A Solution For Establishing Product-Manufacturing-Energy-Consumption Allowance In Discrete Manufacturing Industry

The manufacturing industry consumes a lot of energy with great low energy efficiency.Therefore, there exist great potentials in the energy saving and emission reduction for the manufacturing industry. It is a hot topic to strengthen energy management for higher energy efficiency, which has been widely studied.The product- manufacturing-energy-consumption allowance(PMECA) is a reasonable quantity criterion of energy consumption for manufacturing unit product in a specific condition. It is significantly importantfor factoryto manage and monitor energyconsumption, improve production technology and organization management, enhance energy efficiency, and promote energy conservation in the whole industry.For discrete manufacturing industry, there exists nosystematic practical solutionavailable to establish the PECAup tonowdue to a number of reasons including the complex composition of the products, multiple energy sources of the manufacturing system, discrete manufacturing process and the dynamic and stochastic characteristics of the energy consumption state and process, and so on.Supported with several projects financed by the Natural Science Foundation of Chinaand the project financed by the National High Technology Research & Development Program of China(863 Program), this thesis focusing on the strategy and solution for establishing PMECAaims to provide a general ideaand framework for establishing PMECAin discrete manufacturing industry.Firstly, the energyconsumption characteristics of discrete manufacturing product and the complex characteristics of PMECAare analyzed. The complex characteristic of discrete system includesmultiple sources of energy consumption, multiple levels of energy consumption, the efficiency characteristic of effective output;the energy-consumption characteristics of discrete manufacturing product and the complex characteristics of PMECA includes the complex tree-structure product and its manufacturing energy consumption, the dynamic relationship between energy consumption and manufacturing equipment, between energy consumption and manufacturing process;the comple x characteristics of PMECA includes the relationshipbetween PMECA and distributed multiple manufacturing systems, the huge amount ofPMEC A lead by the infinite variety of product, the short effect of PMECAcaused by the short market life cycle of product, the multiple levels of PMECA index, the restriction and guidance characteristics of PMECA.Secondly,a strategy is proposedto establishPMECA. For general products, the related PMEC A making strategy is given by combiningthe PMEC A with the corresponding manufacturing system. For a specific product which is in huge quantity and with a large volume ofenergy consumptions, and whose manufacturing processes and equipment are relatively certain, the uniformed PEC A making strategyis suggested. Moreover, the specific procedures of above two strategies are detailed in this document.Thirdly, aPMEC Amodel is presented. Based on the characteristicsof PMECA, the notion of the energy-consumption stepis given to describe varioustypes of energy-consumption procedures in the whole manufacturing process uniformly.Then the hierarchy index of PMECAispresented. Therefore,the composition model and mathematical model of product, part and workpieceare established.Finally, the solution for establishing PMECA is proposed. The solution inc ludes three levels:the related PMEC A solution, thepart- manufacturing-energy-consumption allowancesolution and the calculation solution of workpiece-energy-consumption allowance.For each level, the solution includes four procedures:establishing basic database of energy consumption, calculatingenergy consumption, evaluating energy consumption and determining the allowance. And the feasibility and possibility of the solution is demonstrated by a realistic case study.