equipment availability and energy efficiency a ... - bdg · machinery association within vdma,...

Equipment Availability and

Energy Efficiency – a

Contradiction?

Verfügbarkeit und Energieeffizienz im

Widerspruch?

Dr. Patrick Reichen

March 5, 2015

2 | © Bühler |

Energy Efficiency vs. Availability

Energy consumption 12.9 kWh/100km

Energy efficiency label A

Empty weight 1270 kg

Power 125 PS

Acceleration 7.2 s

Availability ?

Energy consumption ~207 kWh/100km

Energy efficiency label ?

Empty weight 2903 kg

Power 300 PS

Acceleration 11.0 s

Availability ?

Source: Hummer, H2

Higher dynamics, stiffness, faster movements require more energy!

Source: BMW, i3

15th International Die Casting Conference | Bad Homburg | March 5, 2015

http://www.google.ch/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0CAgQjRw&url=http://newscarreviews.com/reviews/2014-hummer-h3-price.html&ei=ndjuVKSgKcnDPM_kgfgO&psig=AFQjCNFG5dY6Vf6oD_xhGxPLBeyV4cfydA&ust=1425025565748918

3 | © Bühler |

Energy Efficiency Becomes Important

Financial and political drives favor energy efficient processes

Trend to higher energy cost

Commitment of Bühler to decrease energy consumption by 25% until 2020

Gas

0

0.02

0.04

0.06

0.08

0.1

0.12

€/kWh

EU Average Germany France

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

0.05

€/kWh

EU Average Germany France

Gas price increased by 86% since 2004 Electricity increased by 45% since 2004

Source: Price development for industrial consumers, Eurostat


4 | © Bühler |

Agenda

1

2

3

Effective Energy Consumption of DC Cells

Cost Impact: Availability vs. Energy Efficiency

Standardized Energy Consumption of DCM


source: IHK source: Fotolia source: Autoweek NL

http://www.google.ch/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.zeeburgnieuws.nl/nieuws/kv_kooldioxide_concentratie_toename.html&ei=wnzxVPikNcOqPNWVgRg&bvm=bv.87269000,d.ZWU&psig=AFQjCNEVvdGot6l2Krl64eZoAav_9uGd3Q&ust=1425198642922102

5 | © Bühler |

Principles of the VDMA Cycle

Part and die independent measure of a die casting machine

Measure for a DCM and NOT a DC Cell

Energy consumption of peripheral components (die tempering, dosing,

spraying, etc.) are not considered

Represents a process near cycle!

Applicable to hot and cold chamber DCM


“The VDMA-Specification was elaborated by a working group of the Foundry

Machinery Association within VDMA, because manufacturers of pressure metal

diecasting machines were increasingly asked for energy efficiency and power

consumption. This VDMA-Specification describes a standardized procedure to

measure energy, whose boundary conditions and the documentation of the results

considering in equal measure the interests of both manufacturer and equipment-

user.” according to VDMA24499

6 | © Bühler |

Standardized Reference Cycle

Process steps 1 2 3 4 5 6 7 8 9 10 11 1

Die Closing

Dosing Time1)

Plunger Forward

Solidification Time1)

Die Opening

Ejector Forward

Extracting Time1)

Ejector Backward

Spraying Time1)

Plunger Backward

Waiting Time2)

Cycle 1 Cycle 2

1) Process-related times defined according

to machine size

2) Time for the DCM to reach status “ready

for next cycle”

for cold chamber DCM only


7 | © Bühler |

VDMA Standard Cycle for a DCM

Dosing time Plunger Forward

Solidification time

Die Opening/Ejector

Extraction Time

Ejector Backward

Spraying Time

Plunger Backward

VDMA Reference Cycle

Die Closing


8 | © Bühler |

VDMA Test Report for DCM

“Energy Certificate” for DCM

Disclosure of key information

Machine size: Carat 320c

Energy consumption:1.615 kWh/cycle

Cycle Time: 84.7 s

Represents a process near cycle

NOT a dry cycle!


9 | © Bühler |

Agenda

1

2

3





10 | © Bühler |

Confidential

Goal: in depth evaluation of the total energy consumption

Focus on electrical energy, compressed gas and cooling water

Results measured in specific energy consumption (related to part weight)

Effective Energy Consumption How to benchmark energy consumption in a real production environment?

Energy Consumption (complete factory 100%)

Al Preparation

DC Cell

DC Machine

50%

12%

1-3%

Definition Boundary

Conditions Definition of Parts


11 | © Bühler |

Confidential

Results Energy Measurement Protocol

Document to show the current energy

consumption of a specific process

Equipment and product dependent

protocol


12 | © Bühler |

Confidential

Results For oil pan, bedplate, shock tower

Approx. Machine Size ~800t ~1800t ~2800-4000t

Values for 1 part Oil pan Bedplate Shock Tower

Electrical [kWhelec/cycle] 1.542 3.879 3.870

Air [Nm3/cycle] 3.407 0.378 6.972 0.774 4.479 0.497

Cooling Water [kWhth/cycle] 0.893 0.013 2.183 0.033 2.159 0.033

Total Energy [kWh/cycle] 1.934 4.685 4.400

Specific Energy [kWh/kg]* 0.921 0.509 0.969

25.0%

13.5%

36.6%

14.0%

2.0% 1.3%

7.7%

31.3%

15.0% 39.8%

4.9% 0.3%

2.8% 5.9%

41.7%

10.5%

32.9%

5.6%

1.1% 2.0% 6.2%

Oil Pan Bedplate Shock Tower

DCM

Spraying

Die Tempering

Press

Extraction

Robot

Part Cooling Dosing Furnace

* part weight


14 | © Bühler |

Confidential

Availability Known as OEE Calculation of OEE Downtime: 93.2 min Planned Production: 660 min

𝑂𝐸𝐸 =567 𝑚𝑖𝑛

660 𝑚𝑖𝑛×

405𝑝

410.7𝑝×

391 𝑝

405 𝑝 = 0.818

Theoretical cycle time: 82.8 s

# of produced parts: 405 parts

# of parts out of spec: 14 parts

Required Information of planned

production time:

0.859 0.986 0.965

**Results based on measurements on Carat180 – 7.7.2014

# of parts that should have been produced in the

available time (uptime/theo. cycle time)

5 automatic

4 semi-automatic

3 manual

2 setup

1 off

0 emergency off


15 | © Bühler |

Impact on Cost and Energy Savings Based on energy measurement of a standard die casting cell

1) Personal and structural, maintenance, capital, consumables, die

Impact of OEE improvement much bigger on the costs per part


18.9%

1.5%

10x higher impact!

15%

e.g. OEE from 0.6 0.75; Energy reduction by 15%

A) Cost for machine utilization1) 150.- €/h f(OEE)

B) Energy costs 0.09 €/kWh f(OEE, Energy)

Production: 7.728 kWh/cycle, Stand-by: 4.694 kWh/cycle

16 | © Bühler |

Summary


Improvement of OEE with higher impact on cost savings

Effective energy consumption as specific value

Quality requirements

Availability of an installation

Hardware configuration

Comparison of different systems only by standardized procedures

e.g. VDMA 24499 for DCM

Equipment Availability and Energy Efficiency – a Contradiction? – No!!

equipment availability and energy efficiency a ... - bdg · machinery association within vdma,...

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