Energy-Oriented Modeling of Hot Stamping Production Line: Analysis and Perspectives for Reduction

This research aims to develop a comprehensive mathematical model to analyze the energy usage of essential equipment in the hot stamping production line (HSPL) and identify opportunities for improving energy efficiency. This involves refining existing models and parameters related to energy consumption in hot stamping to ensure precise energy usage monitoring throughout the HSPL. The main focus is on accurately calculating and validating the energy consumption efficiency of equipment within a product’s production cycle on the roller hearth furnace’s HSPL. The model has proven to be highly accurate in predicting energy consumption for various equipment. The average energy consumption of the HSPL in the case study is calculated as 0.597 kwh/kg, and the actual measurement is 0.625 kwh/kg. However, it revealed significant deviation in the cooling system, primarily due to the incorrect water pump head parameters utilization. As per the model’s calculations, most energy consumption is attributed to the furnace (77.51%), followed by the press (10.92%), chillers (6.86%), cooling systems (2.76%), and robots (1.95%). Actual measurements and model calculations highlight mismatches between equipment power ratings and actual demand, resulting in average operating power significantly lower than the rated power. In line with efforts to promote low-carbon manufacturing, practical approaches are being explored to conserve energy and enhance overall process efficiency by refining process parameters, reducing quenching duration, improving SPM on the production line, and adjusting load matching.