Model-based monitoring of the energy demand of hydraulic deep-drawing presses
Research Task/Objectives
Energy consumption share of a hydraulic deep-drawing press (1600 kN press, deep drawing process)
Rising energy costs generate the demand for energy monitoring solutions featuring the analysis of sub-processes as well as the energetic optimization and control of the overall machine process.
Complex interdependencies between the subsystems of deep-drawing presses and the limited number of sensors complicate the measurement of energy consumption as well as breaking it down to different subsystems and –processes. The project aims at
implementing an algorithm able to monitor the machines energy demand in time by a model-based calculation of missing sensor data. Consequently the energy demand is displayed without the need for additional sensors. The obtained data allows an energetic process optimization.
Approach/Results
Energy flow diagram for plunger-drive with subsystems
Starting with measurements at a representative hydraulic deep-drawing press methods for a detailed monitoring of energy demands in subsystems are being developed and evaluated. These models use heuristic and physical parametrisation to analyse energy data without using additional sensors. An evaluation shows potentials and limitations of the used models.
The algorithm is being integrated in a real machine control to show production cycle’s energy demand in real time on a graphic user interface.
The presented research activities are part of the project Ref. No. KF2452605LP3, which was funded by the German Federal Ministry for Economic Affairs and Energy within the ZIM programme. The project was realized in cooperation with the company "TRsystems GmbH".