SBM 1300 Research Project: Energy Efficiency in Machine Tools (2019)

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SBM 1300 – Research Project (2019)
Assignment 3
Energy Efficiency of Machines
Student Name:
Student ID:

Table of Contents
1. Introduction..................................................................................................................................3
2. Data Collection and Analysis......................................................................................................3
2.1 Models for Energy Management...........................................................................................4
2.1.1 Energy-Monitoring Functional Module..........................................................................5
2.1.2 Energy-Control Functional Module................................................................................6
2.2 The purpose of Acquiring and Monitoring of Data...............................................................6
2.2.1 IT structure......................................................................................................................6
2.2.2 The IT structure to fulfill the purpose of Energy Monitoring........................................7
2.3 Understanding and Addressing the Research Questions.......................................................7
2.3.1 Machine-Tools affecting the Energy-Efficiency of the Machines.................................8
2.3.2 Energy Monitoring and Data Analysis as an Addressing Approach............................10
2.4 Analyzing the Data and Finding the Efficiency Measures..................................................11
2.4.1 Data Analysis................................................................................................................11
2.4.2 Measures taken for Energy Efficiency.........................................................................11
2.5 Efficiency and its Elements.................................................................................................12
2.5.1 Energy Consumption Models and their Needs.............................................................13
2.5.2 Energy-Consumption Models for Machines.................................................................14
2.5.6 Forecasting the Consumption.......................................................................................15
2.5.7 Factors Affecting Energy Consumption.......................................................................15
2.5.8 Decomposition of Energy Consumption......................................................................16
3. Recommendations and Future Work.........................................................................................17
3.1 Recommendations................................................................................................................17
3.2 Future Work.........................................................................................................................18

4. Conclusion.................................................................................................................................18
References......................................................................................................................................20
List of Figures
Figure 1: Functions of Energy Management...................................................................................5
Figure 2: Energy Management and Functional Blocks Used..........................................................6
Figure 3: GDS Representation.........................................................................................................8
Figure 4: Power Flow in the Machine Tools...................................................................................9
Figure 5: Breaking-down the Energy Consumption......................................................................10
Figure 6: States of Machine Tool..................................................................................................15
Figure 7: Diagrammatical Representation of a Power Profile.......................................................16

1. Introduction
Collection, analysis, processing, manipulation, and analysis of data is very important and is an
important prerequisite for establishing the facilities for energy efficient machinery and products.
It enables the researchers to further assess the “Key Performance Indicators” and monitoring the
status and conditions which helps in the evaluation and identification of the measures for the
efficiency of the machines.
This report provides a standardizes and detailed approach towards the data collection and
analysis techniques for machines and the related components. The data collection techniques are
directly linked with the ways of storing and monitoring the data collected on the production
machines. Besides all the collection, monitoring, processing and analysis methods, this report
also consists of various mechanisms and methods to empower the machines and the PLCs along
with the functions to control the access energy. The report also focuses on the ways to minimize
the CO2 emission and operational costs of the production machines. Implementations of different
energy control methods are presented with an overview of Energy Optimization.
This section of the report will provide some easily understandable set of measures and
techniques of data collection and analysis on data relevant to the energy and related production
machines. Furthermore, some of the tools and techniques to improve the energy efficiency of
machines will also be provided along with some approaches to efficiently acquire the energy
data.
2. Data Collection and Analysis
The energy efficiency of the machines is a major concern for all the production industries. There
was a time when the production companies did not have any strong information on the efficiency
and the energy consumptions of all the production machines and related components. But there
was a practice of monitoring the energy to have better transparency about the use of energy and
to identify measures to improve the efficiency of the machines. To continuously improve the
practices of energy efficiency it is important to collect and study the energy data. A lot of
machines cannot be put on standby during the breaks and switching on/off these machines

consumes a lot of energy. Various software measures can be put into action to overcome this
problem.
2.1 Models for Energy Management
In order to spread the use of energy latest technologies which increase the energy efficiency in
the manufacturing and production industry, various methods of collecting and analyzing the data
are to be implemented. Therefore, a lot of programmable and customizable functions are
structured to manage the energy data and information about the daily consumptions of the
machines. These functions consist of various data-collection, energy-monitoring, data-
processing, energy-control, and data-analysis modules are available to determine the average
energy consumption of a machine used in the production industry.
Figure 1: Functions of Energy Management
 Energy Monitoring – Identifies the amount of energy intake and utilization by a
machine on a daily basis.
 Data Collection – Gathering information about energy consumption from various
companies and industrial activities.
Energy
Management
Functions
Data
Analysis
Energy
Monitoring
Data
Collection
Data
Processinng
Energy
Control

 Data processing – Data collected from various sources are used to develop management
functions to monitor and control energy.
 Energy Control – Measures and processes to limit the access use of energy by any
machine. This can be done by shutting down the unnecessary loads on the production
machines.
 Data Analysis – The overall data about the energy consumption rates and production
requirement which is stored collected is analyzed using various data mining and analysis
tools to come up with a successful and effective energy efficiency solution.
Figure 2: Energy Management and Functional Blocks Used (Abele, Panten & Menz, 2015:p.304)
Above-discussed functions are used to analyze and collect data on various problems associated
with the energy efficiency of the industrial machines. The data management techniques based on
these functions will help in addressing the research question proposed in the previous assessment
tasks and also in the collection and standardization of the data (Abele, Panten & Menz, 2015).

2.1.1 Energy-Monitoring Functional Module
This function is used to acquire data about the daily consumption and use of energy resources by
different mechanical instruments or machinery. It also helps in the identification of a machine’s
potential to save energy. Some of the major tasks to be considered while implementing this
function are:
 Identifying all the devices relevant to energy efficiency, like pumps, motors, rotors,
grinders, etc.
 Identification of the type of energy data available for the machines, such as data from
meters and datasheets.
 Designing and modeling the blueprint and physical structure of the machines to
parameterize the values gained by the functions (Abele, Panten & Menz, 2015).
2.1.2 Energy-Control Functional Module
This function focuses on controlling and limiting the amount of energy used by a machine daily
by frequently switching the machines ON/OFF and by putting them into energy-efficient modes.
These functional blocks make sure that there is no unnecessary load on the machines and these
machines consume the minimum required energy. Some of the tasks to be considered in the
implementation of these functions are:
 There should be short breaks to switch the machines in order to avoid continuous
operation which can result in heating up of machines.
 Effectively long breaks when machines can be powered off for a few hours or days.
 There can also be a lot of unscheduled breaks due to intervention by clients or lack of
resources.
 The control system should have a proper definition of all the switchable devices.
 Identifying the safety and communication protocols in the machines.
 Having proper knowledge of all the available energy modes in the machine.
 Proper modeling and development of the body of the machine

2.2 The purpose of Acquiring and Monitoring of Data
2.2.1 IT structure
The Information Technology structure acquired by the machine tools is divided into 3 different
levels which are identified as “Drivers & Sensors”, “Programmable Logic Controller” and
“MES”. All these levels are composed of various other components like PLC, PCs, drives, etc.
The function of the drive level is to move the work-piece and the tools. The Numeric Control
provides the signals referring to the motion of the machine parts, where some commands are
predefined.
2.2.2 The IT structure to fulfill the purpose of Energy Monitoring
There are various applications developed to monitor the energy consumptions at real-time. These
applications need specifically high rates of input data. For example, it should be able to identify
the peaks in the power level when the tools in the machine change. To fulfill the monitoring
purpose, GDS can be used according to the requirements.
Figure 3: GDS Representation (Battula, 2019:p.2)
There are multiple methods provided as a part of an interface that can support data processing in
order to acquire various figures, like overall consumption or daily consumptions. To fulfill this
requirement, MATLAB is used. Customizable DLLs can be developed using the MATLAB to
used along with the methods. DLL then processes the raw input data which can be stored in the
database (Battula, 2019).

2.3 Understanding and Addressing the Research Questions
In the previous assessments report, some major research questions on the “Energy Efficiency of
Production Machines” were identified. These research questions will be addressed using the data
collected on the proposed topic.
As the use of the machine tools is increasing massively, causing a lot of environmental problems
and risks, it has become very crucial to address this issue and limit the amount of energy
consumed daily. The proposed research questions are comparatively broad: “What material
affects the consumption rates?”, “How to feed rate can increase the energy efficiency rate?”,
What factors affect the efficiency of an operating machine?”, “How the built structure affects the
efficiency?”, etc. are some of the major research questions. After researching and various
reviews, it was identified that the main answer to these energy efficiency problems was in
understanding the model of energy-consumption for various types of tools used in machines.
The major problems in analyzing the energy efficiency of the machines and improving it are
addressed by capturing the data on various component levels are addressed in an innovative way.
This collected data is further analyzed using various logics and can be displayed i
2.3.1 Machine-Tools affecting the Energy-Efficiency of the Machines
Along with different types of drive units, the tools used in the machines also need different
auxiliary components to fulfill the major purpose of increasing the life of the machine. These
components include some lubricants for cooling and removing friction, hydraulics, coolants, etc.
Figure 4: Power Flow in the Machine Tools (Dietmair & Verl, 2009:p.63)

One of the main impacts on the efficiency of a particular machine is from the amount of load put
on that machine. Results from some studies conclude that the consumption of the daily energy by
these production machines can be decreased significantly by taking some specific measures like:
 By optimizing the constructional work and the built structure of the machine. This
includes reducing the weight of the machine and methods to decrease friction between
the moving parts of the machine.
 Implementing the drives and other machine components which are efficient on their own.
 By properly segmenting and distributing the dimensions of the machines and another
related device.
 By optimizing the production process while operating the machine.
 Removing the unwanted load from the machine when the machine is running (Dietmair
& Verl, 2009).
These measures can be used to address the efficiency concerns and can save a lot of energy to be
consumed by the machines. Similarly, the devices and production processes consuming intensive
energy can also be identified by some metering and monitoring techniques. The better
transparency of the energy consumption promoted the use of technologies which improves the
efficiency of the machines. This is because the results can be easily noticed figuratively. Thus,
there are some major researches going on to develop some ways to perfectly monitor the energy
with the support of models and calculations. The evaluation procedure to be carried out will be
different for various components of the machines. This is due to the uniqueness of all the
components of a machine. The variations in the energy consumption of the machines before and
after applying the measures for saving the energy can be depicted as follows:

Figure 5: Breaking-down the Energy Consumption (Herrmann et al., 2009:p.366)
The left image shows the configuration and energy distribution of the stock machines and the
right image shows the configuration after the application of saving measures (Herrmann et al.,
2009).
2.3.2 Energy Monitoring and Data Analysis as an Addressing Approach
This part shows the procedures and approaches used to gather and analyze the data to answer the
research questions. The data circles around the energy the occurrences of the efficient activities
and frontiers, and assess their potential in improving the efficiency of the machines.
Methods Description Considerations
1. Preparation and
Collection of Data
Power meters and data reading devices
can be attached to machines, like
boilers, grinders, rotors, etc. and
periodic consumption readings can be
generated. This phase will provide rich
information about the operational
characteristics of machines.
The collection of data is
continuously expanding
process and thus the readings
should be taken in a limited
and controlled way to avoid
crowding in the warehouse.
2. Analyzing the
Correlations
The high-level information collected by
the meters and the parameters of
Various factors may affect
these correlations, such as

various components is then compared
to generate the correlation and
dependency between them.
environmental temperature,
humidity, load amount, power
supplied, internal
temperature, friction, etc.
3. Identifying the
Efficiencies of
Machines
Every organization sets its baseline for
efficiency measurement. A target is set
to be achieved for the operational
system. Frontiers can be used to
identify the best possible efficiency
target. CCR model is used to identify
these frontiers.
A large target which is
difficult to achieve will
demotivate the employees.
4. Quantifying the
Potentials of
Energy Saving
The potential of the machine can be
identified by calculating the difference
between the ongoing consumption and
the overall frontier specified.
The efficiency of the
individual machines can be
calculated but not of the
entire production system.
2.4 Analyzing the Data and Finding the Efficiency Measures
2.4.1 Data Analysis
The collected by the sensors and data receivers is added to the datasets in which measurements
are stored based on particular sensors and timeframes. The formulas used in this data analysis to
calculate the energy are displayed in the below table.
Variables Used Formulas Purpose of the Formula
Ec is the total energy
consumption by 1 component.
n is the total components
P(t)c is a component’s average
power
D(t)1 is the time of capturing
the data
D(t)2 is the time of completing
Ec = P(t)c * D(t)1 The energy of a specific
component for a given time
interval is calculated
Ep = Ec of all the components
Ep = ∑c=1 to n P(t)c * D(t)2
The energy of all machine
components at runtime is
calculated
D(t)2 = TNC_End – TNC_Start Determines the correct runtime
of the machine by calculating