Measure energy consumption, avoid wear

Smart Energy Monitoring: Analyze energy consumption per cycle directly in the drive – without external sensors

20:24:13 | 2022-11-06

 

 

 

In times of rising energy costs, solutions are in demand that can help determine energy consumption and then reduce it in a targeted way. If such an energy measurement tool can also be used to detect wear, machine manufacturers and operators would benefit twice over. 

With its new Smart Energy Monitoring software function, Baumüller now presents a solution for the intelligent energy monitoring of machines and systems. With this function, the energy consumption of individual production orders can be transparently recorded and, in a second step, optimized on the basis of a reference value. The reference measurement also serves as an initial value for detecting energy deterioration in the production process. Warning and error thresholds can then be set up on the basis of these values.

Figure 1: The Smart Energy Monitoring software function can be used both to identify and exploit optimization potential based on energy consumption (green bar) and to monitor mechanical changes based on threshold values (red bar) | Figure: Baumüller

The software is loaded directly into the servo-controller and is therefore easy to retrofit. Energy consumption is recorded directly via the intelligent drive. This saves additional costs for external sensors and reduces the amount of wiring required.

Transparency from each axis to the entire system
With the new function, the energy consumption of each individual axis can be determined per cycle. The energy measurement is performed autonomously and in real time in the Baumüller b maXX servo converters used. In the higher-level PLC function in the b maXX converter, a software module analyzes the transferred measured values and subsequently calculates, among other things, the actual energy consumption per axis as well as across all axes. The values are then shown in the machine visualization. Alternatively, a dashboard also displays the results of the measurement, which are directly transferred from the b maXX converter via open IoT interfaces, such as OPC UA.

Figure 2: The newly developed Smart Energy Monitoring software solution can be used to determine and optimize the energy consumption of each individual axis per cycle | Figure: Baumüller

For the machine manufacturer or end user, this function offers the following possibilities:
• Optimization of the machine cycle reduces the energy consumption of the machine
and accordingly of individual energy consumers within the machine  Lower
production/energy costs during operation
• Optimization of the machine cycle regarding the use of energy in the DC link  Lower
production/energy costs during operation
• Representation of energy consumption per part  Facilitates and improves the
calculation of production costs
• Energy deterioration (e.g. increasing mechanical wear) is automatically detected on
the basis of adjustable warning and error thresholds  Maintenance for increased
machine availability can be planned and carried out in a cost-optimized way
• Interfaces to comprehensive energy measurement systems possible  Transparency
of the entire machine’s energy consumption
Baumüller Group Press Release
• Machine-specific key figures can be generated  Improved process optimization,
including monitoring
• Transparency of energy consumption  Assists in the determination of the Product
Carbon Footprint (PCF)
Software functions
The Smart Energy Monitoring software function can be applied in the softdrivePLC of the
Baumüller converter and operated via a higher-level control unit. This control unit is
manufacturer-independent. The module in the Baumüller control unit works with the current
energy values from the converters, generates a reference, and can compare subsequent
cycles with this reference using defined threshold values. In addition to the relative changes to
the reference, the actual values can be displayed in a visualization.
The following parameters are calculated:
• Predicted energy consumption per cycle
• Actual energy consumption of the drive per cycle
• Actual energy consumption of the drive per order
• Comparison of the predicted and the actual energy consumption

 

 

 

Figure 3: The Smart Energy Monitoring software function can be applied in the softdrivePLC
of the Baumüller converter and operated by means of a higher-level control unit | Figure:
Baumüller
Process optimization based on regenerative effects
To support production in optimizing the machine cycle, the software calculates the
regenerative effect, also referred to as the “green factor.” This provides information about the
potential for process optimization. This key figure can be improved by ensuring that the process
makes more optimal use of the energy regenerated in the braking process. For example, after
braking one axis, another axis can be accelerated again with the DC link energy. These
Baumüller Group Press Release
measurement methods help machine operators to perform their production processes with the
highest possible energy efficiency.
Preventive machine protection through comparison routine
The new software function continuously measures and adjusts the machine’s power
consumption. If the energy balance deteriorates and higher average values are output, further
analysis can be carried out on this basis. Any wear or need for maintenance can thereby be
detected immediately. This can prevent both an increase in energy costs and unplanned
maintenance work and breakdown times, improving machine availability at the same time. The
threshold values for error and warning messages can be set individually.

Based in Nuremberg, Baumüller is a leading manufacturer of electric automation and drive
systems. At production sites in Germany, the Czech Republic, Slovenia, and China as well as
in over 40 branches worldwide, around 2,000 employees develop and produce intelligent
system solutions for machine manufacturing and e-mobility.
In addition, the range of services offered by the Baumüller Group includes engineering,
assembly, and industrial relocation as well as services, thus covering all aspects of life cycle
management.

World Media Group (WMG) News Service

 

 

 

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