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Procedia CIRP 61 (2017) 365 – 369

The 24th CIRP Conference on Life Cycle Engineering

Energy Efficiency in Machine Tool Operation by Online Energy

Monitoring Capturing and Analysis
Juergen Lenz*1, Jan Kotschenreuther2, Engelbert Westkaemper1
1
Graduate School advanced Manufacturing Engineering, University of Stuttgart, Nobelstr. 12, 70569 Stuttgart, Germany
2
MAG IAS GmbH, Salacher Straße 93, 73054 Eislingen, Germany

* Corresponding author. Tel.: +49 711 687 031 33; E-mail address: Juergen.Lenz@gsame.uni-stuttgart.de

Abstract

The first step to lower energy impact of products is to quantify the current impact. The mayor energy consumer in machine tools is not the spindle,
it`s the auxiliary units, such as pneumatic, hydraulic system, actuators, chip disposal and others. The quantification is achieved by precise
measurements from signals by the PLC with high sampling rates. The analysis of this data is done by Engineering Apps (eApps). The analysis of
the energy per component reveals the potential for energy reduction. The reduction can be achieved by switching to a more efficiency component.
In this research examples of component substitution measurements have been performed for more efficient electrical motors, cutting fluid pumps,
compressors vs. controlled compressors and start-stop hydraulic power packs. The stand-by energy analysis is similar to the component energy
analysis and reveals the potential for setting some components to sleep mode during stand-by. Examples of analysed sleep mode components are
chip disposal, cutting fluid pump, pneumatic and hydraulic system. As a result the energy usage can be displayed and visualized in various ways
such as energy per part, energy per time or energy per shift. The energy usage visualization can be split into usage per component. These results
can also be displayed online on mobile devices.
© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2017 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering.
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering

Keywords: Miling; Energy; Monitoring

1. Introduction and Motivation
One definition of sustainability is that products are designed
for their whole life cycle with minimized influence on the
environment [1]. The life cycle of the product consists of three
stages. These stages are manufacturing, service and
recycling [2]. The stage of manufacturing alone accounts for
one-fourth of global energy usage [3]. This number is the
manufacturing sector as a whole. The leading consumer of
energy within this sector are the production machinery. There
are numerous motivation causes to reduce this energy
consumption [4]. The leading cause for the operating company
is the reduction of the Total Cost of Ownership (TCO), but the
higher goal is the sustainable manufacturing of goods with
minimal (electrical) energy required to support the energy
transition into electrical energy production with a smaller
environmental footprint.
The first step to lower this impact is to quantify the current
impact. This impact is depending on the usage of the operating
company. Therefore it has to be measured and evaluated on an
individual basis. Evaluation of various energy efficiency
measures gives a base line for a decision for the altering of
different components of the machine tool.
The eApps concept is providing engineers and technicians
with such tools for enhancing their daily work through
information technology available anytime and anywhere [5],
[6].
This paper shows an implementation of energy monitoring
on a component basis of a mill machine tool. The paper is
structured as follows: Section two gives an overview of
relevant work by others. Section three shows the basic idea and
the IT-architecture of the concept. Section four states the
analytical processes of the raw data from sensors. Section five
elaborates on the energy efficiency idea of the improvement of
each component. Section six shows the implementation with an

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering
doi:10.1016/j.procir.2016.11.202
366 Juergen Lenz et al. / Procedia CIRP 61 (2017) 365 – 369
exemplary milling machine. Section seven is dedicated to the
findings of the implementation. The results are given for each
component and for the machine tool as a whole.
The paper closes with the conclusion in section eight.
2. State of the Art
The ISO 14955 standard defines the system boundaries and
the environmental evaluation of machine tools [7]. To reduce
the energy consumption within those system boundaries
parameter settings, tools or components have to be altered.
One approach is the change in milling strategy. This is done
by optimising the process parameter to achieve a minimal
energy consumption in respect to the material removed. Mori
[8], [9] and Diaz [10], [11] are examples in this category.
Change of milling strategy can be contradictory to minimal
process time or quality [12].
A different approach is tool selection. Cutting tools with the
same operational goal are evaluated in regard to the influence
on energy consumption. An example of this idea is
Neugebauer [13].
An energy saving approach without interference in the
actual process is the reduction of stand-by energy used. Warm
up sequences have to be activated in advance of the usage in
order not to extend the operation time. Strategies for these
warm-up periods have been developed [14].
In order to make statements not on a system level but on a
component level additional data is required. Demonstrations of
these type of energy monitoring [15] and interfaces [16] have
been developed for this specific application domain.
3. Approach
The problem of energy consumption measurement and
energy efficiency improvement is addressed with an innovative
way to captures energy data on a component level. Afterwards
the captured data in analysed with an implemented logic and
can be displayed on a mobile device.
The main goal of the energy data analysis is the evaluation
of different components. The evaluation outcome will tell
whether or not an upgrade to more efficient component type
will be rewarded in a reasonable amount of time. This
evaluation is different each time and for each component due
to the unique nature of the parts being manufactured. The
successful implementation of more efficient components will
depend on the usage of the machine instead of a constant power
demand.
Figure 1-left shows the typical machine tool energy
breakdown according to Dahmus [17]. Figure 1-right shows the
transition into power consumption usage on the usage of the
machine tool.
The analysis is done for each of the components and the
potential energy saving for evaluated measures are listed. This
is done without altering the milling operation strategy.
The intended system includes a mobile device in order to
show and discuss the solution on the shop floor and in an office
away from the operational machine tool. Doing so the shift
supervisor can show the results to the operator and increase the
transparency with the captured as-is-data and the calculated
KPIs.
Machining Machining
Variable Power
Consumption
Periphery Periphery
Constant Power
Consumption
Coolant Coolant
Hydraulic
Hydraulic
Hyd
y raulic
Electric base load Electric base load
Number of Parts produced Number of Parts produced
Fig. 1 Machine Energy Consumption Breakdown
Left: stock configuration; Right: after applied energy saving measures
4. Energy Data Analysis
The captured data is available in data sets consisting of one
measurement per sensor per timestamp.
The notations of the variables in the Equations listed below:
x ‫ܧ‬௖ denotes the energy consumed by one component
x ݊ denotes the number of components
x ܲത ሺ‫ݐ‬ሻ஼ denotes the average power for a specific component
x ο‫ݐ‬ଵ denotes the timespan of the data capturing
x ο‫ݐ‬ଶ denotes the timespan of the machining of the workpiece
As stated in Equation 1 the energy per component is tracked
for the duration of a defined timespan
EC = ܲതሺ‫ݐ‬ሻ஼ ‫  כ‬ο‫ݐ‬ଵ (1)
The energy per part is the sum of the machine tool
components during the runtime of the NC-Program (Eq. 2)
ƒ”–ൌσ௡௖ୀଵ ‫ܧ‬௖ ൌσ௡௖ୀଵ ܲതሺ‫ݐ‬ሻ௖ ‫  כ‬ο‫ݐ‬ଶ (2)
The exact duration of the runtime of a specific part is
determined via the difference between the timestamp of the
NC-Block with the program start and the timestamp of the
program end block, which is usually the M30-word. (Eq. 3)
ο‫ݐ‬ଶ ൌ ܶே஼̴ா௡ௗ െ  ܶே஼̴ௌ௧௔௥௧ (3)
This information feeds into the calculation of the ecological
footprint of the final product. For instance in the automotive
sector the OEM uses this information as part of the final
footprint of a vehicle.
Additionally the information is used to perform
accumulated shift energy consumption.
In cases of a series production passive condition monitoring
uses this information to trigger a warning after a threshold of a
certain amount of additional energy used for the identical part.
 Juergen Lenz et al. / Procedia CIRP 61 (2017) 365 – 369
5. Energy Efficiency Measures
Each component is redesigned with possible technical
additions in order to improve energy efficiency. Some auxiliary
units can be altered from previously constant power
consumption into power consumption depending on the usage.
For each component the technical solution to this transition
is different and explained in the following paragraphs.
5.1. Component 1 – IE2 / IE3 Drives
Efficiency classes of line operated AC motors are defined in
the IEC 60034-30-1 Standard [18]. The IE3 class is called the
Premium Efficiency Class. The Standard gives a minimum
efficiency factor for the output power. Drives with higher
standards are priced higher.
5.2. Component 2 – Interval Chip Disposal
In the standard implementation the chip conveyor unit is
operating during the whole execution of an NC-program. The
idea to lower energy consumption is to switch the chip
conveyor off during the time when no milling takes place. The
decision to switch off is based on the current NC-Block of the
NC-program. In case of G0 Block the chip conveyor is switched
off and in case of chip removal operation such as G1, G2, G3
and other machine cycles the chip conveyor is switched on and
kept on with an additional time after the machining block.
5.3. Component 3 – Start-Stop-Hydraulic
The hydraulic system of a milling machine tool is in the
standard implementation running constantly to ensure high
pressure supply for actors and valves.
P auxiliary units entirely. These auxiliary units consist of the
pressure adjustable
regulated pressure
pump reservoir control output flow
function
Fig. 2 Hydraulic Diagram
The hydraulic design implementation as shown in Figure 2
has an additional pressure reservoir. In this setting the
hydraulic pump is trigger in case of low pressure in the pressure
reservoir. If there is sufficient pressure in the pressure reservoir
the hydraulic pump remains off.
5.4. Component 4 – Regulated Cooling Fluid Pump
In the standard implementation the pump for the cooling
fluid is triggered via the NC-Block. It can be activated or
deactivated. The more efficient approach allows specific
settings for each application. In case less heat has to be
removed less circulation in the cooling fluid system needed, for
instance 5 bar instead of 8 bar. This requires a
revolution-regulated pump and additional logic block in the
367
machine control in order to interpret the trigger signals specific
for the cooling pump.
5.5. Component 5 – Regulated Compressor for Re-Cooling
Unit
The Re-Cooling-Unit is responsible for cooling various
machine elements such as the spindle and linear drives. In
addition to that the machining area inside the machine tool is
cooled. The compressor of the Re-Cooling-Unit is controlled
by the energy transferred by the system. This is measured via
the cooling fluid temperature in the feed and return lines and
implanted in a control system as shown in Figure 3.
Compressor speed control
temperature of feed and return line
Compressor
Fig. 3 Compressor Control System
5.6. Component 6 – Thermostat for Electric Cabinet Cooling
In the standard implementation the electric cabinet is cooled
by a cooling unit. This unit is operating constantly to ensure
that the electrical circuits do not malfunction due to too high
temperatures. This task is in the standard implementation not
depending on the heat generated by the electrical components
and not depending on the surrounding factory temperature. The
suggested implementation uses a temperature threshold to shut
down the cooling unit and activate it again on a lower
temperature level.
5.7. Component 7 – Sleep Mode
The sleep mode gives the PLC the ability to shut off
following components:
ƒ Hydraulic pump
ƒ Pneumatic supply
ƒ Chip Conveyor
ƒ Low Pressure Cooling Fluid Unit
ƒ High Pressure Cooling Fluid Unit
ƒ Energy Supply for Drives
These triggers to shut off certain components entered in the
system and can be stored in an Energy Saving Profile.
Examples of these rules options are:
ƒ No parts in the transfer system
ƒ Planned halt at the end of a NC-program
ƒ Stand-by of processing machine tool
ƒ Tailback of parts at the transfer system
Each of the individual components can be associated with one
rule option and can be triggered immediately or with a time
delay.
In case all sleep mode functions are activated the only
remaining power consumers are the PLC and the HMI.
368 Juergen Lenz et al. / Procedia CIRP 61 (2017) 365 – 369

6. Implementation Concept

As demonstrator machine the SPECHT Series 600 DUO by

MAG IAS GmbH was chosen. It is a twin-spindle CNC-
Milling-Centre with axis acceleration up to 15 m/sec2 and
spindle revolutions up to 18,000 rpm, spindle power up to max.
81.5 kW and spindle torque up to max. 1,146 Nm. Its machine
tool control is Sinumerik 840D by Siemens. An
implementation overview is shown in Figure 4.

L1
L2
L3
N
Electric Energy compressed air Coolant
PAC 4200 SD 8000 SM 9000

I/O Group ET 200 S

Fig. 5 GUI of the mobile Energy Monitoring eApp

PROFIBUS
The GUI shows current and accumulated energy
840 D - Data blocks consumption on a component basis as well as on a part basis.

HMI 7. Results

The as-is-power consumption depends mainly on the

OPC-UA specific part being produced and on the utilization of the
Webservice machine for the defined timespan of the analysis.
eApp Edge Cloud In the scope of this analysis conducted the SPECHT 600
machine, produced a standard workpiece in this case a cylinder
head and had a utilization of 5000 hours in production, 2000
Fig. 4 Architecture of Energy Efficiency eApp
hours waiting for material (stand-by) and 1500 hours in sleep
mode. The process parameter for the milling process were not
altered. The NC-program was designed to have a minimal
The stock configuration of this machine required additional production time for the standard workpiece.
items to enable the energy data extraction. The list of the items Due to different initial invest costs for each energy
used in the implementation is given in Table 1. efficiency measures the return on invest (ROI) for each energy
efficiency measure differs. Also the price of electricity will
Table 1. Sensor Equipment used for Demo Implementation influence the decision to invest in certain energy efficiency
measures.
Item Vendor
Table 2 shows the results of the potential energy saving for
Converter 150/5A 2,5VA MBS each component and the method how the saving is achieved.
Terminal block 282-870 Wago
I/O Group ET 200 S Siemens
Table 2. Energy Saving Potential per Component
Power Monitor PAC 4200 Siemens
Component Energy Saving Method
Ethernet/PROFINET Module Siemens
IE 3 Drives 360 W Substitution
Interval Chip Disposal 100 W Start/Stop

The installation of the power monitor PLC module and the Start-Stop-Hydraulic 400 W Start/Stop
integration with the main PLC adds additional variables which Regulated Cooling Fluid Pump 2000 W Regulated
can be requested from outside via the OPC-UA interface. The Regulated Compressor for Re-Cooling 2000 W Regulated
request is done by an IT-service which performs the energy Thermostat for Electric Cabinet Cooling 180 W Regulated
analysis and offers the results via a web service interface. The Sleep Mode 250 W Start/Stop
mobile app can now request this data via the web service.
A snapshot of the GUI of this mobile App is shown in
Figure 5.
 Juergen Lenz et al. / Procedia CIRP 61 (2017) 365 – 369
Figure 6 shows the power consumption for the described
scenario with a stock configuration of the machine and
afterwards with all the described energy efficiency measure
installed. An overall reduction of 28 % power consumption
was achieved.
SPECHT
Series .
10,1
All Energy
Efficiency .
7,2
Measures
0 2 4 6 8 10 12
Consumption in [kW]
Fig. 6 Comparison of Power Consumption for the Demo Scenario
8. Conclusion
This paper shows a concept to measure auxiliary units
during operation and an assessment of the potential energy
saving. The process parameters were not altered, the milling
strategy remained the same. A reduction of 28 % power
consumption was achieved.
The efficiency of the machine tool was increased by altering
its auxiliary components. These subsystems were either
substituted, switched off and on when needed or were
retrofitted with a regulatory control.
The machining process remained untouched. The NC-
program settings such as feed rate and spindle revolutions
stayed the same. Additionally optimizing these settings may
increase efficiency further, but it will also lead to different
process results such as surface roughness.
An energy data analysis to show energy per part and per shift
was develop and implemented. Also a comparison of different
shifts was implemented.
The results allow passive condition monitoring. Warnings
can be implemented in case of rising of energy consumption
per component. These can hint to tool wear or problems with
certain components.
Although energy consumption of the machine is reduced
additional energy consumption of the sensors, cloud service
and the mobile device were created. This leads to a small
rebound-effect, however the savings and additional benefits
prevail by large.
Acknowledgements
This research and development project is funded by the
German Federal Ministry of Education and Research (BMBF)
within the Research Program “Forschung für die Produktion
von morgen " (fund number 02PJ2564) and managed by the
PTKA Project Management Agency Karlsruhe in Karlsruhe
Technology Institute (PTKA). The authors would also like to
thank the German Research Foundation (DFG) for financial
support of the Graduate School of Excellence advanced
Manufacturing Engineering (GSaME).
369
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