Study of Syncronous Optimization of Machining Efficiency and Energy Consumption and Idle Machining Monitoring

• Main Authors: CHUN-YI LEE, 李軍逸
• Other Authors: SHIH-MING WANG
• Format: Others
• Language: zh-TW
• Published: 2017
• Online Access: http://ndltd.ncl.edu.tw/handle/84539646650687449056

碩士 === 中原大學 === 機械工程研究所 === 105 === Motor is the main energy consumption in the CNC tool machine. Generally, the energy consumption of 3-axis CNC machine including spindle motor, servo motor of XYZ axis, auto-tool change motor, and chip removal motor. However, the auto-tool change motor and chip removal motor are not significantly influenced the total energy consumption because is not frequently be used. Spindle motor and servo motor can be used to analyze the relationship between machining process and energy consumption. Both energy consumption and machining efficiency are simultaneously considered. To obtain optimal machining efficiency and energy consumption cost, the optimal combination of cutting parameter according to the motor energy consumption characteristics must be selected. Firstly, understanding the relationship between cutting load on the motor performance and energy consumption. Thus, establish algorithms for simultaneous processing efficiency and energy consumption optimization. Furthermore, human machine interface was designed, and finally a machining optimization assisted system that help engineer to identify “energy and productivity efficiency” optimum machining parameter was created. In this study, simultaneous optimization of productivity efficiency and energy saving for CNC machine tool was investigated. Relationship between spindle rpm, feed rate, and energy consumption were analyzed, and then analysis modelling was created. Special algorithm was used to establish energy saving analysis, and included in the human machine interface as well as in the system. Experiment was carry out to verify the proposed system. The experiment result showed a significant energy consumption between without cutting and with cutting. The servo motor under certain feedrate exhibits lower energy consumption. The may be related to characteristics of machine structure (i.e. friction of rail). This phenomenon can be used to modify machining parameter in order to achieve optimum production efficiency and energy saving. Air cutting during machining process will affect the machining efficiency and utilization rate. Minimizing of air cutting time is also one of the optimization parameter. Investigation of air cutting time is one of the objective in this study. Online spindle current change was used to determine whether the cutter is in process of cutting or air cutting. At the same time, NC program was also used to help decide it, and also to avoid wrong diagnosis of spindle current change that affected by other circumstances. The online air cutting monitoring module that built using C# language program is use to monitor G01, G02, G03 of NC program. The analysis result of effective machining and ineffective machining were displayed on human machine interface. Experimental and verification of the system were carried out. The experimental results showed that the error range of the monitoring is within one second. This can be used as a basis for optimizing machining path and minimizing air cutting time.