Integrating Electric Energy Demand of Machine Tool

Processes as Resource for Production Planning Software

Detlef Gerhard

TU Wien, Mechanical Engineering Informatics and Virtual Product Development Group

Abstract. Electrical energy consumption of machine tools and production facil-

ities for the production of goods is not included in the production planning pro-
cess at present. This article presents first results of an ongoing research project
with the aim to consider electrical energy demand besides other resources like
personnel or machine capacity as planning dimension in software systems for
planning and optimization (Manufacturing Execution Systems - MES). Addi-
tionally, in the sense of a holistic PLM approach, this aspect and the resulting
information should be lead back to the product creation process. One goal of the
project is therefore, that energy demand can be taken into account in the data
models and in corresponding planning and optimization algorithms of
detail planning systems or manufacturing execution system, Furthermore, it is
necessary to define the corresponding interfaces between the involved IT-systems
at the various levels. Another goal of the project on methodical level is a detailed
systematic analysis and determination of possible potentials in terms of profitabil-
ity, planning horizons of electrical power production forecasts, specific savings
depending on the particular production technology of specific sectors, and inte-
gration e.g. to intelligent building management systems in order to be able to
plan holistically.

Keywords: MES, PLM, Energy Efficiency, Production Planning, Ecodesign.

1 Introduction
The industrial sector was responsible for nearly half of the total consumption of elec-
trical energy in Austria in 2009 (Statistic Austria 2009); about twice as much as the
consumption in private households. Thus, the industrial sector has got a higher
leverage in comparison to the smart grid approaches for households that cause high
transaction costs for building the technical infrastructure. Additionally, production
planning is already done professionally using appropriate IT systems. Of course, the
demand for electrical power may not always be the priority factor in the production
planning, yet it makes sense to involve or to use it for optimization. Besides the possi-
bility of saving energy, for example by efficient electric drives, the possibility of plan-
ning energy demands in the production also offers savings and optimization potential.
On the one hand, the proportion of the cost of electrical energy in manufacturing com-
panies is up to 15% of overall production costs and thereby significant (Neugebauer
et al 2012), on the other hand it is also possible to negotiate price reductions with the

© Springer International Publishing Switzerland 2015 29

M. Fathi (ed.), Integrated Systems: Innovations and Applications,
DOI: 10.1007/978-3-319-15898-3_2
30 D. Gerhard

electric power supplier, if the power demand or load profile for a given planning hori-
zon can be defined. If it is further considered that only about 5% to 20% (Kovacic et
al 2013) of the energy input is actually used for the cutting process itself, it is evident
that there is a huge potential for an increased resource efficiency in the production
industry which can be leveraged. Apart from the business aspect, there is also the
energy economics aspect. There is an optimization potential given in being able to
buffer the volatility of the constantly growing share of the renewable energies photo-
voltaic and wind power, i.e. to better coordinate the supply side and the demand side
by appropriate planning means. Energy generation of renewable sources is – within a
reasonable but limited planning horizon – adequately plan-able (Fig. 1). If on the
other hand energy consumption is planned, it is possible to balance demand and sup-
ply. The planning horizon of detailed production planning is in the same range as the
horizon of renewable energy sources.

Fig. 1. Comparison of planned and actual energy generation from renewable sources (EEX
2014)

In the sector of discrete industrial production of goods and products, there are three
levels of control circles which have to be taken into account:

Level 1: Machine
Increase in energy efficiency in the sense of an optimization of energy consumption
of the machine components and aggregates is a major goal on this level (Müller et al
2009). Energy efficient drives allow for the reduction of electrical energy demand.
Sensing and controlling energy demand or a tooling machine leads to the ability to
predict energy demand of a work piece. (Abele et al 2012). Technology parameters of