Simulation Modeling for Energy-Flexible Manufacturing: Pitfalls and How to Avoid Them

Jana Köberlein, Lukas Bank, Stefan Roth, Ekrem Köse, Timm Kuhlmann, Bastian Prell, Maximilian Stange, Marc Münnich, Dominik Flum, Daniel Moog, Steffen Ihlenfeldt, Alexander Sauer, Matthias Weigold and Johannes Schilp
Additional contact information
Jana Köberlein: Fraunhofer IGCV, Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Am Technologiezentrum 10, 86159 Augsburg, Germany
Lukas Bank: Fraunhofer IGCV, Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Am Technologiezentrum 10, 86159 Augsburg, Germany
Stefan Roth: Fraunhofer IGCV, Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Am Technologiezentrum 10, 86159 Augsburg, Germany
Ekrem Köse: Fraunhofer IPA, Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Nobelstraße 12, 70569 Stuttgart, Germany
Timm Kuhlmann: Fraunhofer IPA, Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Nobelstraße 12, 70569 Stuttgart, Germany
Bastian Prell: Fraunhofer IWU, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, 09126 Chemnitz, Germany
Maximilian Stange: Fraunhofer IWU, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, 09126 Chemnitz, Germany
Marc Münnich: Fraunhofer IWU, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, 09126 Chemnitz, Germany
Dominik Flum: PTW TU Darmstadt, Institute of Production Management, Technology and Machine Tools, Technical University of Darmstadt, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany
Daniel Moog: PTW TU Darmstadt, Institute of Production Management, Technology and Machine Tools, Technical University of Darmstadt, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany
Steffen Ihlenfeldt: Fraunhofer IWU, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, 09126 Chemnitz, Germany
Alexander Sauer: Fraunhofer IPA, Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Nobelstraße 12, 70569 Stuttgart, Germany
Matthias Weigold: PTW TU Darmstadt, Institute of Production Management, Technology and Machine Tools, Technical University of Darmstadt, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany
Johannes Schilp: Fraunhofer IGCV, Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Am Technologiezentrum 10, 86159 Augsburg, Germany

Energies, 2022, vol. 15, issue 10, 1-25

Abstract: Due to the high share of industry in total electricity consumption, industrial demand-side management can make a relevant contribution to the stability of power systems. At the same time, companies get the opportunity to reduce their electricity procurement costs by taking advantage of increasingly fluctuating prices on short-term electricity markets, the provision of system services on balancing power markets, or by increasing the share of their own consumption from on-site generated renewable energy. Demand-side management requires the ability to react flexibly to the power supply situation without negatively affecting production targets. It also means that the management and operation of production must consider not only production-related parameters but also parameters of energy availability, which further increase the complexity of decision-making. Although simulation studies are a recognized tool for supporting decision-making processes in production and logistics, the simultaneous simulation of material and energy flows has so far been limited mainly to issues of energy efficiency as opposed to energy flexibility, where application-oriented experience is still limited. We assume that the consideration of energy flexibility in the simulation of manufacturing systems will amplify already known pitfalls in conducting simulation studies. Based on five representative industrial use cases, this article provides practitioners with application-oriented experiences of the coupling of energy and material flows in simulation modeling of energy-flexible manufacturing, identifies challenges in the simulation of energy-flexible production systems, and proposes approaches to face these challenges. Seven pitfalls that pose a particular challenge in simulating energy-flexible manufacturing have been identified, and possible solutions and measures for avoiding them are shown. It has been found that, among other things, consistent management of all parties involved, early clarification of energy-related, logistical, and resulting technical requirements for models and software, as well as the application of suitable methods for validation and verification are central to avoiding these pitfalls. The identification and characterization of challenges and the derivation of recommendations for coping with them can raise awareness of typical pitfalls. This paper thus helps to ensure that simulation studies of energy-flexible production systems can be carried out more efficiently in the future.

Keywords: industrial demand-side management; energy-flexible manufacturing systems; simulation pitfalls; simulation of material and energy flows (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2022
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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