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Strategies and Methods for the Energy Efficient Production of Electric Drives

机译：高效节能生产电驱动器的策略和方法

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This paper presents methods and experiments for the assessment and evaluation of energy efficiency strategies for manufacturing processes in the field of electric drives production. First, the system for the Least Energy Demand Method will be explained. The basic idea of this calculation is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the measured energy consumption. Using these values as well as further derived indicators for energy efficiency, the main energy consumers within the field of electric drives production are identified. Subsequently, these processes are analysed and optimized to achieve major energy saving instructions. From an energy point of view during the stator production chain, especially the impregnation process and the joining process have to be optimized as, in the here presented measurements, the impregnation process amounts to more than 80?% of the cumulated energy demands. Moreover, the process of joining insulated copper wires of the stator windings to corresponding cables shoes is optimized, as it shows strong energy saving potentials. Additionally, the power consumption values within the state of the art joining process are varying strongly thus leading to higher load peaks within the production line, which have to be reduced. Regarding energy efficiency within the manufacturing of permanent magnet synchronous rotors, the process of magnet assembly also has to be evaluated. It can be subdivided into magnet manufacturing, logistics, magnetization and assembly. A major part of the energy used in this process is accounted for by means of transportation, especially when considering that magnetized magnets need larger packaging volumes and weights due to the ferromagnetic shielding and spacers to support handling of the magnet bodies. Thus, the energy efficiency can be increased considerably by shifting the magnetization step directly to right before the assembly step. In addition, energy can be saved by optimizing the magnetization process according to the magnetization strategy and the interaction of all process parameters, such as capacity of the magnetizer, inductivity and size of the magnetizing coil, magnet size, material and coating.
机译：本文介绍了用于评估和评估电驱动器生产领域制造过程的能效策略的方法和实验。首先，将解释用于最小能量需求方法的系统。该计算的基本思想是基于理论上所需的能耗与所测得的能耗之比，对能源效率进行比较和评估。使用这些值以及进一步得出的能效指标，可以确定电气驱动器生产领域的主要能源消耗者。随后，将对这些过程进行分析和优化以实现主要的节能指示。从定子生产链的能量角度来看，尤其是浸渍过程和连接过程必须进行优化，因为在这里介绍的测量中，浸渍过程占总能量需求的80％以上。此外，优化了将定子绕组的绝缘铜线连接到相应的电缆靴的过程，因为它具有强大的节能潜力。另外，现有技术的连接过程中的功率消耗值变化很大，因此导致生产线中的负载峰值更高，必须降低负载峰值。关于永磁同步转子制造中的能源效率，还必须评估磁体组装过程。它可以细分为磁体制造，物流，磁化和组装。该过程中使用的能量的大部分是通过运输来解决的，尤其是考虑到由于铁磁屏蔽层和支撑磁体的处理的垫片，磁化的磁体需要更大的包装体积和重量时。因此，通过将磁化步骤直接移到恰好在组装步骤之前，可以显着提高能量效率。另外，可以根据磁化策略和所有工艺参数（例如，磁化器的容量，磁化线圈的电感率和尺寸，磁体尺寸，材料和涂层）的相互作用来优化磁化过程，从而节省能源。

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