Energy Consumption Of Machine Research Articles

Efficiencies through the Automatic Control of Age-Profiled Manufacturing Machines: A Case Study of Cost-Saving in an Irish Production Facility

Abstract: This paper asked if an effective energy measurement and monitoring system could be designed which was capable of controlling production machines to reduce operational costs. The solution had to be itself a low cost which could also be relatively easily deployed in developing regions. Developing regions are typically characterized by production facilities with outmoded equipment, but often have one or two more advanced machines available. This study identified a solution which evaluated energy consumption of machines at rest and oil consumption. It found that these two variables, when profiled against machine age, could be controlled in such a way as to significantly reduce production costs. Tests showed that, in addition to these variables, surge featured as an important variable which needed to be added to the control model. The solution itself could be deployed with very low cost. The experiment was carried out on CNC machines in a manufacturing site in Ireland.

The Use of the PEMS Equipment for the Assessment of Farm Fieldwork Energy Consumption

<abstract> <b><sc>Abstract. </sc></b>This article presents investigations of fuel consumption and CO₂ emission of a farm tractor operating with a cultivator. The cultivator has been designed to operate at greater speeds of up to 15 km/h. During the tests, the tractor operated with different speeds, which influenced the fuel consumption and the time of operation. An increase in the cruising speed resulted in greater fuel consumption and a reduced time of operation. A fuel consumption curve was determined depending on the tractor speed. At the same time, the authors assessed the quality of the cultivation through soil analysis after the cultivation. The fuel consumption was measured with the carbon balance method – the most accurate method available. Such measurements were performed by the Portable Emission Measurement System (PEMS) equipment. The investigations utilizing the PEMS equipment enable measurements of the exhaust emissions under actual operating conditions, during fieldwork. The methodology used in the research is the most accurate and most reliable one currently available. It takes into account all of the variables of actual operation. This method is a state-of-the-art achievement in exhaust emissions measurement and has great potential. It may be successfully used for research related to assessment of energy consumption of farm tractors depending on the analyzed factors, e.g. type of soil, design of tools, and method of fieldwork. The performed tests allowed formulating conclusions related to the influence of the speed of the farm tractor with the cultivator on fuel consumption and emission of CO₂. From the test, it follows that upon reaching a certain operating speed the increment of the fuel consumption is getting smaller while the time efficiency increases. The authors also observed that the above did not have impact on the quality of the cultivation. The presented results of the investigations and their analysis confirm the usefulness of the applied methodology in the assessment of energy consumption of farm tractors and machines during fieldwork operation.

An analysis framework for characterization of electrical power data in machining

Electrical power data of machining has become more and more vital due to the increasing concerns on the energy efficiency. As a kind of easily available real-time signal, electrical power data in machining involves diverse characteristics related to technical specification and operational production of machine tools and workpieces. To efficiently exploit the various characteristics involved in electrical power data, this paper proposes a framework to analyze characteristics of electrical power data in machining. Firstly, the sample experiment for turning the round stock on a lathe is carried out to investigate the characteristics implied in the real-time electrical power data. Based on it, a framework is derived to analyze characteristics from three aspects, energy-specific characteristic of machining, state-specific characteristic of machine tools and operation-specific characteristic of workpieces. The case with three scenarios is presented to demonstrate the potential applications of the framework, which is effectively utilized in analyzing energy consumption of machining, monitoring states of machine tools and automatically identifying the types of machining workpieces.

GreenBearings – Friction Behaviour of DLC-Coated Dry Running Deep Groove Ball Bearings

Due to the use of rolling bearings instead of plain bearings friction and wear are drastically reduced in all kind of machines. However, despite the high technical standard of modern rolling bearings there is still a significant potential for optimization. Preliminary Studies show a reduction of the friction torque of up to 44 % compared to conventional rolling bearings because of the use of tribological coatings in certain applications. Based on the millionfold usage of rolling bearings in all industrial fields the reduced lost energy adds up to a remarkable potential for energy savings. If friction and wear are lowered sufficiently, the use of conventional lubricants based on mineral oil can be successively decreased or even completely avoided. In the latter case, the socalled dry running of the rolling bearing, the energy consumption of machines and systems can additionally be reduced significantly. For example, pumping stations or compressed air units, which would be necessary for transporting or spraying the lubricants, can then be saved.This paper presents first results of DLC-coated deep groove ball bearings, which are tested in a four-bearing-test-rig under purely radial load with respect to their friction and wear behaviour.

Trade-off analysis between machining time and energy consumption in impeller NC machining

Electrical energy is directly linked to society's prosperity across the globe; much of this due to the diverse innovations on manufacturing processes. Keeping pace with the high energy demand growth will require constant efforts in terms of investment and research in order to bring new alternatives of usage. This paper outlines the application of multiple response optimization in order to analyze the trade-off between machining time and energy consumption in 5-axis impeller rough machining to find a possible balance between them. It is well known that a higher speed reduces machining time but increases energy consumption, and vice versa. A quantitative form of the relationship between the involved factors was obtained by utilizing response surface methodology (RSM) together with the desirability function method. Four independent factors were selected, namely, spindle speed, feed rate, depth and width of cut. The responses are the consumed energy and the machining time. The results showed that selecting an appropriate feed rate is crucial to balance the trade-offs between energy and time. Spindle speed is the major factor for energy consumption, while width of cut is the most influential factor for machining time. Multiple response optimization of the cutting conditions for impeller roughing.Substantial improvement by balancing the factors in machining processes.Balancing factors can be the best optimization for a multiple response problem.2.7mm of width, 1.8mm of depth, 8,000 rpm, and feed 740 mm/minprovide best balance.The proposed model showed congruence between theoretical and practical results.

Energy system diagnosis of paper-drying process, Part 1: Energy performance assessment

ABSTRACTPaper drying is a highly energy-intensive and complicated multivariate process. The dryer section plays an important role in the energy consumption of a paper machine, especially of thermal energy. A comprehensive method for assessing the energy performance of the dryer section was investigated in this study to improve energy efficiency. This method was divided into three component processes: energy and evaporation load audit, field test and observation, and energy flow analysis and energy efficiency estimation. In a case study, we found that the method could, in addition to analyzing the key factors that restrict drying efficiency, also depict the details of energy consumption clearly. At the same time, several significant energy-saving measures were suggested to improve the energy efficiency of the paper-drying process.

Development of the Energy-smart Production Management system (e-ProMan): A Big Data driven approach, analysis and optimisation

Given the challenges in increasing energy prices and environmental issues, energy efficiency is becoming a major concern in manufacturing industries. To reduce energy consumption, manufacturing operations need to develop energy efficient techniques. This development will also help reduce greenhouse gas emissions and production costs. The aim of this research is to create a simulation methodology and to investigate the modelling of thermal and energy management (called e-ProMan) across manufacturing site. Using simulation, the ‘e-ProMan’ system generates a real-time, virtual and user-friendly factory model. A ‘Big Data’ approach is taken in which a large set of data are acquired from both inside and outside the factory in order to analyse the correlation between work flow, data flow and energy flow to provide real-time decision making. In particular, four data sources are gathered including weather forecast, temperature and humidity sensors, machine energy consumption and production process and scheduling. The ‘e-ProMan’ system is specifically designed to suit manufacturing operations of small and medium sizes to complement limited budget and lower resources especially in data gathering infrastructures.

3D numerical investigation of the performance of microgroove textured cutting tool in dry machining of Ti-6Al-4V

In this paper, the performance of microgroove textured cutting tools in dry three-dimensional (3D) turning of Ti alloy (Ti-6Al-4V) is investigated using AdvantEdge finite element simulation. Microgrooves are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purposes are to examine the effect of microgroove textured cutting tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microgroove parameters are examined: microgroove width, microgroove depth, and edge distance (the distance from cutting edge to the first microgroove). Their effects are assessed in terms of the cutting forces and chip-tool contact length. It is found that microgroove textured cutting tools generate lower cutting forces and consequently lower the energy consumption for machining. The microgroove width, microgroove depth, and edge distance all have influence on cutting forces in their own ways. This research provides insightful guidance for optimizing cutting tools in terms of cutting forces and energy consumption.

Research on Energy Consumption Test and Data Process Method of Gravure Printing Machine

In order to achieve high-speed gravure printing machine energy consumption tested and analyzed process efficiently, put forward a kind of electric energy balance test and analysis method, using power analyzer acquire and record the electric energy balance parameters of motors input ports of the three-phase power supply, and processing the data with the method of successive difference. By means of experiment, tested and analyzed the main motor energy consumption of gravure printing machine, the results verify the feasibility of electric energy balance test method and the method of successive difference.

Design and optimization of a new kind of hydraulic cylinder for mobile robots

In order to improve the efficiency of multi-actuator mobile robots hydraulic system, this paper proposes a new kind of cylinder whose effective area is variable. The new cylinder has multi chambers which can be connected with each other or to a main system circuit by controlling switching valves. On the one hand, the new cylinder can make sure that the load pressure of all actuators is almost equal through varying effective area. On the other hand, the new cylinder can realize the flow recovery through that return chambers are connected with feeding chambers. Therefore, the new cylinder can reduce overall machine energy consumption by reducing throttling losses and allowing energy recovery. The performance of the new cylinder is analyzed through building the mathematical model. Based on the evaluated results, in order to further improve the performance of the load match of the cylinder and avoid the deflection of the main piston, the structure of the cylinder is optimized. Finally, an optimized cylinder is shown in this paper which has well performance of the load match.

Assessment of Energetic Leverage Effect Using a Virtual Prototype

The so-called energetic leverage effect describes the influence of manufacturing strategies on the energy balance in the use-phase of tribological components in technical products. The objective of the presented approach is to consider this effect in early phases of product engineering of construction and agriculture machinery with the help of a prospective life-cycle-assessment.In the approach a virtual prototype is developed. This enables a quantitative assessment of the use-phase of a product in early product development phase. The virtual prototype simulates the behavior of considered components, in this case gear wheels, and the effect on the energy consumption of the whole machine in its use-phase. In different simulation runs gear wheels with differences in surface quality, tribological characteristics but also in energy consumption during their production-phase resulting from different manufacturing strategies are compared. The life-cycle-assessment ensures that energy consumption of all life cycle phases is included and optimized.

Analysis and Structure Optimization of the Wind Distribution of Nozzle in the Gravure Printing Drying System

The drying system plays an important role in printing speed and energy consumption of gravure printing machine. Nozzle is a factor which decides heated air distribution in drying system finally. This research makes a model for the structure of nozzle and takes a numerical simulation analysis of heated air field with hydrodynamic theory. The defect of structure is found through the distribution of velocity, temperature and trajectories. A crosswind landing area is added around outlet area of nozzle. In this study, it is evaluated that the distribution of the wind field. It is found that the velocity and pressure of heated air in the vortex area between substrate and nozzle by the cross-wind board can be improved from the simulation results. The study has significance on optimizing the structure of nozzle and improving efficiency of drying system.

Optimizing Power Consumption for Sustainable Dry Turning of Treated Aluminum Alloy

Machining companies can implement sustainable manufacturing using steps to improving the performance of economic, environmental and social. One of the steps is to perform the efficiency of energy consumption (mainly electricity) in machining. This paper describes a case study which investigates the effect of cutting parameters on power consumption and surface roughness by applying design of experiments. Dry turning of treated Al-11%Si alloy using coated carbide tool at different cutting speed (70, 130 and 250 m/min) and feed (0.05, 0.10 and 0.15mm) was investigated. The results showed an optimum effect of cutting parameters that was obtained at low feed rate and high cutting speed, as shown by the model solutions.

A Forging Hardness Dispersion Effect on the Energy Consumption of Machining

A Forging Hardness Dispersion Effect on the Energy Consumption of Machining

Numerical investigation of the performance of microbump textured cutting tool in dry machining of AISI 1045 steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip–tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

Impact of Blade Angle on Miscanthus Harvesting Energy Requirement

Abstract. Miscanthus is emerging as a promising feedstock for domestic biofuel production. However, inefficiencies of the machinery that is used for harvesting bioenergy crops such as miscanthus currently prohibit commercial production. The performance of a mower-conditioner used to harvest miscanthus was evaluated, and modifications to the disk head were made to allow the machine to operate more efficiently. It was also hypothesized that the harvest energy requirement of the mower-conditioner in miscanthus could be reduced by increasing the blade oblique angle. Blades with oblique angles of 20° and 30° were manufactured and fitted to the disk mower-conditioner. When combined with data collected from a real-time yield sensing system, the data collected regarding the machine performance resulted in point-specific and overall machine energy consumption information. The 30° oblique angle resulted in a 27% reduction in the energy requirement, with an energy consumption of 13.5 MJ Mg -1 as compared to 18.5 MJ Mg -1 for the conventional straight (0°) blades. Further studies are needed to examine the overall life of the angled blades as well as the feasibility of their application to other crops harvested by disk mower-conditioners, such as hay and forage.

Assessment of cutting energy consumption and energy efficiency in machining of 4140 steel

Machining operations such as turning, milling, and drilling are commonly employed machining processes in industry. With the push toward a future of sustainable manufacturing, machining processes need to be evaluated and optimized accordingly. This paper focuses on the energy aspects in metal cutting and attempts to provide an overall assessment of energy consumption and energy efficiency against the operating conditions. Specifically, the effects of tool geometry and cutting parameters in turning of ANSI 4140 steel are investigated through numerical experiments using finite element simulation. The variables considered include cutting speed, rake angle, nose radius, and edge radius. The effects of these parameters on cutting energy consumption and cutting efficiency are analyzed. The results show that the effects of these parameters on cutting energy and cutting efficiency are different. Strategies for minimizing cutting energy and maximizing cutting efficiency are suggested.

A Study on Energy Consumption of a CNC Milling Machine Based on Cutting Force Model

Machining operations are performed by machine tools with a large amount of energy consumed for material removal. Understanding and characterizing the energy consumption is essential to explore the potential of energy-saving in energy-efficient machining. For this purpose, this paper proposes a method for modeling energy consumption of end milling operation which is based on cutting theory. The cutting power model is verified with experiments on a CNC milling machine. According to the calculated and experimental results, it is clear that the theoretical prediction can predict the mean cutting power successfully as validated by actual measurements.

A Hybrid Genetic Algorithm for the Energy-Efficient Virtual Machine Placement Problem in Data Centers

Server consolidation using virtualization technology has become an important technology to improve the energy efficiency of data centers. Virtual machine placement is the key in the server consolidation technology. In the past few years, many approaches to the virtual machine placement have been proposed. However, existing virtual machine placement approaches consider the energy consumption by physical machines only, but do not consider the energy consumption in communication network, in a data center. However, the energy consumption in the communication network in a data center is not trivial, and therefore should be considered in the virtual machine placement. In our preliminary research, we have proposed a genetic algorithm for a new virtual machine placement problem that considers the energy consumption in both physical machines and the communication network in a data center. Aiming at improving the performance and efficiency of the genetic algorithm, this paper presents a hybrid genetic algorithm for the energy-efficient virtual machine placement problem. Experimental results show that the hybrid genetic algorithm significantly outperforms the original genetic algorithm, and that the hybrid genetic algorithm is scalable.

413 設備のエネルギ消費傾向を考慮したエネルギブロックモデルによる環境配慮型スケジューリング(OS6,OS8 : 環境配慮型生産システム性産システムの国際展開(1))

The current trends of rising energy price compel manufacturers to improve energy efficiency and saving. This paper proposes an energy-aware scheduling method using an energy-block modeling which considers combination of each machine's energy consumption pattern. The energy-block represents whole power profiles during one processing job and that is modelled as combined multiple rectangle energy pieces Each machine has specific energy consumption pattern for a processing job. This paper examines single objective to minimize total tardiness by changing the parameter of constraint of energy max peak. The proposed model is applied to an experiment with some cases of different combinations of blocks, and it is confirmed the balance of energy max peak and make span.