Virtual machine tool

The simulation model

Ever-increasing demands on the productivity and efficiency of machine tools require verification of the control application software throughout the development process, as well as approaches to energy and resource conservation from the very first day of the product life cycle.

The benefit lies in testing the operational safety and reliability of the entire system – comprising the control system and the machine – even before commissioning. This is achieved by developing a simulation model of the machine tool. The model is then linked to a real control system for ‘hardware-in-the-loop simulation’.

Energy measurement

For energy efficiency analyses of old and new machines, energy measurements are carried out in advance on the actual machine tool using FLUKE 434 II measurement equipment. The measurement results obtained are read out via a USB interface using device-specific software and are available in standard formats for further processing.

Validation and determination of energy efficiency

This alone allows conclusions to be drawn about the components relevant to energy consumption. Comparing the simulation model with the actual energy flows serves to validate the model. The result is the identification of cost-effective energy efficiency measures based on the developed simulation model. Corresponding results from the field of machine tool manufacturing indicate potential savings of up to 50 per cent, relative to a specific manufacturing task. This principle can easily be applied to other machine tools. There are no restrictions regarding the machine’s connected load.

Project experience

Sectors: Mechanical engineering, energy technology, environment and transport
References: Research projects in industrial measurement technology