Transcript Slide 1
Modeling the Power Consumption of a Fadal VMC20 Milling Machine Mark Hansen, EE Student Department of Industrial and Manufacturing Engineering Green Manufacturing Faculty Advisors: Dr. Janet Twomey, Dr. Bayram Yildirim, Dr. Lawrence Whitman, Dr. Jamal Sheikh-Ahmad Green Manufacturing Team Members: Rebekah Drake, Prashant Lodhia Supported by NSF CAREER: DMI-973347 Energy and Manufacturing • Overall Research Objective – To identify the environmental impacts of the manufacturing system so that we can mitigate their adverse impacts – My responsibilities as the E E on the team • A Problem in Manufacturing – Energy consumption impacts the environment. – By describing and predicting energy consumption, we can find ways to mitigate those impacts. • A Starting Point – Modeling the energy consumption of a single milling machine. Experimental Setup Experimental Setup • Machine: Fadal VMC20 Vertical Milling machine • Procedure: Manufacture a simple aluminum part • Data Collection: Sampling total instantaneous power consumption of the machine The Machine Lights and Controls Spindle Table Coolant Pump The Part 8mm Aluminum 2 Holes 0.25’’ in Diameter 8mm Deep X Cut 2.5’’ Long 0.04’’ Deep Y Cut 3’’ Long 0.04’’ Deep The Data Collection Device • Device Specs. – Portable device – Three-phase power measurement – Instantaneous measurement of both voltage and current – Maximum sampling rate of 250 samples per second Data Analysis Instantaneous Power Consumption 3500 3000 Watts 2500 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Instantaneous Power Consumption 3500 Machine Startup 3000 2500 Watts Lights & Controls 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Instantaneous Power Consumption 3500 Coolant Pump Startup 3000 Watts 2500 Coolant Pump 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Instantaneous Power Consumption 3500 Coolant Pump Power-On Spike Spindle Startup 3000 Spindle Watts 2500 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Instantaneous Power Consumption 3500 Rapid Axis Movement 3000 Watts 2500 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Instantaneous Power Consumption 3500 Machining Startup 3000 TIP + Slow (Feed) Axis Movement Watts 2500 2000 1500 1000 500 0 0 5 10 Seconds 15 20 Percentage Energy Consumption Percentage of Energy Consumed Total Energy Consumed: 27,931 Joules (0.47 kWh) 100% Tip + Axis Movement: 5,826 Joules Spindle: 9,647 Joules Coolant Pump: 2,444 Joules 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Lights & Controls: 10,014 Joules Goals of Future Research • Use this data to predict the energy consumption of a more complicated part, given the same machine and material, without repeating the data-collection and analysis. • Simulate production runs of many parts over time.