SBM1300 Research Project: Energy Efficiency of Machines

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SBM1300 Research project
Assessment 2
Topic: Energy Efficiency of Machines
Student ID
Student Name

Contents
Introduction......................................................................................................................................3
Research Motivations......................................................................................................................4
Significance.....................................................................................................................................4
Research Questions..........................................................................................................................5
Need for analysis of energy efficiency of machines....................................................................5
Questions for analyzing the energy efficiency of machines........................................................5
Sub-questions for analyzing the energy efficiency of machines.................................................6
Literature Review............................................................................................................................6
Research Design and Methodology...............................................................................................12
Conclusion.....................................................................................................................................14
References......................................................................................................................................15

Introduction
This research paper is based on the energy competence of machines. The paper will provide an
overview of the approaches regarding the development of energy efficient models to determine
the consumption of energy by the machines at the manufacturing and production industries. The
research paper will discuss the motivation and the significance of the study highlights the
importance of energy efficiency of machines in increasing productivity and addressing the
emerging issue of the energy crisis. Several research papers will be approached for justifying the
issue and getting an overview of the different technologies that are introduced for determining
the consumption of energy by machines and tools for increasing the energy efficiency of
machines. Different research methodologies will be discussed along with the methods for the
collection of data regarding the energy efficiency of machines. The research paper will discuss
the challenges faced regarding maintaining the energy efficiency of machines and the
technological barriers in determining the efficiencies of the machines.

Research Motivations
The main objective of the research project is to address the issue regarding the energy
competence of the machines and determining the parameters guiding competence of the
machines. The motivation of this research project is from increasing rise in the price of energy
due to the depletion of the energy resources and the effect it is causing to the environment, with
an objective of addressing all this issue by improving the efficiency of the machines by the
conservation of energy with a sustainable energy management and reduction in the emissions
that are caused from the inefficient performance of the machine operations.
The energy efficiency of a machine determines the amount of useful energy or product that is
produced by a machine from its input. Research in the field us required for getting a clear view
of some of the concepts that are needed to be addressed to increase the efficiency of machines.
Many studies are carried out in order to prepare models and determine tools for calculating
energy consumption by machines. The issue needs to be addressed more in the manufacturing
industries as manufacturing industries are a major energy consuming and energy producing
sector and the energy efficiency is one of the key factors towards sustainability. The processing
of machines is basically based on the parameters that drive the energy consumption by the
machines and the rate of energy utilization by machines affect the production by the machine
(Kurtus, 2016).
Significance
The energy efficiency of the machine is concerned about how much energy is turned into a
useful form by the machines and the percentage of energy that is lost due to heat and friction
during the machine operation. The significance of this study is to address the imbalance that is
causing due to rising energy demands and the supply of energy. So the efficient use of energy by
the machines in the manufacturing industry is an emerging issue to be addressed in recent days.
It is important to suggest technologies for energy saving by minimizing the losses by the
machines. The operating skill of the machines needs to be addressed for increasing the efficiency
of the machine. The mechanized industries have now included the management of energy

efficiency of the machines as a factor for the decision making in the industry for decreasing the
maintenance cost of the machines, increasing flexibility and productivity of the industry (Spacey,
2017).
Research Questions
Need for analysis of energy efficiency of machines
The key aim of this research project is to identify the solutions regarding the issue of depleting
energy sources and the increasing rate of energy consumption by machines which in the case is
also affecting the environment with more carbon emission due to inefficient machines. The
energy efficiency of the machines is important to look after according to the rising energy cost
and the growing energy consumption and requirement in the market. The goal of reducing the
energy utilization of the machine is to increase the efficiency of the machines to produce better
manufacturing service and goods. The efficiency of a machine is also concerned with the amount
of energy that is lost due to the friction and heat loss during the time of its operations. The
efficiencies of machines also depend upon its design a compound machine has low efficiencies
compared to the efficiency of the simple machines compound machines contain more moving
parts which increase the friction and in turn increase the loss of energy due to friction (Green,
2015).
Questions for analyzing the energy efficiency of machines
Various question and sub-questions that are aroused and to be answered during addressing the
problem of decreasing the consumption of energy and increasing the efficiency of machines are
listed below:
Using the heat foams in increasing the performance of the machines that are involved in
the heat exchangers.
The energy consumption of machines is directly proportioned to the material of the
machines so the energy consumption of the machines is affected by the material of the
machine.

The rate of energy efficiency is increased by the performance of the machines that
depends upon the rate of production of finishing product.
Design of the machines influences the energy consumption and efficiency of the
machines.
Use of conservation voltage reduction (CVR) in the system of machines distribution can
affect the rate of energy consumption by machines.
The rate of the generation of the product is proportional to the energy efficiency of the
machine.
Sub-questions for analyzing the energy efficiency of machines
The structure of the material that is used for the production of the machine influence the
rate of production of the product as it influences the efficiency of the machine.
Increasing Efficiency of the machines is required for future loss of the company due to
investment in the maintenance of the machine.
Regular and proper maintenance of the machines helps in increasing the efficiency of the
machine.
Thermal insulation of the machines helps in saving energy and increases the efficiency of
the machine.
Turing the data into information’s that are actionable help in the increase in the efficiency
of machines and saves energy according to the speed of the demand.
The rate of power utilization by the machine is also affected by the rate of the feed of the
machine.
Literature Review
The efficiency of a machine depends upon the consumption of energy by the machine and the
state of the machine. Energy competence of the machine is determined by its rate of consumption
of energy from any small energy source and less wastage of energy.
According to the authors Zhou, Li, Li, Meng, Li, and Xu The consumption of energy by the
machines is growing at a continuous rate from the last decades. According to the authors, the
energy efficiency of machines is the long-lasting workability of the machine compared to an

older version of the machine with similar energy consumption by the machine also when a
machine produces the same amount of energy as in traditional machines but with less power
consumption. The specific utilization of energy is referred to the relationship between the
parameters involved in the processing of the power in the machine and the utilization of energy
by the machine that is reflected as the energy efficiency of the techniques and tools of machines
that is in the point of view of machine output according to the machine input. Due to the increase
in the price of energy utilization and the decrease in the resources of energy production
sustainability on energy consumption is introduced by the authors. In the manufacturing industry,
the evolution of the efficiency of the manufacturing machines and preparing models of energy
consumption by the tools are the basic steps for saving the consumption of energy by the
machines in the manufacturing industry. The manufacturing industry is facing problems
regarding the cost of interruption and productivity during the development of energy efficiency
or conservation models. The manufacturing industry is introducing certain tools such as
environment measurement of the machine tool, optimization tool, design tool and scheduling
organization tools for increasing the energy efficiency of machines in this industry. It has been
proved that the energy consumption by the machines during operations is greater than the energy
theta is calculated theoretically during the formation of the chip. The author’s categorized the
energy utilization of the machines into 3 different categories:
 First model based on the consumption of energy in a linear cutting type that is basically
on the rate of the removal of materials.
 The second model is based on the detailed parameter type modeling of the energy
utilization by the machines in the linear cutting model.
 The third model is about the consumption of energy in a different process that is involved
in the manufacturing industry.
The authors introduced two methods of improving the energy consumption by machines in their
research paper; the first is updating the current models of energy consumption of machines
through relationship analysis of processing condition in which the machine is operating, parts
tools and machine tools. Second is the introduction of a scientific index system of evaluation for
the evaluation if the energy competence of the machines (Zhou, Li, Li, Meng, Li and Xu, 2016).

According to the authors Apostolos, Alexios, Georgios, Panagiotis, and George, the evolution of
the energy efficiency of machines in the manufacturing industry is important as it proves to be
one of the biggest customers of energy with about 33% utilization of energy acrossthe globe and
the largest emitter of carbon. In manufacturing industry machines partially produces products
based on the input and the remaining portion of the input apart from the generation of useful
product turn into waste or as loss of heat. Machines only use the same part of the energy from the
input to produce the actual product and the best part of the energy is used for the other peripheral
function and losses. Due to the increase in the price, the manufacturing industries are now
focusing on the reduction of energy consumption by the machines and attaining sustainability
practices for energy consumption. Due to the increasing consumption of energy and the energy
loss new monitoring management tools are been introduced with an initiative to generate more
with less. A machine uses energy to produce the product as well as uses energy for the
processing of its parts for generating the end product (Apostolos, Alexios, Georgios, Panagiotis
and George, 2013).
According to the authors Gutowski et al. the energy required for the processing of the machine is
much higher than the energy that is required for the peripheral activities in the manufacturing
equipment in the process that involves the supply of the lubrication, technical aeration and the
coolant pumps attached to the machines. The machines involved in the production operational
unit uses energy by up to 13%. The energy efficiency of machines is defined as the ratio of
energy that is provided as an input ton the machine to the total quantity of energy theta is used by
the machine for the production of useful product apart from the machine losses. Mathematically
it is given as,
Eefm= E Energy input to the machine / E Total energy that is used by the machine
Where m = Machine
The primary step for achieving the energy efficiency of the machine is the categorization and
organization of the peripheral devices that are involved in the processing and manufacturing
processes. The peripheral process determines the machine output thus the energy utilization of a
single machine is to be estimated along with the side-line machines. So the consumption of

energy needs to be maintained at the production level for attaining flexibly at the cost of the
production and the time constraints (Gutowski et al, 2013).
According to the authors May, Barletta, Stahl and Taisch, the first and foremost step for
measuring the efficiency of energy are measuring the equipment performance, performance of
the factory environment and the performance of the peripheral equipment. Although the
measurement the efficiency of machines is a tough task to be accomplished so different tools and
techniques are evolving for the measuring of the efficiency of machines. Various energy
efficiency models for machines are prepared with the use of modern tools and technologies for
evaluating the energy consumption by the machines. The models that are developed for the
determining or defining the energy consumption of machines not only focus on detecting the
problem for reduced energy efficiency of a machine but also provide solutions for increasing the
efficiency of machines with less consumption of energy. The recent approaches that are used in
the industries are lacking the indicator that uses the energy use profiles for detecting the use of
power by the process and the machines. Thus Energy based performance indicators are now
introduced by various productions and manufacturing industries for determining the efficiency of
the machines. A model is developed with 7 steps procedure for developing energy focused and
production focused performance indicators that are the key to the manufacturing industries. The
model that is based on 7 steps of key indicators is termed as e-KPIs that basically operate in the
relationship based on cause-effect. The model identifies the area of weakness for the decreasing
energy competence of the machine and defines the areas of improvement of energy competence
in the manufacture unit of the industries (May, Barletta, Stahl and Taisch, 2015).
According to the authors Bernoulli reliability model, the main economical procedure for
increasing the energy competence of machines in the manufacturing unit is the control in energy
consumption in the production unit of an industry. The authors discussed the reduction of the
consumption of energy by the machines through scheduled starting and shutting off machines. A
model is developed for the situations of production where the cycle time of the machine is more
than the downtime of the machine that is named as Bernoulli reliability model for the machines.
This model is applicable to the machines at the automotive paint industries and all-purpose
assembly. With the use of the transient system analysis, a technique for the evolution of the
machine analytical performance is developed for the serial lines of Bernoulli with the machine

efficiencies that are dependent on time. By the use of this model or tool, the engineers at the
manufacturing and the production unit can easily predict the performance of machines in terms
of it efficiency depending on the input based on real-time with the high amount of accuracy.
According to the line of the requirement if the manufacture activities the model or the tools can
determine the proper starting and shutdown time of the machines. This method of preparation of
schedule based on machine operation of machines proves to increase the energy efficiency of
machines defining less loss of energy (Bernoulli reliability model, 2012).
According to the authors, Ruiz, Fontes and Silva, the use of the parallel manipulators in the
industries can help in achieving a higher energy efficiency of machines. Serial manipulators are
mostly been used by the industries as the parallel manipulators have a drawback of singularity at
the operational units. For increasing the efficiency of the kinematic machines parallel
manipulators are used that is coupled or added with a redundancy. A novel technologies based on
the hierarchy are discussed by the authors in this paper. This involves the management if a single
machine according to the application level. Novel lubrication and systems for assisted machining
are the technologies that are used for detecting the level of energy consumption by the machines.
The new machines based on energy efficiency are expected to be more lightweight and more
compact compared to traditional machine tools. The measurement of the efficiency of machines
is important to ensure energy saving for another sector in the industry (Ruiz, Fontes and Silva,
2015).
According to the author Salonitis and Ball, the efficiency of a machine is determined by
monitoring the energy utilization of the machine. There are several types of designs of machines
that have evolved for minimizing the energy consumption by machines and increasing
efficiency. Many recent types of research are carried out for dealing with the issue of energy
efficiency of machines in the manufacturing industry. Several methods are introduced regarding
the measurement of the energy use by a machine, Unit process energy method and Energy blocks
methods are such two such methods to determine the consumption of energy. Modeling tools are
introduced for determining the rate of consumption of energy by the machines. The total amount
of energy that is consumed by machines is dependent on two factors the energy required for
processing on the machine and the energy consumed by the peripheral subsystems.

Mathematically the total energy consumption by a machine tool for performing its activity is
given as:
E total = E process + E peripherals
Where,
E process is the physical energy essential to run the procedure on the machine that is depending on
the process mechanics.
E Peripherals is the extra amount of energy that is required or utilized by the tools of the machines.
All the manufacturing process holds a common characteristic irrespective of conventional
processor non-conventional process that is even an idle machine consumes or utilizes almost
50% of the maximum power that is generated to it so a productive or better machine design can
help in the reduction of energy consumption by the machine for example: Using a common
peripheral system that for linking different machines systems. Optimizing the strategy of the
manufacturing process can also reduce the energy utilization by machines and thus increasing the
efficiency of machines. The energy efficiency of machines is supported by increasing the
competence of the mechanized process. Thus the models and methods of energy consumption by
machines are for evaluating or comparing the integral efficiency of energy consumption by the
machines at production, technological processes, and all the technological machines. Lifecycle
impact assessment methodology is used for determining the ecological footprints for the
consumption of energy by various machines for specified work. A machine contains different
types of auxiliary components and motors and the energy consumed by these auxiliary
components differ during the different machine operations. Various chemical-based methods and
models are also used for determining the process of production and the energy consumption by
the machines. The increases in the consumption of energy due to the low efficiency of machines
are increasing the cost of energy. During the operation of roughing the system of cooling and the
main system, the drive is used for the reduction of the energy utilization of the machines but the
power utilization of this machines are less during the finishing operations of the machines.
Various technologies are used nowadays to check the efficiency of the machines for checking the
effectiveness of the machines (Salonitis and Ball, 2013).

Research Design and Methodology
Different research methodologies are identified for determining the efficiency of machines
during the manufacturing process. Depending on the research work on the energy efficiency of
machines from various journals, conference articles, project reports and research on the energy
consumption policies of machines following methods are identified for finding the efficiency of
machines:
Overall Machine Effectiveness (OEE): Overall machine effectiveness is used to measure
the performance of a machine along with its availability and the scores based on the
quality of the product it is generating with consumption of less energy. The performance
scores of the machine, the quality percentage, and the availability if the machines are
multiplied to obtain the effectiveness or the performance of the machines that ultimately
determines the energy efficiency of the machine.
Energy Consumption Model: Cutting type modeling, detailed parameter type modeling
and modeling based on consumption of energy in the manufacture procedure are some of
the energy utilization models that are prepared for defining and finding the efficiency of
machines. These modeling’s are to determine the current efficiency of the machine and
determining ways to increase efficiency.
Bernoulli reliability model: This model proves to be an effective method to determine the
efficiency of machines. The operational efficiency of a machine is increased when more
than one operation is performed on it at the same point of time.
Novel Hierarchy: For the management if a single machine efficiency and the level of
application of the machine novel hierarchy is the best-prepared methodology. These new
technologies are for improving the efficiency of the machines (Kurtus, 2016).
Correlation models of cutting energy: Cutting tool performs certain functions to increase
the machine efficiency at the time of load when multiple operations are feed on the
machine at the same point of time. The efficiency of a machine is straight proportioning
to its cutting edge.
Energy Algorithm: The physical state of the machine determines the rate of consumption
of energy by the machine. The working method or structure that is followed by a machine
determines the energy algorithm of the machine.