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Energy Savings in the Real Production Environment


Besides these key comparison figures for the machine being used, the diecaster naturally always wants to know the total consumption of resources and, consequently, the costs per part produced in the real manufacturing scenario. Tis is the actual benchmark used in the competition between foundries. What actually counts for the overall optimization of energy consumption, therefore, is not only the reduc- tion of the electrical energy required for the machine, but also the energy required for melting the metal or to make additional resources available such as compressed air or cooling water. Further studies also have shown the spraying process is responsible for a disproportionally high portion of the total energy consumption because of the amount of compressed air energy it requires (Fig. 3). Tis is often underestimated when only electrical energy used in the casting cell is measured.


Energy Measurement Report Identifies Potential


An energy measurement report can provide concrete statements that represent the data captured in an actual pro-


实际生产环境中的节能


除对正在使用的压铸机的这些关键比较数据外, 压铸企业总是想了解真实生产环境中资源的总消耗以 及每个铸件的生产成本。这就是铸造企业在竞争中实 际的评价基准。因此,对综合能耗优化起作用的,不 仅在于降低设备所需的电能,还有金属熔炼所需的 能源,或者新增其他资源,如压缩空气或冷却水。进 一步的研究还表明,由于压缩空气的需求量上升, 喷涂是导致总能耗不成比例高出的那部分的原因(图 3)。当铸造单元中只测量电能消耗时,这一现象常 被低估。


能量测量报告凸显潜力


能量测量报告可以提供具体的信息,表明某个铸 件在实际生产条件下的各种数据以及数据之间的关


Fig. 5: Result of a fictitious calculation model for estimating the influence of the OEE and of the energy efficiency on energy savings and cost of parts. The model assumes the following: machine use


150 €/h, energy costs 0.09 €/kWh, energy consumption during pro- duction 7.728 kWh/cycle, stand-by energy consumption a) 4.694 kWh/cycle, b) 1.0 kWh/cycle. The costs of materials are not taken


into account. ∆OEE: improved OEE, ∆E: energy reduction, OEE0 original value prior to optimization of the OEE.


图5:为估算设备综合效率(OEE)和能效对节能和铸件成本 的影响而建立的模拟计算模型结果。该模型假设:设备150欧 元/小时,能源成本0.09欧元/千瓦时,生产中的能耗7.728千瓦 时/周期,待机能耗a)4.694千瓦时/周期,b)1.0千瓦时/周期。 材料成本未计算。∆OEE:提高的设备综合效率,∆E:减少的能 源,OEE0


:设备综合效率优化之前的原始值。


50 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2015


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