a new framework method for describing & modeling machine tools energy consumption shang zhendong...

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 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

http://homepage.hit.edu.cn/pages/gaodong/1

http://homepage.hit.edu.cn/pages/gaodong/1

Outline

6







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


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







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%


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


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







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







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: [email protected]: +86 151 0457 2076

a new framework method for describing & modeling machine tools energy consumption shang zhendong...

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