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Energy-Efficient Product and Process Innovations in Production Engineering
Production Systems

Active Principles of Low-Energy, Intelligent Production Systems

On the one hand, the goal is the creation of an accounting framework and a scientific method for the determination of indicators for the evaluation of the energy efficiency on the equipment side. Here the energy-related aspects of production systems can be both qualitatively and quantitatively described and evaluated. In conjunction with the process-related accounting framework from the process chains field of action, this creates an important building block for the overall accounting of entire factory systems. On the other hand, the accounting framework is an important prerequisite for the second major objective of this field of action, namely the targeted reduction of the overall energy requirement of production systems through the development of methods, tools and solutions. Here the overall energy footprint of production systems can only be elevated to a new qualitative and quantitative level through the holistic optimisation of component efficiencies, the effective interaction of components within the overall system, the consistent application of the energy cycle principle and requirement-focussed energy management. The research results of the production systems field of action, as well as other eniPROD fields of action, are thus demonstrated on the basis of their overall interaction with a specially developed machine tool.


Energy Accounting and Management

The majority of the energy used by cutting machine tools connected to the main power supply is consumed in auxiliary systems. The proportion of the energy consumption attributed to machining is generally low. Auxiliary units in production systems contribute significantly to the total energy consumption of a production system. To date, there is no known holistic method for calculating the overall energy requirement which, alongside energy consumers such as the main and secondary drive systems, also takes account of auxiliary units as well as hydraulic, pneumatic and kinetic energy. Alongside energy utilisation on account of the optimised efficiency of the production system, in future the use of energy cycles (energy recovery) is set to increase in significance. Ensuring the energy-efficient open-loop and closed-loop control of electromechanical axes is another focus of the research.

Energy-Efficient Core Components

More energy-efficient core components make a con¬siderable contribution to reducing the overall energy requirement of machine tools, as a result of which they are an important research topic.
Within the field of action, the specific points of focus are the development of lightweight components, the development of components with minimal thermal expansion in order to reduce cooling cost, the establishment of energy harvesting and recuperation and the development of self-sufficient adaptronic components.

Energy-Optimised Structural Principles
Due to the interactions between individual components, reducing the energy consumption in machines and equipment requires hierarchical systems analyses and holistic optimisation strategies since, alongside purely energy-related aspects, classic functional and economic criteria must also be considered a priori. In particular, an increase in energy efficiency, while maintaining processing accuracy and productivity, thus requires comprehensive research work.

Heads of the Field of Action

Prof. Reimund Neugebauer

President of the Fraunhofer-Gesellschaft

Prof. Welf-Guntram Drossel

Professorship for Machine Tools and Forming Technology



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