Quantitative Analysis Of Energy Consumption And Carbon Emissions Due To Machine Operation

Manufacturing enterprises around the world are facing ever-increasing pressureto reduce their reliance on fossil fuels and reduce their carbon footprint. Thispressure is driven by concerns related to climate change, energy costs, and energysecurity. The adoption of sustainable manufacturing practices and technologiesoffers industry an effective route to improve economic, environmental, and socialperformance. As a energy-intensive manufacturing process, the machining systemplays an important role for sustainable manufacturing. Therefore, reducing energyconsumption of machining system not only benefits the manufacturers economicallybut also improves the environmental performance of machining-based consumerproducts. The aim of this paper is to develop a method for analysing energyconsumption and carbon emissions due to machine tool operation quantitatively atmachine level and shop-floor level.Firstly, this paper proposes a method for analysing energy consumptionquantitatively based on modeling and simulation at machine level. Energyconsumption model of machine components relies on observed data as the inputvalue for modeling. In order to acquire accurate and effective data, a powermonitoring platform was developed on a HURCO milling center. Then, a virtualmachining module was developed to validate the proposed method.Secondly, this paper proposes a method to calculate energy consumption ofmachining systems for shop-floor using ProModel simulation. Machine tool energyconsumption at shop-floor level was calculated by considering different operatingstates based on power profile. The procedure of the proposed method wasintroduced and some strategies for reducing energy consumption at shop-floor levelwere also presented in this paper. In addition, a numerical simulation case study on aflywheel production system was implemented to introduce the application of theproposed method.Based on the lifecycle carbon emission factors of different electricitygeneration technologies, a method for transforming electrical energy used inmanufacturing directly into carbon emissions was introduced.Finally, the method for the analysis of energy consumption and carbonemissions due to machine tool operation at machine level and shop-floor level wasimplemented into a software tool based on Visual Basic language.