Optimizing Energy

Efficiency with FlexSim

FlexSim Energy Simulation Module

(*)

(*) by Flexcon s.r.l.

rev 3.0 - 10/09/2015

Energy Prices in the last 30 years

World prices for energy, 19912010 2000 = 100

Germany

http://en.wikipedia.org/wiki/Energy_economics

Electric power prices

in Eurocent per kWh
Source Eurostat

Austria
Sweden
*3 in 10 years

Spain

UK

Energy Oriented Design

Emerging from the challenge to reduce energy
consumptions in production and logistics systems is the
need for energy simulation tools to be used more
effectively to support integrated decision making in early
design phases.

FlexSim Energy Simulation

FlexSim Energy Simulation
is a module, developed
from Flexcon, which
extends Flexsim object s
capabilities to the
simulation of energy
consumptions.
It is installed on top FlexSim GP and enables the
modelling of various energy utilization on every
FlexSim object.
Supports any type of energy and material
requested from an equipment, simulated
according to its real utilization mode.
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Setup

Install FlexSim Energy

Simulation on your module
folder and start FlexSim.
From the FlexSim Toolbox
select Energy Simulation and
install in your model s Toolbox
the Consumption Analysis
object.

Model Configuration

For each model s

power source define a
proper Energy Class.

Energy Class represents a type of power supply

coming for a single identified power source (eg.
electricity, steam, cooling water, .).
It has an individual unit definition (Consumption
and Absorption) as well as a specific cost profile.
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Model Configuration

FlexSim objects can be

linked to many specific
energy classes, with
instances (energy
types) that represent
the power consumption
of an individual device.

Different energy types

of the same object can
be instances of the
same energy class.

Each energy type defines the way the object is using a

specific (power) supply.
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Model Configuration

One object could need of an energy type in

several ways :
With a fixed absorption quota (background/stand-by
consumption).
For each flow item entering the object.
Depending on the objects state times.

By default, every energy setting is defined as

Added value energy, that means is an active
part of the manufacturing transformation
process. If not they can be marked as Non
added value ( with *).
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Energy Simulation
Using FlexSim Energy
Simulation is easy :
Turn On the GUI switch
(green) and activate the
energy simulation module.
Run the simulation.
Get energy consumptions
from the report tab.
Export data to a csv or xml
file.

Energy Groups
Energy groups are logic relation between objects,
allowing the simulation of collective consumptions (f.e.
equipment powered from the same cabinet).
Each group gather energy consumption for every
energy type and class used from its members.
Group s members are selected from the GUI s object
lists.

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Energy Reports
Reports are available for each object, group,
energy type and energy class :

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Actual power absorption

(Fixed / Background, per
Item, per States).

Full power absorption

statistics (Min/Avg/Max
=> Fixed/Background, per
Item, per States).

Overall Energy
Consumption (Fixed /
Background, per Item, per
States).

Energy utilization
efficiency.

Energy Reports
With Enable Sampling checked on, objects collect
their consumption data for a defined sampling
frequency, they can be later displayed in the
FlexSim Dashboard.

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Energy Reports
Energy Consumption Data can be exported in csv
and xml formats, for additional analysis.

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Optimizing Energy
Efficiency with FlexSim

Test Case 01

Test Case 01
Test Case is on a simple manufacturing cell, on which a
part received a CNC roughing, then a partial assembly
and finally is CNC finished; 50% are also labeled. 100%
of the production is stored and then shipped to
customers.

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Test Case 01
Roughing CNC Station is semi-automatic, requires one
monitoring operator; it has 5 different power
requirements :

CNC Control

Drives Feeding

Auxiliary Components

Cooling Lubricant

Compressed Air

Finishing CNC differs from Roughing only for the fully

automatic operating mode.
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Test Case 01
Roughing and Finishing CNC energy configuration is per
state, with 4 energy types :

Electr CNC (CNC Control).

Electr Auxiliary (Auxiliary Components + Drives Feeding as NVA fixed

absorption).

Electr Cooling Lubricant.

Electr Compressed Air.

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Test Case 01
Assembly Station is fully manual, with 3 different power
requirements :

Tool Feeding (Electr Tools, state depending)

Auxiliary Components (Electr Auxiliary, fixed NVA)

Compressed Air (Electr Compressed Air, state depending)

Automatic Labeler has the same requirement types.

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Test Case 01
ASRS has 1 main power requirement (Electrical Power),
defined as state depending.

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Test Case 01
All the conveyors have 1 main power requirement
(Electrical Power), defined as following :
Basic power absorption is state depending, with only
conveying state set as non NVA.
Additional absorption according to its current content
(Absorption per Item).

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Test Case 01
Energy groups are functional collection of objects which
allow monitoring energy consumptions with a different
perspective :
Conveyors.
Assy Stations
CNC Stations
All Machines

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Test Case 01

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Optimizing Energy
Efficiency with FlexSim

Energy module s analytics

Flexsim Energy Simulation

When Flexsim simulation is running, if FlexSim
Energy Simulation GUI is switched on :
Every time a flowitem enters or
leaves or a state change happens
in a monitored object, energy
consumption and absorption data
are updated.
This also reflects the group and
overall statistics.
If Enable sampling is checkedon, all the statics are collected
with a defined frequency and
grouped by certain period of time
(to get hourly consumptions per
day, f.e.)

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Flexsim Energy Simulation

Flexsim Energy Simulation on every model s
change (flowitem + states), update statistics data
on each energy type monitoring the three power
consumption causes :

These elements might contain some non added

value consumptions reasons, then the efficiency
for a given energy type/class is :

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Flexsim Energy Simulation

The Fixed absorption is used for background
consumptions (equipment s stand-by, heating of
buildings ) :

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Flexsim Energy Simulation

If absorption depends also from the type and number of
products in the equipment, the energy consumption is
calculated in the following way :

Item Type definition uses itemtype filtering :

Range of itemtypes are specified as 1-3, 7-11; comma separates

different ranges; combined definitions are allowed : 1,2,3,7-11

If left blank means All Item Types

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Flexsim Energy Simulation

The absorption depending on the objects state is
calculated in the following way :

Every State Change perform a fixed consumption that lasts

the % of State Time (power absorption peak).
The object s time spent in given state is multiplied per its
relevant absorption
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Optimizing Energy
Efficiency with FlexSim

Development Status

Development Status
Energy Simulation module is available with FlexSim 7.54
and actually used only in Flexcon projects.
Some additional development steps are planned to fulfill
new projects demand, extending the module utilization to
end users :
Core and GUI general stabilization; additional Dashboard
charts, updated xml reports.
Development of a Energy Supply FlexSim class (a limited,
time dependent energy source); modeling network of
energy supply objects.
Transformed Energy Class : support of Energy Classes
created from other Energy Classes (f.e. compressed air
needs electricity to be produced).
Energy costing calculation model, cost based optimization,
cost report.
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Flexcon s.r.l.
Viale Risorgimento, 16
I10092 Beinasco (TO) Italy
+39-011-1968-2600
http://www.flexcon.it
info@flexcon.it