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Research Papers

A Simplified Machine-Tool Power-Consumption Measurement Procedure and Methodology for Estimating Total Energy Consumption

[+] Author and Article Information
Jang-Yeob Lee

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Leejjang123@snu.ac.kr

Yong-Jun Shin

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Shinyj007@gmail.com

Min-Soo Kim

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Kim.minsoo0330@gmail.com

Eun-Seob Kim

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Eskim8710@gmail.com

Hae-Sung Yoon

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Hsyoon7@snu.ac.kr

Sung-Yong Kim

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: Syk15402@gmail.com

Yeo-Chan Yoon

Mem. ASME
Hyundai WIA Co., Ltd.,
Uwang, Republic of Korea;
S/W Research Team,
Hyundai Motors Research Center,
Samdong, Uiwang 437-040, Korea
e-mail: ycyoon@hyundai-wia.com

Sung-Hoon Ahn

Mem. ASME
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1205, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mail: ahnsh@snu.ac.kr

Sangkee Min

Mem. ASME
Department of Mechanical Engineering,
University of Wisconsin-Madison,
1039 Engineering Hall,
1513 University Avenue,
Madison, WI 53706;
School of Mechanical and
Aerospace Engineering,
Institute of Advanced Machinery and Design,
Seoul National University,
Building 301, Room 1405, Gwanak-Ro 1,
Gwanak-Gu, Seoul 151-744, Korea
e-mails: sangkee.min@wisc.edu; smin@lbl.gov

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 9, 2015; final manuscript received September 1, 2015; published online November 16, 2015. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 138(5), 051004 (Nov 16, 2015) (9 pages) Paper No: MANU-15-1281; doi: 10.1115/1.4031713 History: Received June 09, 2015; Revised September 01, 2015

Various methods have been developed to describe the energy consumption of machine tools; however, it remains challenging to accommodate the wide variety of machine tools that exist using a single model. In this paper we propose a method to model the energy consumption of machine tools by decoupling the energy of the components of the machine tool from the cutting energy. A procedure is developed to describe the characteristics of the energy consumption of machine tools, which is applied to six different machines. The experimental results show that the cutting energy can be decoupled from the component energy. In this manner, a simplified energy consumption model is developed that can be applied to a wide variety of different machine tools.

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References

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Figures

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Fig. 1

Example power profile and power measurement procedure

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Fig. 2

Decomposition of additional electrical power requirement

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Fig. 3

The spindle power of the machine tools

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Fig. 4

The feed drive power of the machine tools: (a) +x‐axis direction, (b) −x‐axis direction, and (c) +z‐axis direction

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Fig. 5

The cutting power of the machine tools

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Fig. 6

Axis orientation of CNC lathe

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Fig. 7

Flow chart describing the power profile simulation

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Fig. 8

Definition of the feed drive position vector

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Fig. 9

Example actual power profile and simulated power profile: (a) actual power profile result and (b) simulated power profile result

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Fig. 10

Simulated power profile of the machine tool peripherals: (a) power profile result of GS400 and (b) power profile result of NL2000SY

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Fig. 11

Simulated power profile of the machine tools: (a) power profile result of GS400 (total power) and (b) power profile result of NL2000SY (total power)

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Fig. 12

The power consumption patterns of the six machine tools (rpm: 1969 min−1, feedrate: 4000 mm/min, MRR: 87,500 mm3/min)

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