Manufacturers are increasingly looking at ways to reduce operating costs through energy
savings. While research has been done to identify energy usage throughout a facility--such as
lighting, computers, heating and cooling--very little research has been done on reducing the
energy consumption of manufacturing equipment. Sample literature review shows the bulk of
research on equipment is for tip energy, the energy when a tool makes contact with a work piece.
This excludes the energy of all the machine’s background processes: motors, pumps, fans, etc.
Several models have been created to predict the energy usage of a machine including both the tip
energy and the energy of the background processes; however, these models are experimental
laboratory studies. The purpose of this thesis is to collect and analyze real-time data of
manufacturing equipment in a production setting. Real-time data is important to understand
energy consumption at the machine level and the product level. This thesis reports on a method
to collect and analyze real-time manufacturing equipment energy data for a simple part. It also
reports on the use of that data to validate the uplci method to estimate the energy consumed for a
part using three uplci’s: turret punch uplci, brake forming uplci and drilling uplci. A data logger
recorder was connected to each machine to record the energy usage as it produced parts. This
data was then broken down into energy modes and analyzed. The results for each machine
showed how the machine utilized energy as it produced parts. The real-time data did not validate
the uplci calculations; however, the method to collect the real-time data was proven and shown
to be easily repeatable by manufacturers. This research provides a solid method for
manufacturers to use to identify areas to reduce their energy costs through improved production
scheduling and CNC programming. / Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Industrial and Manufacturing Engineering.
| Identifer | oai:union.ndltd.org:WICHITA/oai:soar.wichita.edu:10057/3475 |
| Date | 08 1900 |
| Creators | Corcoran, Samantha L. |
| Contributors | Twomey, Janet M. |
| Publisher | Wichita State University |
| Source Sets | Wichita State University |
| Language | en_US |
| Detected Language | English |
| Type | Thesis |
| Format | ix, 79 p. |
| Rights | Copyright Samantha L. Corcoran, 2010. All rights reserved |
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