On lines running two shifts or more, a gantry robot consumes power even when it is not moving. Motor inrush current, the electricity behind compressed air for pneumatic grippers, and control cabinets and peripherals left on during idle time all feed the same bill. Savings should therefore be sought across the whole system, not only at the main drive.

Right-sizing at selection is the starting point. Choose the model from part weight, travel and cycle time, keep sensible margins on motors and gearboxes without oversizing, and compress travel as far as the layout allows. Excess travel means a heavier beam and higher starting power; over-spec equipment can consume more electricity over its life than it saves on price.

Motion planning affects consumption just as directly. Servo energy depends largely on how often and how hard the axes accelerate, so S-curve profiles, fewer intermediate points and merged moves between neighbouring stations lower peak current, while smooth transitions without hard stops also cut mechanical shock and grid disturbance.

Standby strategy is often ignored. During changeovers, waiting and breaks the machine may sit energised. Program graded standby: hold position for short waits, but for long ones disable the servos, cut gripper air and switch off lighting and fans as needed. Make restart homing and checks a simple standard routine, or operators will bypass the feature.

Compressed air is a hidden cost: converted to electricity it costs far more than an electric gripper of equal holding force. Size the air supply to actual demand, fix joint leaks promptly, shut off air between picks, and add pressure-holding accumulators to vacuum circuits. Regular leak surveys with a flow meter are a routine most plants skip.

Regenerative energy deserves recovery. Braking energy from Z-axis descent and beam deceleration is usually burnt off in resistors, a real loss on long-travel, high-frequency duty. Servos with energy feedback or a shared DC bus can return it to the grid; whether this pays back depends on cycle density, and is worth calculating for heavy long-travel lines.

Energy saving needs data. Meter drives, air and overall consumption separately on an energy dashboard to judge whether measures work. Electricity per unit produced is more telling than a main-meter reading, and abnormal swings often point to mechanical drag, air leaks or poor lubrication, so the same data serves as evidence of machine health in daily checks.

In projects covering truss manipulators, gantry robots, truck loading, AS/RS and seventh-axis systems, Truman advises on selection, standby and air-side savings matched to each cycle and duty. Energy work need not be drastic: standby modes and leak repair alone show results in running cost within a short period for most plants.