An integrative approach for implementing needs-based process operation in parts drying to increase resource efficiency

Parts drying is the final step of aqueous parts cleaning and an integral part of most metalworking production process chains. Due to limited scientific attention so far, it holds significant optimization potential due to a lack of insight into the complex mechanisms influencing the process outcome. The broad variety of parts further complicates part-specific process optimization required to increase its resource efficiency. To meet these challenges, the following paper presents an integrative approach for systematically configuring needs-based parts drying processes as a measure to reduce the parts drying process’ resource consumption while maintaining acceptable process outcomes. The approach integrates different methods for conceptualizing and synthesizing various systems to increase transparency into the parts drying process and apply necessary adjustments. The conceived tools are based on a comprehensive knowledge base regarding the considered product, drying system, and production environment. The tools are then implemented to the system at hand and their influence on the process’ performance and resource consumption are evaluated as a final step of the approach. The approach is applied to a convective parts drying system with energy consumption as the main resource to be reduced. Two use cases allowing for different levels of automation in process adjustment are considered. A significant increase in energy efficiency is demonstrated in both cases, with a reduction of energy consumption of the drying system by 24.1 % through manual adjustment of the drying parameters and 61.8 % via automatic control.