Work program
Estomad work packages:WP 1 - WP 2 - WP 3 - WP 4 - WP 5 - WP 6
The project is organized in 7 work packages (WPs), of which results will be measured at four milestones (MS). The work packages and their interrelationships are shown in Fig 1.
Fig. 1: overview of the work packages of the ESTOMAD project
WP 1: Research and Technological Development
The goal of this WP is to collect the necessary information and data to serve the other WPs by performing specification and survey studies. A distinction in surveys is made as follows:
a) A survey study is performed to chart the required/desired ICT tools which industry would need: (1) to take into account energy efficiency as a design attribute (high level application) in the full product design cycle; (2) to analyse existing products (i.e. machines) to optimize their energy consumption and increase their energy efficiency (low level application).
b) A survey study is performed to identify typical systems, subsystems or components used in machine design for which energy efficiency is an attribute. E.g. electrical engines, guides, movement convertors (e.g. cams), rotating axis, controllers, storage elements (e.g. electrical, mechanical, hydraulic, pneumatic, etc.).
c) A survey study is performed on existing modelling paradigms and niche tools with a very high focus towards modelling of energy behaviour within machines, at system level, but also at both subsystem and component level. There is currently a lot of fragmentation in knowledge between various engineering fields.
Based on these surveys the specifications of the ESTOMAD framework will be detailed.
WP 2: Energy component/subsystem methodology
The general objective of WP2 is to develop a modelling methodology for individual components and looking at an architecture for inter-component communication to describe subsystems. The idea is to derive energy balances for machinery by decomposition of the machine in particular elements which have influence on the energetic state of the machine. To do so on a system/subsystem/component level, the interaction between electrical, mechanical and other types of elements with respect to energy flow will have to be analysed and a methodology has to be developed to be able to do so.
Based on the survey studies performed in WP1, especially b) and c), methodology development is performed on two scales:
(1) on component level
(2) on subsystem level (i.e. assembly of components).
Development on component level will focus on the understanding of the behaviour of single components. Not only the, most often obvious or well know, primary functional behaviour needs to be described in mathematical formulations. The focus of WP2 is on developing formulations which cover the description of power and energy quantities of individual components: i.e. ways how components generate energy, dissipate energy, store energy or exchange energy with other components. The latter is related to methodology development on the second scale, the subsystem level method development.
WP 3: Energy design and system methodology
The general objective of WP3 is to develop an energy design and system methodology. The methodologies developed in WP2 can only be used if good component/subsystem models are available and if new information that is gathered during testing can be compared to simulation results, or even integrated in the simulation models to improve accuracy. It is unrealistic that a very wide variety of subsystem models will made by machine builders, as they acquire many subsystems from suppliers. A more reasonable approach is therefore to involve subsystem manufactures in the modelling and designing process and acquire models through suppliers. However, for such approach to work, all involved parties (1) have to be willing to cooperate and (2) methodologies and tools have to be adopted to support such integrated design approach.
Therefore, this WP will develop an abstract framework for energy evaluation and design for energy-efficiency analysis of machine designs taking into account the interaction between machine designers and their suppliers. This framework will make use of the component/subsystem modelling methodology developed in WP2. Different energy processes will be defined for the various assembled systems. Specific methodologies for energy optimization and efficient use of resources will be developed, thus defining a simulation framework that can be flexibly extended to integrate more aspects provided by different suppliers in a fully automated way.
WP 4: Implementation of ESTOMAD framework
The general objective of WP4 is the embedding of the developments of WP2 and WP3 on the CAE tool AMESim. In order to be able to use an ICT software tool in an industrial analysis or design cycle, it has to be embedded in an industrially applicable framework, which allows sufficient flexibility, but also ensures robust usage. WP4 will focus on the enhancement of the existing AMESim software tool with the energy modelling and interfacing methodologies developed in WP2 and WP3. Note that, although the methods will be implemented onto the existing AMESim platform, they are more generally applicable also for usage with other platforms.
WP 5: Validation of methodologies/software tools
The general objective of WP5 is to validate the methodologies and software tools which are developed in WP2, WP3 and WP4 on industrial use cases. After implementation of the verified methodologies onto an industrially available platform, WP5 will validate the methodologies on a number of real industrial test cases provided by the industrial partners.
JOBS will work on the energy consumption modelling of their LinX and Jomach 146 milling centres.
Fig. 2: LinX milling centre
PICANOL will work on the energy consumption modelling of a weaving loom (see Fig. 3).
Fig. 3: PICANOL Weaving machines
FIDIA is also a machine tool manufacturer, but will focus its participation to the project mainly as component/subsystem supplier of Numerical Control, Motors and Drives.
WP 6: Dissemination and exploitation
The general objective of WP6 is the overall project management and to ensure the dissemination of ESTOMAD results within the consortium and towards the wider EU community. The project benchmarks will be used to organize industrial workshops on both analysis methodologies and component modelling.