Iolution for Data Collection of Standby Time and Energy Consumption in CNC Machine Tools

 

As the digital transformation of the manufacturing industry and the requirements for energy conservation and consumption reduction continue to rise, the operational efficiency and energy management level of CNC machine tools have increasingly become the focus of enterprises. Traditional management methods rely on manual recording and empirical judgment, making it difficult to accurately obtain real-time status and energy consumption data of machine tools. This leads to issues such as low equipment utilization, severe energy waste, and a lack of data-driven support for operation and maintenance decision-making, which restrict the improvement of enterprise production efficiency and green manufacturing capabilities.

A certain mechanical processing enterprise owns multiple CNC machine tools of different brands and models, distributed across various workshops. The management is crude, and the status is opaque. Machine tools continue to consume electricity even in non-processing states such as standby and idling. However, due to the lack of effective monitoring means, the enterprise cannot accurately evaluate equipment utilization and energy consumption distribution, making it even more challenging to implement refined energy efficiency management. How to achieve real-time collection, analysis, and optimization of machine tool operational status and energy consumption data has become an urgent need for the enterprise to advance intelligent manufacturing and energy-saving transformation.

In response, WideIOT has deployed machine tool data acquisition gateways to connect with CNC machine tools from FANUC, Mitsubishi, Siemens, and other manufacturers, as well as smart electricity meters and other devices. These gateways enable real-time collection of key data such as the on/off status, operating mode, spindle load, standby duration, real-time power, and cumulative energy consumption of CNC machine tools. The data is then uploaded to the factory management platform via the factory intranet or 4G/5G networks, enabling real-time monitoring, intelligent analysis, and visual management of the operational efficiency and energy consumption of machine tools. This provides reliable data support for enterprises to optimize equipment scheduling, reduce standby energy consumption, and enhance energy utilization efficiency.


 

Implemented Functions1. Real-time Monitoring and Visualization of Machine Tool Status

Real-time collection of status data such as machine tool operation, standby, shutdown, and alarms is conducted, with visualization displayed through cloud platform dashboards, large-screen views, and WeChat mini-programs. It supports multi-dimensional viewing of equipment real-time status and online rates by workshop, production line, and individual machine.

2. Automatic Statistics and Analysis of Standby Time

The system automatically records the standby time of machine tools during non-processing states, distinguishing between planned and unplanned standby times. It calculates standby durations and frequencies, generating equipment utilization reports to help managers identify optimization opportunities in production scheduling and equipment allocation.

3. Sub-item Collection and Trend Analysis of Energy Consumption Data

Real-time collection of data such as total electricity consumption, power consumption of each module, and standby power consumption of machine tools is carried out. It supports energy consumption statistics and trend analysis by shift, day, week, and month, identifying high-energy-consuming equipment and abnormal power consumption behaviors to provide a basis for energy-saving transformations.

4. Energy Efficiency Alarms and Intelligent Notifications

Based on preset energy consumption thresholds and standby duration rules, the system automatically issues energy efficiency alarms, such as "standby timeout" and "abnormal idling power consumption," and promptly notifies equipment or energy management personnel via WeChat, SMS, email, etc., enabling timely intervention.

5. Equipment Energy Efficiency Reports and OEE Analysis

The system quickly generates reports such as Overall Equipment Effectiveness (OEE) reports, energy consumption ranking reports, and standby analysis dashboards, supporting data export and multi-dimensional comparative analysis. This provides decision support for enterprise production management, equipment maintenance, and energy efficiency evaluation.

6. Remote Maintenance and Data Integration

Through the remote configuration and debugging functions of the gateway, it supports remote viewing of equipment parameters and fault warnings. Additionally, the system provides open APIs to support integration with production management systems such as MES and ERP, enabling data interconnection and business collaboration.



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