Post on 24-Dec-2015
A New Framework Method for Describing & Modeling Machine Tools Energy Con
sumption
Shang Zhendong
Harbin Institute of Technology
International Conference on Sustainable Manufacturing
Outline
2
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
Outline
3
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
Brief introduction to Harbin Institute of Technology (HIT)
4
Found in 1920 because of Middle East Railway.
3 campus: Harbin Campus, Weihai Campus and Shenzhen Graduate School.
School motto: Strict Standard and Sufficient Effort.( 规格严格 功夫到家 )
21 schools/departments, about 43,000 full-time students
Brief introduction to my tutor: Prof. Gao Dong
5
His current research interests include
Cutting Theory of Difficult to Process Materials
Error Compensation Technology of Machine Tool
Sustainable Manufacturing
Personal homepage: http://homepage.hit.edu.cn/pages/gaodong/1
Outline
6
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
Brief introduction to our project
Development of the Green Manufacturing Assessment Tool and Its Database for Machine Tool and Construction Machinery
Supported by the National High Technology Research and Development Program of China. ("863"Program , 2014AA041503)
The project is undertaken by the following entities:
Harbin Institute of Technology
Shandong University
Tsinghua University
Qiqihar No.2 Machine Tool Group Co., Ltd.
Shantui Construction Machinery Co.,Ltd.
Began in 2014, and no results being obtained now.7
Brief introduction to our project
Development of ERWC (Energy, Resource, Waste, Carbon) model
Energy consumption monitoring system based on motion control of machine tool
Energy and carbon emissions analysis of typical machining process
Green manufacturing assessment and optimization based on carbon emissions indicators
Development of green manufacturing assessment tool
8
Main Research Task
Green M
anufacturing Assessment Tool
5Database of
Cutting Energy
Model of Energy Consumption and Carbon
Emissions
Energy and Carbon Analysis of typical machining process
Datebase of
Carbon Emission
Database of Energy Consump
tion
Green Manufacturing Assessment based on Carbon Emissions Indicators
1
4
Energy Consumption Model based on motion
control and its monitoring for machine tool
2
3
Energy labelHigh
Low
ERWCModel
Outline
9
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
Background & literature review
ENERGY, RESOURCE & ENVIRONMENT
PROBLEM has become the bottleneck
problem of economic development & social
progress
Lots of GREEN MANUFACTURING research
has been implemented by both developed
and developing countries, along with the
enactment of more and more rigorous
environment laws
Energy saving has become an important task
in manufacturing, especially in machine
tools areas due to the great energy
conserve potential , with the widely use of
them.
Background of research
<30%>50%
Background & literature review
Why energy consumption describing and modelling are needed?
Supervisor: we need tools to assess MTs EC level
Designer: we want to find the MTs EC hotspots
User: how to use MTs energy effectively
What aspects should be reflected?The overall level of energy consumption
Energy consumption of the machine parts/subsystems
MTs energy consumption characteristics and its prediction during use.
Research requirement
The first step
Background & literature review
Based on operation EC and machining EC
Based on EC of MTs subsystem/parts
Based on EC profiles of discrete machine event
Based on motion control
12
Shao, 2004
Behrendt, 2012
Zeina, 2012
Jia Shun, 2014
Classify the existing research into 4 categories according to their technical characteristics
EC model based on operation EC and machining EC
• Tool tip energy
• Operational energy
13
Behrendt, 2012
Ecutting=∫Pcutting dt=∫ FcuttingV c dt
Ecutting=SEC×MRV
Theoretical Experimental
Definition Experiment
? ?
Average EC Difficult to use Expensive
Provides convenient for qualitative analysis. Tool tip EC accounts for very small part in
total Limited guidance for optimizing MTs design Limited guidance for energy saving
operation Not suitable for EC level assessment of MTs
EC model based on EC of MTs subsystem / parts
Subsystem Parts Function
Spindle drives Main spindle motor Besides rotary motion, holds as well as centers work piece
Rotary tool spindle
motor
Rotary motion for cutting tool
Servo drives i-axis motor Linear motion for cutting tool towards i-axis
Tailstock motor Besides rotary motion, holds as well as centers work piece at
tailstock
Turret motor Rotary motion for cutting tool change
Hydraulic
system
Hydraulic unit motor Rotary motion for pump to supply clamping pressure
Cooling and
lubrication
system
Lubricant pump motor Rotary motion for pump to supply lubricant
Oil cooler pump motor Rotary motion for pump to supply oil cooler circuit
Control system Spindle amplifier /
Frequency converter
Transfer numerical control signal for spindle rotation speed into
adjusted electrical signal
Servo amplifier /
Frequency converter
Transfer numerical control signal for servo feed into adjusted
electrical signal
Auxiliary
system
Computer and display Processing and visualization of program
Lighting Lightning the work area
Fan Air flow generation for cooling electrical components
Periphery
system
coolant pump motor Rotary motion for pump for supply coolant circuit with pressure
Chip conveyer motor Rotary motion for chip conveyer
Tool change arm
motor
Rotary motion for tool change
Li Wen, 2011;
胡韶华 ,2012
Shao, 2004
Describe the input energy distribution clearly, which is helpful to MTs designer to find EC hotspot
Reflect MTs EC characteristics comprehensively
Doesn’t consider the using profile of MTs and obtained the average EC value estimation rather than the actual value
Insufficient guidance for MTs users.
EC model based on EC of MTs subsystem / parts
Zeina, 2012Tao, 2013
Tao, 2013
Give full consideration to the use of the MTs Provide designers and users with greater generality and flexibility in
MTs EC assessment Ignore MTs dynamic, which may have significant effect on MTs EC
EC model based on EC profiles of discrete machine event
EC model based on motion control
Motion
type
Motion Symbol Function
Basic Basic
Movement
BM State in which machine tool is ready but do
nothing
Auxiliary Cutting Fluid
spraying
CFS Motion for spraying cutting fluid to cutting
area
Automatic
Tool Changing
ATC Motion for cutting tool change
Air
cutting
Spindle
Rotation
SR Rotary motion of spindle in the specific speed
Spindle
Rotation
Acceleration /
Deceleration
SPA/D Rotary motion of spindle with rotary speed
increase/decrease
Feeding FD Motion of feeding axis according interpolation
instruction
Rapid Feeding RF Motion of feeding axis to position in the
maximum speed
Cutting Material
Removal
MR Motion of tool contact and remove the
material
呂景祥 , 2014
EC model based on motion control
Lay the solid foundations for estimating
the EC of machining process Has been validated on two CNC lathes The feasibility for other types of MTs
and machining processes still need to
be tested. Too much movement defined
Jia Shun,
2013
Outline
19
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
A new framework method for describing and modeling machine tools energy consumption
System boundaryDefinitions & assumptionsFramework methodExperiment verify ( next step work )
System boundary
BaseSpindle
sys.Feed sys.
Electrical energy
Compressed air
Tools , cutting fluid & lubricant
Air exchange
Contaminated cutting fluid
Hydraulic sys
LightingAir
conditioner
Coolant sys.
... Worn toolsRaw materials
Machine Tool
Definitions5 basic movements
Machine tool event Any operation or command can cause the MT states change, including on/off operation of MT power, lighting system, air-conditioning system, etc, execution of specific G/M codes, and so on.
Movement Symbol Description
Spindle
Rotation
SR Rotary motion of spindle, include steady state,
accelerate process and decrease process
Feed FX, FY, FZ, Fa,
Fb
Motion of feeding axis
Rapid Feed RFX, RFY,
RFZ, RFa, RFb
Motion of feeding axis to position in the
maximum speed
Material
Removal
MR Motion of tools contact and remove materials
Tool
Change
TC Motion of tool change
Assumptions/FactsMTs are in certain state at anytime
the states here include but not limited to on/off states of MTs parts/subsystems, choice of tools, motion condition, material remove rate.
EC of some parts/subsystems are constant, and can be seen as on/off variable the EC of these parts are determined by the on/off state
of themselves and has no attachment with other partsthese parts include cooling sys., lighting sys., lubricant
sys., fans, operation panel, control units, chip conveyor unit, signal sys., etc.
Assumptions/FactsVariable EC is caused by MT motion, and each
motion corresponds to one specific EC profileMotion control based model
MTs current state is determined by the former state and machine events-->events flowEvents driving based model
Machining process consists of a series of state --> states flowFeature based prediction
Framework method
CoolingLightingLubricantFansOperation panelControl unitsChip conveyor unitSignal sys...
SRFX, FY, FZ, Fa, FbRFX, RFY, RFZ, RFa, RFbMRTC
MRR1# tool 2# tool
ON/OFF state of power constant parts/subsys
Motion state of MTs
Cutting state of MTs
Former state of MTs
CoolingLightingLubricantFansOperation panelControl unitsChip conveyor unitSignal sys...
SRFX, FY, FZ, Fa, FbRFX, RFY, RFZ, RFa, RFbMRTC
MRR1# tool 2# tool
ON/OFF state of power constant parts/subsys
Motion state of MTs
Cutting state of MTs
Current state of MTs
Events flowPower on/off of MTs
Power on/off of power constant parts/subsys
Execution of G/M codes
...Clamping state variable
Fixed EC
Variable EC
Database
Motion energyCutting energyTime identifying
Experiment verify hasn’t been done
• The method montened above can reflect MTs EC characteristics comprehensively and precisely in theory• But experiments are still expected to verify the idea.
Outline
27
Brief introduction to HIT & my tutor
Brief introduction to our project
Background & literature review
A new framework method for describing and modeling machine tools energy consumption
Full framework of my work
Full framework of my work
Supervisor
Designer
User
Energy efficiency
High
Low
Time Precision Lubricate Energy Carbon
q Key impact factors and their characteristicsq Orthogonal experimentq Most energy saving machining condition
q Power information collection
q State information collection
Standard test workpiece
Standard NC Programe
Test standard
Data process procedure
EC test report
Thanks for your attention!
Shang ZhendongHarbin Institute of TechnologyEmail: ShangZD@hit.edu.cnTEL: +86 151 0457 2076