Energy-Oriented Modeling of Hot Stamping Production Line: Analysis and Perspectives for Reduction

Qiong Liu, Quan Zuo (), Lei Li, Chen Yang, Jianwen Yan and Yuhang Xu
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Qiong Liu: School of Mechanical Engineering, Anhui University of Science and Technology, Huainan 232001, China
Quan Zuo: School of Mechanical Engineering, Anhui University of Science and Technology, Huainan 232001, China
Lei Li: School of Mechanical Engineering, Anhui University of Science and Technology, Huainan 232001, China
Chen Yang: School of Mechanical Engineering, Anhui University of Science and Technology, Huainan 232001, China
Jianwen Yan: School of Mechanical Engineering, Anhui University of Science and Technology, Huainan 232001, China
Yuhang Xu: School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China

Energies, 2024, vol. 17, issue 22, 1-27

Abstract: This research aims to develop a comprehensive mathematical model to analyze the energy usage of essential equipment in the hot stamping production line (HSPL) and identify opportunities for improving energy efficiency. This involves refining existing models and parameters related to energy consumption in hot stamping to ensure precise energy usage monitoring throughout the HSPL. The main focus is on accurately calculating and validating the energy consumption efficiency of equipment within a product’s production cycle on the roller hearth furnace’s HSPL. The model has proven to be highly accurate in predicting energy consumption for various equipment. The average energy consumption of the HSPL in the case study is calculated as 0.597 kwh/kg, and the actual measurement is 0.625 kwh/kg. However, it revealed significant deviation in the cooling system, primarily due to the incorrect water pump head parameters utilization. As per the model’s calculations, most energy consumption is attributed to the furnace (77.51%), followed by the press (10.92%), chillers (6.86%), cooling systems (2.76%), and robots (1.95%). Actual measurements and model calculations highlight mismatches between equipment power ratings and actual demand, resulting in average operating power significantly lower than the rated power. In line with efforts to promote low-carbon manufacturing, practical approaches are being explored to conserve energy and enhance overall process efficiency by refining process parameters, reducing quenching duration, improving SPM on the production line, and adjusting load matching.

Keywords: hot stamping process chain; energy consumption; low carbon manufacturing; energy saving (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: 2024
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