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ProcediaProcedia
CIRP 00CIRP
(2017)
81000–000
(2019) 1325–1330
www.elsevier.com/locate/procedia
52nd CIRP Conference on Manufacturing Systems
52nd CIRP Conference on Manufacturing Systems
Advances in energy-related plant simulation by considering
Advances in CIRP
load and28th energy-related
temperature plant
profiles simulation
inMay
Design Conference, discrete event
2018, Nantes,by considering
simulation
France
load and temperature profiles in discrete event simulation
A new methodology to analyze
Andreas the functional
Mayr*, Tobias Lechler, Toniand physical architecture of
Donhauser,
existing products for an
Maximilian
Andreas assembly
Metzner,
Mayr*, Eike oriented
Schäffer,
Tobias Eva
Lechler, product
Fischer,
Toni family
Jörg
Donhauser, identification
Franke
Maximilian Metzner, Eike Schäffer, Eva Fischer, Jörg Franke
Institute for Factory Automation and Production Systems (FAPS), Friedrich-Alexander University Erlangen-Nuremberg (FAU),
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Fuerther Str. 246b, 90429 Nuremberg, Germany
Institute for Factory Automation and Production Systems (FAPS), Friedrich-Alexander University Erlangen-Nuremberg (FAU),
Fuerther Str. 246b, 90429 Nuremberg, Germany
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +49 911 5302-9064; fax: +49 911 5302-9070. E-mail address: andreas.mayr@faps.fau.de

**Corresponding
Correspondingauthor.
author.Tel.:
Tel.:+33
+493911 5302-9064;
87 37 fax: +49
54 30; E-mail 911 5302-9070.
address: E-mail address: andreas.mayr@faps.fau.de
paul.stief@ensam.eu

Abstract
Abstract
Abstract
Discrete event simulations are one of the most used techniques by manufacturing system designers. In order to extend the traditional material
flow with an advanced energy simulation, this paper presents two specially developed extension modules for the widely used software Tecnomatix
InDiscrete
today’s
Plant
event
Simulation.
simulations
business are one
Inenvironment, theoftrend
contrast to other
the most
approaches,
usedmore
towards techniques
product
the FAPS
by manufacturing
variety
energy and is
module
system designers.
customization
not only based is unbroken.In order
Due to
on fixed values,
extend
tobut
thison the traditional
development,
measured load
material
the profiles.
need of
flow and
agile withreconfigurable
an advanced energy simulation,
production systemsthisemerged
paper presents
to two
cope specially
with variousdeveloped
products extension
and modules
product for the
families. To widely
design used
and software
optimize Tecnomatix
production
Furthermore, the FAPS temperature module for tracking the products’ temperature through the whole process chain is introduced. The latter
Plant Simulation.
systems well as Into contrast to other approaches, the FAPSproduct
energyanalysis
module methods
is not only arebased on fixed values,
most but on known
measured load profiles.
module as is particularly choose the
suited for optimal
identifying product
savings matches,
potential in energy-intensive thermal needed.
processes. Indeed, of the methods aim to
Furthermore,
analyze a productthe or
FAPS temperature
one product family module
on the for tracking
physical theDifferent
level. products’product
temperature through
families, the whole
however, process
may differ chain
largely is introduced.
in terms The latter
of the number and
module
nature of iscomponents.
particularly suited
This for identifying
fact impedes ansavings potential
efficient in energy-intensive
comparison and choice of thermal processes.
appropriate product family combinations for the production
© 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecom-
system.
© 2019AThe new methodology
Authors. is proposed
Published
mons.org/licenses/by-nc-nd/3.0/) by Elsevier to analyze
Ltd. existing products in view of their functional and physical architecture. The aim is to cluster
©
these2019
This The
products
is an Authors.
openinaccess
new Published
assembly by Elsevier
oriented
article under Ltd.families
product
the scientific
CC This is license
BY-NC-ND an
foropen
the access articleofunder
optimization the assembly
existing CC BY-NC-NDlines and
(http://creativecommons.org/licenses/by-nc-nd/3.0/)license
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creation of future reconfigurable
Peer-review under responsibility of the committee of the 52nd CIRP Conference on Manufacturing Systems.
mons.org/licenses/by-nc-nd/3.0/)
Peer-review
assembly underBased
systems. responsibility
on Datum of Flow
the scientific committee
Chain, the physicalofstructure
the 52ndofCIRP Conference
the products on Manufacturing
is analyzed. FunctionalSystems.
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aPeer-review
Keywords:
under responsibility
functionaldiscrete
analysis is performed.
event
ofMoreover,
the scientific
simulation; plant simulation;
committee
a hybrid of the 52nd
energy functional
CIRP Conference
and profile;
simulation; load physical architecture
load
on Manufacturing
management;graph (HyFPAG)
temperature
Systems.
profileis the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
Keywords:
example of discrete event simulation;
a nail-clipper is used toplant simulation;
explain energy simulation;
the proposed methodology.load profile; load management;
An industrial case studytemperature profile families of steering columns of
on two product
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
©1.2017 The Authors. Published by Elsevier B.V.
Introduction electric motor production, previous research has already
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference
demonstrated 2018. arrangement of heating and cooling
that a clever
1. Introduction electric motor production, previous research has already
The energy transition poses new challenges for industry. processes
demonstrated can that reduce throughput
a clever times of
arrangement as heating
well asand
the cooling
overall
Keywords: Assembly; Design method; Family identification
DueThe to the increasing share of non-adjustable,
energy transition poses new challenges for industry. renewable en- energy consumption [4,5].
processes can reduce throughput times as well as the overall
ergy
Due to sources, the organizational
the increasing effort for matching
share of non-adjustable, renewable demand en- Discrete
energy event simulation
consumption [4,5]. can assist in forecasting and eval-
and supply of electrical energy is increasing.
ergy sources, the organizational effort for matching demand Therefore, new uating the impact
Discrete event simulationof such flexibility
can assistmeasures on production.
in forecasting and eval-
tariff
1.and structures
Introduction enable manufactures to actively
supply of electrical energy is increasing. Therefore, new participate in However,
of the product
uating most
the impact of the
range existing approaches
and characteristics
of such flexibility measureson energy
manufacturedsimulation
and/or
on production.
the electricity
tariff structuresmarketenableand to adjust their
manufactures demand to
to actively the current
participate in only include
assembled
However, in average
most the load
thisofsystem. values
In
existing this in the simulation
context,
approaches the main model
on energy with-
challenge
simulationin
electricity
theDue price.
to the
electricity In
market order to achieve
fastanddevelopment economic
to adjust their in advantages,
the todomain
demand the current in-
of out taking
modelling
only include andtheir actual
analysis
average profile
loadisvalues
now not characteristics
only
in the into
to cope model
simulation account.
with single
with-
creased
electricitytransparency
communication price.and and
In order improved
an ongoing predictability
to achievetrend of the plant’s
of digitization
economic advantages, and
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products,
out taking this
theirpaper
a limited shows
product
actual how
range
profile orthe conventional
existing
characteristicsproduct material
into families,
account.
load requirements
digitalization,
creased transparency are needed
manufacturing
and improved[1,2].
enterprises are facing
predictability important
of the plant’s flow
but simulation
also to bethis
Therefore, software
ablepaper
to analyze Tecnomatix
showsand how Plant
to compare Simulation
products to
the conventional can be
define
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Measures
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in today’s
load requirements the plant’s
market[1,2].
are needed energy flexibility
environments: a continuing not only extended
new
flowproduct by
simulation energy
families. aspects
softwareIt can considering
be observed
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Plant classical existing
can be
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or features.
temperature
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shortened of electrical
affect the product
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In addition,
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However, models
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related work,the
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2212-8271 © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
To cope with this augmenting variety as well as to be able to
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
product structure on a physical level (components level) which
identify
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Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems.
2212-8271 © 2019 The Authors. Published by Elsevier Ltd.
This is an©open
2212-8271 2017access article Published
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10.1016/j.procir.2019.04.021
 1326 Andreas Mayr et al. / Procedia CIRP 81 (2019) 1325–1330
2 Andreas Mayr et al. / Procedia CIRP 00 (2019) 000–000
FAPS temperature module is introduced. Their use, functional-
ity and collaboration is described in more detail in separate sec-
tions. Finally, the paper concludes with validation cases from
industrial practice as well as an outlook on future research.
2. Related work and concept of the extension modules
2.1. Energy simulation in the manufacturing sector
Based on a detailed analysis of existing research approaches,
Thiede [6] identified three principle paradigms for combining
energy and material flow simulation. For the latter, discrete
event simulation software such as Tecnomatix Plant Simulation
or Delmia are widely used [6].
In paradigm 1, the energy-related simulation is performed
after the material flow simulation has been fully completed.
Following this approach, Heilala el al. [7] uses Microsoft Ecxel
to calculate environmental metrics based on the results of a
material flow simulation in Visual Components. Other authors
such as Johansson et al. [8], Weinert [9] or Haag [10] also
follow this paradigm. However, the disadvantages are apparent:
Since the data coupling between the two domains is
unidirectional, the material flow cannot be influenced by the
energy forecast. This eliminates the potential to simulate the
effects of energy flexibility measures.
Therefore, paradigm 2 enables a bidirectional connection
between the energy and material flow simulation models. For
example, Peter et al. [11] interconnect the discrete event
simulation software Plant Simulation with MATLAB Simulink
based on a third software called SimAssist (SimPlan AG) which
ensures time synchronization and data exchange. Other authors
such as Junge [12] or Hesselbach et al. [13] also adopt this
paradigm for coupling energy and material flow simulation.
The drawbacks are the increased effort through the separate
modelling of both domains, redundancies through double data
management and high requirements on time synchronization.
The energy-related extension modules developed at the
institute FAPS follow the third paradigm, in which both models
are integrated into one simulation tool offering a one-stop
solution. This approach has the advantage that only one
simulation model needs to be built. In addition, the simulation
results can be analyzed under the consideration of both the
material flow and energy requirements. However, it must be
ensured that the material flow simulation does not lose its
discrete character due to the coupling with a time-oriented
energy model.
In addition to the examples given here, several other
approaches exist that can be assigned to the aforementioned
paradigms. In this respect, please refer to recent literature
reviews on energy simulation such as [14] or [15].
2.2. Basic concept of the developed extension modules
Simulating the material flow including all relevant produc-
tion, storage and transport activities represents a key compo-
nent of the digital factory [16]. Compared to other simulation
tools on the market, Tecnomatix Plant Simulation is very easy-
to-use and enables a flexible way of working with the model
[16]. According to Wenzel and Peter [17], it is likely the most
frequently used discrete event simulation tool in the automotive
industry. Therefore, this research mainly focuses on extending
Plant Simulation, whereas the basic concept can also be applied
to alternative discrete event simulation software.
Since version 11, Plant Simulation has been equipped with
the so-called Energy Analyzer, which allows the consideration
of energy aspects in a limited manner. By indicating the aver-
age load for the different operating states of a material flow
element, the total energy consumption can be determined [16].
However, since the load of a machine fluctuates, especially
with longer process times, the use of average values represents
a gross simplification. In addition, neither start-up and switch-
off peaks nor the influence of different product variants are
taken into account by the integrated solution.
Just before the launch of the Energy Analyzer, researches of
the institute FAPS developed a first version of an extension
module which allows for load profiles instead of mere average
values – the so-called FAPS energy module [18]. Due to the
fine-granular load profiles, the resulting energy simulation is
much more accurate, especially with regard to load peaks. This
in turn allows precise predictions on electricity costs that might
be subject to time-varying electricity prices in near future [19].
Further optimization potentials can be revealed by the addi-
tionally developed FAPS temperature module [4]. By indicat-
ing temperature profiles, the products’ temperature through the
whole process chain can be tracked. In addition, the actual start-
ing temperature of a workpiece significantly influences the du-
ration of thermal processes as well as the corresponding energy
consumption. Therefore, both modules can be used separately
or in combination.
As Fig. 1 shows, the starting point is always an existing ma-
terial flow model (Step 1). After inserting the respective mod-
ule, settings must be made (Step 2). This particularly includes
the provision of the required profiles, which are cumulated over
time during the simulation (Step 3). After completing the sim-
ulation, the results can be evaluated using suitable visualiza-
tions and key indicators (Step 4).
1. Insertion of the modules in the model 2. Setup of the modules
Energy
Module
Energy Temperature Temperature
Module Module Module
4. Analysis of the results 3. Execution of the simulation
Ta get temper ature:
Var_A 35°C
Var_B 38°C
Energy Module
Stator produc tion
Consumption
Share of working state
Consumption Costs Temperature
Share of working state Module
Fig. 1. Basic procedure for using the FAPS energy and temperature module.
While the energy and temperature module have already been
introduced separately in earlier work [4,18–20], this paper pre-
sents both modules together in a uniform and structured way,
while highlighting recent developments. In addition to the
standardization of the graphical user interface (GUI), espe-
cially the functional range of the temperature module has been
extended.
 Andreas Mayr et al. / Procedia CIRP 81 (2019) 1325–1330 1327
Andreas Mayr et al. / Procedia CIRP 00 (2019) 000–000 3

3. FAPS energy module for Plant Simulation maining states. If necessary, an attribute for the further differ-
entiation of load profiles within a state can be defined, e.g. the
The FAPS energy module represents an extension for the product variant, element’s capacity usage or product tempera-
software Plant Simulation, adding appropriate functionalities ture (see section 5). In addition, the electricity tariff must be
for the simulation and calculation of load profiles, energy con- defined if the calculation of costs is needed. The input as well
sumptions and costs at plant and product level. While an easy- as re-import of existing tariffs is also covered by the GUI.
to-use GUI is available for the user, the following section par-
ticularly deals with the underlying functionality of the energy Table 1. Overview of load profiles needed for the energy module [19].
module before, during and after the simulation. States Phase Profile type Load profile Attribute
Working Productive Terminated Working
3.1. Before simulation: Input of energy data Setting-up Productive Terminated Setting-up
Optional
Waiting Unscheduled Periodic Waiting / Basic (e.g. variant,
Fig. 2 exemplarily shows one of the measured load profiles Blocked Unscheduled Periodic Blocked / Basic capacity,
temperature)
of a milling machine. As can be seen, the load requirements Failed Unscheduled Periodic Failed / Basic
differ significantly along the individual operating states. While Paused Scheduled Periodic Waiting / Basic
the processed product variant might also influence the load re-
quirements of material flow elements such as a machine, a con- 3.2. During simulation: Recording of the load profiles
veyer belt’s load will rather depend on its capacity utilization
[19]. Therefore, the load must be measured at all operating During the simulation, the module instances record the load
states, if necessary depending on influencing attributes such as profiles of the objects considered in their network, depending
variant or utilized capacity. When planning a new production on the state and the variant being processed. By recursively
system, the load profiles can alternatively be derived from sim- calling up the respective instances of the module, an arbitrarily
ulations or reference processes. Since no universal categoriza- deep model structure can be processed. Fig. 3 illustrates how
tion of a plant’s energy states exists [19], the existing states in the load profiles are gradually aggregated starting from the en-
the material flow simulation are taken as a basis and extended ergy module instance in the deepest subnetwork up to the one
by new energy states such as standby and power-up. in the root network. In doing so, the module instance in the root
network finally comprises the sum of all load profiles.
SB PU Wt Working Wt Working
1200
Factory
Effective power [W]

1000
network
Root

800

600

400 SB: Standby

PU: Power-up
subnetwork

200 Wt: Waiting

1st level

Manufacturing Assembly ...

0
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0
Time [s]

Fig. 2. Load profile of a milling process along different operating states [19].
subnetwork
2nd level

Due to a missing energy management system at production

level, the required profiles are usually not recorded during op-
eration. As a result, additional efforts for the acquisition of en-
ergy data represent a decisive obstacle for the application of
energy simulations. Kohl [19] thus deals with the question of
how a suitable database for load forecasts can be created with
the aid of smart measurement systems. Besides proper measur-
ing devices [21], an OPC UA-based information model for an
automated data acquisition is presented [22]. For the storage of
time-based load profiles, relational structures such as SQL da-
tabases or simple Excel tables show high applicability.
When the energy module is inserted into the main network,
module instances are automatically created in all subnetworks.
In this context, the term network is defined as the summary of
several material flow elements or other networks to a superior
element. In each network, all relevant material flow elements,
e.g. machines, assembly stations or conveyer belts, are auto-
matically detected and linked to the energy module. Via the
GUI, the user can then choose the elements to be included and
import the required load profiles as shown in Table 1. While
exact profiles are indispensable for the working and setting-up
states, a basic consumption level can be assumed for the re-
Machine 1 Machine 2 Machine 3 Machine 4
Fig. 3. Recursive calling of module instances in a hierarchical structure [19].
Changes in state are recognized by so-called observers, a
well-known pattern in software engineering. For each relevant
material flow element, the corresponding observers are as-
signed when the energy simulation is initialized. As shown in
Fig. 4, the observer named Observer_Working detects that the
winding machine changes to the working state. In this way, the
load profile matching the present product variant is copied from
the table Profile_Working to the results table. While the load
profile for the working state is entered prospectively, it must be
entered retrospectively for states without a fixed duration, e.g.
waiting. If the working state is interrupted, e.g. by a failure, the
load profile will be truncated to the actual processing time.
If the recording of product-related energy indicators is acti-
vated (see section 3.3), a reference to the load profile is stored
in a table carried with the respective workpiece. Having passed
all production steps, the product’s footprint is transferred to the
global results table before being deleted in a drain. For taking
pauses into account, the corresponding shift calendar of the
1328 Andreas Mayr et al. / Procedia CIRP 81 (2019) 1325–1330
4 Andreas Mayr et al. / Procedia CIRP 00 (2019) 000–000
model must be observed as well. Since the load profiles are
transferred as a whole, the time-discrete character of the mate-
rial flow simulation is retained at any time.
Besides observers, so-called control methods are also avail-
able, allowing the energy module to intervene in the material
flow. This is relevant, for example, for evaluating various
standby strategies since additional transition times may delay
the material flow [19]. According to paradigm 3, the energy
module thereby exceeds its purely observant role and enables
the required intermeshing of the two simulation domains.
Before simulation During simulation
Model
Winding
Working?
Variant?
Reference
to load profile
Profile_Working Observer_Working
Search load profile for variant Record load profile
Energy Module
Profile_Setting-up Profile_Waiting Observer_Setting-up
Search load profile
Profile_Blocked Profile_Failed Observer_Blocked
Input of energy data Recording of the load profiles
Fig. 4. Recording load profiles using the observer pattern.
3.3. After simulation: Calculation and visualization
At the end of the simulation, different key indicators are cal-
culated from the recorded load profiles in the results table. In
this context, a general distinction is made between plant-related
and product-related energy indicators.
For the plant-related energy indicators, the temporal devel-
opment of the load and the cumulative energy consumption are
most important with regard to the resulting electricity costs. For
instance, the energy consumption can be obtained by calculat-
ing the summation of discretized load profiles. The temporal
granularity 𝛥𝛥𝛥𝛥 of the imported load profiles is selected in the
setup phase in order to not restrict the user to special input data.
In addition, the load maxima are particularly relevant as they
determine the required installed power and the power costs.
The key indicators can not only be viewed for the overall
model, but also for the individual networks and elements. For
further analysis, an overview of the elements’ shares in the
model’s maximum is advantageous in order to identify the driv-
ers for peak loads. With regard to the energy consumption, the
state-based indicators provide information about non-value-
adding periods, being a basis for energy efficiency measures.
Product-related key indicators provide a better comparabil-
ity between different production systems, as their size is rela-
tivized. In addition, the company's product portfolio can be
evaluated with regard to energy aspects. In contrast to the plant-
related energy indicators, only the energy consumption caused
by the elements’ working states can be uniquely assigned to the
respective workpieces. The product-related total consumption,
on the other hand, could be estimated in analogy to an overhead
cost distribution as described in [19].
While a dashboard shows the most important key indicators
at a glance, various diagram types are available for visualiza-
tion purposes (see Fig. 1). Based on this, different measures can
be derived: For example, non-value-adding phases such as
waiting times can be optimized through the use of standby
functions. In the case of productive phases such as the working
state, measures like a load-optimized production sequence
come into play. By identifying the relevant starting points, the
energy module significantly supports the selection of the most
effective measures for energy saving.
4. FAPS temperature module for Plant Simulation
The temperature module was developed as a further exten-
sion module for Plant Simulation, adding appropriate function-
After simulation
alities for the simulation of the products’ temperature profiles.
4.1. Before simulation: Input of temperature data
Crimping
Waiting?
In contrast to the energy module, the temperature profiles
Energy_Results Energy_Diagram can be represented by approximated equations instead of
memory-intensive time series. This not only allows the deriva-
Observer_Waiting tion of profiles for different starting temperatures but also the
Record load profile
calculation of the required heating or cooling times.
Observer_Failed
However, the modelling of thermal processes is very com-
plex due to the wide variety of influences [23]. In this context,
Calculation and visualization
the use of second degree polynomials represents a relatively
simple approximation of the temperature change for real appli-
cations. For example, the heating process of an electric drive’s
rotor can be approximated quite exactly by a second degree
polynomial as described in [4]. Also for cooling, the approxi-
mation by a polynomial is suitable under constant conditions as
the experiment in Fig. 5 shows.
120
Measured rotor temperature
100 Second degree polynomial approximation
Temperature [°C]
80
60
T(t) = 0,0159t2 - 1,9927t + 95,879
40
R² = 0,9847
20
0 10 20 30 40
Time [min]
50 60 70 80
Fig. 5. Approximation of the cooling curve of an electric drive’s rotor.
According to Kohl et al. [4], however, these second degree
polynomial approximations can hardly be transferred to differ-
ing conditions, e.g. changed characteristic, number or position-
ing of workpieces in an oven. Furthermore, the time period is
limited since the cooling profile approximated by a second de-
gree polynomial does not asymptotically approach the ambient
temperature but rises again after reaching the apex.
Under certain conditions, the temperature behavior can al-
ternatively be described by Newton’s cooling law (1). Accord-
ing to [24], this law successfully describes cooling curves in
many low temperature applications. It states that the rate of
change of the workpiece temperature is proportional to the dif-
ference between its initial temperature 𝑇𝑇� and the constant tem-
perature 𝑇𝑇� of the surrounding medium [23]. The time constant
𝑘𝑘 depends on the workpiece properties such as heat capacity,
size or geometry and can be obtained by experiments [24].
𝑇𝑇(𝑡𝑡) = (𝑇𝑇� − 𝑇𝑇� ) ∙ 𝑒𝑒 ��� + 𝑇𝑇� (1)
Moreover, the user can also specify user-defined equations
in the latest version of the FAPS temperature module. Just like
the energy module, the temperature module has to be loaded
 Andreas Mayr et al. / Procedia CIRP 81 (2019) 1325–1330
Andreas Mayr et al. / Procedia CIRP 00 (2019) 000–000
into the class library and then be inserted into a Plant Simula-
tion model. Subsequently, several methods are started in the
background analyzing the structure of the material flow model.
During the setup phase, the user is requested to enter all tem-
perature-relevant settings, especially the equations for approx-
imating the temperature behavior of the individual product var-
iants and belonging workpieces in the various process steps. If
no equation is given, it is assumed that the workpiece tempera-
ture does not change during the respective process step. With
temperature-relevant process steps, however, two types of pro-
cesses must be distinguished: temperature-driven and time-
driven processes.
Temperature-driven processes refer to the case when a
workpiece is heated or cooled down to a certain temperature
and then directly transferred to the next process step. For ex-
ample, cooling buffers are used to cool down previously heated
workpieces to a defined harmless temperature for subsequent
manual assembly steps. Another example would be a heating
system which continuously measures the actual workpiece tem-
perature to avoid overheating. For temperature-driven pro-
cesses, it is the task of the temperature module to determine the
actual time required. To realize this feature, a pull-control
method is automatically assigned to all material flow elements
with targeted temperature change.
In contrast, time-driven processes refer to the case when a
workpiece is heated or cooled for a certain time regardless of
its actual temperature, whether active or passive. An example
for the latter would be heated workpieces that slowly approach
the ambient temperature during a subsequent transport. In ad-
dition, a time-driven oven process is often used to cure adhe-
sives for a specified time. With time-driven processes, it is the
task of the temperature module to determine the temperature
when leaving the respective process step.
4.2. During simulation: Recording of the temperature profiles
With regard to the simulation execution, the main difference
between the energy module and the temperature module lies in
the objects to be observed. While the energy module primarily
records the load profiles of the relevant material flow elements
such as machines, the temperature module mainly tracks the
product’s temperature through the whole simulated production
chain. Material flow elements are only influenced if they rep-
resent temperature-driven processes, i.e. processes with adapt-
ing working times (Fig 6).
During the simulation, mobile units are constantly created,
transported from one process to another and finally get de-
stroyed in a drain. Analogous to the energy module, changes
are monitored by various observers. In the event of a location
change, the aforementioned temperature- and time-driven pro-
cesses have to be distinguished. If a workpiece is to be trans-
ferred to a temperature-driven process, the pull control deter-
mines the required working time beforehand on the basis of the
stored equation. The target temperature is then visualized using
a display panel beneath the element’s icon. In the case of time-
driven processes, the temperature is updated when leaving the
respective process step after the specified time. Thereby, the
temperature profile and passing process steps are all stored in
1329
5
the attributes of each unit. When a drain is finally reached, an-
other observer will be triggered in order to store the product’s
temperature profile to an internal results table.
During simulation
Temperature
Module
Temperature
Calculate actual temperature
Module
Set working time of
and store it in attributes temperature-driven process
Model
Mobile unit Material flow element
e.g. workpiece e.g. heating system
Fig. 6. Application cases and objects considered by the temperature module.
4.3. After simulation: Calculation and visualization
After completing the simulation, the results are automati-
cally presented via the uniform GUI (see Fig. 1). The GUI pro-
vides the working time for temperature-driven processes as
well as the recorded products’ temperature profiles along the
production chain. The latter can be visualized using appropriate
diagrams or exported as a table, e.g. to Microsoft Excel.
In doing so, the evaluation forms the basis to detect savings
potential in energy-intensive thermal processes. On the one
hand, the effects of temperature-driven processes on the mate-
rial flow as well as the load profiles can be precisely simulated.
On the other hand, a clever plant arrangement can avoid unnec-
essary heating and cooling phases and thus save energy.
5. Collaboration of both modules
After the two modules have been presented separately, this
section deals with their interaction. In general, there is a unidi-
rectional dependency between the two modules, i.e. the results
of the temperature module have an influence on the results of
the energy simulation. Firstly, the temperature-driven change
in the processing time causes a machine to be either longer or
shorter in the working state. This results in a change of the en-
ergy demand of the machine concerned. Secondly, the load pro-
file of a thermal process might also depend on the workpiece’s
starting temperature. For example, an oven that is controlled to
400 °C requires significantly more energy to maintain its tem-
perature if a workpiece with only 100 °C arrives than one with
380 °C. In such cases, the workpiece’s starting temperature can
be specified as a distinguishing attribute for load profiles in the
setup of the energy module (see Table 1).
6. Validation based on industrial case studies
In [19], the presented energy module was validated using
different production plants from research and industry. Based
on a manual energy data acquisition, the load profile of a fully
automated production cell could be forecast with an average
deviation of 3.3 %. By means of an automated data acquisition,
the average error could even be reduced to 1.3 %. In the case
of manual work shares, the total energy consumption of the
production system could at least be predicted several weeks
ahead with a deviation of approximately 10 %. [19] Using the
example of an electric motor production, various savings
measures could be derived [25].
1330 Andreas Mayr et al. / Procedia CIRP 81 (2019) 1325–1330
6 Andreas Mayr et al. / Procedia CIRP 00 (2019) 000–000
Since the temperature module’s calculation is not based on
measured profiles but on approximated equations, its accuracy
depends decisively on the quality of the approximation used.
For validation, it was used in a simulation of the manufacturing
process for calcium silicate masonry units (CS) [26]. In this
process, the cooling curve of the CS is relevant for the total
energy consumption, since the compound as well as the green
bodies formed from it contain heat energy from an exothermic
reaction. This is to be retained over the course of the process,
since less heat energy then has to be supplied during the hard-
ening of the CS green bodies. In order to approximate the cool-
ing behavior with (1), several measurement series were carried
out at regular intervals for various production batches. Using
these equations, the cooling curves could be precisely simu-
lated in the material flow simulation, as an average deviation
of only 0.74 % from the regression curve of the measured tem-
perature compared to the simulated one was achieved.
7. Conclusion and outlook
This paper shows how the discrete event simulation soft-
ware Tecnomatix Plant Simulation can be extended by energy
aspects using two specially developed extension modules.
While the energy module allows the simulation of load profiles,
the temperature module enables the tracking of the products’
temperature along the entire process chain. Based on the simu-
lation results, different energy savings potentials can be identi-
fied, especially in thermal processes.
Looking to the future, both modules offer numerous expan-
sion potentials due to their high performance and modularity.
Inspired by [27], a continuous energy simulation during opera-
tion could contribute to the decision-making basis for reacting
to short-term events, such as disruptions in production or price
changes on the electricity market. Beyond this, the effort re-
quired to build the underlying material flow model must be fur-
ther reduced. For example, industry-specific module kits with
predefined modules may represent a simple and fast solution to
enable a simulation-based evaluation of alternative process
chains [28]. Last but not least, the acquisition of load and tem-
perature profiles must be improved, as missing data still repre-
sents one of the major obstacles to the successful application of
energy simulations. In this context, the automated acquisition
of energy data paves the way for various Industry 4.0 applica-
tions, such as condition monitoring of machines based on intel-
ligent energy profiling [22].
Acknowledgements
The authors would like to express their sincere thanks to the
Bavarian State Ministry for Science, Research and Culture for
funding this project in the framework “Green Factory Bavaria”.
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