQ Performance Understood •  Power Profile and Energy Intensity Understood

SLS •  Part cycle time in minutes, hours, or days •  Stepper Motor Drives •  Laser System with Mirrors •  May require local chiller •  PQ Performance Not Well Understood •  Power Profile and Energy Intensity Not Well understood

CNC


PQ Tests: Voltage Sag Tests

• Completed: – America Makes:

• FDM Machine • SLS Machine

– Confidential Manufacturer: • FDM Machine

• Planned in June 2014: – ORNL MDF

• Electron Beam Melting

• SLS Machine

EPRI & FirstEnergy Performing Voltage Sag Testing

At America Makes


SLS Machine Test Result Excerpts… • No UPS in system design • Machine does not meet SEMI F47

• Estimated Shutdowns/Year* per based on plant location – Transmission ~ 6.6 – Sub T ~ 7.0 – Distribution ~ 11.6

• EPRI indentified simple improvements that will make the machine more robust

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

0 20 40 60

% N

omin

al V

olta

ge

Voltage Sag Duration (Cycles)

SLA Dropout

SEMI F47

* Based on findings from Transmission–Distribution Power Quality Report (TPQ-DPQ III) , EPRI May 2014


FDM Machine Test Excerpts… •  At manufacturing site, FDM machines

contain both an internal UPS and are fed from an external 80kVA UPS.

•  This finding was curious until EPRI Conducted voltage sag testing of the machine downstream of the 80kVA UPS.

•  Machine was robust to voltage sags and found to meet SEMI F47 and IEC 61000-4-34

•  However, machine was found to go into a shutdown mode for any interruption 2 seconds and longer even when it could have continued powering unit for seconds longer –  Coincides with utility recloser timing on

the faulted feeder •  EPRI will work with OEM to recommend

increasing the timing past 2 seconds as the default to work in harmony with the utility power systems.

Faulted Feeder “A”

Adjacent Feeder “B”

Line to Ground

FaultProtectiveRelays

(reclosers)

Subs

tatio

n B

us

TD 1 TD 2

Initial Fault

Reclose Attempt 2

TD 3

Reclose Attempt 3

Reclose Attempt 1

TimeR

MS

Volta

ge

TD 1 TD 2

From Initial Fault Reclose Attempt 2

TD 3

Reclose Attempt 3

Reclose Attempt 1

Sag Event Sag Event Sag Event Sag Event

Time

RM

S Vo

ltage

Adjacent Feeder “B”

Faulted Feeder “A”


FDM Machine Test Excerpts…

•  Testing at America Makes revealed the FDM machine continued to run, during voltage sags, but there was product deformation.


Power and Energy Intensity Test Results (10 tests Completed so Far)

Model Type Test Loca/on Make Model Material Part Density Build Time

Average Power (W)

Energy (Wh)

Part Weight (g)

Energy Intensity (Wh/g)

or (kWh/kg)

Energy Intensity ( BTUs/g)

Energy Intensity (j/g) or (kj/kg)

Desktop ORNL MDF Stratasys Maker Bot Replicator 2 PLA NIST Ar<fact 100% 5hr 42min 58.42 333 112 2.97 10.14 10,704

Desktop America Makes Lulzbot TAZ 3 PLA Octopus 50% 32 min 55 32 6 5.33 18.20 19,200

Desktop ORNL MDF Cubify Cube 2 PLA NIST Ar<fact 50% (Strong) 7hr 17min 46.41 338 51 6.63 22.61 23,859

Desktop ORNL MDF Stratasys Maker Bot Replicator 2x PLA NIST Ar<fact 100% 5hr 38min 123.02 693 99 7.00 23.88 25,200

Desktop ORNL MDF CMECNC Rostock PLA NIST Ar<fact 100% 5hr 26min 132.52 720 89 8.09 27.60 29,124

Desktop Confiden<al Stratasys Uprint SE Plus ABS M30 NIST Ar<fact 100% 3hr 27 min 390 1270 94 13.51 46.10 48,638

Floor America Makes M-‐Lab ExOne Metal logo par<al 100% 3hr 15 min 153 485 21 23.10 78.80 83,143

Floor America Makes Stratasys Fortus 400MC ABS M30 NIST Ar<fact 100% 4hr 23 min 1561 7368 96 76.75 261.87 276,300

Floor Confiden<al Stratasys Fortus 900MC ABS M30 NIST Ar<fact 100% 4hr 23 min 2451 10626 96 110.69 377.67 398,475

Floor America Makes 3D

Systems + NESLAB

SLS S Pro 60HDHS + Chiller

SLS Duraform

PA NIST Ar<fact 100% 2hr 45 min 2451 16626 72 230.92 787.89 831,300


Energy Intensity Test Samples


Plastics Additive Manufacturing Build Times & Average Power (NIST Artifact, 100% Dense)

5.70

3.45

0.06

2.45

0.00

1.00

2.00

3.00

4.00

5.00

6.00

Desktop FD

M

Desktop FD

M

Desktop FD

M

Desktop FD

M

Floor FDM

Floor FDM

Floor SLS

Hours

Average Power (kW)


Plastics Additive Manufacturing Energy Intensity (kWh/kg), NIST Artifact, 100% Dense

0.00

50.00

100.00

150.00

200.00

250.00

Desktop FD

M

Desktop FD

M

Desktop FD

M

Desktop FD

M

Floor FDM

Floor FDM

Floor SLS

Ener

gy In

tens

ity (k

Wh/

Kg)

Additive Manufacturing Machine Type

Finding: Desktop Units were able to produce the same NIST part at 1/10 to 1/20th the Energy Intensity of the

Floor Models.


Next Steps

•  Continue collaboration with SMLC, DOE, ORNL, America Makes, OEMs and others to leverage success.

•  Continue to understand these new loads through measurement of power and energy intensity.

•  Continue collection of PQ data through testing and measurements.

•  End goal is the development or adoption of a PQ standard for advanced manufacturing to help ensure equipment is robust to typical voltage sags and momentary interruptions seen on the electrical grid.

beyond 3d printing – new demand on electric infrastructure

Documents