Simulation of Energy Consumption During Machine Tool Operations Based on NC Data
Akio Hayashi, Fumiya Arai, and Yoshitaka Morimoto
Kanazawa Institute of Technology
7-1 Ohgigaoka Nonoichi, Ishikawa 924-8501, Japan
Recently, measures to address environmental problems and resource problems have been strongly desired. Consequently, the energy saving of machine tools has been promoted at production sites. Thus, the efficiencies of motors and coolants have been improved for the energy saving of machine tools. However, replacing machines and peripherals is time-consuming and expensive. Therefore, we focused on the power consumption by the feed drive system and spindle of a machine tool during machining. Considering of the energy conservation in the feed drive system and spindle is practical and effective to existing machine tools. In this study, we propose the simulator that calculates the energy consumption of the feed drive system and spindle using the NC program. It is possible to calculate the energy consumption without actual machining and measuring. Using the simulation result, we can change the tool path and machining conditions, leading to a reduction in machining power consumption. This study devised a method for calculating the power consumption of the feed drive system using the NC program using only the reference power consumption of the machine tool. Then, the measured and simulated power consumptions for machining were compared to verify the validity of the proposed method.
-  A. Vijayaraghavan and D. Dornfeld, “Automated energy monitoring of machine tools,” CIRP Annals – Manufacturing Technology, Vol.59, No.1, pp. 21-24, 2010.
-  H. Murata, N. Yokono, S. Fukushige, and H. Kobayashi, “A Lifecycle Simulation Method for Global Reuse,” Int. J. Automation Technol., Vol.12, No.6, pp. 814-821, 2018.
-  K. Ishizaki and M. Nakano, “Forecasting Life Cycle CO2 Emissions of Electrified Vehicles by 2030 Considering Japan’s Energy Mix,” Int. J. Automation Technol., Vol.12, No.6, pp. 806-813, 2018.
-  H. Narita, “A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2 Emissions and Machining Costs in Determining Cutting Conditions,” Int. J. Automation Technol., Vol.9, No.2, pp. 115-121, 2015.
-  C. Herrman, S. Thiede, S. Kara, and J. Hesselbach, “Energy oriented simulation of manufacturing systems – Concept and application,” CIRP Annals – Manufacturing Technology, Vol.60, No.1, pp. 45-48, 2011.
-  S. Rahimifard, Y. Seow, and T. Childs, “Minimising Embodied Product Energy to support energy efficient manufacturing,” CIRP Annals – Manufacturing Technology, Vol.59, No.1, pp. 25-28, 2010.
-  E. O’Driscoll, D. O. Cusack, and G. E. O’Donnell, “The Characterisation of Energy Consumption in Manufacturing Facilities – A Hierarchical Approach,” Int. J. Automation Technol., Vol.7, No.6, pp. 727-734, 2013.
-  T. Samukawa and H. Suwa, “An Optimization of Energy-Efficiency in Machining Manufacturing Systems Based on a Framework of Multi-mode RCPSP,” Int. J. Automation Technol., Vol.10, No.6, pp. 985-992, 2016.
-  M. Nakaminami, T. Tokuma, K. Matsumoto, S. Sakashita, T. Moriwaki, and K. Nakamoto, “Optimal Structure Design Methodology for Compound Multiaxis Machine Tools-III – Performance Evaluation –,” Int. J. Automation Technol., Vol.2, No.1, pp. 71-77, 2008.
-  T. Ogawa, “Building of Efficient, Energy-Saving Lines with an Extremely-Compact Machining Center and CNC Lathe,” Int. J. Automation Technol., Vol.4, No.2, pp. 150-154, 2010.
-  M. Mori, M. Fujishima, Y. Inamasu, and Y. Oda, “A study on energy efficiency improvement for machine tools,” CIRP Annals – Manufacturing Technology, Vol.60, No.1, pp. 145-148, 2011.
-  R. Neugebauer, M. Wabner, H. Rentzsch, and S. Ihlenfeldt, “Structure principles of energy efficient machine tools,” CIRP J. of Manufacturing Science and Technology, Vol.4, No.2, pp. 136-147, 2011.
-  K. Sugimura and K. Suzuki, “Using Intermittently Operated Oil Hydraulic Pump Unit with Accumulator to Save Energy,” Int. J. Automation Technol., Vol.6, No.4, pp. 426-433, 2012.
-  N. Uchiyama, Y. Ogawa, and S. Sano, “Energy saving for gantry-type feed drives by synchronous and contouring control,” Int. J. Automation Technol., Vol.6, No.3, pp. 363-368, 2012.
-  Y. Oda, M. Fujishima, and Y. Takeuchi, “Energy-Saving Machining of Multi-Functional Machine Tools,” Int. J. Automation Technol., Vol.9, No.2, pp. 135-142, 2015.
-  H. Ohtani, “Development of Energy-Saving Machine Tool,” Int. J. Automation Technol., Vol.11, No.4, pp. 608-614, 2017.
-  M. Fujishima, H. Shimanoe, and M. Mori, “Reducing the Energy Consumption of Machine Tools,” Int. J. Automation Technol., Vol.11, No.4, pp. 601-607, 2017.
-  A. Ogawa, A. H. Pandyaswargo, D. Yoshidome, and H. Onoda, “Environmental and Economic Evaluation of a Mechanical Biological Treatment System for a Small and Medium-Sized Waste Treatment Facility Considering the Karatsu Smart Disaster-Resilience Base Construction Project,” Int. J. Automation Technol., Vol.14, No.6, pp. 984-998, 2020.
-  T. Samukawa, K. Shimomoto, and H. Suwa, “Estimation of In-Process Power Consumption in Face Milling by Specific Energy Consumption Models,” Int. J. Automation Technol., Vol.14, No.6, pp. 951-958, 2020.
-  T. Schudeleit, S. Züst, L. Weiss, and K. Wegener, “Machine Tool Energy Efficiency – A Component Mapping-Based Approach,” Int. J. Automation Technol., Vol.10, No.5, pp. 717-726, 2016.
-  O. L. Avram and P. Xirouchakis, “Evaluating the use phase energy requirements of a machine tool system,” J. of Creaner Production, Vol.19, No.6-7, pp. 699-711, 2011.
-  U. Götze, H.-J. Koriath, A. Kolesnikov, R. Lindner, and J. Paetzold, “Integrated methodology for the evaluation of the energy- and cost-effectiveness of machine tools,” CIRP J. of Manufacturing Science and Technology, Vol.5, No.3, pp. 151-163, 2012.
-  F. Draganescu, M. Gheorghe, and C. V. Doicin, “Models of machine tool efficiency and specific consumed energy,” J. of Materials Processing Technology, Vol.141, No.1, pp. 9-15, 2003.
-  N. Diaz, K. Ninomiya, J. Noble, and D. Dornfeld, “Environmental impact characterization of milling and implications for potential energy savings in industry,” Procedia CIRP, Vol.1, pp. 518-523, 2012.
-  L. Hu, C. Peng, S. Evans, T. Peng, Y. Liu, R. Tang, and A. Tiwari, “Minimising the machining energy consumption of a machine tool by sequencing the features of a part,” Energy, Vol.121, pp. 292-305, 2017.
-  A. Hayashi, R. Iwase, R. Sato, and K. Shirase, “Measurement and Simulation of Energy Consumption of Feed Drive Systems,” J. of Mechanics Engineering and Automation, Vol.4, No.3, pp. 203-212, 2014.
-  R. Sato, K. Shirase, and A. Hayashi, “Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-Axis Machining Center,” J. of Manufacturing Science and Engineering, Vol.140, No.2, Article 021008, 2018.
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 International License.