For years, energy efficiency throughout all lifecycle phases of a machine has been one of the main focuses of the company. For the user this means a reduction of the overall process costs while maintaining a consistently high level of productivity, quality and reliability of the machine. Tis competence has now
been complemented by manu- facturing technology that ad- dresses sustainability concerns, resulting in cost reduction. We provide three elements as the basis for higher energy efficiency: consumption-opti- mized machine components, needs-oriented project-plan- ning, and optimized machining processes.
Automotive Demands Energy Accountability For some time, our automo-
tive customers have placed a focus on energy efficiency in their performance specifica- tions. For this purpose, the use of components and assemblies in the machine tools—motors and pumps, for example—is determined by the component approval process. At the same time, there are requirements in terms of soſtware and maxi- mum pressures used in pneu- matic systems. It is no longer sufficient to provide the electri- cal supply data of a manufac- turing system. Instead, a clear statement on energy consump- tion must be provided. Here are some examples: • State-of-the-art drive technology with energy recovery in regenerative mode.
• Use of hydraulic valves providing the possibility to reduce energy demand from 30 to 8 W.
• Standby solutions provided by the CNC control, e.g. allowing the switching off of motors progressively when not in use.
• Outside temperature guided, requirements-based cooling capacity, using one unit for a number of differ- ent cooling tasks.
According to our definition, a machine or system reaches
the highest level of efficiency when it achieves a specified productivity. Tis, for example, includes progressive shutdown of the control by means of standby mode. Each new machine tool from Heller comes with many ways to optimize energy con- sumption of the machine components. Tis includes individual regulation of chip conveyors or pressure regu- lation during coolant unit run times and run-on times. Motors can be adjusted to the machine requirements. Energy consumption can also be reduced by us- ing drive modules with lower power ratings. Heller machines have been using low-watt valves for years and we focus on having just one cooling system in the overall machine. State-of-the-art simula-
tion technology enables us to reduce moving masses and with that the electri- cal energy required for generating highly dynamic movements. Also, we continue to col-
laborate with other manu- facturers of machines and components. Partly with the support of BMBF (the German Federal Ministry of Education and Research) we have been able to optimize the necessary periph- eral equipment including hydraulics, coolant or refrig- eration units.
In terms of machine design, machine concepts with
optimized topology, or mechanical structure, provide high material damping. As a result, process stability increases and cycle times decrease while power requirements are cut. Te thermally stable machine concept illustrates the tremendous energy savings that can be achieved. It minimizes thermal growth, reduces warm-up times, and eliminates the need for extensive shop air conditioning. In single-shiſt operation, energy savings of up to 6% can be
achieved simply by reducing the warm-up phase. Significant savings potentials also result from standby strategies, such as
Motorized Vehicle Manufacturing 75
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