Enhancing Machine Tool Performance through Analysis and Implementation of an IoT-Based Energy Monitoring System

Abstract

Reducing the energy consumption of machine tools holds significant potential for enhancing the environmental performance of manufacturing systems. Given the mounting concerns regarding stringent environmental regulations, energy efficiency has emerged as a pivotal metric within the manufacturing industry. To address this imperative, the adoption of an Energy Monitoring System (EMS) framework is indispensable for pinpointing the energy usage of each machine tool on shop floors. This study introduces the implementation of an EMS tailored to CNC groove grinding machine tools at BOSCH Limited. The system, developed and engineered by Siemens, facilitates real-time data collection through energy meters, with the data being transmitted to a host computer via the RS485 serial communication protocol and continuously stored in a database. Consequently, energy consumption parameters are effectively tracked, archived, and visually represented in graphical formats. The accessibility of energy data is ensured through a connected Human-Machine Interface (HMI), offering a standard interface for monitoring energy consumption during specific operations and for particular part types. Additionally, the data is stored in a generic data server for ongoing monitoring and further computational analysis, facilitated by the Sentron software app. Moreover, the quantification of energy control functions for each machine is achieved through precise measurements obtained from signals processed by the Programmable Logic Controllers (PLCs). This capability enables the machines to dynamically adjust energy modes, thereby optimizing energy costs per part.