Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

The future of computing beyond Moore's Law.

Moore's Law is a techno-economic model that has enabled the information technology industry to double the performance and functionality of digital electronics roughly every 2 years within a fixed cost, power and area. Advances in silicon lithography have enabled this exponential miniaturization of electronics, but, as transistors reach atomic scale and fabrication costs continue to rise, the classical technological driver that has underpinned Moore's Law for 50 years is failing and is anticipated to flatten by 2025. This article provides an updated view of what a post-exascale system will look like and the challenges ahead, based on our most recent understanding of technology roadmaps. It also discusses the tapering of historical improvements, and how it affects options available to continue scaling of successors to the first exascale machine. Lastly, this article covers the many different opportunities and strategies available to continue computing performance improvements in the absence of historical technology drivers. This article is part of a discussion meeting issue 'Numerical algorithms for high-performance computational science'

Simulation modelling and strategic change : creating the sustainable enterprise

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Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Buckling and strength analysis of panels with discrete stiffness tailoring

Continuous variation of stiffness across flat plates has been shown, theoretically, to improve buckling performance by up to 60%. However, steered fibre manufacturing methods cannot achieve the minimum radius of curvature required for improvement whilst maintaining a high deposition rate. An alternative concept, Discrete Stiffness Tailoring (DST), which varies stiffness within a ply through discrete changes of angle, is compatible with high rate deposition methods such as Advanced Tape Laying. Through the simple example of redistribution of the material in a quasi-isotropic [±45/90/0]2S laminate whilst maintaining ply percentages, DST is shown both experimentally and theoretically to improve buckling stress by at least 15% with no indication of failure in regions of discrete angle change (seams). However, the reduced tensile strength of seams obtained by virtual and experimental testing means that increased buckling performance in the principle load direction needs to be balanced against loss of transverse strengthThis work was supported by the UK EPSRC ADAPT research project (grant number EP/N024508/1) which is gratefully acknowledged. Richard Butler is supported by a Royal Academy of Engineering and GKN Aerospace Research Chair. Lucie Culliford’s PhD studentship is 50% funded by GKN Aerospace

A simple energy usage toolkit from manufacturing simulation data

A fundamental problem in energy management is the inability to clearly predict any possible energy saving opportunities. The cost of both under or overestimating potential returns on investment can be prohibitive to a decision maker. In recent years the simulation of energy usage using existing manufacturing simulation tools has increased in popularity among researchers, but it is energy managers who need to see the benefits of this discipline. This paper proposes an interactive manufacturing energy management tool which makes use of existing productivity simulation models for the prediction of energy usage. An interactive Microsoft® Excel® based tool is developed to control Lanner’s WITNESS® discrete-event simulation software using Microsoft® Visual Basic® for Applications. The tool has the ability to predict potential areas where energy saving opportunities can be made within a complex manufacturing line, and is accessible from management presentations and proposals. The interactivity of the tool provides an environment which facilitates efficient hypothesis testing. The paper includes an industrial case study where the approach was used to quantify theoretical savings from certain energy usage reduction scenarios within a complex automotive engine manufacturing line

Factory eco-efficiency modelling: data granularity and performance indicators

Eco-efficiency is becoming an increasingly important performance measure. Currently manufacturers rely on reactive methods such as auditing for assessment. There are still significant theoretical and practical barriers including a lack of knowledge regarding the selection and composition of appropriate data granularities, model quality to improve decision making, and split incentives between facilities and manufacturing asset management. The purpose of this paper is to show the application of an eco-efficiency modelling framework in the case of a fast-moving consumer goods factory. The framework composes resource and production data. These are analysed with respect to three data granularity factors, asset subdivision, time-step, and resource magnitude. Modelling is used to represent asset eco-efficiency across available subdivisions using performance indicators

A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines