Active energy saving strategy for sensible manufacturing systems operation based on real time production status

Energy consumption becomes a very important performance indicator of manufacturing system. By turning non-bottleneck machines into sleep mode, energy saving system operation in real time will be indispensable strategy for modern information rich manufacturing system under Industry 4.0 environment. From the system perspective, a general energy saving operation strategy is proposed to utilize the transient production status of machines and buffers by active sensing and responding in a serial tandem line. A definition of sensible manufacturing system is given to describe the characteristics of the new generation manufacturing system. Based on the captured real time data, the energy saving opportunities are analyzed without sacrificing the production throughput. The key modules including energy saving window, active machine model with sensible ability and multi-granularity state chart model for machine control are described. Some preliminary simulation results are given to show the feasibility and effectiveness of proposed energy saving control strategy.