Development of dynamic energy benchmark for mass production in machining systems for energy management and energy-efficiency improvement

The energy benchmark has been recognised as an effective analytical methodology and management tool that helps to improve the efficiency and performance of energy utilisation. With a wide distribution and large amount of energy consumption at a low efficiency, machining systems have considerable energy-saving potential. In this study, a new concept of dynamic energy benchmark contributing to energy management and energy-efficiency improvement in machining systems is proposed to overcome deficiencies of previous energy benchmarks. This paper illustrates the concept and connotation of the dynamic energy benchmark and presents a method for developing the dynamic energy benchmark for mass production in machining systems. According to analysis of the energy consumption and the dynamic energy benchmark for machining systems, the dynamic energy benchmark is developed in three steps: (i) the establishment of the database, (ii) the acquisition of the energy consumption and determination of the dynamic energy benchmark, and (iii) the development of a benchmark rating system using the benchmark. Furthermore, a case study involving the establishment of a dynamic energy benchmark for the workpiece in a real machining plant is examined, illustrating the practicability of the proposed method.