A hybrid simulation approach for predicting energy flows in production lines

Figures & data

Figure 1 General structure of the hybrid simulation strategy.

Figure 2 Simulink diagram of the case study.

Figure 3 Production sequence signal generation and regulation.

Figure 4 Signal transformation of energy signature model (ESM).

Figure 5 Block diagram of the volume prediction method.

Figure 6 Block diagram of the sequence record & delay method.

Table 1 R² analysis of the regression model.

	CW (%)	HW (%)	Electrical demand (%)	NG to paint shop (%)	Total EC output energy (%)
R^2	69.65	5.46	43.10	58.29	46.51
R^2 (adj)	68.60	2.20	41.14	56.85	44.67

Table 2 Comparison between production prediction model, time delay model and regression analysis.

Energy (MW/h)s	HW	CW	Elect	NG	Prod volume (unit/day)
Production prediction model	185	175	583	652	863
Time delay model	186	177	586	651	863
Regression analysis	188	178	587	653	863

Figure 7 (a) The regression model predictions versus actual plant data using productivity; (b) the predictions versus actual readings using number of units and working hours; both for the case of electricity from the grid.