Feature Energy Efficient Production


Flexibilty and energy cost saving are important aims of manufacturing system engineers, as Kistler Instruments explains


nergy saving is cur- rently vital in manufac- turing as increasing energy prices impose severe pressures on prof- itability. For example, Volkswagen CEO, Martin Winterkorn, is far from unique in seeking a 25% reduction in energy con- sumption at the company’s factories by the year 2018. Achieving such ambitious targets is neither easy nor simple and demands contri- butions from all parts of the company although the largest potential savings are to be found in the manufac- turing operation. However, making changes to produc- tion processes can be expen- sive and disruptive, which can negate the energy cost savings unless older, inflexible, energy hungry methods can be replaced with flexible, energy efficient methods that will quickly deliver signif- icantly lower operating costs.


Aiming for fast payback E


Calculation


Kistler’s core competence is the development, production and use of sensors for measuring pressure, force and acceleration


A production line equipped with six electro-mechanical press-fit processes will pro- duce a total saving of €60,000 (£51,000) per year on energy consumption, operating technology and maintenance cost compared with a hydraulic or pneu- matic system. This delivered a payback period of only 18 months - more than short enough to win board


approval for the installation.


The energy savings added up to several hun- dred thousand kWh per year, i.e. about two mil- lion kWh over the usual system service life.


One area where this can be achieved is in press- fit operations where old hydraulic and pneumatic systems can be replaced with current electro- mechanical joining systems with a very short pay- back period, plus the flexibility to respond quickly and economically to market demands. “We often find hydraulic joining systems on transmission and gearbox assembly lines, for example, where gears are pressed onto shafts or bearings and bushes. Several such systems are each supplied by a hydraulic unit,” explained Norbert Bäuml, global sales manager for joining systems at Kistler, “Hydraulic systems generate cost pools related to energy usage, maintenance, oil changes and space requirements. They need oil lines, a means to collect any fluid leakage as well as a cooling system. In addition, there is the regular need to change the oil in the hydraulic units. All of which consume both energy and money.”


Electro-mechanical joining systems only con- sume energy when they are actually performing pressing operations. They do not use oil and have very low maintenance requirements. Manufacturing engineers are able to design and install production processes that are more flexi- ble, quieter and cleaner, using electrical systems and more importantly, these systems reduce both maintenance and energy costs, compared with older hydraulic and pneumatic systems. The initial investment into electro-mechani- cal press-fit technology is greater than hydraulic or pneumatic technology. However, there are other important factors besides the initial


Automation FEBRUARY 2013 Other countries


In emerging countries like China and India, the energy costs might be lower, so the ROI will be somewhat slower. However, the energy supply is often not as secure as in western industrial nations which encourages planners of new instal- lations to concentrate on minimising energy con- sumption - this is what Electromechanical NC Joining Systems deliver.


Electromechanical NC joining systems from Kistler are coordinated systems with integrated sensor technology and powerful force displace- ment evaluation for complete process monitor- ing and documentation of all measurement results, for example, for usage in higher level quality systems.


Kistler Instruments www.kistler.co.uk T: 01256 741 550


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* More than 20,000 sensors. * Factory Automation. * Process Automation. * Hazardous Areas. * Harsh Environments. * Measurement & Inspection. * Miniature Sensors. * Vision Systems. * Machine Safety. * Vehicle Detection. * Flow & Temperature.


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investment. With mainte- nance and energy costs con- tinuing to increase, the lower operating costs of electro- mechanical systems means that the return on investment (ROI) begins almost immedi- ately, giving an exception- ally short payback period.


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