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A former remote area power supply was converted to a smart cogeneration subnet with combined heat and power to develop and validate a forecast based energy management at the University of Applied Sciences in Offenburg/Germany. Locally processed weather forecasts and forecasted demand profiles are integrated to allow a precise reaction to changes of fluctuating power sources, changes in scheduled demand profiles and to improve the energy efficiency of the supply. The management of the electrical and thermal storages is influenced by the forecasted energy contributions and the forecasted demand. Further approaches should improve the accuracy of forecasting algorithms and integrate parameter models gained of a detailed monitoring to realize predictive controllers.
The PHOTOPUR project aims to develop a photocatalytic process as a type of AOPs (Advanced Oxidation Processes) for the elimination of plant protection products (PPP) of the cleaning water used to wash sprayers. At INES a PV based energy supply for the photocatalytic cleaning system was developed within the framework of two bachelor theses and assembled as a demonstration unit. Then the system was step by step extended with further process automation features and pushed to a remote operating device. The final system is now available as a mobile unit mounted on a lab table. The latest step was the photocatalytic reactor module which completed the first PHOTOPUR prototype. The system is actually undergoing an intensive testing phase with performance checks at the consortium partners. First results give an overview about the successful operation.
Three real-lab trigeneration microgrids are investigated in non-residential environments (educational, office/administrational, companies/production) with a special focus on domain-specific load characteristics. For accurate load forecasting on such a local level, à priori information on scheduled events have been combined with statistical insight from historical load data (capturing information on not explicitly-known consumer behavior). The load forecasts are then used as data input for (predictive) energy management systems that are implemented in the trigeneration microgrids. In real-world applications, these energy management systems must especially be able to carry out a number of safety and maintenance operations on components such as the battery (e.g. gassing) or CHP unit (e.g. regular test runs). Therefore, energy management systems should combine heuristics with advanced predictive optimization methods. Reducing the effort in IT infrastructure the main and safety relevant management process steps are done on site using a Smart & Local Energy Controller (SLEC) assisted by locally measured signals or operator given information as default and external inputs for any advanced optimization. Heuristic aspects for local fine adjustment of energy flows are presented.
The twin concept is increasingly used for optimization tasks in the context of Industry 4.0 and digitization. The twin concept can also help small and medium-sized enterprises (SME) to exploit their energy flexibility potential and to achieve added value by appropriate energy marketing. At the same time, this use of flexibility helps to realize a climate-neutral energy supply with high shares of renewable energies. The digital twin reflects real production, power flows and market influences as a computer model, which makes it possible to simulate and optimize on-site interventions and interactions with the energy market without disturbing the real production processes. This paper describes the development of a generic model library that maps flexibility-relevant components and processes of SME, thus simplifying the creation of a digital twin. The paper also includes the development of an experimental twin consisting of SME hardware components and a PLC-based SCADA system. The experimental twin provides a laboratory environment in which the digital twin can be tested, further developed and demonstrated on a laboratory scale. Concrete implementations of such a digital twin and experimental twin are described as examples.
Particle and Gaseous Emissions of Diesel Engines Fuelled by Different Non-Esterified Plant Oils
(2007)
The particulate matter and gas emissions of several plant oils are analyzed in the hot exhaust gas under various engine conditions at different speeds and loads The measurement data are compared to the emission values of conventional diesel fuel (gas oil). The investigation concentrates on a modern common rail TDI light duty diesel, four cylinders, for passenger cars. The differences in the gas and particulate matter emission - compared to conventional diesel fuel - are remarkably low for the diesel engine which is properly adjusted for the plant oils. Emission data of an old heavy duty diesel engine are also shown for comparison reasons and reveals large differences. Differences are found in the pressures of the indicator diagram, time resolved over the crank angle. Plant oils consistently exhibit a higher cylinder pressure. The TEM investigation confirms the differences found by the LPME (long path multi-wavelength extinction) on-line analysis.
Non-Esterified Plant Oils as Fuel -Engine Characteristics, Emissions and Mutagenic effects of PM-
(2009)
Plant oils may be used as a sustainable, nearly CO2 neutral fuel for diesel engines. This work investigates experimentally the particulate and gaseous emissions of diesel engines fuelled with non-esterified, pure plant oils with the quality standard of DIN V 51605 (Weihen-stephan RK-Qualitätsstandard 05/2000). The data are collected from three engines:
Common rail passenger car engine from OPEL AG
Truck engine from VOLVO
Truck engine from MAN AG
All engines have been correctly adjusted to plant oil operation.
The OPEL and VOLVO engines served for the basic investigations. The emissions of the MAN engine have been used to perform AMES tests to analyze possible health impacts of plant oil operation.
The experimental data show a reduction of particulate matter compared to traditional gasoil which may yield up to 50 % for. The particulate matter shows same primary particle sizes but the agglomerates as collected on TEM grids are different - the plant oil soot particles tend to form larger aggregates [4]. The gaseous emissions of CO and hydrocarbons HC are generally lower compared to the operation with gasoil. However, the NOX emissions are slightly higher. This may be contributed to the measured higher combustion chamber pressures and temperatures when fuelled by plant oils.
Emission samples have been extracted from ESC cycles of 13 step tests to perform the AMES test which give indication on carcinogen substances. The AMES test results gave no indication of mutagenic effects exceeding the detection limits. No significant differences could be found comparing the emissions of plant oil and gasoil operation. Thus, it can be stated that the emission from plant oil operation does not have a health impact different to traditional gas oil. This is in contrast to some other publications — a deeper insight shows that these investigations did not properly modify the engine for plant oils. It is mandatory to make the engine modification to pre-warm the plant oils to approx. 90°C prior to injection. The engine's warm-up phase needs special care to avoid any coking at the injection system and combustion chamber surfaces. The publications where a higher health risk was claimed to be found in the exhaust of plant oil fuels, did not pre-warm the plant oils — cold plant oils have been injected in the combustion chamber instead. This results in incomplete atomization and incomplete combustion with a lot of hazardous emission species (see also [4,11]. Such an operation will damage the engine after relatively short times and is, therefore, not realistic.
The investigated fuels had some influence on the engine characteristics. Higher temperatures and pressures in the cylinder have been detected for some plant oils compared to gasoil. This increase is explained by the higher oxygen content within the plant oils.
Offenburg university of Applied Sciences offers pre-study extracurricular preparatory courses for future engineering students in mathematics and physics. Due to pandemic restrictions, the two-week preparatory physics course preceeding winter term 2020/21 was presented as an online -only course.
Students enrolled to the course attended eight online lect ures of approximately 90 minutes duration followed by a group assignment. Both lectures and tutoring to the group assignment used a videoconference system with group sizes of 120 (lecture) and 6 (peer instruction and group assignments). The eight lectures focused on the high school physics curriculum of mechanics, electricity, thermodynamics and optics. Each lecture included four “peer instruction” questions to improve student activation. Student responses were collected using an audience response online tool.
The “peer instruction” questions were discussed by the students in online groups of six students. These groups also received written group assignments consisting of common textbook exercises and additional problems with incomplete information. To solve these problems, groups were encouraged to discuss possible solutions. The on-line course attendance was monitored and showed a characteristic exponential “decay” curve with a half-life of approximately 18 lectures which is comparable to conventional courses: Around 73% of the students enrolled in the preparatory course attended all eight lectures. In addition to the attendance, the progress of the participants was monitored by two online tests: A pre-course online test the first course day and a post -course online test on the last day.
The completion of both tests was highly recommended, but not a formal requirement for the students. The fraction of students completing the pre-course, but not the post-course test was used as an estimate for the drop-out rate of (34±3)%.
The aim of the paper was to investigate the energy saved in the shift from separate generation of thermal and electrical energy to trigeneration at the energy facility in Offenburg University of Applied Sciences (HS OG). The energy facility at HS OG used a traditional heating system and electricity from grid until 2007 afterwhich they installed a trigeneration system to meet its continuously changing dynamic thermal and electrical demands. This paper highlights the methodology that had been derived to analyze and study the effect of this shift based on the energy consumption data available from 2004 to 2011, which were scarce due to the limited monitoring. From the energy analysis, we concluded that 8 % primary energy was saved in this shift at the energy facility of HS OG. And from economical perspective 5 % useful thermal energy and 39 % useful electrical energy was saved in this shift at the energy facility of HS OG. Nevertheless, the term energy saving, in general, is very relative and complex to define in such a changeover.
The uncertain and time-variant nature of renewable energy results in the need to deal with peaks in the production of energy. One approach is to achieve a load shift and thereby help balancing the grid by using thermally Activated Building Systems (TABS). Control systems currently in place do not exploit the full potential of TABS. This paper reviews how Model Predictive Control can possibly reduce the fluctuations of the demand and supply of (renewable) energy as it enables the TABS to react to the dynamics of weather and its impact on the grid at any time.
Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material’s yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.
The ability to change aerodynamic parameters of airfoils during flying can potentially save energy as well as reducing the noise made by the unmanned aerial vehicles (UAV) because of sharp edges of the airfoil and its rudders. In this paper, an approach for the design of an adaptive wing using a multi-material 3D printer is shown. In multi-material 3D printing, up to six different materials can be combined in one component. Thus, the user can determine the mixture and the spatial arrangement of this “digital material” in advance in the pre-processing software. First, the theoretical benefits of adaptive wings are shown, and already existing adaptive wings and concepts are explicated within a literature review. Then the additive manufacturing process using photopolymer jetting and its capabilities to print multiple materials in one part are demonstrated. Within the scope of a case study, an adaptive wing is developed and the necessary steps for the product development and their implementation in CAD are presented. This contribution covers the requirements for different components and sections of an adaptive wing designed for additive manufacturing using multiple materials as well as the single steps of development with its different approaches until the final design of the adaptive wing. The developed wing section is simulated, and qualitative tests in a wind tunnel are carried out with the wing segment. Finally, the additively manufactured wing segment is evaluated under technical and economic aspects.