A new approach for machine's management: from machine's signal acquisition to energy indexes

In the highly competitive modern-day industrial landscape, characterized by globalization and resource scarcity, manufacturers are striving to improve economic and environmental performance. Innovation that enables self-adjustment, control and optimization of the energy consumption of individual machines continues. However, more research is needed if such systems are to be deployed successfully, especially considering the complex characteristics of the energy flows in the factory. In this paper we propose a novel approach to the coordination of information, processing and sensing systems for energy and resource efficient production systems. By leveraging on a recently-developed framework focusing on physical flows of energy, materials and waste we propose a solution based on specific energy efficiency KPIs and an online data acquisition/processing system, that enables real-time monitoring of the current status of the machining process and lagging assessment of system energy efficiency. The proposed solution allows the identification of abnormal energy consumption during the operational machine cycle, caused by incorrect part dimensioning or erroneous cutting conditions programmed by the process engineer, enabling identification of potential disruptions with different gravity levels, and delivery of meaningful alarms for the operator. Adaptive control of the machine cutting conditions or even trajectory re-programming is then possible, by correlating the energy-consumption data with other data, such as head temperature. Furthermore, by analysing the energy consumption of value and non value adding activities over complete production cycles (such as a shift or day), it is possible to monitor the progress of production systems toward achieving energy efficiency targets and to conduct root-cause analysis of inefficient energy usage for continuous improvement programs. We tested the proposed solution, modeling, index system ad online data acquisition/processing platform, through an industrial case study by deploying the developed hardware and software modules on a Nicolas Correa S.A. VERSA milling machine.