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Sensors to Revolutionize Manufacturing
DOE Sensors & Automation
2007 Annual Portfolio Review
ROBOTICALLY ENHANCED ADVANCED MANUFACTURING CONCEPTS TO OPTIMIZE ENERGY,
PRODUCTIVITY, AND ENVIRONMENTAL PERFORMANCE
Joseph M. Pack The Timken Company, Canton Ohio
DOE Sensors & Automation 2007 Annual Portfolio Review Joseph Pack / 1
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Project Description
Need
Early in 2004, the Robotically Enhanced Manufacturing Line (REML) was conceived for the production of small lots of tapered roller bearing races. REML was seen as an opportunity to utilize Timken steel tubing with microstructures optimized for REML processes, to reduce energy consumption, improve productivity, reduce health and safety risks, and reduce environmental impact when compared to conventional, low volume industrial bearing manufacturing lines.
Project Description / Goal(s) Construct an advanced, low-volume manufacturing line for the production of
industrial bearing races.
The line consists of processes for cold working and green machining, for thermal treatment, and for finishing and inspection of the bearing races.
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Project Description – REML green cell
sawn slug, rolled blank,
green machined race
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Project Description – REML thermal treatment cell
green machined race, hardened race,
tempered race
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Project Description – REML thermal treatment cell
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Project Description- REML finishing cell
heat treated race, finish machined race
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Project Description- REML finishing cell
The operating power consumption of the light weight, high speed
gantry robot is about one-half that of the conventional gantry robot
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CAMotConvent
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Project Description
Core Technology & Transformational Elements
Energy-efficient induction heating processes, which operate on demand, replace continuously heated, energy over-sized furnaces. Robotics which tend the processes thereby reducing manual labor and repetitive labor. CAMotion Inc. low-mass, high-speed gantry robot in the finishing cell which relies on sensors not structural rigidity for positioning accuracy “brains not brawn”.
Key Project Deliverable(s)
Analysis of potential 1. for energy savings for bearing races and other heat treated, metal products 2. for productivity increases 3. for reduction of environmental impact, health and safety risks as compared to a conventional, low-volume bearing race manufacturing line (low-volume manufacturing line or cells for other heat treated, metal products)
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Project Description
Industries for Application The REML technologies will in general be extendible beyond bearings to the manufacture of many types and forms of heat treated and finished machined metal parts.
Crosscutting Applicability Industrial Heating Equipment
Heat Treating
Industrial Materials
Robotics
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Energy Savings
How energy is saved Use of energy-efficient induction heating processes, which operate on demand,
replace continuously heated, energy over-sized furnaces. Use of multi-function finishing assets which replace multiple, single-function finishing
assets.
Measuring line annual energy savings 1) The energy consumption of all energy consumers within REML was measured while
processing the baseline part and while at idle. Energy forms included electricity, natural gas, process gases, compressed air, and water (chilled, tower, city). Human energy was not included.
2) The energy consumption of all energy consumers of the conventional baseline, low volume line while processing reference-sized parts and while at idle. These measurements were made at a Timken industrial bearing plant in Canton, Ohio.
3) Duty cycles (processing versus idle times) were measured for all producing assets of the REML line and the conventional line while producing the baseline part.
4) Line annual energy consumptions were computed and comparisons were made assuming equivalent annual line production of approximately 51,000 races per year.
DOE Sensors & Automation 2007 Annual Portfolio Review Joseph Pack / 10
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Energy Savings
The REML line in its Annual Energy Consumption current state of
(51,000 Races Annual production) development has been measured to be about
1,594,342 22% (338,000 kVA-hrs 1,600,000 per year) less energy 1,400,000 intensive than the 1,200,000 1,256,388 baseline conventional 1,000,000 low volume line
kVA-hrs 800,000 assuming equivalent 600,000 annual production 400,000
GREEN HEAT
FINISH
17,840
1,322,533
253,969175,181
999,860
81,348 volume of bearing races.
BASELINE Additional savings are 0
200,000 REML possible if flow through
green cell is batch rather TREAT TOTAL than single piece flow.
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Anticipated Economic Impact and Value Proposition
Annual energy cost savings per REML line (338,000 kVA-hrs/yr) * ($0.06 / kVA-hrs) = $20,300 / yr Additional savings are possible if flow through green cell is batch rather than single
piece flow. Generally extendible to manufacture of metal parts in the US (gears, sleeves, rods,
any ring geometry)
Productivity improvement
Reduced labor content Reduced flow time Reduced unit cost Make to order with low run volumes
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Other Important Metrics
Productivity (lower energy cost, dramatically reduced flow time, reduced labor content, lower unit cost for small run volumes)
UNIT COST COMPARISON
Log Units Per Run
Uni
t Cos
t CONVENTIONAL LINE
REML LINE
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Other Important Metrics
Environmental Impact Reduction
REML would result in an estimated annual reduction of emission of approximately 43,780 lbs CO2 of and approximately 220 lbs of un-combusted methanol vapors into the air. Eliminates hazards and wastes associated with periodic removal and replacement of insulating bricks in conventional furnaces.
Health and Safety Risk Reduction, Ergonomics Improvement Health and Safety Risk Assessments were completed for each asset by a Timken Health and Safety and Environmental Compliance Analyst.
Compared to the conventional line, the REML line substantially reduces the risk of ergonomic injuries (musculoskeletal disorders) as a result of the robotic machine tending and other forms of automation which eliminate or reduce the need for human /machine manual interaction, repetitive motion and frequent material handling.
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Project Status Timeline
2 0 0 6 2 0 0 7
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2 0 0 8 2 0 0 4 2 0 0 5 I n t e g r a t e t h e r m a
t r e a t m e n t a n d s h c e l l s t h r o b o c s . A c q r e
s e c o n d a r y a s s e t s .
A s s e t o p t i m z a t i o n .
T r ia l p r o d u c t o n r u n s .
m p r o v e m e n t e s t i m a t e s .
P r o c e s s a d d i t io n a s t e e g r a d e s
t h e r m a t r e a t m e n t D e p l o y g r e e
a n d s s e t s t o p r o d u c t n . C e a n d l in e C A D A .
S p e c a n d
p u r c h a s e o r
a s s e t s
R E M L
D e p t h e r m a t r e a t m e n t
a s s e t s t o p r o d u c t o n .
L i c e n s e t e c h n o o g e s
n o n - c o m p e t t o r s
DOE Sensors & Automation 2007 Annual Portfolio Review Joseph Pack / 15
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Next Steps & Commercialization
All current contract milestones are completed. Ongoing effort to optimize and qualify inductive heating and
tempering efficiency and post-heat treat metallurgical properties of new steel grades, new (larger) part sizes and new part geometries and features (flanges, holes, slots, grooves).
Complete an associated investigation of opportunities for deployment of the thermal treatment cell into Timken’s Industrial Bearing Business.
The Timken Company and its supplier of induction heating equipment will investigate licensing of induction heating technology to non-competitors of The Timken Company. The Timken Company will be the point of contact.
CAMotion Inc. will promote and offer low-mass, high-speed gantry robotics, similar to that featured in the REML finish cell, to industry.
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Commercial/Technical Risks Remaining
Achieving induction heating processes which achieve the required control over temperature uniformity across fullrange of part diameters, widths, and cross sections.
Marketplace acceptance of non-conventional materials
and manufacturing processes. (Employ existing
customer notification, acceptance, and approval
practices).
Production service reliability especially of machine
tending robotics. High technical sophistication of line
assets, robotics and systems. (Development of Total
Productive Maintenance TPM programs, Condition
Monitoring).
DOE Sensors & Automation 2007 Annual Portfolio Review Joseph Pack / 17
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Summary
10 REML Lines per Year Beginning 2007
240 Conventional to REML Conversions by 2030
1% Cost of Energy Increase per Year
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
2005 2010 2015 2020 2025 2030 $0
CUMULATIVE REML SAVINGS POTENTIAL IN US
Meg
a VA
-hrs
$10,000,000
$20,000,000
$30,000,000
$40,000,000
$50,000,000
$60,000,000
$70,000,000
$80,000,000
Year’s energy output of
100 Mega Watt Power Plant
10 Lines 240 Lines
DOE Sensors & Automation 2007 Annual Portfolio Review Joseph Pack / 18
Sensors to Revolutionize ManufacturingProject DescriptionREML green cellREML thermal treatment cellREML finishing cell
Energy SavingsAnticipated Economic Impact and Value PropositionOther Important MetricsProject Status TimelineNext Steps & CommercializationCommercial/Technical Risks RemainingSummary
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