Component Energy Modelling for Machine Tools

Rising energy costs and strict CO₂ traceability regulations create demand for monitoring energy and CO₂ emissions in manufacturing. This paper presents a framework for modelling component-wise energy models with deployable accuracy. In many factories, power meters log data at a sampling rate of 1–2 Hz, so short start-up peaks of components are underestimated. Manufacturers want to exploit this information to support operational decisions, such as peak shaving and optimising energy contract costs. To enable data-driven decisions with limited measurement infrastructure, energy models must extrapolate component behavior from sparse data. The framework is based on power measurements in accordance with ISO 14955-3, ensuring that the load characteristics required for subsequent modelling are known. The measurements are then segmented, and regressions are fitted for each segment. As a case study considering the mist extractors of two different machine tools, the proposed segmentation achieved determination coefficients (R²) of up to 0.94 in the complex ramp-up phase. The resulting models are compact, interpretable, and suited for energy monitoring on edge devices. The contribution is a reproducible framework for delivering peak-aware, component-level energy models from low-frequency industrial power meter data.