Integrated Planning of Heat Flows in Production Systems (eBook)

Foreword 6
Acknowledgements 8
Contents 10
Acronyms 12
List of Figures 17
List of Tables 22
1 Introduction 24
1.1 Motivation and Problem Statement 24
1.2 Research Objective and Work Structure 29
References 31
2 Heat Flows in Production Systems and its Modeling and Simulation 33
2.1 Heat Flows in Production Systems 33
2.1.1 Production Management 33
2.1.2 Hierarchy Levels and Factory of the Future Understanding 35
2.1.3 Flows in Production Systems 37
2.1.4 Handling Complexity of Production Systems 43
2.2 Modeling and Simulation of Heat Flows in Production Systems 45
2.2.1 Simulation Paradigms 47
2.2.2 Multi-level Simulation in Production Systems 49
2.2.3 Heat Integration 50
2.2.4 Heat Pinch Analysis and Design 52
2.2.5 Mathematical Modeling and Optimization 58
2.3 Preliminary Conclusion 59
References 61
3 State of Research 66
3.1 Definition of Evaluation Criteria 66
3.2 Delimitation of Adjacent Fields of Research 73
3.3 Review of Relevant Research Approaches 77
3.4 Discussion of the Review and Future Research Demand 82
References 85
4 Concept for an Integrated Planning of Heat Flows in Production Systems 91
4.1 Formulation of Concept Objectives and Requirements 91
4.2 Derived Production System Perspective 95
4.3 Concept Development 100
4.3.1 Conceptual Frame 101
4.3.2 Allocation of System Levels and Methods 107
4.4 Methods for Identification/Quantification (II) 108
4.4.1 Machine Behavior Model Gallery (A) 109
4.4.2 TBS Behavior Model Gallery (B) 133
4.4.3 Production System Planning and Control Behavior Model (C) 153
4.4.4 (Waste) Heat Integration (D) 162
4.4.5 (Waste) Heat Targeting (D1) 165
4.4.6 (Waste) Heat Improved Design (D2) 170
4.4.7 (Waste) Heat Storage Placing (E) 173
4.4.8 Data Consolidation (F) 178
4.5 Analysis and Visualization (III) 180
4.5.1 Machine Heat Map (*A) 181
4.5.2 Machine and TBS Related Energy Value Stream Mapping (*B) 183
4.5.3 Production Performance Indicator Calculations and Visualization (*C) 185
4.5.4 (Waste) Heat Design Options (*D) 190
4.5.5 (Waste) Heat Storage Positions (*E) 191
4.6 Application Procedure 193
References 199
5 Exemplary Application of Concept 206
5.1 Components Manufacturing 207
5.2 Cooling Water System 218
5.3 Integration into Learning Factory 229
References 236
6 Summary and Outlook 237
6.1 Summary 237
6.2 Critical Review 239
6.3 Outlook 241
References 243
Appendix A Further Exemplary Machine Type Models 245
A.1 Hard Chrome Plating Model 245
A.2 Die Casting Machine Model 254
A.3 Heat Treatment Model 256
Appendix B Data Tables for the Cooling Tower(s) Model 259
B.1 Material Values of Saturated Air 259
B.2 Enthalpy-Dependent Temperatures and Water Loads of Saturated Air 260