Industrial managers overseeing machine shops may approach professionals working in the energy, utilities and building management sectors to get energy-saving advice. That is an increasingly common goal, especially with electricity costs rising in many areas of the world and some people needing to run machines longer to achieve the necessary output.
Which techniques and technologies can assist in these situations?
Digital Twins Allow Testing Process Changes
Machine shop workers may suspect that specific process alterations will cause significant energy savings. However, many feel reluctant to try them, worrying they will bring unintended consequences.
Digital twins prevent such outcomes because they are replicated versions of real-life assets. They can be tweaked in simulated controlled environments to learn about the potential effects before implementing a change.
One digital twin specifically for machine shop tools lowers test machining times by up to 75% and makes production occur as much as 40% faster. Those advantages save energy by limiting unproductive machine operations, enabling people to primarily run them only when necessary for progressing with specific jobs.
Digital twins are also useful for helping people see the likely impacts of adding new machines or expanding the workforce. Since those decisions require more resources than some less involved changes, most operators understandably want to know what they can expect by proceeding with them.
Robotic Welding Systems Improve Precision
Many shop managers have transitioned to robotic welding systems, using them to partially or fully replace manual methods. Although this decision has comparatively higher upfront costs, it addresses many hidden aspects that can raise overall expenses. For example, welding robots can reduce rework and minimize errors, elevating energy efficiency in the process.
Robotic systems typically provide highly consistent results if properly configured. That precise repeatability can save machine shops energy because operators run the equipment for shorter periods but get the same or better output.
Decision-makers must determine the best time to bring robotic welding equipment into existing processes, and some may decide to introduce it on a phased basis first. Having robot welders working alongside those performing manual processes allows them to calculate the energy saved and other benefits.
Algorithms Predict Cutting Tool Wear
Operators may also waste energy and time if they continue using overly worn cutting tools. These take longer than usual to get the desired results, leading to unproductive outcomes.
Researchers have investigated the effectiveness of applying machine learning algorithms to cutting tools, using them to predict their current states and the likelihood of breakage. Operators can change tools earlier and get better results while using the machine if they know those details in advance.
Experiments showed this approach was more than 98% accurate in predicting tool wear. Although most shop managers will not have the resources to build customized algorithms, some might adapt this option by using it with connected sensors, which are more readily available.
Some off-the-shelf possibilities have built-in algorithms that are similarly effective once they are trained in real-world situations.
Energy Audits Reveal Hidden Inefficiencies
Energy audits are fantastic resources for pinpointing the equipment and processes that use the most energy. Personnel can also dig deeper to determine the likely reasons why.
Shop managers could see the results and realize it is time to upgrade to a more energy-efficient machine or invest in more operator training to prevent costly mistakes and workflow bottlenecks. Many people do not grasp the extent of existing problems until they review official reports confirming them.
Since external experts perform energy audits, these examinations provide informed advice from people with fresh perspectives. It may take those who become extremely familiar with a shop’s operations due to daily involvement longer to spot issues.
Multiple Options Provide Flexibility
When professionals working in the energy, utilities and building management industries receive requests from machine shop personnel who want to save energy, these are some of the top techniques and technologies that can achieve the goal.
Parties will find the most success with them when tailoring implementation plans to fit their specific needs, budgets and challenges. Such individualization encourages people to make thoughtful changes that connect to overarching aims
