D5.1 Energy-oriented Machine-level configuration

E2COMATION intends to address the optimization of energy usage, at multiple hierarchical layers of a manufacturing process as well as considering the whole life-cycle perspective across the value chain. To reach this goal, we propose a bottom-up approach: first, we find local optimal configurations at the machine-level layer which are then integrated into the global perspective. The deliverable D5.1 reports the activities of Task 5.1 - Machine-level energy configuration. The main goal of Task 5.1 is to provide sustainability Pareto fronts at the machine-level layer (i.e. the set of configurations where it is impossible to improve quantity-quality without increasing energy-material costs, and it is impossible to reduce energy-material costs without decreasing quantity-quality). In order to describe relationships between energy/material consumption and process quantity-quality at the machine level, combined physics- and data-driven digital twins and their reduced, and hence fast to evaluate, surrogate models are developed. These models provide energy consumption, production rate and quality estimates in different configurations and later they are probed by optimization procedures in order to draw Pareto fronts. This document is divided into three chapters. Chapter 1 introduces the proposed approach for the determination of sustainability Pareto fronts by manipulating digital twins within optimization procedures. In Chapter 2, the high-level structure and low-level descriptions of the energy-aware digital twins developed for the manufacturing process of fiberboards (KASTA use-case) are provided. Chapter 3 describes the surrogate modelling, the machine-level energy consumption optimization procedure and the evaluation of the sustainability Pareto fronts, that are embedded in a software module called MTEC.