Sustainable Manufacturing Systems: An Energy Perspective

Description

Sustainable Manufacturing Systems Learn more about energy efficiency in traditional and advanced manufacturing settings with this leading and authoritative resource Sustainable Manufacturing Systems: An Energy Perspective delivers a comprehensive analysis of energy efficiency in sustainable manufacturing. The book presents manufacturing modeling methods and energy efficiency evaluation and improvement methods for different manufacturing systems. It allows industry professionals to understand the methodologies and techniques being embraced around the world that lead to advanced energy management. The book offers readers a comprehensive and systematic theoretical foundation for novel manufacturing system modeling, analysis, and control. It concludes with a summary of the insights and applications contained within and a discussion of future research issues that have yet to be grappled with. Sustainable Manufacturing Systems answers the questions that energy customers, managers, decision makers, and researchers have been asking about sustainable manufacturing. The book’s release coincides with recent and profound advances in smart grid applications and will serve as a practical tool to assist industrial engineers in furthering the green revolution. Readers will also benefit from: A thorough introduction to energy efficiency in manufacturing systems, including the current state of research and research methodologies An exploration of the development of manufacturing methodologies, including mathematical modeling for manufacturing systems and energy efficiency characterization in manufacturing systems An analysis of the applications of various methodologies, including electricity demand response for manufacturing systems and energy control and optimization for manufacturing systems utilizing combined heat and power systems A discussion of energy efficiency in advanced manufacturing systems, like stereolithography additive manufacturing and cellulosic biofuel manufacturing systems Perfect for researchers, undergraduate students, and graduate students in engineering disciplines, especially for those majoring in industrial, mechanical, electrical, and environmental engineering, Sustainable Manufacturing Systems will also earn a place in the libraries of management and business students interested in manufacturing system cost performance and energy management. Cover Title Page Copyright Page Contents Author Biography Preface Acknowledgments List of Figures Part I Introductions to Energy Efficiency in Manufacturing Systems Chapter 1 Introduction 1.1 Definitions and Practices of Sustainable Manufacturing 1.1.1 Current Status of Manufacturing Industry 1.1.2 Sustainability in the Manufacturing Sector and Associated Impacts 1.1.3 Sustainable Manufacturing Practices 1.2 Fundamental of Manufacturing Systems 1.2.1 Stages of Product Manufacturing 1.2.2 Classification of Manufacturing Systems 1.2.2.1 Job Shop 1.2.2.2 Project Shop 1.2.2.3 Cellular System 1.2.2.4 Flow Line 1.2.2.5 Continuous System 1.3 Problem Statement and Scope Problems References Chapter 2 Energy Efficiency in Manufacturing Systems 2.1 Energy Consumption in Manufacturing Systems 2.1.1 Energy and Power Basics 2.1.2 Energy Generation 2.1.2.1 Primary Energy 2.1.2.2 Secondary Energy 2.1.3 Energy Distribution 2.1.3.1 Electricity 2.1.3.2 Steam 2.1.3.3 Compressed Air 2.1.4 Energy Consumption 2.1.4.1 Indirect End Use 2.1.4.2 Direct Process End Use 2.1.4.3 Direct Non-process End Use 2.2 Energy Saving Potentials and Energy Management Strategies for Manufacturing Systems 2.2.1 Machine Level 2.2.1.1 Intrinsic Characteristics of Machine Tools 2.2.1.2 Processing Conditions 2.2.2 System Level 2.2.2.1 Inhomogeneous System 2.2.2.2 Machine Maintenance 2.2.3 Plant Level 2.2.3.1 Indirect End Use 2.2.3.2 Direct Non-process End Use 2.3 Demand-side Energy Management 2.3.1 Electricity Bill Components 2.3.1.1 Electricity Cost 2.3.1.2 Demand Cost 2.3.1.3 Fixed Cost 2.3.2 Energy Efficiency Programs 2.3.3 Demand Response Programs 2.3.3.1 Incentive-based Programs 2.3.3.2 Price Base Options Problems References Part II Mathematical Tools and Modeling Basics Chapter 3 Mathematical Tools 3.1 Probability 3.1.1 Fundamentals of Probability Theory 3.1.1.1 Basics of Probability Theory 3.1.1.2 Axioms of Probability Theory 3.1.1.3 Conditional Probability and Independence 3.1.1.4 Total Probability Theorem 3.1.1.5 Bayes´ Law 3.1.2 Random Variables 3.1.2.1 Discrete Random Variables 3.1.2.2 Continuous Random Variables 3.1.3 Random Process 3.1.3.1 Discrete-time Markov Chain 3.1.3.2 Continuous-time Markov Chain 3.2 Petri Net 3.2.1 Formal Definition of Petri Net 3.2.1.1 Definition of Petri Net Execution Rules of Petri Net 3.2.2 Classical Petri Net 3.2.2.1 State Machine Petri Net 3.2.2.2 Marked Graph 3.2.2.3 Systematic Modeling Methods 3.2.3 Deterministic Timed Petri Net 3.2.4 Stochastic Petri Net 3.3 Optimization Methods 3.3.1 Fundamentals of Optimization 3.3.1.1 Objective Function 3.3.1.2 Decision Variables 3.3.1.3 Constraints 3.3.1.4 Local and Global Optimum 3.3.1.5 Near-optimal Solutions 3.3.1.6 Single-objective and Multi-objective Optimization 3.3.1.7 Deterministic and Stochastic Optimization 3.3.2 Genetic Algorithms 3.3.2.1 Initialization 3.3.2.2 Evaluation 3.3.2.3 Selection 3.3.2.4 Crossover 3.3.2.5 Mutation 3.3.2.6 Termination Criteria 3.3.3 Particle Swarm Optimizer (PSO) 3.3.3.1 Initialization 3.3.3.2 Evaluation 3.3.3.3 Personal and Global Best Positions 3.3.3.4 Updating Velocity and Position 3.3.3.5 Termination Criteria Problems References Chapter 4 Mathematical Modeling of Manufacturing Systems 4.1 Basics in Manufacturing System Modeling 4.1.1 Structure of Manufacturing Systems 4.1.1.1 Basic Components 4.1.1.2 Structural Modeling 4.1.1.3 Types of Manufacturing Systems 4.1.2 Mathematical Models of Machines and Buffers 4.1.2.1 Timing Issues for Machines 4.1.2.2 Machine Reliability Models 4.1.2.3 Parameters of Aggregated Machines 4.1.2.4 Mathematical Model of Buffers 4.1.2.5 Interaction Between Machines and Buffers 4.1.2.6 Buffer State Transition 4.1.2.7 Blockage and Starvation 4.1.3 Performance Measures 4.1.3.1 Blockage and Starvation 4.1.3.2 Production Rate and Throughput 4.1.3.3 Work-in-process 4.2 Two-machine Production Lines 4.2.1 Conventions and Notations 4.2.1.1 Assumptions 4.2.1.2 Notations 4.2.2 State Transition 4.2.2.1 State Transition Probabilities 4.2.2.2 System Dynamics 4.2.3 Steady-state Probabilities 4.2.3.1 Identical Machines 4.2.3.2 Nonidentical Machines 4.2.4 Performance Measures 4.2.4.1 Blockage and Starvation 4.2.4.2 Production Rate 4.2.4.3 Work-in-process 4.3 Multi-machine Production Lines 4.3.1 Assumptions and Notations 4.3.1.1 Assumptions 4.3.1.2 Notations 4.3.2 State Transition 4.3.2.1 State Transition Probabilities 4.3.2.2 System Dynamics 4.3.3 Performance Measures 4.3.3.1 Blockage and Starvation 4.3.3.2 Production Rate 4.3.3.3 Work-in-process 4.3.4 System Modeling with Iteration-based Method 4.4 Production Lines Coupled with Material Handling Systems 4.4.1 Assumptions and Notations 4.4.1.1 Assumptions 4.4.1.2 Notations 4.4.2 State Transition and Performance 4.4.2.1 Blockage and Starvation 4.4.2.2 Production Rate Problems References Chapter 5 Energy Efficiency Characterization in Manufacturing Systems 5.1 Energy Consumption Modeling 5.1.1 Operation-based Energy Modeling 5.1.2 Component-based Energy Modeling 5.1.3 System-level Energy Modeling 5.2 Energy Cost Modeling 5.2.1 Energy Cost Under Flat Rate 5.2.1.1 Energy Consumption Cost 5.2.1.2 Demand Cost 5.2.2 Energy Cost Under Time-of-use Rate 5.2.2.1 Energy Consumption Cost 5.2.2.2 Demand Cost 5.2.3 Energy Cost Under Critical Peak Price (CPP) 5.2.3.1 Energy Consumption Cost 5.2.3.2 Demand Cost Problems References Part III Energy Management in Typical Manufacturing Systems Chapter 6 Electricity Demand Response for Manufacturing Systems 6.1 Time-of-use Pricing for Manufacturing Systems 6.1.1 Introduction to TOU 6.1.2 Survey of TOU Pricing in US Utilities 6.1.3 Comparison of Energy Cost Between Flat Rate and TOU Rates 6.2 TOU-based Production Scheduling for Manufacturing Systems 6.2.1 Manufacturing Systems Modeling 6.2.2 Energy Consumption and Energy Cost Modeling 6.2.3 Production Scheduling for TOU-based Demand Response 6.2.3.1 Production Scheduling Problem Formulation 6.2.3.2 PSO Algorithm for Near-optimal Solutions 6.2.3.3 Case Study Setup 6.2.3.4 Optimal Production Schedules 6.3 Critical Peak Pricing for Manufacturing Systems 6.3.1 Introduction to Critical Peak Pricing (CPP) 6.3.2 Comparison of Energy Cost Between TOU and CPP Rates Problems Appendix 3.A Supplementary Information of Demand Response Tariffs References Chapter 7 Energy Control and Optimization for Manufacturing Systems Utilizing Combined Heat and Power System 7.1 Introduction to Combined Heat and Power System 7.2 Problem Definition and Modeling 7.2.1 Objective Function 7.2.1.1 Electricity Cost 7.2.1.2 Operation Cost for the CHP System and Boiler 7.2.2 Constraints 7.3 Solution Approach 7.3.1 Initialization 7.3.2 Evaluation 7.3.3 Updating Process 7.4 Case Study 7.4.1 Case Study Settings 7.4.2 Results and Discussions Problems References Chapter 8 Plant-level Energy Management for Combined Manufacturing and HVAC System 8.1 Definition and Modeling 8.1.1 Objective Function 8.1.1.1 Calculate TEL(t) 8.1.1.2 Estimate q(t) 8.1.2 Constraints 8.2 Solution Approach 8.2.1 Initialization 8.2.2 Evaluation 8.2.3 Updating Process 8.3 Case Study 8.3.1 Model Settings 8.3.2 Results and Discussions Problems References Part IV Energy Management in Advanced Manufacturing Systems Chapter 9 Energy Analysis of Stereolithography-based Additive Manufacturing 9.1 Introduction to Additive Manufacturing 9.1.1 Illustration of MIP SL-based AM Process 9.2 Energy Consumption Modeling 9.2.1 Energy Consumption of UV Curing Process 9.2.2 Energy Consumption of Building Platform Movement 9.2.3 Energy Consumption of Cooling System 9.3 Experimentation 9.3.1 Experiment Design Methodology 9.3.2 Experiment Apparatus 9.4 Results and Discussions 9.4.1 Baseline Case Results Using Default Conditions 9.4.2 Factorial Analysis Results 9.4.3 Product Quality Comparison Problems References Chapter 10 Energy Efficiency Modeling and Optimization of Cellulosic Biofuel Manufacturing System 10.1 Introduction to Cellulosic Biofuel Manufacturing 10.2 Energy Modeling of Cellulosic Biofuel Production 10.2.1 Energy Modeling of Biomass Size Reduction Process 10.2.2 Energy Modeling of Biofuel Chemical Conversion Processes 10.2.2.1 Heating Energy 10.2.2.2 Energy Loss 10.2.2.3 Reaction Energy 10.2.2.4 Energy Recovery 10.2.2.5 Total Energy Consumption 10.3 Energy Consumption Optimization Using PSO 10.3.1 Problem Formulation 10.3.2 Solution Procedures 10.3.2.1 Initialization 10.3.2.2 Evaluation 10.3.2.3 Updating Process 10.4 Case Study 10.4.1 Case Settings 10.4.2 Energy Analysis of Baseline Case 10.4.2.1 Energy Consumption Breakdown 10.4.3 Energy Analysis of Optimal Results Problems References Chapter 11 Energy-consumption Minimized Scheduling of Flexible Manufacturing Systems 11.1 Introduction 11.2 Construction of Place-timed PN for FMS Scheduling 11.2.1 Basic Definitions of PN 11.2.2 Place-timed PN Scheduling Models of FMS 11.3 Energy Consumption Functions 11.3.1 Calculating the Earliest Firing Time of Transitions 11.3.2 Two Energy Consumption Functions 11.3.2.1 Energy Consumption Function E1 11.3.2.2 Energy Consumption Function E2 11.4 Dynamic Programming for Scheduling FMS 11.4.1 Formulation of DP for FMSs 11.4.1.1 States and Stages 11.4.1.2 State Transition Equation 11.4.1.3 Bellman Equation 11.4.2 Reachability Graph of PNS 11.4.3 DP Implementation for Scheduling FMS 11.5 Modified Dynamic Programming for Scheduling FMS 11.5.1 Evaluation Function of Transition Sequences 11.5.2 Heuristic Function 11.5.3 MDP Algorithm for FMS Scheduling 11.6 Case Study 11.7 Summary Problems References Part V Summaries and Conclusions Chapter 12 Research Trends and Future Directions in Sustainable Industrial Development 12.1 Insights into Sustainable Industrial Development 12.2 Energy and Resource Efficiency in Manufacturing 12.2.1 Equipment Design 12.2.2 Smart Manufacturing 12.3 Industrial Symbiosis 12.4 Supply Chain Management 12.5 Circular Economy 12.6 Life Cycle Assessment References Glossary Acronyms Index EULA