„NCplus – Process and value creation-oriented controlled machine tool“

The overall objective of the research project NCplus was the development and prototypical implementation of technologies that enable process and value creation-oriented operation of cutting machine tools. The project was funded by the Federal Ministry of Education and Research (BMBF) and carried out in cooperation with renowned partners from industry.

perpendo succeeded, in the course of a process and energy flow analysis, in obtaining detailed knowledge of the energy flows in the two studied machine tools through extensive measurement sequences. Special attention was given to the distribution of consumed energy in the various modules and components.

Machine tool DMC 80 H

Machine tool DMC 80 H

These analyses were used to provide a detailed breakdown of the consumed energy (value, dissipation, heat etc.). From the findings improvement approaches and ideas to increase the energy efficiency were identified and significant savings potentials uncovered and quantified. The findings in the context of the energy flow analysis served as a data basis used by the project partners in other work packages for the prototypic implementation of more efficient components.

Besides the spindle and axis drives, the cooling system as well as the hydraulic and emulsion supply was the focus of the research. In the course of the final measurements of the energy flows of the prototype machine, it was found that the energy needs of a typical industrial machining process can be reduced by around 35 % through the improvements identified. Especially the power consumption of the cooling system was significantly reduced. The original vapor-compression chiller was replaced by a (free-cooling) fan cooler, resulting in energy savings of two-thirds for the cooling system.

Comparison of Power Consumption: Reference Maschine vs. Prototype Machine


"This research and development project was funded by the Federal Ministry of Education and Research (BMBF) in the framework „Research for the production of tomorrow“ and supported by the Project Management Agency Karlsruhe (PTKA). The author is responsible for the content of this publication."


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