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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

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.


Project Description – REML green cell

sawn slug, rolled blank,

green machined race


Project Description – REML thermal treatment cell

green machined race, hardened race,

tempered race


Project Description – REML thermal treatment cell


Project Description- REML finishing cell

heat treated race, finish machined race


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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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)


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


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.


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.


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


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


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.


Project Status Timeline

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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


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.


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).


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


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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