As part of the transfer project, an energy check was developed specifically for companies, which was developed and piloted using a CNC machine from IWN. The energy check offers the possibility of recording various energy-relevant parameters in detail over a defined period. These include electricity curves, temperatures and flow profiles. In conjunction with expert analyses, the data collected makes it possible to identify well-founded savings potentials – as was successfully demonstrated in the example at IWN.
The challenge:
In order to meet the climate targets while maintaining competitiveness and counter the rising energy costs triggered by the current energy crisis, companies must identify and exploit potentials for energy optimization in the short term and to a greater extent.
Sensor data-based energy saving service from Fraunhofer IOSB-INA
Scalable production data acquisition systems are used via simple access to energy data on machines and systems. These include energy meters that can record energy data without significant intervention in the electrical installation of the machines. For the energy measurements, only access to the three phases of the machine power supply and a reference voltage via a CEE socket are required. The recorded energy data can be stored and visualized locally or in the cloud in conjunction with optionally additional sensor data. This offers the possibility of continuously recording production data over a certain period (e.g. one week), displaying it on a dashboard and saving it. Following the measurement campaign, Fraunhofer researchers model and classify the data. From this, IWN can generate energy footprints. Set target values can be brought together with energy consumption and the product. This then gives the company the opportunity to make suggestions in live operation as to how current production can be adjusted in order to achieve a historically known footprint that cannot currently be achieved due to changes in raw materials or changes in production conditions. Companies also receive the OEE value of their machine(s) and, if applicable, important information on recognized anomalies in the production process.
An exemplary analysis by Fraunhofer IOSB-INA illustrates this: During the energy data acquisition of a machining machine, it was found that hydraulic pumps were not switched off after the end of the shift. This led to unnecessary energy consumption of approx. 7.2 kW per machine outside of working hours. Extrapolated to one year, this results in additional annual costs of around €7,400 per machine, based on an electricity price of 50 cents/kWh.
The findings show how unnecessary costs can be avoided through targeted energy analyses. Further information on the energy check and the procedure can be found on the Fraunhofer IOSB-INA website.