Towards Energy Transparent Factories (Sustainable Production, Life Cycle Engineering and Management)

"This monograph provides a methodological approach for establishing demand-oriented levels of energy transparency of factories. The author presents a systematic indication of energy drivers and cost factors, taking into account the interdependencies between facility and production domains. Particular attention is given to energy flow metering and monitoring. Readers will also be provided with an in-depth description of a planning tool which allows for systematically deriving suitable metering points in complex factory environments. The target audience primarily comprises researchers and experts in the field of factory planning, but the book may also be beneficial for graduate students." -- Orbis Yale University Library Foreword 6 Acknowledgments 7 Contents 9 List of Figures 12 List of Tables 21 Symbols 24 Abbreviations 27 1 Introduction 29 1.1 Present Situation and Problem Statement 29 1.2 Research Objective and Problem Solving Approach 34 References 36 2 Energy Flows in Factories 38 2.1 Factory Environment 38 2.1.1 Levels of Abstraction Within a Factory 39 2.1.2 Functional Structure of a Factory 40 2.1.3 Entities of a Factory 42 2.2 Energy Flows and Energy Conversion in Factories 44 2.2.1 Definition of Energy and Related Terms 44 2.2.2 Energy Types at the Factory Gate 47 2.2.3 Factory Internal Energy Conversion for End Usage 51 2.2.4 Dynamics of Energy Utilisation and Related Cost Factors 58 References 63 3 Energy Management in Factories 65 3.1 Energy Management from Facility and Production Perspective 65 3.1.1 Energy Management from a Technical Facility Perspective 66 3.1.2 Energy Management from a Production Perspective 68 3.1.3 Integrated Energy Management 70 3.2 Energy Flow Data Acquisition and Automation 71 3.2.1 Energy Flow Data Acquisition 71 3.2.1.1 Liquid, Steam and Gas Flow Measurement 78 3.2.2 Factory Automation Systems 81 3.2.3 Building Automation Systems 83 3.3 Review of the State of the Art and Barriers for Integrated Solutions 85 References 92 4 Approaches for Energy Data Acquisitioning and Monitoring 96 4.1 Background for Selecting and Evaluating Existing Approaches 96 4.2 Investigation of Adjacent Fields of Research 100 4.3 Review of Energy and Data Acquisition and Monitoring Approaches 102 4.4 Discussion and Comparison of the Review 109 4.5 Derivation of Further Research Demand 112 References 115 5 Concept for Energy Transparent Factories 119 5.1 Synthesis of Requirements into Concept Specifications 119 5.1.1 Energy Transparency 121 5.1.2 Holistic Factory View and Relevant Entities and Flows 124 5.2 Conceptual Framework 126 5.2.1 Factors Influencing Metering Strategies 127 5.2.2 Derivation of the Conceptual Framework 129 5.3 Planning Tool for Metering Strategies 133 5.3.1 Transparency Objectives 133 5.3.2 Factory System Modelling 144 5.3.3 Guided Decision Support 158 5.3.4 Metering Strategy Formulation 167 5.4 Toolbox for the Operation of Energy Monitoring 199 5.4.1 Integrated Energy Management 199 5.4.2 Energy Transparency Cockpit 211 References 225 6 Application of Concept 229 6.1 Application Case: Die Lernfabrik---A Research Lab 229 6.1.1 Energy Cockpit 232 6.1.2 EnyFlow---Energy Flows Made Transparent 235 6.1.3 Dynamic Energy Value Stream Monitor 238 6.2 Application Case: Battery Lab Factory Braunschweig 241 6.2.1 Transparency Objective 241 6.2.2 Factory System Modelling 242 6.2.3 Decision Support 243 6.2.4 Metering Strategy Formulation 244 6.2.5 Energy Transparent Z-Folding Machine 247 6.3 Application Case: Electronics Production 249 6.3.1 Transparency Objectives 249 6.3.2 Factory System Modelling 250 6.3.3 Decision Support 251 6.3.4 Metering Strategy Formulation 252 6.3.5 Energy Aware Enterprise Resource Planning 255 References 257 7 Summary and Outlook 258 7.1 Summary 258 7.2 Concept Evaluation 262 7.3 Outlook 264 Reference 266 Appendix A: Extending Tables and Figures 267 Appendix B: Excursus 280 Previous Publications of the Author 304 Front Matter....Pages i-xxxii Introduction....Pages 1-9 Energy Flows in Factories....Pages 11-37 Energy Management in Factories....Pages 39-69 Approaches for Energy Data Acquisitioning and Monitoring....Pages 71-93 Concept for Energy Transparent Factories....Pages 95-204 Application of Concept....Pages 205-233 Summary and Outlook....Pages 235-243 Back Matter....Pages 245-284