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Energy Consumption Evaluation in Stamping Workshops via a Discrete Event Simulation-Based Approach

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Abstract

Stamping is employed in a wide range of applications in industry, which is composed of discrete flow energy-intensive processes. Durations of stamping activities are much shorter than that of mold changing and transportation, which makes energy consumption in stamping workshops greatly affected by the production scheme and the proportion of transportation volume. Different from machining that has been widely discussed, there is less research on energy saving in stamping workshops. This paper aims to evaluate the energy consumption of stamping on the workshop level. A theoretical model and a discrete event simulation model were developed based on energy flow and material flow in the workshop. The theoretical model was used to calculate each component of energy consumption based on production-related data. The simulation model was used to predict the overall energy required in the workshop when subjected to changes in its production conditions. Impacts of influence factors, including machine failure rate, proportion of transportation volume, and production scheme on energy consumption, makespan, and machine utilization rates, were studied to find opportunities for energy reduction and production efficiency improvement. Finally, a case study of a stamping workshop for forklifts validated the proposed approach, and  optimization measures were suggested, implemented, and verified. Results have found that under the same production scheme (suppose each press has the same failure rate), the balance between energy use and makespan was achieved when the proportion of transportation volume was 1/2. This simulation-based approach provides a useful tool for evaluating and reducing energy consumption and helps operators to perform energy-saving actions in stamping workshops.

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Abbreviations

B t :

The proportion of transportation volume

C x :

Completion time of part x

C xi :

Completion time of process i of part x

DE :

Direct energy consumption

\(E_{m}^{{\text{S}}}\) :

Energy consumption of press m to startup

\(E_{{xin_{x} m}}^{{{\text{FF}}}}\) :

Energy consumption of fast falling (when process i of batch nx of part x is performed by press m)

\(E_{{xin_{x} m}}^{{{\text{SF}}}}\) :

Energy consumption of slow falling (when process i of batch nx of part x is performed by press m)

\(E_{{xin_{x} m}}^{{{\text{Pr}}}}\) :

Energy consumption of pressing (when process i of batch nx of part x is performed by press m)

\(E_{{xin_{x} m}}^{{{\text{FR}}}}\) :

Energy consumption of fast returning (when process i of batch nx of part x is performed by press m)

\(E_{xinxm}^{{{\text{SR}}}}\) :

Energy consumption of slow returning (when process i of batch nx of part x is performed by press m)

E P :

Energy consumed by processing

E M :

Energy consumed by stamping machining

E S :

Energy consumed by machine startup

E I :

Energy consumption in the period of machine idling

E T :

Energy consumed by transportation

F r :

Machine failure rate

I :

i = {1, 2, …, In}, The process for the part.

I x :

Number of processes that part x contains

IE :

Indirect energy consumption

K :

Replication number of the simulation

m :

m = {1, 2, …, M}, The set of machines for process i

n x :

nx = {1, 2, …, Nx}, The batch of the part

O xi :

Process i of part x

\(P_{m}^{{\text{S}}}\) :

Power of press m to startup

\(P_{{xin_{x} m}}^{{{\text{FF}}}}\) :

Power of fast falling (when process i of batch nx of part x is performed by press m)

\(P_{{xin_{x} m}}^{{{\text{SF}}}}\) :

Power of slow falling (when process i of batch nx of part x is performed by press m)

\(P_{{xin_{x} m}}^{{{\text{Pr}}}}\) :

Power of pressing (when process i of batch nx of part x is performed by press m)

\(P_{{xin_{x} m}}^{{{\text{FR}}}}\) :

Power of fast returning (when process i of batch nx of part x is performed by press m)

\(P_{{xin_{x} m}}^{{{\text{SR}}}}\) :

Power of slow returning (when process i of batch nx of part x is performed by press m)

\(P_{m}^{{\text{I}}}\) :

Power of idling of press m

P T :

Power of the equipment for transportation

\(P_{x}^{{\text{E}}}\) :

Power of relevant equipment for maintaining the working environment when producing part x

\(P_{xi}^{{\text{E}}}\) :

Power of relevant equipment for maintaining the working environment when producing process i of part x

Q xn :

Quantity of batch nx of part x

S :

Production scheme

\(t_{{xin_{x} m}}^{{\text{I}}}\) :

Duration of press m in the period of machine idling when process i of batch nx of part x is performed by press m

\(t_{{xin_{x} m}}^{{\text{T}}}\) :

Duration of transportation batch nx of part x when process i of batch nx of part x is performed by press m

T :

Makespan in the workshop

TE :

Total energy consumption in the workshop

U :

Machine utilization rates

x :

x = {1, 2, …, X}, The set of parts to be produced

α :

Decision variable, where α is ‘1’ if process i of batch nx of part x is performed by press m, and is ‘0’, otherwise

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant Number U20A20295).

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Authors and Affiliations

  1. Key Laboratory of Green Design and Manufacturing of Mechanical Industry, Hefei University of Technology, 193 Tunxi Road, Hefei, 230009, China

    Wei Xiong, Haihong Huang, Lei Li, Lei Gan, Libin Zhu & Zhifeng Liu

  2. School of Mechanical Engineering, Hefei University of Technology, 193 Tunxi Road, Hefei, 230009, China

    Wei Xiong, Haihong Huang, Lei Li, Lei Gan, Libin Zhu & Zhifeng Liu

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  1. Wei Xiong
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Appendices

Appendix 1

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Table 6 Production-related data in the stamping workshop
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6.

Appendix 2

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Table 7 Average values of energy consumption and makespan
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7.

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Xiong, W., Huang, H., Li, L. et al. Energy Consumption Evaluation in Stamping Workshops via a Discrete Event Simulation-Based Approach. Int. J. of Precis. Eng. and Manuf.-Green Tech. 9, 1543–1562 (2022). https://doi.org/10.1007/s40684-021-00411-x

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