Académique Documents
Professionnel Documents
Culture Documents
Abstract: Understanding and estimating the energy consumed by machining are essential tasks
as the energy consumption during machining is responsible for a substantial part of the environmental burden in manufacturing industry. Facing the problem, the present paper aims to
analyse the correlation between numerical control (NC) codes and energy-consuming components of machine tools, and to propose a practical method for estimating the energy consumption of NC machining. Each energy-consuming component is respectively estimated by
considering its power characteristics and the parameters extracted from the NC codes, and
then the procedure estimating energy consumption is developed by accounting for the total
energy consumption of the components via the NC program. The developed method is verified
by comparing the estimated energy consumption with the actual measurement results of
machining two test workpieces on two different machine tools, an NC milling machine and an
NC lathe, and is also applied to evaluate the energy consumption of two different NC programs on
the NC milling machine. The results obtained show that the method is efficient and practical, and
can help process planning designers make robust decisions in choosing an effective energyefficient NC program.
Keywords:
INTRODUCTION
Chongqing
University,
Chongqing
400030,
256
Table 1
257
NC tag
Energy-consuming component
Operation behaviour
Spindle
M03, M04
M00, M01, M02, M05, M30
M00, M01, M02, M30
M07, M08
M00, M01, M02, M09, M30
Spindle
z/y/z axis feed
F
T
G00
G01, G02, G03
3.1.1 Estimation of Em
3
tcs
3.1.2 Estimation of Ec
Ec can be estimated by equation (2), in which the cutting power pc and the cutting time parameters must
be satisfied. The cutting time is calculated based on
the tool path and the cutting speed vc, both of which
are derived from NC files. The cutting power pc can be
written as equation (4) [17]
pc Fc vc
258
Fig. 1
6
Fig. 2
m Z
X
i1
tfei
tfsi
pi dt
Erfeed
! B
ZtB
prx
tA
dt
ZtD
tA
pry
dt
ZtC
prz dt
tA
8
Since each axis feed motor moves at the same
speed vr, equation (8) can also be rewritten as follows
Erfeed A ! B prx pry prz tC tA
prx pry tD tC prx tB tD
9
where
tC tA z2 z1 =vr
tD tC y2 z1 =vr
tB tD x2 y1 =vr
10
Effeed A ! B
ZtB
pfx pfy dt
11
tA
where pfx
12
vy vf sin a
13
tB tA
vf
pos0 posa
numpos ntool
17
where pos0, posa, numpos, and ntool are, respectively, the initial position of the turret, the
designed position by NC codes, the number of
tool posts in the turret, and the rotation speed of
the turret.
The power of the tool change motor ptool is a constant value for a specific machine tool, and it is
obtained referring to the specification documents of
machine tools.
3.4 Energy consumption estimation of
coolant pump
where
q
x2b y2b
and pfy
259
15
18
Fig. 3
Energy consumption of fan motors and servos systems constitutes the fixed energy consumption
for keeping the machine tool in an operational
state. Similarly, the energy consumption of fan
Proc. IMechE Vol. 226 Part B: J. Engineering Manufacture
260
19
Figure 4 depicts the procedure of energy consumption estimation that includes the following three
steps.
Step 1: parse NC files to extract the tags for identifying
the energy-consuming components.
Step 2: estimate energy consumption of the components controlled by the corresponding tags.
Fig. 4
Step 3: sum up the energy consumption of the components to obtain the total energy consumption of
the machine tool.
Furthermore, Step 2 is classified into several parallel sub-steps as shown in Fig. 4, the details of which
are as follows.
Sub-step 2.1: tag S marks the spindle speed ns which
is used as the input parameter to acquire the
power pm. Since tag M controls the turning on/
off state of spindle motors, the spindles running
time is calculated by identifying the turning on
tags and stopping ones. Equation (2) is used to
estimate energy Em based on the spindle power
pm and the running time tms and tme.
Sub-step 2.2: tag M also marks the turning on/off
state of coolant pumps, so the running time tcos
and tcoe of the coolant pump motors are similarly
estimated for one of the spindles. According to
equation (18), the running time tcos and tcoe, and
the acquired coolant pump power pcool are used to
calculate Ecool.
261
respectively; the workpiece type and process parameters are listed in Table 2.
According to the machining requirements and
process parameters, NC codes are programmed to
machine the workpiece on the PL700 machine
centre. The detailed information for estimating
energy consumption is parsed based on the NC
codes shown in Table 3.
The power parameters of energy-consuming components are given by simple measurements on PL700
as shown in Table 4. Based on the detailed information in Table 3, the power parameters in Table 4, and
the equations presented in section 3, the energy consumption of each component for machining the
example workpiece is estimated as shown in Table 5.
In order to compare the estimated energy consumption with the actual one, the example workpiece
In the above steps, the power parameters of components required for estimation can be obtained with
a small number of simple measurements, or from the
machine and component documentations.
Fig. 5
Example workpiece
CASE STUDIES
Table 3
Value
Workpiece
Spindle speed
Feed speed
Cutting depth
Machine tool
C45
2000 r/min
1500 mm/min
0.2 mm
PL700
NC code
Component(s)
Behaviour description
N100 G21
N104 . . . G0 X0 Y0
S2000 M03
N106 . . . Z100 M8; N108 Z3
Spindle motor
Coolant pump motor
Fan motor and servos system
262
Table 4
Power parameter
Value (W)
pservo pfan
pcool
pfx
pfy
prz
pfz
pm
pc
601
340
15
15
770
32
160
100
Table 5
Energy consumption estimation of each component for machining the example workpiece
Consumed
energy
(103 kWh)
Energy
parameter
Energy-consuming
component(s)
Efix
Ecool
Effeed
Erfeed
Em
Ec
3.97
2.24
0.06
0.06
0.01
0.26
1.06
0.59
8.25
Total
consumed
energy
(103 kWh)
Fig. 6
Comparison of energy consumption (percentage of total): (a) the estimated values; (b) the
actual measurement values
Table 6
8
7
-3
Energy(10 Kw.h)
263
Energy
parameter
Erfeed
Em
1
0
Efix
Ecool
Em
Efeed
Em
Ec
Fig. 7
Efeed
Ec
Efix
: Feed motor
Ecool
Total
Ec
: Machining
Fig. 8
Energy-consuming component(s)
Fan motor servos system
x-axis feed motor (feed speed)
z-axis feed motor (feed speed)
x-axis feed motor (rapid movement)
z-axis feed motor (rapid movement)
Spindle motor, unloaded (energy
consumption for running
spindle of machine tool)
Spindle motor, machining (energy
consumption for cutting
workpiece)
Efix
Effeed
Total
consumed
energy
(103 kWh)
Consumed
energy
(103 kWh)
287.51
0.72
17.41
0.10
5.24
345.56
1311.26
1967.80
264
Fig. 9
10
NC1
NC2
Energy(10-3Kw.h)
Fig. 10
CONCLUSIONS
Authors 2011
REFERENCES
1 Anderberg, S. E., Kara, S., and Beno, T. Impact
of energy efficiency on computer numerically
controlled machining. Proc. IMechE, Part B:
J. Engineering Manufacture, 2010, 224, 531541.
doi: 10.1243/09544054JEM1712.
2 Dahmus, B. J. and Gutowski, G. T. An environmental analysis of machining. In Proceedings of 2004
ASME International Mechanical Engineering
Congress and RD&D Expo, California, USA, 1319
November, 2004, pp. 110.
3 Herrman, C., Bergmann, L., Thiede, S., and Zein, A.
Energy labels for production machines an
approach to facilitate energy efficiency in production systems. In Proceedings of 40th CIRP
International Seminar on Manufacturing systems
location, Liverpool, UK, 30 May1 June, 2007.
4 Liu, F., Xu, Z. J., and Dan, B. Energy performance of
machining systems and its application, 1995 (China
Machine Press, Beijing).
5 Draganescu, F., Gheorghe, M., and Doicin, C. V.
Models of machine tool efficiency and specific consumed energy. J. Mater. Process. Technol, 2003, 141,
915.
6 Pfefferkorn, F. E., Lei, S., Jeon, Y., and Haddad, G. A
metric for defining the energy efficiency of thermally
assisted machining. Int. J. Machine Tools Mf., 2009,
49, 357365.
7 Rajemi, M. F., Mativenga, P. T., and Aramcharoen,
A. Sustainable machining: Selection of optimum
turning conditions based on minimum energy considerations. J. Cleaner Prod., 2010, 18, 10591065.
8 Kalpakjian, S. and Schmid, S. Manufacturing engineering and technology, 1999 (Addison-Wesley
Publishing Company, Boston, Massachusetts).
9 Kordonowy, D. N. A power assessment of machining
tools, 2002 (BSc Thesis, Department of Mechanical
Engineering, Massachusetts Institute of Technology,
Cambridge, Massachusetts).
10 Gutowski, T., Dahmus, J., and Thiriez, A. Electrical
energy requirements for manufacturing processes.
In Proceedings of 13th CIRP International
Conference on Life cycle engineering, Leuven,
Belgium, 30 May2 June, 2006, pp. 623627.
11 Shi, J. L., Liu, F., Xu, D. J., and Xie, D. The power
balance equation about the NC machine tools main
driver system driven by VVVF. Chin. J. Mech. Engng,
2010, 46, 118124.
12 Hu, S. H., Liu, F., He, Y., and Peng, B. Characteristics
of additional load losses of spindle system of
machine tools. J. Adv. Mech. Des. Syst. Mfg, 2010, 4,
12211233.
13 Avram, O. I. and Xirouchakis, P. Evaluating the use
phase energy requirements of a machining tool
system. J. Cleaner Prod., 2011, 19, 699711.
14 Liu, Y. and Yuan, J. Q. Technical basis of mechanical
manufacturing 2000 (Chongqing University Press,
Chongqing, China).
265
APPENDIX
Notations
A
B
Ec
Ecool
Efeed
Effeed
Erfeed
Efix
Em
Espindle
Etool
Etotal
fu
Fc
l
m
ns
ntool
numpos
pc
pcool
pfan
pi
pm
pservo
266
ptool
pfx
pfy
prx
pry
prz
pos0
posa
sz
tA
tB
tC
tce
tcoe
tcos
tcs
tD
te
tfei
tfsi
tme
tms
ts
ttool
vc
vr
z