List of Figures
xxiii
Figure 5.17 Machine logic and power consumption profile
with varying idle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 5.18 Energy savings through idle state avoidance . . . . . . . . . . . . . 114
Figure 5.19 Consumption peak avoidance in production lines . . . . . . . . 114
Figure 5.20 Status and peak load optimization of a four-machine
scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 5.21 The process of simulation-based optimization . . . . . . . . . . . 119
Figure 5.22 Conceptual model for the simulation-based
optimization of energy efficiency . . . . . . . . . . . . . . . . . . . . . . 120
Figure 5.23 AnyLogic’s hybrid simulation engine architecture . . . . . . . . 124
Figure 5.24 Integration of MATLAB libraries . . . . . . . . . . . . . . . . . . . . . . 125
Figure 5.25 Fictional production scenario of a die-cast part
processing line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 5.26 Machine delay calculation logic . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 5.27 Starting and ending of production shifts . . . . . . . . . . . . . . . . 130
Figure 5.28 Machine set up for the depiction of realistic energy
load profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 5.29 Definition of internal state transitions . . . . . . . . . . . . . . . . . . 131
Figure 5.30 Implementation of the individual simulation focuses
in an overall model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 5.31 Implementation of the retention time in the machine
logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 5.32 ‘Select machine function’ logic . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 5.33 Throughput time estimation . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 5.34 Prepare machine functionality . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 5.35 Objective setup of total energy consumption optimizer . . . . 138
Figure 5.36 Parameter and model time setup for the optimization
experiment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 5.37 Optimization experiment visualization in AnyLogic . . . . . . 142
Figure 5.38 Insertion of the offset time for shifting of machine
starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 5.39 Depiction of the offset effect for one machine . . . . . . . . . . . 143
Figure 5.40 Setup of the peak optimization experiment . . . . . . . . . . . . . . 145
Figure 5.41 Results of the total consumption optimization . . . . . . . . . . . 146
Figure 5.42 Results of the peak consumption optimization . . . . . . . . . . . 147
Figure 5.43 Peak optimization experiment in combination
with the use of mean values for the energy
consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 6.1
Bosch production lines 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . 157
xxiii
Figure 5.17 Machine logic and power consumption profile
with varying idle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 5.18 Energy savings through idle state avoidance . . . . . . . . . . . . . 114
Figure 5.19 Consumption peak avoidance in production lines . . . . . . . . 114
Figure 5.20 Status and peak load optimization of a four-machine
scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 5.21 The process of simulation-based optimization . . . . . . . . . . . 119
Figure 5.22 Conceptual model for the simulation-based
optimization of energy efficiency . . . . . . . . . . . . . . . . . . . . . . 120
Figure 5.23 AnyLogic’s hybrid simulation engine architecture . . . . . . . . 124
Figure 5.24 Integration of MATLAB libraries . . . . . . . . . . . . . . . . . . . . . . 125
Figure 5.25 Fictional production scenario of a die-cast part
processing line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 5.26 Machine delay calculation logic . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 5.27 Starting and ending of production shifts . . . . . . . . . . . . . . . . 130
Figure 5.28 Machine set up for the depiction of realistic energy
load profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 5.29 Definition of internal state transitions . . . . . . . . . . . . . . . . . . 131
Figure 5.30 Implementation of the individual simulation focuses
in an overall model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 5.31 Implementation of the retention time in the machine
logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 5.32 ‘Select machine function’ logic . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 5.33 Throughput time estimation . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 5.34 Prepare machine functionality . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 5.35 Objective setup of total energy consumption optimizer . . . . 138
Figure 5.36 Parameter and model time setup for the optimization
experiment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 5.37 Optimization experiment visualization in AnyLogic . . . . . . 142
Figure 5.38 Insertion of the offset time for shifting of machine
starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 5.39 Depiction of the offset effect for one machine . . . . . . . . . . . 143
Figure 5.40 Setup of the peak optimization experiment . . . . . . . . . . . . . . 145
Figure 5.41 Results of the total consumption optimization . . . . . . . . . . . 146
Figure 5.42 Results of the peak consumption optimization . . . . . . . . . . . 147
Figure 5.43 Peak optimization experiment in combination
with the use of mean values for the energy
consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 6.1
Bosch production lines 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . 157