applied

sciences
Article
An Accuracy-Efficiency-Power Consumption Hybrid
Optimization Method for CNC Milling Process
Shih-Ming Wang 1,2, *, Chun-Yi Lee 1 , Hariyanto Gunawan 1 and Chin-Cheng Yeh 1
1 Department of Mechanical Engineering, Chung Yuan Christian University, Taoyuan 32023, Taiwan;
sasuke0673@gmail.com (C.-Y.L.); harrywey@cycu.edu.tw (H.G.); jano.yeh@shl-group.com (C.-C.Y.)
2 Technology Center, Walsin Lihwa Corporation, Taipei 110, Taiwan
* Correspondence: shihming@cycu.edu.tw




Received: 3 March 2019; Accepted: 8 April 2019; Published: 10 April 2019


Abstract: This study proposes a hybrid optimization method which can help users to find optimal
cutting parameters which will provide better efficiency and lower power consumption for a milling
process. Empirical models including performance-power consumption characteristic curves of servo
motors were built, and an optimization algorithm adopting the empirical models with procedure
guiding function was developed. The empirical models were built based on the measurements
from planned machining experiments with different combination of machining parameters including
spindle speed, feedrate, and chip load, etc. After integrating the models and algorithm, an optimization
system with human machine interface, which has procedure guiding function, was developed. The
system can recommend optimal machining parameters for a milling process for shorter machining time
and lower electricity costs based on the original machining parameters. Finally, cutting experiments
were conducted to verify the proposed system, and the results showed that the proposed method
can effectively enhance efficiency by 42.06% and save 34.74% in machining costs through reducing
machining time and electrical power consumption.

Keywords: optimization; power consumption; machining efficiency; machining cost

1. Introduction
Increasing power efficiency in production is a prime target for many companies, for a number of
different reasons. Power consumption is an important factor in operating cost. An efficiency power
consumption system with high-performance output and higher productivity requiring less power is
expected. In machine tool production, Computer Numerical Control (CNC) machine is usually used to
produce the precision product. When the machining capacity is higher and machining time is longer,
significantly higher power consumption will occur. In the past, enterprises use the shortest machining
time to increase machine utilization and productivity. However, the shortest machining time does not
always mean the lowest cost, because more power consumption is needed to finish the machining in a
shorter time. As known, the energy crisis is accelerating, and energy costs are rapidly increasing so it
will be beneficial if machining time was shorter and simultaneously, the power consumption lower.
Moreover, most of the factories and power companies have signed an electric power contract, so if
electricity consumption exceeds the contract, the cost of electricity will be greatly increased. Therefore,
if the machine power consumption characteristics can be known, it can help the planning of production
scheduling and cost.
In recent years, research on power consumption has grown rapidly. Gontarz et al. [1] introduced
a new physical modeling method to predict the effects of power consumption and thermal effect
for different modes of the turning machine tool and its components. A modeling framework was
established and used to simulate power consumption. Abdoli et al. [2] explored the relationship

Appl. Sci. 2019, 9, 1495; doi:10.3390/app9071495 www.mdpi.com/journal/applsci

Appl. Sci. 2019, 9, 1495 2 of 20

between cutting parameters and machine power consumption. The power consumption model was
established based on this relationship, and the model can be used for production line planning.
Diaz et al. [3] estimated the cutting power consumption and spindle motor power consumption
through an empirical formula. Mori et al. [4] suggested reducing the power consumption by reducing
the machining time or synchronizing the spindle speed acceleration/deceleration and the feedrate
system. Draganescu et al. [5] proposed a model to calculate power consumption, machine efficiency
and material removal rate for metal cutting. To establish the relationship between the above parameters,
the experimental data and response surface methodology (RSM) were used. Kara et al. [6] proposed
an empirical model to describe the relationship between power consumption of the material removal
process and process variables. The power consumption model for calculating the material removal rate
and the amount of cutting was developed.
To carry out the above development, extensive experimental research and data analysis of
machine power consumption characteristics are necessary. Many companies will collect various
data, such as production data, quality data, production environment data, etc., to analyze production
management and develop decision based policy. However, the enterprises rarely collect production
parameters and power consumption data for analysis. Hence, when an enterprise wants to control
power consumption, they lack the necessary data support. Although some enterprises are concerned
about power consumption, it is manually collected and calculated. In addition, the power consumption
data acquisition and analysis method is lacking. Some researches related to process monitoring have
developed, for example, Dimla et al. [7] used various sensor signals to develop cutting monitoring
of metal cutting. Usui et al. [8] proposed an analytical method based on orthogonal cutting data
for machining and tool wear characteristics, to predict various tool shape and cutting conditions.
Prickett et al. [9] used a machine controller to monitor the process and detect tool breakage signals.
Cai et al. [10] proposed a feedback method to predict tool wear, milling error and online compensation.
Li et al. [11] used sensor technology to detect tool wear and faults, and predict the impact of tool wear
to surface quality. Choi et al. [12] used an intelligent online system to monitor tool wear.
Although some researches on power consumption have been performed, they usually only focus
on power consumption or processing independently, and still lack a method which can synchronously
optimize the machining accuracy, production efficiency, and power saving. The objective of this
research is to establish the hybrid optimization of machining accuracy, production efficiency, and power
consumption. The characteristics of motor power consumption during machining were investigated.
Furthermore, the relationship between machining parameters and motor power consumption was
created. Moreover, the optimization algorithm of production efficiency and power saving was built.
Finally, the hybrid optimization system was created by using Visual C# language. With this system,
the user can import the Numerical Control (NC) program to optimize the parameters. Then the system
will analyze and calculate the optimal machining time, power consumption, and recommend the
machining parameters for better efficiency, lower power consumption, with the same product quality.

2. Algorithm and Method

To determine the optimal machining parameters for better machining efficiency and lower power
consumption without losing machining accuracy, it is necessary to understand the relationship between
machine power consumption characteristics, machining parameters, and machining quality. Empirical
models were first built based on the data (power consumption vs. motor speed or power consumption
vs. machining feedrate) collected from the designed experiments. To separate the influence of cutting
in motor power consumption, the data collection experiments were divided into two categories:
(1) measurements without cutting load and (2) measurements with cutting load. Based on the collected
data, a motor power consumption characteristics model with respect to machining parameters was
built. Based on the model, the algorithm to search the machining parameter for shorter machining time
and lower power consumption was developed. When a milling process and expected improvement of
machining efficiency are given, the associated machining feedrate and spindle speed will be calculated
the theoretical cutting equation, and used as initial values to search based on the motor power
consumption characteristics model for the optimal parameters which have a lower motor power
consumption.
Appl. Sci.
To 2019, 9, 1495
analyze 3 of 20
the relationship between electrical power consumption and machining conditions,
the investigation and analysis of spindle motor and servo motor were important. The analysis
process, first, used various machining parameters to observe the motor power consumption to
based on the theoretical cutting equation, and used as initial values to search based on the motor
understand the motor characteristics and power consumption, then established the relationship
power consumption characteristics model for the optimal parameters which have a lower motor
model between machining parameters and power consumption, the synchronous optimization
power consumption.
algorithm of production efficiency and power consumption was established, and a human machine
To analyze the relationship between electrical power consumption and machining conditions, the
interface (HMI) was designed, to become the optimization manufacturing assisted system. The main
investigation and analysis of spindle motor and servo motor were important. The analysis process, first,
function is the optimization of machining parameters to obtain power and production efficiency
used various machining parameters to observe the motor power consumption to understand the motor
without decreasing the machining accuracy. Figure 1 shows the flowchart of the research.
characteristics and power consumption, then established the relationship model between machining
Different materials with different machining conditions will cause different electrical power
parameters and power consumption, the synchronous optimization algorithm of production efficiency
consumption, and the reasonable chip load of the cutter for different materials will be different too.
and power consumption was established, and a human machine interface (HMI) was designed, to
Although the method and algorithm proposed in this study can be applied to different materials, the
become the optimization manufacturing assisted system. The main function is the optimization of
performance–power consumption characteristic curves of servo motors (such as power consumption
machining parameters to obtain power and production efficiency without decreasing the machining
vs. motor speed, or power consumption vs. machining feedrate) need to be investigated and built for
accuracy. Figure 1 shows the flowchart of the research.
different materials as core important data/information for implementation.

Figure 1. Flowchart of research. CNC: Computer Numerical Control; NC: Numerical Control.
Figure 1. Flowchart of research. CNC: Computer Numerical Control; NC: Numerical Control.
Different materials with different machining conditions will cause different electrical power
2.1. Optimization
consumption, and of the
Power Consumption
reasonable chip load of the cutter for different materials will be different too.
Although the method
The cutting speed andin algorithm
the cuttingproposed
process inis this study canto
proportional bethe
applied to different
spindle materials,
motor speed, and the
performance–power consumption characteristic curves of servo motors (such
cutting feedrate is proportional to the servo motor speed. To shorten the machining time for as power consumption
vs. motor speed,
improving or power
machining consumption
efficiency, vs. machining
the feedrate feedrate)
of the servo motorneed to betoinvestigated
needs be increased. and built for
However,
different
increasing materials as core
the feedrate important
of the data/information
servo motor will increase for
the implementation.
chip load and cutting resistance, hence, it
will affect the tool life and machining accuracy. To avoid this effect, the spindle speed needs to be
2.1. Optimization
increased of Power
at the same time,Consumption
so the chip load is kept maintained. However, the increasing of spindle
speedTheandcutting
feedratespeed in theincrease
cause an cutting in powerisconsumption.
process proportional to In the
this spindle
study, power
motor consumption
speed, and the is
measured
cutting for different
feedrate spindle speeds,
is proportional thenmotor
to the servo the influence of machining
speed. To shorten theparameters on machine
machining time power
for improving
consumption
machining is created
efficiency, thefor the establishment
feedrate of the servoofmotor
an optimized
needs to design algorithm.
be increased. However, increasing the
feedrate of the servo motor will increase the chip load and cutting resistance, hence, it will affect the
tool life and machining accuracy. To avoid this effect, the spindle speed needs to be increased at the
same time, so the chip load is kept maintained. However, the increasing of spindle speed and feedrate
cause an increase in power consumption. In this study, power consumption is measured for different
Appl. Sci. 2019, 9, 1495 4 of 20

spindle speeds, then the influence of machining parameters on machine power consumption is created
for the establishment of an optimized design algorithm.
According to the spindle speed–motor power consumption characteristic curve and feedrate–motor
power consumption characteristic curve, the model of the relationship between machining parameters
and power consumption can be established by the polynomial curve fitting method, then analyzed to
determine the influence of each parameter on machine power consumption and the influence of the
combination of parameters on machine power consumption. To reduce machining time by increasing
the servo feedrate (i.e., increasing the servo motor speed) without affecting the tool life and machining
accuracy, it is necessary to maintain the cutting load per tooth (chip load), so the spindle speed needs to
be increased.
In the optimization procedure, first of all, the user needs to roughly define the expected increase
of feedrate for better machining efficiency, and the system will then search the optimal feedrate close
to the expected feedrate, which has lower electrical power consumption for the related servo motors,
based on the pre-built empirical model. After the optimal feedrate is selected, the spindle speed is
calculated to remain the same chip load for the cutter to avoid deteriorating the cutter life. Since the
optimal feedrate was selected based on the goal of efficiency improvement, the optimal combination
of parameters can provide better efficiency, better electrical power consumption, and almost the same
tool life. The relationship of chip load, spindle speed, and feedrate is expressed in Equation (1).

C p = F/( N × z) (1)

where CP is the chip load (mm/tooth), F is the feedrate (mm/min), N is the spindle speed (rpm), and z
is the number of teeth.
When optimizing machining, the required spindle speed is entered to the machining parameters–
power consumption module to calculate the power consumption change. To make the power saving
and machining cost of production easy to understand for industry, the machine power consumption
is converted into electricity cost. The machining efficiency can be determined as machining cost
saving, which can be obtained by multiply the machining time saving and machining cost as shown in
Equation (2).
Mcr = Mt × hr (2)

where Mcr is machining cost saving, Mt is machining time saving (hr), and hr is machining cost
(NTD/hr).
Figure 2 shows the optimization algorithm of machining and power consumption. If the electricity
cost of the shortened machining time exceeds the basic electricity cost, the system re-finds the
machining parameters to obtain optimal machining efficiency and power consumption based on
Equation (1) and the spindle speed–motor power consumption module and the feedrate–motor power
consumption module. The final machining time must be less than the initial machining time to achieve
lower cost.
Appl. Sci. 2019, 9, 1495 5 of 20
Appl. Sci. 2019, 9, x FOR PEER REVIEW 5 of 21

Figure 2. Optimization algorithm of machining and power consumption.

Figure 2. Optimization algorithm of machining and power consumption.
After establishing the empirical models the for relationship between machining parameters and
After establishing the empirical models the for relationship between machining parameters and
power consumption, an optimization system was developed in visual C# language. The user can
power consumption, an optimization system was developed in visual C# language. The user can
enter the machining information (such as original NC program, machining precision requirement,
enter the machining information (such as original NC program, machining precision requirement,
tool diameter, etc.) and the expected improvement in machining efficiency from the human machine
tool diameter, etc.) and the expected improvement in machining efficiency from the human machine
interface (HMI). After that, the system will automatically calculate the recommended optimal machining
interface (HMI). After that, the system will automatically calculate the recommended optimal
parameters. In the procedure, the system will guide the user to enter the expected feedrate for
machining parameters. In the procedure, the system will guide the user to enter the expected feedrate
optimization, and then the system will re-calculate and find the optimal machining parameters. Finally,
for optimization, and then the system will re-calculate and find the optimal machining parameters.
the optimal parameters will be saved as a CSV file or TXT file, and meanwhile, the parameters can also
Finally, the optimal parameters will be saved as a CSV file or TXT file, and meanwhile, the parameters
be uploaded to the cloud database with a JSON data format. Through the Ethernet and Fanuc Open
can also be uploaded to the cloud database with a JSON data format. Through the Ethernet and Fanuc
CNC API Specification (FOCAS), two-way communication between the CNC machine controller and
Open CNC API Specification (FOCAS), two-way communication between the CNC machine
hybrid optimization module was established for data acquisition and transferring command to the
controller and hybrid optimization module was established for data acquisition and transferring
CNC controller of a machine tool.
command to the CNC controller of a machine tool.
2.2. Hybrid Optimization System
2.2. Hybrid Optimization System
The HMI is designed and becomes the optimization manufacturing assisted system. The system
The HMIthe
can calculate is designed
machining andtime,
becomes the optimization
machining cost, and manufacturing assisted
total cost as shown system.3.The
in Figure system
The user
needs to input regular electricity fees, base machining costs, and NC program, then the systemneeds
can calculate the machining time, machining cost, and total cost as shown in Figure 3. The user will
to input regular
calculate electricity
the amount fees,
of three base
axes machiningand
movements, costs, and NCto
according program, then the consumption
feedrate–power system will calculate
model,
the amount
analyze of three axes
the machining movements,
time, machining andcost,
according to feedrate–power
and total consumption
cost. The machining model, analyze
cost is calculated from
power consumption (kW) multiplied machining time (hr). The user can enter the requiredfrom
the machining time, machining cost, and total cost. The machining cost is calculated power
machining
consumption
parameters (kW) multiplied
according their needs,machining
then the time
system(hr).
willThe user can
calculate theenter the required
machining time as machining
shown in
parameters according their needs, then the system will calculate the machining
Figure 3. The system can recommend optimal parameters, and the user can select this recommended time as shown in
Figure 3. The system can recommend optimal parameters, and the user
parameter and directly modify and export the optimized parameters as the NC program.can select this recommended
parameter and directly modify and export the optimized parameters as the NC program.
Appl. Sci. 2019, 9, 1495 6 of 20
Appl. Sci. 2019, 9, x FOR PEER REVIEW 6 of 21

Figure 3. Machining
Figure efficiency
3. Machining and power
efficiency andconsumption hybrid optimization
power consumption human machine
hybrid optimization humaninterface
machine (HMI).
interface (HMI).
3. Experiments
3. Experiments
3.1. Experiment Design
Basically, higher
3.1. Experiment Designspeed will produce higher power consumption, so an experiment with various
speeds of spindle motor and X-, Y-, Z-axis servo motor were carried out to study the characteristic
Basically, higher speed will produce higher power consumption, so an experiment with various
of the motor power consumption. The experiment was divided into two parts: without cutting load
speeds of spindle motor and X-, Y-, Z-axis servo motor were carried out to study the characteristic of
and with cutting load conditions. Assuming that the spindle motor speed sets 500 until 3000 RPM
the motor power consumption. The experiment was divided into two parts: without cutting load and
with
withthe increasing
cutting step of 500, Assuming
load conditions. a power consumption measurement
that the spindle motor speed is performed for the
sets 500 until spindle
3000 RPM motor
with
under these spindle
the increasing step speeds,
of 500, atopower
obtainconsumption
the relationship between spindle
measurement speed and
is performed forpower consumption.
the spindle motor
Similarly,
under theseassuming thatspeeds,
spindle the servotofeedrate
obtain sets
the 200, 500, 1000, between
relationship 1500, 2000,spindle
2500, 3000,
speed3500,
and4000, 4500,
power
5000, 5500, 6000 mm/min, a power consumption measurement is performed for
consumption. Similarly, assuming that the servo feedrate sets 200, 500, 1000, 1500, 2000, 2500, 3000,the servo motor under
these
3500,servo
4000, feedrates,
4500, 5000,to5500,
obtain
6000themm/min,
relationship between
a power servo feedrate
consumption and power
measurement consumption.
is performed for the
For investigation of power consumption with cutting load, because of
servo motor under these servo feedrates, to obtain the relationship between servo feedrate anddifferent cutting conditions,
power
the cutting load is also different, hence, the motor will have different power consumptions. Therefore,
consumption.
different
For cutting parameters
investigation were taken
of power to investigate
consumption with the relationship
cutting betweenofcutting
load, because loading
different and
cutting
power consumption. The cutting conditions are shown in Table 1. The
conditions, the cutting load is also different, hence, the motor will have different power machining parameters are
according to theTherefore,
consumptions. tool material, hardness
different of workpiece
cutting parameters material,
were takenmillingto speed, and material
investigate removal
the relationship
rate (MRR). By using the equation V = π × D ×
between cutting loading and power consumption. The cutting conditions are shown in Table 1.speed,
N /1000, we can obtain the required spindle The
and using equation
machining F = fare
parameters × zaccording
× N, we to canthe
obtain
tool the feedrate
material, (mm/min),
hardness where V ismaterial,
of workpiece the milling speed
milling
(m/min);
speed, and D material
is the diameter
removal ofrate
tool(MRR).
(mm); N Byisusing
the spindle speed V
the equation =π ×
(rpm); F isD the
× N /1000, (mm/min);
feedrate we can obtainf is
the
thematerial
requiredremoval rate (mm/t);
spindle speed, and usingz is equation
the number F =off teeth
× z ×(t).
N, we can obtain the feedrate (mm/min),
where V is the milling speed (m/min); D is the diameter of tool (mm); N is the spindle speed (rpm);
F is the feedrate (mm/min); f is the material Table 1. Cuttingrate
removal condition.
(mm/t); z is the number of teeth (t).
Workpiece Material Cast Iron (HB244)
Table 1. Cutting condition.
Workpiece dimensions 550 × 100 × 100 mm
Workpiece Material
Cutting tool
CastCarbide
Iron (HB244)
end mills
Workpiece dimensions 550 x 100 x 100 mm
No. of teeth 4 teeth
Cutting tool Carbide end mills
Tool diameter 25 mm
No. of teeth 4 teeth
Tool diameter 25 mm
Appl. Sci. 2019, 9, 1495 7 of 20

The machining parameters are shown in Table 2. Eight kinds of spindle speed, three kinds of
feedrate, three kinds of feed per tool were taken, so a total of 24 combinations of parameters. Each
parameter was tested five times.

Table 2. Machining parameters.

Subject Experiment 1 Experiment 2

Milling speed (m/min) 30~60 30~60
Chip load (mm/t) 0.12, 0.15, 0.18 0.12, 0.15, 0.18
Spindle speed (rpm) 450~750 1000~2750
Feed rate (mm/min) 192~540 480~1980
Width of Cut (mm) 20 20
Depth of Cut (mm) 4 4

3.2. Instrument and Data Acquisition

A CNC horizontal milling machine Dah Lih MCH-500 with X, Y, Z axis stroke 750×680×600 mm,
spindle maximum speed 10,000 rpm, equipped with Fanuc controller is used in this experiment.
The spindle and three servo motor power consumption are captured using Archmeter PA310 power
meter. The power meters PA310 (hereinafter referred to as the power meter) were mounted on the
spindle and three servo motor of R, S, T wire. RS232 cable is used to connect the motors and computer,
then the power consumption data are captured via Servebox and stored in the computer.

4. Results and Discussions

From the experiment data, the analysis was conducted to investigate the relationship between
cutting parameters and power consumption, and, thus, establish the regression equation using the
polynomial regression method to achieve the purpose of optimizing machining efficiency and low
power consumption.

4.1. Power Consumption Analysis without Cutting Load

According to the experiment scheme in the previous section, the experimental data can be divided
into spindle and three servo motors. In the spindle experiments, six machining parameters were
taken from 500 to 3000 rpm, with an increasing step every 500 rpm. The power consumption for each
spindle speed parameter is shown in Figure 4. The experiment 1 to 3 and 4 to 6 were measured on
different dates. It showed each power consumption value is very close to each other, around 0.00006 to
0.00009 kW. The power consumption does not significantly increase when the spindle speed increases.
The reason is perhaps that the spindle is only in the idle state rather than the cutting state, so there
is no cutting resistance, hence, increasing the spindle speed will not significantly affect the spindle
power consumption.
For X-axis servo motor, 13 combinations of feedrate were carried out from 200 mm/min until
6000 mm/min. The ommencinh feedrate was 200 mm/min and after 500 mm/min, the feedrate was
increased every 500 mm/min up to 6000 mm/min. Figure 5 shows the resulting power consumption
for different feedrates. The experiment was repeated three times, and the results were reproducible.
However, only a few of data showed a difference of about 0.005 kW, even at the feedrate of
4500 mm/min, the maximum difference was 0.01 kW. As seen in Figure 5, the power consumption
increase rate is about 0.00125 kW per 500mm/min when the feedrate is 200 to1500 mm/min, but
at feedrate of 2000 mm/min it reduces. When the feedrate is in the range of 2000 to 4000 mm/min,
the power consumption trend is higher with an increase rate of about 0.0025 kW per 500 mm/min.
However, at the feedrate of 4000 mm/min the power consumption is significantly reduced, but in
the feedrate range of 4500 to 6000 mm/min the power consumption rises quickly with increasing
Appl. Sci. 2019, 9, 1495 8 of 20

value of 0.005 kW per 500 mm/min. The increasing trend is higher than the first two feedrate sections.
It can be concluded that increasing feedrate will increase power consumption, but when the feedrate is
2000 mm/min and 4500 mm/min the power consumption is lower. Moreover, it recommends to use
these two2019,
Appl. Sci. feedrates
9, x FORto obtain
PEER lower power consumption.
REVIEW 8 of 21

Appl. Sci. 2019, 9, x FOR PEER REVIEW 9 of 21

Figure4.4.Relationship
Figure Relationshipbetween
betweenspindle
spindle speed
speed vs.
vs. power consumption w/o
w/ocutting
cuttingload.
load.

For X-axis servo motor, 13 combinations of feedrate were carried out from 200 mm/min until
6000 mm/min. The ommencinh feedrate was 200 mm/min and after 500 mm/min, the feedrate was
increased every 500 mm/min up to 6000 mm/min. Figure 5 shows the resulting power consumption
for different feedrates. The experiment was repeated three times, and the results were reproducible.
However, only a few of data showed a difference of about 0.005 kW, even at the feedrate of 4500
mm/min, the maximum difference was 0.01 kW. As seen in Figure 5, the power consumption increase
rate is about 0.00125 kW per 500mm/min when the feedrate is 200 to1500 mm/min, but at feedrate of
2000 mm/min it reduces. When the feedrate is in the range of 2000 to 4000 mm/min, the power
consumption trend is higher with an increase rate of about 0.0025 kW per 500 mm/min. However, at
the feedrate of 4000 mm/min the power consumption is significantly reduced, but in the feedrate
range of 4500 to 6000 mm/min the power consumption rises quickly with increasing value of 0.005
kW per 500 mm/min. The increasing trend is higher than the first two feedrate sections. It can be
concluded that increasing feedrate will increase power consumption, but when the feedrate is 2000
mm/min and 4500 mm/min the power consumption is lower. Moreover, it recommends to use these
two feedrates to obtain lower power consumption.
Since the power consumption at the feedrate of 4500 mm/min is large, this data is excluded in
the average calculation. Figure 6 shows the average calculation result, and each section regression
equation can be obtained as follow:
Figure 5. Relationship between X-axis motor feedrate vs. power consumption w/o cutting load.
Figure 5. Relationship between X-axis motor feedrate vs. power consumption w/o cutting load.
y = −0.0014𝑥 + 0.0078𝑥 − 0.0029 (3)
Since the power consumption at the feedrate of 4500 mm/min is large, this data is excluded in
the average calculation. Figure
y = 6−0.0003𝑥
shows the+average
0.0021𝑥calculation
− 0.0031𝑥result, and each section regression
+ 0.0063 (4)
equation can be obtained as follow:
y = −0.0016𝑥 + 0.0128𝑥 − 0.0014 (5)
y = −0.0014x2 + 0.0078x − 0.0029 (3)

y = −0.0003x3 + 0.0021x2 − 0.0031x + 0.0063 (4)

y = −0.0016x2 + 0.0128x − 0.0014 (5)

Appl. Sci. 2019, 9, 1495 9 of 20
Figure 5. Relationship between X-axis motor feedrate vs. power consumption w/o cutting load.

Figure 6. Curve of average X-axis motor feedrate vs. power consumption w/o cutting load.
Figure 6. Curve of average X-axis motor feedrate vs. power consumption w/o cutting load.

For Y-axis servo motor, the parameter is similar to X-axis servo motor experiment, commencing
For Y-axis servo motor, the parameter is similar to X-axis servo motor experiment, commencing
at 200 mm/min and rising to 6000 mm/min with an increasing step of 500 mm/min. Figure 7
at 200 mm/min and rising to 6000 mm/min with an increasing step of 500 mm/min. Figure 7 shows
shows the relationship Y-axis motor upward direction with power consumption for different feedrates.
the relationship Y-axis motor upward direction with power consumption for different feedrates. It is
It is seen the power consumption rate for feedrate range 200 to 1000 mm/min is about 0.0025 kW
seen the power consumption rate for feedrate range 200 to 1000 mm/min is about 0.0025 kW per 500
per 500 mm/min but smaller at a feedrate of 1500 mm/min. When the feedrate range is between
mm/min but smaller at a feedrate of 1500 mm/min. When the feedrate range is between 1500 and
1500 and 2000 mm/min the power consumption increase rate is 0.005 kW per 500 mm/min, but a
2000 mm/min the power consumption increase rate is 0.005 kW per 500 mm/min, but a feedrate of
feedrate
2500 to of 2500mm/min
3000 to 3000 mm/min
exhibits aexhibits a decreasing
decreasing trend.the
trend. When When the feedrate
feedrate is between
is between 30005500
3000 and and
5500 mm/min
mm/min the power
the power consumption
consumption gradually
gradually increases
increases fromkW
from 0.008 0.008 kW
up to up to
0.015 kW.0.015
FromkW.
theFrom the
results,
results, the power consumption tends to increase with feedrate increase, but a feedrate
the power consumption tends to increase with feedrate increase, but a feedrate of 1500 mm/min, 3000of 1500 mm/min,
3000 mm/min,
mm/min, and 6000
and 6000 mm/min
mm/min showed
showed lowerlower
powerpower consumption.
consumption. Therefore,
Therefore, thesethese
threethree feedrates
feedrates can
Appl. Sci. 2019, 9, x FOR PEER REVIEW 10 of 21
can be considered to obtain lower power consumption without decrease
be considered to obtain lower power consumption without decrease machining efficiency.machining efficiency.

Figure 7. Relationship between Y-axis motor (up direction) feedrate vs. power consumption w/o
Figure 7. Relationship between Y-axis motor (up direction) feedrate vs. power consumption w/o
cutting load.
cutting load.
Figure 8 shows the power consumption of Y-axis motor downward direction. It is seen the power
Figure 8 shows the power consumption of Y-axis motor downward direction. It is seen the power
consumption at a feedrate of 200 mm/min and 500 mm/min is greater than the feedrate of 1000 to
consumption at a feedrate of 200 mm/min and 500 mm/min is greater than the feedrate of 1000 to
3500 mm/min. This perhaps is due to the influence of spindle weight. To maintain the low feedrate,
the current must be increased to overcome the impact of spindle weight. When the feedrate is over
3500 mm/min, the power consumption increases with the increasing rate of 0.002 kW per 500
mm/min. As seen in Figure 8, the feedrate range of 1000 to 3500 mm/min provided lower power
 Figure 7. Relationship between Y-axis motor (up direction) feedrate vs. power consumption w/o
cutting load.
Appl. Sci. 2019, 9, 1495 10 of 20

Figure 8 shows the power consumption of Y-axis motor downward direction. It is seen the power
consumption at a feedrate of 200 mm/min and 500 mm/min is greater than the feedrate of 1000 to
3500 mm/min. This perhaps is due to the influence of spindle weight. To maintain the low feedrate,
3500 mm/min. This perhaps is due to the influence of spindle weight. To maintain the low feedrate,
the current must be increased to overcome the impact of spindle weight. When the feedrate is over
the current must be increased to overcome the impact of spindle weight. When the feedrate is over
3500 mm/min, the power consumption increases with the increasing rate of 0.002 kW per 500 mm/min.
3500 mm/min, the power consumption increases with the increasing rate of 0.002 kW per 500
As seen in Figure 8, the feedrate range of 1000 to 3500 mm/min provided lower power consumption
mm/min. As seen in Figure 8, the feedrate range of 1000 to 3500 mm/min provided lower power
without loss of machining efficiency, so this feedrate range can be considered for machining. Compare
consumption without loss of machining efficiency, so this feedrate range can be considered for
to up direction power consumption, the down direction power consumption is lower. This is because
machining. Compare to up direction power consumption, the down direction power consumption is
more power is needed to overcome spindle weight during toward up.
lower. This is because more power is needed to overcome spindle weight during toward up.

Figure 8. Relationship between Y-axis motor (down direction) feedrate vs. power consumption w/o
cutting load.

Figure 9 shows the average calculation of Y-axis up direction power consumption, then the
regression equation can be obtained as follows: Equation (6) for a feedrate of 500 to 1500 mm/min,
Equation (7) for a feedrate of 1500 to 2000 mm/min, and Equation (8) for a feedrate of 2000 to
6000 mm/min.
y = −0.0015x2 + 0.0048x + 0.0053 (6)

y = 0.0046x + 0.0017 (7)

y = −0.0001x3 + 0.0016x2 − 0.0058x + 0.0155 (8)

Figure 10 shows the average calculation of Y-axis down direction power consumption, and the
regression equation can be obtained as follows: Equation (9) for a feedrate of 500 to 3500 mm/min,
and Equation (10) for a feedrate of 3500 to 6000 mm/min.

y = 0.0001x2 − 0.0009 + 0.0044 (9)

y = 0.0003x3 − 0.0038x2 + 0.0145 − 0.0087 (10)

Regarding Z-axis servo motor, the experiment parameters are similar to X- and Y-axis, 13 parameter
combination feedrates from 200 mm/min up to 6000 mm/min with increasing step 500 mm/min.
Figure 11 shows the experiment results for different feedrates. As seen, the results are mostly
reproducible. Only a few of the data have a 0.005 kW difference, such as at the feedrate of 5500
the difference is 0.012 kW. As seen in Figure 11, the power consumption rate at a feedrate of 200 to
1500 mm/min is 0.001 kW per 500 mm/min, but at a feedrate of 2000 mm/min the power consumption
Appl. Sci. 2019, 9, x FOR PEER REVIEW 11 of 21

Figure 8. Relationship between Y-axis motor (down direction) feedrate vs. power consumption w/o
cutting load.
Appl. Sci. 2019, 9, 1495 11 of 20
Figure 9 shows the average calculation of Y-axis up direction power consumption, then the
regression equation can be obtained as follows: Equation (6) for a feedrate of 500 to 1500 mm/min,
Equation
is (7) When
decreased. for a feedrate of 1500
the feedrate to is
range 2000
2500mm/min, and Equation
to 3500 mm/min, (8) forconsumption
the power a feedrate ofrate
2000 to 6000
increases
mm/min.
about 0.002 kW per 500 mm/min. When the feedrate is 4000 mm/min and 4500 mm/min, the power
consumption is reduced, but at a feedrate range of 4500 to 6000 mm/min the power consumption rate
y = −0.0015𝑥 + 0.0048𝑥 + 0.0053 (6)
increase is about 0.003 kW per 500 mm/min. It can be seen that the overall power consumption tends to
increase with the increasing feedrate, buty =at0.0046𝑥
a feedrate of 2000 mm/min, 2500 mm/min, 4000 mm/min,
+ 0.0017 (7)
and 4500 mm/min the power consumption is lower. These feedrates can be considered as the machining
parameter to obtain lower power consumption
𝑦 = −0.0001𝑥 without production
+ 0.0016𝑥 efficiency
− 0.0058𝑥 + 0.0155 loss. (8)

Appl. Sci. 2019, 9, x FOR PEER REVIEW 12 of 21

Figure 9. Curve of average Y-axis motor (up direction) feedrate vs. power consumption w/o cutting load.
Figure 9. Curve of average Y-axis motor (up direction) feedrate vs. power consumption w/o cutting
load.

Figure 10 shows the average calculation of Y-axis down direction power consumption, and the
regression equation can be obtained as follows: Equation (9) for a feedrate of 500 to 3500 mm/min,
and Equation (10) for a feedrate of 3500 to 6000 mm/min.
𝑦 = 0.0001𝑥 − 0.0009 + 0.0044 (9)

𝑦 = 0.0003𝑥 − 0.0038𝑥 + 0.0145 − 0.0087 (10)

Figure 10. Curve of average Y-axis motor (down direction) feedrate vs. power consumption w/o
Figure 10. Curve of average Y-axis motor (down direction) feedrate vs. power consumption w/o
cutting load.
cutting load.

Regarding Z-axis servo motor, the experiment parameters are similar to X- and Y-axis, 13
parameter combination feedrates from 200 mm/min up to 6000 mm/min with increasing step 500
mm/min. Figure 11 shows the experiment results for different feedrates. As seen, the results are
mostly reproducible. Only a few of the data have a 0.005 kW difference, such as at the feedrate of
5500 the difference is 0.012 kW. As seen in Figure 11, the power consumption rate at a feedrate of 200
to 1500 mm/min is 0.001 kW per 500 mm/min, but at a feedrate of 2000 mm/min the power
consumption is decreased. When the feedrate range is 2500 to 3500 mm/min, the power consumption
rate increases about 0.002 kW per 500 mm/min. When the feedrate is 4000 mm/min and 4500 mm/min,
the power consumption is reduced, but at a feedrate range of 4500 to 6000 mm/min the power
consumption rate increase is about 0.003 kW per 500 mm/min. It can be seen that the overall power
consumption tends to increase with the increasing feedrate, but at a feedrate of 2000 mm/min, 2500
mm/min, 4000 mm/min, and 4500 mm/min the power consumption is lower. These feedrates can be
the power consumption is reduced, but at a feedrate range of 4500 to 6000 mm/min the power
consumption rate increase is about 0.003 kW per 500 mm/min. It can be seen that the overall power
consumption tends to increase with the increasing feedrate, but at a feedrate of 2000 mm/min, 2500
mm/min, 4000 mm/min, and 4500 mm/min the power consumption is lower. These feedrates can be
Appl. Sci. 2019, as
considered 9, 1495 12 of 20
the machining parameter to obtain lower power consumption without production
efficiency loss.

Figure 11. Relationship between Z-axis motor feedrate vs. power consumption w/o cutting load.
Appl. Sci.Figure
2019, 9,11.
x FOR PEER REVIEW
Relationship between Z-axis motor feedrate vs. power consumption w/o cutting load. 13 of 21
Since the power consumption at a feedrate of 5500 mm/min has a larger difference, it will be
Since the power consumption at a feedrate of 5500 mm/min has a larger difference, it will be
excluded from the average calculation analysis. Figure 12 shows the average calculation result, and
excluded from the average calculation analysis. Figure 12 shows the average calculation result, and
the regression equation of each section can be obtained as follow: Equation (11) for a feedrate of 500
the regression equation of each section can be obtained as follow: Equation (11) for a feedrate of 500
mm/min to 2000mm/min, Equation (12) for a feedrate of 2000 to 4500 mm/min, Equation (13) for a
mm/min to 2000mm/min, Equation (12) for a feedrate of 2000 to 4500 mm/min, Equation (13) for a
feedrate of 4500 to 6000 mm/min.
feedrate of 4500 to 6000 mm/min.
0.0008x2 ++
y 𝑦==−−0.0008𝑥 0.0039𝑥
0.0039x ++ 0.0004
0.0004 (11)
(11)

0.0001x3 ++0.0014x
y𝑦==−−0.0001𝑥 2
0.0014𝑥− − 0.0014𝑥
0.0014x + 0.0034
+ 0.0034 (12)
(12)
y = −0.0003x2 + 0.0043x + 0.0024 (13)
𝑦 = −0.0003𝑥 + 0.0043𝑥 + 0.0024 (13)

Figure 12. Curve of average Z-axis motor feedrate vs. power consumption w/o cutting load.
Figure 12. Curve of average Z-axis motor feedrate vs. power consumption w/o cutting load.
As seen in Figure 12, when the feedrate is 500 mm/min, the power consumption is 0.004 kW.
As seen in Figure 12, when the feedrate is 500 mm/min, the power consumption is 0.004 kW. If
If the feedrate is increased to 1500 mm/min, the power consumption is 0.005 kW. When the feedrate
the feedrate is increased to 1500 mm/min, the power consumption is 0.005 kW. When the feedrate
increases to 3000 mm/min, the power consumption is 0.006 kW. If in the beginning, the machining
increases to 3000 mm/min, the power consumption is 0.006 kW. If in the beginning, the machining
used a feedrate of 500 mm/min, the power consumption is 0.004 kW per second, so for an hour
used a feedrate of 500 mm/min, the power consumption is 0.004 kW per second, so for an hour the
power consumption 0.004 kW/sec X 3,600 sec/hr = 14.4 kWh. When the machining feedrate is 1500
mm/min for which the machining efficiency increases three times, the power consumption is 0.005
kW/sec X 3,600 sec/hr = 18 kWh. When the machining feedrate is 3000 mm/min for which the
machining efficiency increase six times, the power consumption is 0.006 kW/sec X 3,600 sec/hr = 21.6
Appl. Sci. 2019, 9, 1495 13 of 20

the power consumption 0.004 kW/sec X 3,600 sec/hr = 14.4 kWh. When the machining feedrate is
1500 mm/min for which the machining efficiency increases three times, the power consumption is
0.005 kW/sec X 3,600 sec/hr = 18 kWh. When the machining feedrate is 3000 mm/min for which
the machining efficiency increase six times, the power consumption is 0.006 kW/sec X 3,600 sec/hr =
21.6 kWh. If we assume for a feedrate of 500 mm/min, the machining time needed is half an hour,
the power consumption is 0.5 hr X 14.4 kWh = 7.2 kWh. If we use the feedrate of 1500 mm/min,
the machining time needed is 10 min, then the power consumption is 3 kWh. Hence, compared to a
feedrate of 500 mm/min, the power saving is 4.2 kWh and also the machining time is three times faster.

4.2. Power Consumption Analysis with Cutting Load

Since the experiment under cutting condition was repeated five times for each parameter, the
average result will be used in the analysis. The result of experiment 1 is shown in Figure 13. The
power consumption trend of X-axis motor for different chip loads is seen. Under the same spindle
speed, a higher chip load (0.18 mm/t) did not consume higher power than the other two smaller chip
loads. For eight different spindle speeds, there are four power consumptions of the 0.18 mm/t chip
load smaller than the power consumption of the 0.15 mm/t chip load. Under the fixed spindle speed,
the feedrate determines the chip load. Similarly, to maintain the same chip load, the feedrate must
Appl. Sci. 2019, 9, x FOR PEER REVIEW 14 of 21
be proportional to the spindle speed. The chip load not only determines the spindle cutting load but
also influences
influences power power consumption.
consumption. TheThe results
results dodo not
not exhibitsignificant
exhibit significantaffection
affectionfor
for spindle
spindle power
power
consumption
consumption due due to
to the
the small
small difference
differenceof
of chip
chipload.
load.

Figure 13. X-axis motor power consumption vs. Spindle speed for experiment 1.
Figure 13. X-axis motor power consumption vs. Spindle speed for experiment 1.
In experiment 2, a larger interval of spindle speed was used to obtain a larger feedrate difference
In experiment
and observe the power 2, aconsumption
larger interval of spindle speed
characteristic of thewas usedservo
feedrate to obtain a larger
motor. feedrate
The power difference
consumption
and observe the power consumption characteristic of the feedrate servo motor.
results of experiment 2 are shown in Figure 14. It is seen, even when the spindle speed was increased The power
to 1000 to 2250 rpm with the maximum feedrate of 270 mm/min, the power consumption ofspeed
consumption results of experiment 2 are shown in Figure 14. It is seen, even when the spindle chip
was of
load increased
0.18 mm/t to is1000 to 2250
smaller rpm load
than chip withofthe
0.12maximum
mm/t andfeedrate
0.15 mm/t. of This
270 mm/min,
is perhapstheduepower
to the
consumption
width of cut 20ofmmchipwhich
load of
has0.18 mm/t80%
reached is smaller than
of cutter chip load
diameter thatofis0.12 mm/t as
classified and 0.15 mm/t.
heavy cutting,This is
thus,
perhaps due to the width of cut 20 mm which has reached 80% of cutter diameter
generating large cutting resistance. Hence, the motor power consumption is increased. In addition,that is classified as
heavythe
when cutting,
spindlethus,
speed generating
was 2250 large cutting
rpm and resistance.
the feedrate 1620Hence,
mm/min, the motor
a sparkpower consumption
was appearing during is
increased. In addition, when the spindle speed was 2250 rpm
the cutting process, so it is not appropriate to increase the feedrate. and the feedrate 1620 mm/min, a spark
was appearing during the cutting process, so it is not appropriate to increase the feedrate.
was increased to 1000 to 2250 rpm with the maximum feedrate of 270 mm/min, the power
consumption of chip load of 0.18 mm/t is smaller than chip load of 0.12 mm/t and 0.15 mm/t. This is
perhaps due to the width of cut 20 mm which has reached 80% of cutter diameter that is classified as
heavy cutting, thus, generating large cutting resistance. Hence, the motor power consumption is
increased.
Appl. In9,addition,
Sci. 2019, 1495 when the spindle speed was 2250 rpm and the feedrate 1620 mm/min, a14
spark
of 20
was appearing during the cutting process, so it is not appropriate to increase the feedrate.

Figure 14. X-axis motor power consumption vs. Spindle speed range of 1000 to 2250 rpm.
Figure 14. X-axis motor power consumption vs. Spindle speed range of 1000 to 2250 rpm.
4.3. Verification
4.3. Verification
4.3.1. Power Consumption without Cutting Load
Appl. Sci. 2019, 9, x FOR PEER REVIEW 15 of 21
4.3.1.To
Power
verifyConsumption
the effectivenesswithout
of theCutting
proposedLoad system, the electricity unit price and machining cost
(hourly-rate)
To verify weretheset as 2.5 NTD/degree
effectiveness and 25 NTD/hour,
of the proposed system, theand a 3-D straight
electricity line and
unit price machining trajectory
machining cost
from (X2000, Y1500, Z1500) to (Z-1500, Y-1500, X-2000) was planned. The
(hourly-rate) were set as 2.5 NTD/degree and 25 NTD/hour, and a 3-D straight line machining cutting path with the same
feedrate
trajectorywasfromrepeated
(X2000,twice.
Y1500, The original
Z1500) feedrateY-1500,
to (Z-1500, for machining 1000 mm/min,
X-2000) was planned. and expected
The cutting path withto
improve
the samefor 3-timeswas
feedrate faster. Based on
repeated those
twice. Theparameters, the system
original feedrate calculated was
for machining and 1000
recommend
mm/min, using
anda
feedrate
expected of 3000 mm/min
to improve foras3-times
shown in FigureBased
faster. 15. Because
on thosethe power consumption
parameters, the systemof three servo motors
calculated and
recommend
was quite small using of 3000ofmm/min
for a feedrate range as shown
1000 to 3000 mm/min in Figure 15. Because
(as shown the power
in Figure consumption
6, Figure 9, Figure 10,
of three
Figure 12),servo motors was
the electricity costquite small
(about onlyfor a feedrate
0.005 range less
kW) is much of 1000
thantothe3000 mm/mincost.
machining (as shown in
Therefore,
Figures
short 6, 9, 10, time
machining 12), the
willelectricity cost (about
be more dominant foronly
the 0.005
overall kW) is Meanwhile,
cost. much less than the machining
to remain the samecost.
chip
Therefore,
load, short speed
the rotation machining time will
of spindle was be more
also dominant
increased fromfor300the
rpmoverall cost.
to 9000 rpm.Meanwhile, to remain
the same chip load, the rotation speed of spindle was also increased from 300 rpm to 9000 rpm.

Figure 15.The
Figure15. Theproposed
proposedparameters
parameters information
information for w/o cuttingload.
w/o cutting load.

Power consumption amounts of the three axes servo motors with a feedrate of 1000 mm/min are
shown in Figures 16–18. In the figures, those with very low power consumption (almost zero)
represent that machine was moving at that time. The total machining time was about 20 min, the
power consumption of X-, Y-, and Z-axis motor were 2.396, 3.619, and 2.178 kW, respectively. The
Appl. Sci. 2019, 9, 1495 15 of 20

Figure 15. The proposed parameters information for w/o cutting load.
Power consumption amounts of the three axes servo motors with a feedrate of 1000 mm/min
Power
are shown in consumption amounts
Figures 16–18. In theoffigures,
the three axeswith
those servovery
motors
lowwith a feedrate
power of 1000 mm/min
consumption (almostare
zero)
shown in Figures 16–18. In the figures, those with very low power consumption (almost zero)
represent that machine was moving at that time. The total machining time was about 20 min, the
represent that machine was moving at that time. The total machining time was about 20 min, the
power consumption of X-, Y-, and Z-axis motor were 2.396, 3.619, and 2.178 kW, respectively. The
power consumption of X-, Y-, and Z-axis motor were 2.396, 3.619, and 2.178 kW, respectively. The
total power consumption was 8.193 kW, and the power consumption cost was about 20.4825 NTD.
total power consumption was 8.193 kW, and the power consumption cost was about 20.4825 NTD.
The machining cost for 20-minutes is about 83.333 NTD. By summing up the power consumption cost
The machining cost for 20-minutes is about 83.333 NTD. By summing up the power consumption
and machining cost, the total cost for this machining process was about 103.833 NTD.
cost and machining cost, the total cost for this machining process was about 103.833 NTD.

Appl. Sci. 2019, 9, x FOR PEER REVIEW 16 of 21

Appl. Sci. 2019, 9, x FOR PEER REVIEW 16 of 21

Figure 16. Power consumption data of X-axis with F1000.
Figure 16. Power consumption data of X-axis with F1000.
Figure 16. Power consumption data of X-axis with F1000.

Figure 17. Power consumption data of Y-axis with F1000.

Figure 17. Power consumption data of Y-axis with F1000.
Figure 17. Power consumption data of Y-axis with F1000.

Figure 18. Power consumption data of Z-axis with F1000.

Figure 18. Power consumption data of Z-axis with F1000.
Figure 18. Power consumption data of Z-axis with F1000.
For a feedrate of 3000 mm/min, the power consumption amounts of the three axes servo motors
are shown in Figures
For a feedrate 19–21.
of 3000 The total
mm/min, machining
the power time was
consumption aboutof6.667
amounts min,axes
the three andservo
the motors
power
consumption
are shown in Figures 19–21. The total machining time was about 6.667 min, and the power
of X-, Y-, and Z-axis were 0.7023, 1.5982, and 1.0192 kW, respectively. The total power
Appl. Sci. 2019, 9, 1495 16 of 20

For a feedrate of 3000 mm/min, the power consumption amounts of the three axes servo motors
are shown in Figures 19–21. The total machining time was about 6.667 min, and the power consumption
of Appl.
X-, Y-,
Sci.and
2019, Z-axis
9, x FORwere 0.7023, 1.5982, and 1.0192 kW, respectively. The total power consumption
PEER REVIEW 17 of 21
was about 3.32 kW, and the cost of the power consumption was 8.3 NTD. For 6.67 min, the machining
Appl. Sci. 2019, 9, x FOR PEER REVIEW 17 of 21
cost was about 27.778 NTD. By summing up the power consumption cost and machining cost, the total
Appl. Sci. 2019, 9, x FOR PEER REVIEW 17 of 21
cost for this machining process was about 36.078 NTD.

Figure 19. Power consumption data of X-axis with F3000.

Figure 19. Power consumption data of X-axis with F3000.
Figure 19. Power consumption data of X-axis with F3000.
Figure 19. Power consumption data of X-axis with F3000.

Figure 20. Power consumption data of Y-axis with F3000.

Figure 20. Power consumption data of Y-axis with F3000.
Figure 20. Power consumption data of Y-axis with F3000.
Figure 20. Power consumption data of Y-axis with F3000.

Figure 21. Power consumption data of Z-axis with F3000.

Figure 21. Power consumption data of Z-axis with F3000.
Figure 21. Power consumption data of Z-axis with F3000.
The comparison of power consumption between actual measured data and the estimated
calculation Figure3.21.
is shown inofTable Power
can beconsumptionthedata of Z-axis with F3000.
The comparison powerItconsumptionseen that
betweenactual power
actual cost
measured is 2data
to 3 NTD (or equivalent
and the estimated
calculation is shown inof
The comparison Table 3. It consumption
power can be seen that the actual
between power
actual cost is 2 data
measured to 3 NTD
and (or
the equivalent
estimated
Appl. Sci. 2019, 9, 1495 17 of 20

The comparison of power consumption between actual measured data and the estimated
calculation is shown in Table 3. It can be seen that the actual power cost is 2 to 3 NTD (or equivalent to 1
to 2 kWH) higher than the estimated calculation. Due to the error between the generated characteristic
curves and the actual values of the three axes servo motors, it is quite acceptable. It was also noted that
the generated characteristic curves had good agreement with the actual measured values (difference
between the actual values and the estimated values were only about 0.1 kWH).

Table 3. Actual and estimated comparison for power consumption without cutting load.

Information Power Costs Machining Costs Total Costs

Processing Source (NTD) (NTD) (NTD)
Calculated by program (F1000) 17.85 83.333 101.183
Calculated with measured data (F1000) 20.482 83.333 103.833
Calculated by program (F3000) 8.3 27.778 36.078
Calculated with measured data (F3000) 8.3 27.778 36.078

As it was noted, when the feedrate was adjusted from 1000 mm/min to 3000 mm/min, the total
power consumption cost was reduced from 21 NTD to 8.5 NTD, and the machining cost decreased
from 83.3 NTD to 27.8 NTD; the total cost was lowered to 36.3 NTD from 104.4 NTD as well. It proved
that when feedrate increased, the motor power consumption may also increase. However, if the
machining time can be significantly shortened, then the total power consumption cost will still be
significantly reduced.

4.3.2. Power Consumption with Cutting Load

The condition used for verification was assumed as electricity fee is 2.5 NTD/degree and the
machine cost is 250 NTD/hour. For machining, a 4-mm depth of cut, and 5-mm width of cut, and
25-mm diameter end mill were used for machining iron. The original spindle speed and feedrate were
1000 rpm and 600 mm/min, respectively, the expected improvement of feedrate was at least 1.5 times
faster. A straight line machining trajectory from (X565, Y-120,), (X-560, Y115,) was planned. The cutting
path was repeated six times, and the total cutting length was 7560 mm. The system analyzed for the
optimal feedrate according to motor power consumption characteristics curves. A feedrate of 1035
Appl.
mm/minSci. 2019,
was 9, xfinally
FOR PEER REVIEW
chosen as the optimal value for the process (as shown in Figure 22). 19 of 21

Figure 22. The proposed parameters information for w/cutting load.

Figure 22. The proposed parameters information for w/ cutting load.
Appl. Sci. 2019, 9, 1495 18 of 20

When a feedrate of 600 mm/min was used, the total machining time was about 12.6 min, and the
total power consumption was about 12.663 kW. After converting, the power consumption cost was
about 31.657 NTD, the machining cost was about 52.5 NTD, and total cost became 84.157 NTD. When
the recommended feedrate of 1035 mm/min was used, the total machining time reduced to 7.3 min,
the total power consumption was about 5.5056 kW. After converting, the power consumption cost was
about 13.764 NTD, and the machining cost is 30.42 NTD. By summing up power consumption cost
and machining cost, the total cost for this process was about 44.184 NTD. Figure 23 shows the power
consumption data for using 600-mm/min feedrate. The X-axis actual measured power consumption
Figure
was 8.485 kW (blue line), 22. the
and The Y-axis
proposed parameters
actual information
measured power for w/ cutting load.
consumption was 4.178 kW (red line).

Figure Actual
23.23.
Figure Actualpower
powerconsumption
consumption with
with cutting load using
cutting load using600-mm/min
600-mm/min feedrate.
feedrate.

When a 1035-mm/min feedrate was used, the X-axis actual power consumption (measured) was
4.543 kW (blue line in Figure 24), and the Y-axis actual power consumption (measured) was 0.9626 kW
Appl.
(red lineSci.in
2019, 9, x FOR
Figure 24).PEER REVIEW 20 of 21

Figure 24. Actual Power consumption with cutting load using 1035-mm/min feedrate.
Figure 24. Actual Power consumption with cutting load using 1035-mm/min feedrate.

The comparison of actual measurement and estimated calculation of power consumption is shown
The comparison of actual measurement and estimated calculation of power consumption is
in Table 4. It was noted that the estimated power consumption in X-axis and Y-axis were smaller
shown in Table 4. It was noted that the estimated power consumption in X-axis and Y-axis were
than the actual measured data. For a feedrate of 600 mm/min, the actual total power consumption
smaller than the actual measured data. For a feedrate of 600 mm/min, the actual total power
consumption for X-axis (3.325 kW) was higher than the estimate, also the Y-axis (1.226 kW) was
higher than the estimated calculation value. For a 1035-mm/min feedrate, the actual total power
consumption for X-axis (3.047 kW) was higher than the estimated value. In addition, the actual total
power consumption of Y-axis (0.5809 kW) was higher than the estimated calculation value. The actual
power consumption was higher than the estimation calculated by characteristics curves which may
Appl. Sci. 2019, 9, 1495 19 of 20

for X-axis (3.325 kW) was higher than the estimate, also the Y-axis (1.226 kW) was higher than the
estimated calculation value. For a 1035-mm/min feedrate, the actual total power consumption for
X-axis (3.047 kW) was higher than the estimated value. In addition, the actual total power consumption
of Y-axis (0.5809 kW) was higher than the estimated calculation value. The actual power consumption
was higher than the estimation calculated by characteristics curves which may be because of the
24 starts and stops of the machine for each machining experiment due to repeating the machining
process for six times. More energy was consumed for the machine starts and stops. In general, the
recommended optimal parameters by the system could improve the machining efficiency and reduce
the total power consumption cost. As it can be seen in Table 4, when the feedrate was adjusted
from 600 mm/min to 1035 mm/min, the power consumption cost was reduced from 31.657 NTD to
13.764 NTD, and the total machining time also dropped from 12.6 min to 7.3 min. It proves that when
the feedrate increase, even if the power consumption of each motor not always decreased, the save
of machining time could reduce the total power consumption cost for synchronously improving the
machining efficiency and power consumption.

Table 4. Actual and estimated comparison for power consumption with cutting load.

Information X-axis Total Power Y-axis Total Power Power Costs

Processing Source Consumption (kW) Consumption (kW) (NTD)
Calculated by program (F600) 5.16 2.952 20.28
Calculated with measured data (F600) 8.485 4.178 31.657
Calculated by program (F1035) 1.496 0.382 4.691
Calculated with measured data (F1035) 4.543 0.963 13.764

5. Conclusions
In this paper, an accuracy-efficiency-power consumption hybrid optimization method was
established. The relationship between motor speed and power consumption with and without cutting
load was created. The synchronous optimization algorithm was developed based on these relationship
models. This study used motor-power consumption characteristic to develop optimization models
and algorithm. According to the models and algorithm, an accuracy-efficiency-power consumption
synchronous optimization system with a procedure-guided HMI was developed. Results of verification
experiments showed that the system can help to select the optimal parameters for better machining
efficiency and power consumption without losing machining accuracy.

Author Contributions: Conceptualization, S.-M.W.; methodology, S.-M.W. and C.-Y.L.; software, C.-Y.L.;
validation, C.-Y.L. and C.-C.Y.; formal analysis, C.-Y.L. and H.G.; investigation, C.-Y.L. and S.-M.W.; resources,
C.-Y.L. and C.-C.Y.; data curation, C.-Y.L.; writing, H.G. and S.-M.W.
Acknowledgments: This study was supported by Ministry of Science and Technology Taiwan under the grant
number MOST 107-2221-E-033-066 and MOST 108-2634-F-033-001.
Conflicts of Interest: The authors declare no conflict of interest.

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