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Intelligent CNC system to improve the energy
efficiency of CNC machine tools
Prof. Liuqun FAN
2
What Why Where How
3
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
4
Machine energy consumption simulation platform
5
lib lib lib
Machine energy consumption simulation platform
6
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
7
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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14
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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16
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.
21
)(...)()( 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
22
23
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
24
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
25
26
I/O
SP
D
EC
AT
E
CA
T
HSHA
SERVO
X Y Z n
DNC
WIS
Diagno.
接口
27
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)
30
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
31
Thank you!
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