The production processes of machine tools constantly require compressed air. In sensor production, various devices required to produce the finished product are manufactured in-house. These processes often take place in a machine tool.
In the production process of the machine tool, compressed air is required:
Compressed air production is one of the major cost factors in manufacturing. This is why energy efficiency measures have such a high potential.
Compressed air indication without condition-based quantity and cost tracking
By default, every machine tool provides general display instruments to indicate the different operating states. However, the process data of the compressed air consumption in correlation with the associated costs are not monitored.
Consequently, an evaluation in terms of energy management and energy efficiency measures is not possible.
Without a database, these questions remain unanswered.
Assessment of compressed air costs for the purpose of implementing energy saving measures
Compressed air monitoring with moneo RTM
moneo RTM is centrally installed on a server.
ifm provides a wide range of automation components. In this application, SD6500 compressed air meters were installed at the compressed air supply of the machine tool and upstream of the compressed air gun.
The sensor data is provided to moneo RTM via an IO-Link master of the AL1350 series. The IO-Link master is connected to the server via an internal VLAN.
Data monitoring, threshold management and calculations are carried out with moneo RTM.
moneo RTM visualises energy-saving potential
Data acquisition, visualisation and offsetting of flow values via moneo RTM provide the basis for calculating different compressed air costs.
These data allow dedicated assessment and organisation of energy-saving measures. Unnecessary costs in standby operation were identified, and the machine tool can now be operated more efficiently without wasting compressed air.
Energy and operating costs could be reduced with the goal of becoming a ‘green factory’.
Get the big picture on the moneo dashboard. The dashboard provides the user with an overview of all relevant process values for this plant.
In the “Compressed air” dashboard, the user sees all relevant compressed air process values for this plant at a glance.
In the ”Machine status” dashboard, the user can see the current operating status of the machine and the elapsed operating time in the relevant machine status.
In the “Process optimization” dashboard, the user can see the energy consumed by machine operating status. The insights gained can be used to optimise the energy consumption.
* Counting start was the set-up of the sensor. A reset can be performed via the sensor or via moneo configure.
** NOTE! A reset also resets all values calculated so far! CDS (Calculated Data Source) stands for a value calculated via the moneo Dataflow Modeler
The analysis function can be used to view further details. The screenshot shows how the operating status of the machine tool can easily be identified via the flow value of the compressed air.
*** To be determined individually depending on the application
As soon as a defined limit value has been exceeded or not reached, a ticket will be created for the corresponding process value. A red traffic light and a pop-up alert message indicate that a pressure threshold was violated.
The ticket can be taken over and processed by the responsible employee. Via the comment function, implemented measures and descriptions of solutions can be documented immediately. The following notification options are available:
Using moneo, much more information can be calculated from the process values of the sensors. The ‘Dataflow Modeler’ enables custom creation of calculated values, e.g. by combining and offsetting data sources from sensors in a data flow model.
Calculation of total compressed air consumption:
Calculation of compressed air costs of the machine tool:
Determination of the machine tool status “Machine on”:
Determination of the machine tool status “Machine off”:
Determination of the machine tool status “Machine standby”:
Calculation of the production time of the machine tool:
Calculation of standby energy costs: