overview


common type used today, integral to consumer electronic devices, such as phones, computers and televisions. They are also used in large-scale applications in industrial motor systems and electricity transmission. PowerA- merica aims to make wide bandgap (WBG) semiconductor technolo- gies cost-competitive with silicon-based elec- tronics by developing critical WBG technolo- gies, spurring demand in high-value markets, supporting and growing a manufacturing base and building the US WBG semiconductor industry through education and training. Energy consump- tion and heat dissipa- tion through racks have increased as miniatur- ized semiconductors are arrayed in high-density processors at IT data centers that monitor and evaluate manufacturing processes and equipment. Such data centers, both within and outside of existing buildings, themselves require thermal management, often through refrigeration cooling systems at a signifi cant energy load. Researchers from Oregon State University’s Energy


Effi ciency Center (Corvallis, OR), in a paper from NAMRC 2014 (in press for SME’s Journal of Manufacturing Systems; http://tinyurl.com/JMS-datacenters), evaluated metrics developed to overcome the energy effi ciency and thermal management challenges at data centers. Measuring the per- formance of IT centers using a combination of metrics can increase the opportunity for considerable energy reduction. Microelectromechanical system (MEMS) technology has helped create wireless sensor networks (WSNs) for real-time environmental (indoor/outdoor), power, process automation and structural monitoring. The metrics explored include one of the most practiced ones, power usage effectiveness (PUE), as well as data center infrastructure energy (DCiE), rack cooling index (RCI), return temperature index (RTI) and supply and return heat indices (SHI, RHI). Future work is suggested on developing


a single metric—for a more straightforward approach—and optimizing operational adjustments based on real-time measurements to more effectively evaluate energy effi ciency and the impact of changes in data centers.


Hydrogen extracted from methane drawn from landfi lls fuels material-handling equipment at the BMW Manufacturing Co. plant in Spartanburg, SC. Shown here is the hydrogen storage and distribution area near the plant’s Energy Center.


At NAMRC 2015 in paper #118, Oregon State authors again discuss manufactur- ing energy analysis of microchannel heat exchangers for high-density servers. Use of microchannel process technol- ogy (MPT) devices to provide liquid cooling is hampered by high manufacturing cost and energy require- ments. Manufactur- ing process energy analysis of a micro-


channel heat exchanger is conducted and compared for photochemical machining and two joining methods, diffusion bonding and laser welding. The latter results in signifi cantly lower life cycle energy impact due to reduced process energy and improved yield.


Geographic Considerations for Solar, Wind A 1976 SME Technical Paper by a Honeywell manager of


solar energy technology described the basic problems stand- ing in the way of rapid commercialization of solar (http:// tinyurl.com/tp76pub78), both of which somewhat still apply today. First was the geographic mismatch among the south- west US’s high insolation (solar radiation received), the high heating requirements of the north and the high population density of the East Coast. Second was the high initial cost of installed systems and the relatively slow economic payback through the displacement of conventional fuel. In the automotive industry, energy use is intensive, making


greenhouse gas (GHG) emission reduction a signifi cant topic. A study reported in a NAMRC 2011 paper (http://tinyurl.com/ tp11pub34) assessed the GHG emission reduction potential of solar PV (photovoltaic), wind and fuel cells at six global General Motors sites, which were selected based on differ- ences in energy supply structure and geographic conditions.


24 — Energy Manufacturing 2015


Photo courtesy BMW Manufacturing Co.


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