As illustrated by the example of a grinding machine, production machinery need, to meet value-added activities, raw energy (electricity, compressed air) and excipients (cooling lubricants). Outputs of the production process, besides the actual product (workpiece) and extract air / heat or waste or by-products (chips, swarf). It should be noted that the consumption behavior of a production machine is not static but dynamic behaves depending upon the operating conditions of the machine. This results in a load profile with characteristic phases whose analysis allows conclusions on the energy consumption of individual components and approaches for improvement. A detailed breakdown shows that in the example is only around 16% of the applied power at all in the actual process (removal of metal by grinding).
Only the (continuous) recording of all relevant consumption allows an evaluation of the efficiency of machines and the derivation of improvement measures. Challenges lie here in the data acquisition and processing, but also in the visualization of energy and material flows on the machine (eg for machine operators). Green4Machine ensures continuous recording of all relevant consumption and allows an assessment of the efficiency of machinery. The basis for this was developed in the BMBF-funded research project Green4SCM in the years 2010-2013. The modular Green4Machine solution consists of:
- Data Transfer: interface to any ERP / MRP system,
- Planning and optimization: additional module energy efficiency optimization for 4APS,
- Detection and action: 4MDE server and I / O hardware for capturing any digital and analog 12V signal sources and actuators functionality, as well as
- Visualization and analysis: Presentation and analysis of energy consumption.