Reducing the energy consumption of industrial robots (IR) that are used in manufacturing systems has become a main focus in the development of green production systems. This is due to the reality that almost all automated manufacturing processes are using IR as the main component. Thus, reducing the energy consumption of IR will automatically reduce operating costs and CO2 emissions. Therefore, a method for reducing the energy consumption of IR in manufacturing systems is desired. Firstly, this paper presents a literature survey of the research in energy consumption analysis of IR that is used in manufacturing processes. The survey found that current research in this field is focused on the development of simulation models of IR that are able to be used to predict its energy consumption. Secondly, a modular model to analyze power consumption and dynamic behavior of IR is developed. Afterward, an experimental investigation is carried out to validate and estimate the accuracy of the model developed. The investigation shows that the developed modular model can be conveniently used to optimize the industrial robot’s operating parameters, which are commonly needed for production planning and at the process optimization stage. In addition, the investigation shows that the process constraints, environment layout, productivity requirement, as well as the robot payload and operating speed are the key factors that must be considered for optimizing the productivity and efficiency of IR.

Reducing the energy consumption of industrial robots in manufacturing systems

Wärme- und Stoffübertragung

This research evaluated the potential for wireless dynamic charging (charging while moving) to address range and recharge issues of modern electric vehicles by considering travel to regional destinations in California. A 200-mile electric vehicle with a real range of 160 miles plus 40 miles reserve was assumed to be used by consumers in concert with static and dynamic charging as a strict substitute for gasoline vehicle travel. Different combinations of wireless charging power (20–120 kW) and vehicle range (100–300 miles) were evaluated. One of the results highlighted in the research indicated that travel between popular destinations could be accomplished with a 200-mile EV and a 40 kW dynamic wireless charging system at a cost of about $2.5 billion. System cost for a 200-mile EV could be reduced to less than $1 billion if wireless vehicle charging power levels were increased to 100 kW or greater. For vehicles consuming 138 kWh of dynamic energy per year on a 40 kW dynamic system, the capital cost of $2.5 billion plus yearly energy costs could be recouped over a 20-year period at an average cost to each vehicle owner of $512 per year at a volume of 300,000 vehicles or $168 per year at a volume of 1,000,000 vehicles. Cost comparisons of dynamic charging, increased battery capacity, and gasoline refueling were presented. Dynamic charging, coupled with strategic wayside static charging, was shown to be more cost effective to the consumer over a 10-year period than gasoline refueling at $2.50 or $4.00 per gallon. Notably, even at very low battery prices of $100 per kWh, the research showed that dynamic charging can be a more cost effective approach to extending range than increasing battery capacity.

Wireless charging in California: Range, recharge, and vehicle electrification

The introduction of electromobility causes major challenges as new components and materials enter vehicle recycling. This paper discusses the current developments in the recycling of traction batteries, electric motors, and power electronics, which constitute the key components of (hybrid) electric vehicles. Both technical and ecological aspects are addressed. Beside base metals, all components contain metals that are considered critical by the EU (European Union), e.g., rare earth elements, cobalt, antimony, and palladium. As electromobility is a new trend, no recycling routes have been established at an industrial scale for these components. The implementation is complicated by small return flows and a great variety of vehicle concepts as well as components. Furthermore, drastic changes regarding design and material compositions can be expected over the next decades. Due to hazards and high weights, there is a strong research emphasis on battery recycling. Most pilot-scale or semi-industrial processes focus on the recovery of cobalt, nickel, and copper due to their high value. Electric motors and power electronics can be fed into established recycling routes if they are extracted from the vehicle before shredding. However, these processes are not capable of recovering some minor metals such as rare earth elements and antimony.

/pdf/current-developments-and-challenges-in-the-recycling-of-key-2rqfkp4j68.pdf

Current Developments and Challenges in the Recycling of Key Components of (Hybrid) Electric Vehicles

Energy Consumption and Dynamic Behavior Analysis of a Six-axis Industrial Robot in an Assembly System

The implementation of green products and matching manufacturing processes increasingly attract public attention. Therefore, the institute FAPS analyzed the joining process as it is identified to be one of the major energy consumers in the context of electric drives manufacturing. The present approach introduces a statistically developed methodology to predict the energy consumption and the resulting connection quality of one of the major, currently available joining techniques. Therefore an analytical model was developed, which was afterwards used to optimize the parameter settings of an industrial cooperation partner.

Evaluation of energy efficient joining processes in the field of electric drives manufacturing considering quality aspects

Due to the scarcity of resources the sustainable production of electric drives has become more and more important. In the context of a potentially huge increase in the demand for electric traction drives by the market of e-mobility, this topic is even more challenging. For this, new topologies with lower requirements for the needed valuable resources, new energy efficient drive concepts, optimized production, and logistic processes in terms of their resource requirements and integrated recycling strategies are presented in this paper.

Energy-efficient production strategies and technologies for electric drives

The paper discusses different automation concepts for the disassembly of surface mounted magnets, and for the removal of the bandaging of rotors. In detail three strategies to recover the magnet bodies of rotors will be presented. Furthermore the paper introduces an innovative disassembly machine, which can handle different variants of the targeted magnets, to avoid the troubles during the manual removal of magnetized magnets from rotors with surface mounted mag-nets.

Disassembly, recycling, and reuse of magnet material of electric drives

Kurzfassung In der von manuellen Arbeitsplatzen gepragten Montage komplexer und variantenreicher Erzeugnisse mit kurzen Produktlebenszyklen mussen die Mitarbeiter als kreative Leistungstrager bei der Bewaltigung der steigenden Anforderungen unterstutzt werden. Zu diesem Zweck wird am Lehrstuhl fur Fertigungsautomatisierung und Produktionssystematik (FAPS) der Universitat Erlangen-Nurnberg die Erstellung, Distribution und Ruckmeldung von Informationen in der Montage auf Basis eines durchgangigen Systemansatzes betrachtet. Die hierbei entwickelten Werkerinformationssysteme konnen einen essentiellen Beitrag zur Beherrschbarkeit der Produktion leisten. Sie unterstutzen durch eine didaktisch-psychologisch aufbereitete Informationsdarstellung das eigenverantwortliche und flexible Abarbeiten der Auftrage und helfen so, unter anderem Rustzeiten zu minimieren, Erfahrungskurveneffekte schneller zu realisieren und technische Anderungen effektiver zu kommunizieren.

Effiziente Erstellung, Distribution und Rückmeldung von Werkerinformationen in der Montage

Constantly rising fuel prices more and more encourage the development of innovative electric vehicle concepts. In order to follow this trend and to increase customer acceptance and the practicality of electro-mobility, vehicle concepts with inductive power transfer systems are developed. These have to be integrated into the production lines of the car manufacturers with in each case several adaptations depending on the different types of electric vehicles. Therefore, different vehicle integration concepts and cost-efficient value chains need to be created in order to allow an early start of production to sell such vehicles.

Production concepts for inductive power transfer systems for electric vehicles

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