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Intelligent CNC system to improve the energy

efficiency of CNC machine tools

Prof. Liuqun FAN

2

What Why Where How

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Design Production

Motivation

Energy Simulation Platform

Machine Energy

Consumption Modell Energy Forecast

Result

耦合

约束

连接

导轨

导轨 定制连接

弹簧-阻尼连接

固定

固定

矩形体

几何体3

几何体4

Realtime Model

Forecast

Monitoring

Optimization

Machine energy consumption simulation platform

Machine Component energy consumption measure

Machine energy consumption modelling

Realtime energy consumption modelling

Intelligent CNC with energy prediction and monitoring

Main task and content

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Machine energy consumption simulation platform

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lib lib lib

Machine energy consumption simulation platform

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Source: ISW

Machine energy consumption simulation platform

Machine Component energy consumption measure

Machine energy consumption modelling

Realtime energy consumption modelling

Intelligent CNC with energy prediction and monitoring

Main task and content

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Machine Component energy consumption measure

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Tested Machine: ETC 3650

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Electric control Cabinet Electrical schematics

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Electrical Schematics components were hierachical arranged.

Testing scenarios

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• 7 testing scenarios were planned, so that energy consumption of all components can be gained.

• Due to limitation of testing equipments some components can be tested in one time. E.g. table right show the tested components in scenarios 1.

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34%

5%

1%

38%

6%

16% 主轴系统

进给系统

换刀系统

辅助系统

控制系统

外设系统

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Machine energy consumption simulation platform

Machine Component energy consumption measure

Machine energy consumption modelling

Realtime energy consumption modelling

Intelligent CNC with energy prediction and monitoring

Main task and content

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Machine

Hydraulics

Motor

Pump

Valve

…

Spindle

Servo

Coolant

Lubrication

…

Machine Component

Machine Energy Consumption

Emachine

= Econst + Ecut + Estate-steady + Estate-trans

Load-dependent energy Load-independent energy

Main Drives Axis 1 Axis n Hydraulics Lubricant … …

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•7 machine states were defined in

advance.

•Model of machine state was made by

conditions and condition

transformation.

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State 1

State 2

State

Trans.

State 1

State 2

Actual

Simplify

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CNC Ready State Time=15min

Hydraulics Cabinet …

Main Drives Servo Axis Coolant

Conveyor …

on

off

Energy

Consumption

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read of simulation input

signal transformation

and expression

write of simulation results

• With stateflow toolbox,

machine tool state-based

simulationmodel of energy

consumption, was programmed

in Matlab/Simulink.

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)(...)()( 2211

1

nn

n

i

ij xFxFxFPP

jnnj

n

i

ijjj t)x(F...)x(F)x(FtPtPE

22111

mnnnnnnnn

m

j

jj

m

j

jprocess txF...xF...txF...xFtPEE

1111111

Machine energy consumption simulation platform

Machine Component energy consumption measure

Machine energy consumption modelling

Realtime energy consumption modelling

Intelligent CNC with energy prediction and monitoring

Main task and content

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NC program

CNC

Machine Automatic

Mode

Jog

Mode

• M03 M04 M05 Spindle on or off

• M06 Tool exchange; M08 M09 Coolant on or off M • G01 Linear interpolation; G02 Circular interpolation

• G33 Thread interpolation G • Spindle speed

S • Feedrate

F

• Tool number T

Spindle on/off

Coolant on/off

Tool Exchange

Axis Move

…

Machine

on

CNC

on Machining Notaus Standby Ready

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Program

Decode Energy Consumption

Model

Lookahead

Interpolate

Position

Control

Servo

PLC

I/O

Machine

Energy Consumption

Optimization

Energy Consumption

Monitoring

Classic CNC

Machine energy consumption simulation platform

Machine Component energy consumption measure

Machine energy consumption modelling

Realtime energy consumption modelling

Intelligent CNC with energy prediction and monitoring

Main task and content

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I/O

SP

D

EC

AT

E

CA

T

HSHA

SERVO

X Y Z n

DNC

WIS

Diagno.

接口

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Time

Energy

Optimized Cycle

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Graphical interactive

user-interface

Up to 10% energysaving potential; (source Siemens)

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a. 直线加减速 b. S曲线加减速

J J

J

Lookahead S-Curve Acc/Dec

Up to 5% energysaving potential; (source Siemens)

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Up to 90% energysaving potential; (source Siemens)

• Coffee break 1

• Lunch break 2

• Other 3

Factory, Workshop and Production Line

Standardized open interface

OPC UA

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Thank you!