Simulation-based machining condition optimization for machine tool energy consumption reduction

Lee, Wonkyun; Kim, Seong Hyeon; Park, Jaesang; Min, Byung Kwon

doi:10.1016/j.jclepro.2017.02.178

Cited by 40 publications

(10 citation statements)

References 26 publications

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“…されている (経済産業省資源エネルギー庁, 2018) (Altıntaş et al, 2016)．そこで，エネルギー効率の向上及び稼働時間の削減により省エネルギー化が進められている．例えば，加工工程に合わせた切削液流量の制御 (Fujishima et al, 2017)，ベッドの冷却機構の制御，主軸の冷却機構の解析 )により最適化が図られてきた．また，待機中の搬送機器の停止 (Fujishima et al, 2017)や複数の工程を集約可能な工作機械の開発 (Ohtani et al, 2017)など，不要な電力消費を避ける方法が検討されている．加工においては，送り速度の高速化が可能な工具の開発や，切削力を基準とした主軸回転数と送り速度の最適化 (Lee et al, 2017)で材料除去率を向上することで周辺装置の稼働時間を削減している．大幅な省エネルギー化を達成するためには，工作機械を構造から見直すことで機械特性を高める必要がある．炭素繊維強化プラスチック(CFRP)は軽量のみならず，工作機械に必要とされる高い剛性と減衰性，低熱膨張率を有しており，駆動部の軽量化と加工の高能率化に貢献する材料として注目を集めている (Möhring et al, 2015) Vol. 11, No.…”

Section: するパリ協定が採択された．現在日本では全エネルギー需要の 40%以上が産業分野，20%以上が運輸分野で消費unclassified

Thermal error and energy-saving performance evaluation of the energy-saving machine tool using new structural materials

Kato

Kono

Yoshioka

et al. 2020

Transactions of the JSME (In Japanese)

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New energy saving methods are required to address global climate change and resource depletion. New structural materials such as Carbon fiber reinforced plastic (CFRP) are used also in nowadays machine tools applications for energy efficiency improvement by weight reduction. This research group succeed in being the first to develop the energy-saving machine tool using new structural materials, mainly CFRP. Furthermore, CFRP is expected to enhance thermal characteristics, which contributes to reduction of warm up drive and implement of idle reduction. First of all, the thermal deformation of the energysaving machine tool is investigated through single axis feed motion by measuring a test bar. It is obtained that the thermal error is obviously suppressed and shows unique behavior in comparison with a based conventional machine tool. Next, the energysaving performance is evaluated through machining test. Warm up drive minimization method is proposed in order to realize high precision form accuracy. The warm up drive time is estimated based on an estimation model, and the energy efficiency of warm up drive is improved 57.0% in comparison with the base machine.

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Section: するパリ協定が採択された．現在日本では全エネルギー需要の 40%以上が産業分野，20%以上が運輸分野で消費unclassified

Thermal error and energy-saving performance evaluation of the energy-saving machine tool using new structural materials

Kato

Kono

Yoshioka

et al. 2020

Transactions of the JSME (In Japanese)

View full text Add to dashboard Cite

show abstract

“…Thus, a sampling time of τ s = 10ms was selected based on a trade-off between the temporal resolution of the signals and the computational time for running the proposed control design. In Figure 4, the proposed manufacturing sequence and the energy consumption profiles of peripheral devices for only one phase are presented, as it is developed in most of reported works [29,30].…”

Section: Case Studymentioning

confidence: 99%

An optimization-based control strategy for energy efficiency of discrete manufacturing systems

et al. 2019

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In order to reduce the global energy consumption and avoid highest power peaks during operation of manufacturing systems, an optimization-based controller for selective switching on/off of peripheral devices in a test bench that emulates the energy consumption of a periodic system is proposed. First, energy consumption models for the test-bench devices are obtained based on data and subspace identification methods. Next, a control strategy is designed based on both optimization and receding horizon approach, considering the energy consumption models, operating constraints, and the real processes performed by peripheral devices. Thus, a control policy based on dynamical models of peripheral devices is proposed to reduce the energy consumption of the manufacturing systems without sacrificing the productivity. Afterward, the proposed strategy is validated in the test bench and comparing to a typical rule-based control scheme commonly used for these manufacturing systems. Based on the obtained results, reductions near 7% could be achieved allowing improvements in energy efficiency via minimization of the energy costs related to nominal power purchased.

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“…From the machine tool and process view, Lee et al [8] proposed a simulation method based on a virtual machine tool to estimate the machining condition considering the energy consumption function or component model. Based on dynamic and kinematic behaviors of machine tools, Bi et al [9] explored relations of machining parameters (cutting force, depth, and feed rate) and energy consumption.…”

Section: Modeling and Simulation Of Energy-efficient Manufacturingmentioning

confidence: 99%

Event-Driven Online Machine State Decision for Energy-Efficient Manufacturing System Based on Digital Twin Using Max-Plus Algebra

et al. 2019

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Energy-efficient manufacturing is an important aspect of sustainable development in current society. The rapid development of sensing technologies can collect real-time production data from shop floors, which provides more opportunities for making energy saving decisions about manufacturing systems. In this paper, a digital twin-based bidirectional operation framework is proposed to realize energy-efficient manufacturing systems. The data view, model view, and service view of a digital twin manufacturing system are formulated to describe the physical systems in virtual space, to perform simulation analysis, to make decisions, and to control the physical systems for various energy-saving purposes. For online energy-saving decisions about machines in serial manufacturing systems, an event-driven estimation method of an energy-saving window based on Max-plus Algebra is presented to put the target machine to sleep, considering real-time production data of a system segment. A practical, simplified automotive production line is used to illustrate the effectiveness of the proposed method by simulation experiments. Our method has no restriction on machine failure mode and predefined parameters for energy-saving decision of machines. The proposed approach has potential use in synchronous and asynchronous manufacturing systems.

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Simulation-based machining condition optimization for machine tool energy consumption reduction

Cited by 40 publications

References 26 publications

Thermal error and energy-saving performance evaluation of the energy-saving machine tool using new structural materials

Thermal error and energy-saving performance evaluation of the energy-saving machine tool using new structural materials

An optimization-based control strategy for energy efficiency of discrete manufacturing systems

Event-Driven Online Machine State Decision for Energy-Efficient Manufacturing System Based on Digital Twin Using Max-Plus Algebra

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