energy efficient targets for machine tools

7/28/2019 Energy Efficient Targets for Machine Tools

1/42

The European Association of the Machine Tool Industries

" where manufacturing begins"Magdalena Garczynska, Technical Manager

The Ecodesign DirectiveEnergy Efficiency Targets for Machine Tools

Magdalena Garczynska, Technical Manager

Project manager of the CECIMO energyefficiency working group

[email protected]


2/42

Energy Eff iciency Targets for Machin e Tools

Agenda

CECIMO and the Machine Tool Industry in Europe

Legislation

Environmental evaluation

Preparatory study CECIMO Self Regulatory Initiative


3/42


CECIMO and the Machine Tool

Industry in Europe

1


4/42


CECIMO is the European Association of

the Machine Tool Industries

It represents:

15 National Associations

1500 companies 80% SMEs

almost the entire metalworking machinetool production in Europe (97%)

21 bn sales in 2011

of the production is exported

of the globalproduction

of the worlds exports



5/42


3 main types of processes

Cut a pattern from a

sheet of metal, forinstance. The technologyused includes cuttingtools, laser, jet of highpressure water

To shape the piece by

bending, stamping

Sculpt a metallic block

by removing material byprocesses like drilling,milling, electrochemicaldischarge



6/42


Material removal /

machiningMetal forming Accessories

ToolsOther machines and

equipment

The machine tool industry comprises



7/42


Examples of end-user products:



8/42


Machine tools help Europe tackle grand challenges. Advances in

machine tools have a direct impact on:

efficiencyandproductivityin all industrial sectors competitiveness

grand societal and economic challenges

Process efficiencyNew power plantsAlternative

powertrains

Weight reduction



9/42


About CECIMO

Founded in 1950

CECIMO: Comit europen de Coopration de lIndustrie de la

Machine-Outil

First main purpose: European exhibitions of machine tools

First E.M.T.E. (European Machine Tools

Exhibitions) held in 1951



10/42


CECIMO Members Key producing countries in 2011

Switzerland12%

Austria

3%

Source data: CECIMO statistics

Germany

46%

Italy

20%

Turkey

2%

Czech Rep.

2%

Others

6%

Spain

4%

France

3%

UK

2%



11/42


Examples of recent and current CECIMO activities

To maintain a Market Intelligence Service gathering anddistributing statistical and economic data and reports.

Economic and market reporting:production, exports, imports and

consumption including forecasts

World statistics on the advanced

machine tools by CECIMO

CECIMO Statistical Toolbox



12/42



To co-ordinate European and international standardization.

Ecodesign and Self-Regulatory

Initiative (SRI) Directive 2011/65/EU on the

restriction of the use of

certain hazardous substances

in electrical and electronic

equipment (RoHS) and theDirective on waste electrical

and electronic equipment

(WEEE)

Participation in ISO TC 39

standard



13/42



To promote innovation and exploitation ofresearch results.

DEMAT

EMC2Factory

EFFRA, Manufuture



14/42


Legislation


2


15/42


Current legislative developments

Europe 2020 target 20%

Energy efficiency action

plan

Roadmap to a Resource

Efficient Europe

Energy efficiency

Directive 2012

Ecodesign Energy-relatedProducts Directive, 2009


16/42


Energy efficiency of products main instrumentsEcodesign Directive 2009/125/EC: framework defining the

rules for setting product-specific requirements/legislation on

energy efficiency and further parameters.

Energy Labelling Directive 2010/30/EU: framework defining

the rules for setting product-specific requirements/legislation on

standard information of the consumption of energy and otherresources

Ecolabel: The EU Ecolabel helps identify products and services that have a

reduced impact on the environment throughout their life cycle, from theextraction of raw material through to production, use and disposal.

Green Public Procurement: Voluntary instrument. GPP can help stimulate acritical mass of demand for more sustainable goods and services which otherwisewould be difficult to get onto the market.

Other related instruments

Energy Efficiency: EU Instruments

Source: European Commission

EU Legislation



17/42


Energy efficiency index of industry

Energy efficiency index of industry

(ODEX)

a weighted average of the specific

consumption index of 10

manufacturing branches

The 10 branches considered in

the calculation are: chemical,

steel,

non ferrous,

cement,

other non metallic,

paper,

food,

machinery,

transport equipment

textile.

Source: ODYSSEE database (last update : August 2009) available at http://www.odyssee-indicators.org/


18/42


Eco Design Directive-Not only Machine Tools

This directive applies to all energy relatedproducts

Examples: Air-conditioning and ventilation systems;

Electric and fossil-fuelled heating equipment

Machine tools

Industrial and laboratory furnaces and ovens

Network, data processing and data storing equipment

Refrigerating and freezing equipment

Sound and imaging equipment

Transformers

Water-using equipment


19/42


Ecodesign & Energy Efficiency: Story so Far.

39 'Lots' with some

50 product groups tocarry out preparatorystudies.

13 Ecodesign

Regulations and 5Energy LabellingRegulations have beenadopted so far.

10 measures underpreparation for adoptionin 2012.

EU Legislation



20/42


Ecodesign Directive: Methodology & Timeline: 2EU Legislation



21/42


Ecodesign General Options for Action

Regulation (most common) based on findings of study,

supplemented over several months by additional bilateral

meetings/ information/ group meetings

Voluntary Agreement (VA)/ Self-Regulation Initiative:

Industry sector may prefer (has the "initiative" to lead

the process) or not (less legal certainty for actors)

Split or combine "Lots", depending on workability/

practicalities of sub-sectors that come to light,

potentially involving part of Preparatory Study being

revisited, if deemed necessary

EU Legislation



22/42


Ecodesign and Competitiveness (Policy-Makingnot Conducted in Isolation): 2012 ENTR Study

Source: Study on the Competitiveness of EU Mechanical Engineering Industry, Ecorys et al, Jan2012, for DG ENTR

EU Legislation



23/42


Ecodesign and Competitiveness: 2012 ENTRStudy, 2nd Table

Source: Study on the Competitiveness of EU

Mechanical Engineering Industry, Ecorys et al, Jan2012, for DG ENTR

EU Legislation



24/42


Preparatory studyMachine Tools and related machineryperformed by Fraunhofer Institute

3


25/42


Product Group StudyObjectives

Assess the EU-27 market

Quantify environmental impacts of the product group as a

whole

Quantify improvement potentials in terms of costs and

environmental impacts

Are policy measures needed to realise savings potentialeffectively?

Source: Fraunhofer Institute CECIMO GA 2012


26/42


Environmental AssessmentsDefinition of Typical Machine Tools (Base Cases)

Metal

working

Wood

working

High

market

relevancy

CNC

(1) CNC machining centres (and similar) x x x

(2) CNC Laser cutting machine tools x x

(3) CNC Bending machine tools (and similar) x x

(4) Non-NC metal working machine tools (and similar) x x

(5) Table saw (and similar) x x

(6) Horizontal panel saw (and similar) x x

(7) Throughfeed edge banding machine (and similar) x x

(8) CNC machining centre (and similar) x x

(9) Welding equipment x x



27/42


Base Case Assessment

Metal working CNC

machining centres

dominating

(throughout all

environmental

indicators)

No full market

coverage through

Base Cases!



28/42


Technical AnalysisImprovement Potential

Survey (supported by

CECIMO):

Estimated savings

potential per option

Ranking of options

Findings:

Numerous savingsoptions

But none of them with a

huge potentialFigure 5-26: Total machinery energy savings potential

Cooling lubrication system

Component group 4: cooling lubrication system

4.1 Discontinuous operating pumps

4.2 Apply minimal quantity lubrication (MQL) whenfeasible

4.3 Adjustable pressure for cooling lubrication

4.4 Controlled flow rate

4.5 Inverter controlled motors for lubrication system

Source: CECIMO/Fraunhofer Institute CECIMO GA 2012


29/42


Improvement Potential

Hypothetical

implementation

of improvement

options one-by-

one Life Cycle

Costs

Total Energy

as

environmentalindicator

(1) CNC machining centres

Total Energy and LCC per Option



30/42


Improvement Potential

Savings potentials at point of Least Life Cycle Costs range

from none to 12%

Most options refer to energy in use, but also material choice and

optimising gas consumption for welding have been addressed

In general there is no single option with a huge environmentalimprovement potential

Moderate savings as stated can be realised only with the

implementation of several individual options and what should be

called good machinery design

Conclusions



31/42


CECIMO Self Regularory

Initiative

4


32/42


Methodology milling and turning

energy consumption in the use phase is the dominating influence for all environmental impacts*

Starting point: Life Cycle Assessment on whole life cycle of a machine tool

Several data sets from European companies

LCA scope:

Materials for production of the machine tool with average consumptions for machining

100.000 hours productive operating with specific average energy consumption (20h/d, 250d/a, 20a )

Consumption of 4.000 kg coolant lubricant in 20 years (assumption)

Consumption of 400 l hydraulic oil in 20 years (assumption)

End-of-Life scenario with credits for recycling of metal and incineration of plastics

* According to CML methodology 2007

Method for the evaluation of machine tools /


33/42


Method for the evaluation of machine tools /

PRELIMINARY Modular approach

spindle

work piece table

drive unit

operator panel

machine base


34/42


CECIMOs SRI: cost/improvement scenarios

investigations

Machining (machine process,

motion and control)

Process conditioning and

cooling

Workpiece handling

Tool handling

Recyclables and waste handling

Machine function

Machine cooling/heating

Individual measure


35/42


Measuring Energy Efficiency

According to ISO 9000, efficiency is the relationship between the

result achieved and the resources used The resources used and the result achieved must be measured

Resources used, i.e. power supplied to the machine tool: electricity,

compressed air, cooling by cold water supply, ambient air, optionally

at stabilized temperature, etc.

Resources can be quantified, with time and effort Result achieved, i.e. parts produced: shape, material, features,

surface quality, precision, etc.

Quantification of results achieved is case-specific

Energy efficiency of machine tools is difficult to quantify anddifficult to judge.


36/42


MEErP (1/2) For Life Cycle Assessment under the ErP directive, MEErP

methodology is mandatory MEErP is a suitable, relatively simple Life Cycle Analysis

tool,

but not for machine tools

Three major obstacles when applying MEErP: For machine tools intended for industrial use, only the use phase is

relevant in respect to energy; MEErP imposes other irrelevant

considerations

Great varietyof products within the machine tools category

Loweffectiveness of general measures derived from base cases

as compared to selective measures, as confirmed by

Fraunhofer/IZM


37/42


Effectiveness

There are no general measures for the improvement of energy

efficiency that would be of high effectiveness

There is a large number of proposals for improvement, but each with

little potential

With selective measures, energy efficiency can be improved more

effectively; Fraunhofer/IZM therefore predicts a higher potential for

an industry driven, voluntary approach

Effective measures require a consideration of the system design and

adapted solutions

On a case-by-case basis, selected single measures can be very

effective

focus on objectives, not on solutions


38/42


Common Ground Clustering

Research will suggest primary fields of actionPreliminary examples for

Common ground clustering

Machine & Process design

related targetsi) No Added Value

Idle state management

ii) Value Added

Process optimization

Factory integration related

targets

i) Heat management

Energy equivalent

resources resourcesmanagement


39/42


ISO - ECO standards initiated ISO: New Working Group under ISO/TC 39 established to deal with

Environmental Evaluation of Machine Tools First standards under the working group:

Guidelines - Integrating environmental aspects into design and development for machine

tools

Machine Tools Test methods for electric power consumption

The standard NWIP ISO 14955 addressing machine tools

(metal-cutting andforming

machines)

trying to be independent from

technologies

cover the whole lifecycle (only

Usephase)

explain limitations

no exceptions to be foreseen right

now

methods for evaluation

Modular approach for all technologies

Th C t


40/42


The Concept

WG in TC 39

Open

CECIMO

task forces

Machine tool

manufacturers

EuropeanCommissionMethod/calculator

for evaluation

Updating list of

improvement potential

Reporting/

monitoring

Proposals for

new improvements

Definitions/

descriptionsTargets

Annual reports

For the success of the CECIMO Self


41/42


For the success of the CECIMO Self

Regulatory Initiative

Any interested stakeholder can get involved in the formulationprocess

For further elaboration of the methodology of the SRIimplementation industry experts are needed

Companies are invited to delegate engineers for the CECIMO

energy efficiency working group

Contact at CECIMO

Mrs. Magdalena Garczynska, Technical Manager

[email protected]


42/42

CECIMO The European Association of the Machine Tool Industries

Avenue Louise 66 | 1050 Brussels | Belgium

Tel.: 00 32 (0)2 502 70 90

Email: [email protected]

Website: www.cecimo.eu

thank you

questions

Magdalena Garczynska, Technical Manager
mailto:[email protected]://www.cecimo.eu/http://www.cecimo.eu/mailto:[email protected]

energy efficient targets for machine tools

Documents