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Simulation Modeling for Energy-Flexible Manufacturing: Pitfalls and How to Avoid Them

Köberlein, Jana ; Bank, Lukas ; Roth, Stefan ; Köse, Ekrem ; Kuhlmann, Timm ; Prell, Bastian ; Stange, Maximilian ; Münnich, Marc ; Flum, Dominik ; Moog, Daniel ; Ihlenfeldt, Steffen ; Sauer, Alexander ; Weigold, Matthias ; Schilp, Johannes (2022)
Simulation Modeling for Energy-Flexible Manufacturing: Pitfalls and How to Avoid Them.
In: Energies, 2022, 15 (10)
doi: 10.26083/tuprints-00021481
Article, Secondary publication, Publisher's Version

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Item Type: Article
Type of entry: Secondary publication
Title: Simulation Modeling for Energy-Flexible Manufacturing: Pitfalls and How to Avoid Them
Language: English
Date: 10 June 2022
Place of Publication: Darmstadt
Year of primary publication: 2022
Publisher: MDPI
Journal or Publication Title: Energies
Volume of the journal: 15
Issue Number: 10
Collation: 25 Seiten
DOI: 10.26083/tuprints-00021481
Corresponding Links:
Origin: Secondary publication DeepGreen

Due to the high share of industry in total electricity consumption, industrial demand-side management can make a relevant contribution to the stability of power systems. At the same time, companies get the opportunity to reduce their electricity procurement costs by taking advantage of increasingly fluctuating prices on short-term electricity markets, the provision of system services on balancing power markets, or by increasing the share of their own consumption from on-site generated renewable energy. Demand-side management requires the ability to react flexibly to the power supply situation without negatively affecting production targets. It also means that the management and operation of production must consider not only production-related parameters but also parameters of energy availability, which further increase the complexity of decision-making. Although simulation studies are a recognized tool for supporting decision-making processes in production and logistics, the simultaneous simulation of material and energy flows has so far been limited mainly to issues of energy efficiency as opposed to energy flexibility, where application-oriented experience is still limited. We assume that the consideration of energy flexibility in the simulation of manufacturing systems will amplify already known pitfalls in conducting simulation studies. Based on five representative industrial use cases, this article provides practitioners with application-oriented experiences of the coupling of energy and material flows in simulation modeling of energy-flexible manufacturing, identifies challenges in the simulation of energy-flexible production systems, and proposes approaches to face these challenges. Seven pitfalls that pose a particular challenge in simulating energy-flexible manufacturing have been identified, and possible solutions and measures for avoiding them are shown. It has been found that, among other things, consistent management of all parties involved, early clarification of energy-related, logistical, and resulting technical requirements for models and software, as well as the application of suitable methods for validation and verification are central to avoiding these pitfalls. The identification and characterization of challenges and the derivation of recommendations for coping with them can raise awareness of typical pitfalls. This paper thus helps to ensure that simulation studies of energy-flexible production systems can be carried out more efficiently in the future.

Uncontrolled Keywords: industrial demand-side management, energy-flexible manufacturing systems, simulation pitfalls, simulation of material and energy flows
Status: Publisher's Version
URN: urn:nbn:de:tuda-tuprints-214813
Classification DDC: 600 Technology, medicine, applied sciences > 620 Engineering and machine engineering
Divisions: 16 Department of Mechanical Engineering > Institute of Production Technology and Machine Tools (PTW)
Date Deposited: 10 Jun 2022 11:07
Last Modified: 14 Nov 2023 19:04
SWORD Depositor: Deep Green
URI: https://tuprints.ulb.tu-darmstadt.de/id/eprint/21481
PPN: 499657837
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