In this edition of the MARS Results Series, we speak with Dr. Markus Maier, Head of the Machine Concepts Group at inspire AG about the energy measurement device.
Understanding exactly where energy is consumed is an important step towards more efficient manufacturing. Developed by MARS partner inspire AG, the energy measurement device combines electrical power and compressed-air measurement to provide energy data for individual machines. The result gives manufacturers a clearer basis for monitoring operations, identifying unexpected demand and making data-driven decisions.
Dr. Markus Maier’s work focuses on machine-tool technologies, digital manufacturing, smart factories and data-driven modelling. In MARS, he contributes expertise in manufacturing systems and machine connectivity. Inspire AG is a Swiss research and technology organization that connects academic research with industrial applications. Within MARS, inspire AG contributes manufacturing expertise, experimental data and process knowledge, and operates one of the project’s manufacturing platforms.
We asked Dr. Markus Maier how the system works, what has already been tested and where the development could go next.
INTERVIEW with Dr. MArkus Maier
In simple terms, what is this MARS result, and what real-world problem does it address?
Dr. Markus Maier: The result is a machine-level energy measurement system for manufacturing. It combines a PLC, a compressed-air flow sensor and electrical power measurement to capture the energy used by individual machines. It helps factories move beyond building-level utility bills and understand where electricity and compressed air are actually consumed.
What makes this result different from what existed before (and why does that difference matter)?
Dr. Markus Maier: The system combines electrical power and compressed-air flow measurement in one coordinated setup, with the PLC linking the sensors and software. This matters because the two energy streams are often monitored separately or not at machine level at all. The common data basis gives a clearer view of machine operation and energy demand.
How do you know it works – what has been tested, demonstrated, or validated so far?
Dr. Markus Maier: The setup has been installed on manufacturing machines and used to measure electrical power and compressed-air consumption in a real operating environment. It demonstrated that both signals can be acquired and made available for further analysis. The system was also made available to colleagues at NTUA and ENSAM for shared use and feedback.
How does this result fit into the bigger picture of the MARS Platform – what role does it play?
Dr. Markus Maier: Within the MARS Platform, the device provides the shop-floor data needed for energy-related digital services. It connects physical machine operation with monitoring and analysis by supplying machine-level electricity and compressed-air data. This creates a practical basis for future assessments, optimisation work and data-driven manufacturing decisions.
What happens next – what are the next steps and what could we realistically see after the project ends?
Dr. Markus Maier: Next steps are to refine the software integration, improve how the data are presented and interpreted, and test the setup in further machine conditions. After the project, the system can support demonstrations and follow-up pilots with manufacturing partners, for example to compare operating modes or identify unexpected compressed-air demand.