Intelligent CNC system to improve the energy efficiency of CNC machine tools

Transcription

1 Intelligent CNC system to improve the energy efficiency of CNC machine tools Prof. Liuqun FAN 上午 9 时 52 分

2 What Why Where How 2

3 Motivation Design Production Machine Energy Consumption Modell Energy Forecast Result Realtime Model 约束 固定 几何体 3 导轨 矩形体 固定 导轨 定制连接 几何体 4 耦合 连接 弹簧 - 阻尼连接 Energy Simulation Platform Forecast Monitoring Optimization 3

4 Main task and content 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 4

5 Machine energy consumption simulation platform lib lib lib 5

6 Machine energy consumption simulation platform Source: ISW 6

7 Main task and content 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 7

8 Machine Component energy consumption measure Tested Machine: ETC

9 Electrical schematics Electric control Cabinet 9

10 Electrical Schematics components were hierachical arranged. 10

11 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. Testing scenarios 11

12 6% 16% 34% 主轴系统进给系统 换刀系统 38% 5% 辅助系统控制系统 1% 外设系统 12

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15 Main task and content 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 15

16 Machine Component Motor Machine Energy Consumption Machine Hydraulics Spindle Servo Coolant Pump Valve E machine = E const + E cut + E state-steady + E state-trans Load-dependent energy Load-independent energy Lubrication Main Drives Axis 1 Axis n Hydraulics Lubricant 16

17 7 machine states were defined in advance. Model of machine state was made by conditions and condition transformation. 17

18 Actual State Trans. State 2 State 1 Simplify State 1 State 2 18

19 CNC Ready State Time=15min Hydraulics Cabinet on Main Drives Servo Axis Coolant off Conveyor Energy Consumption 19

20 read of simulation input With stateflow toolbox, machine tool state-based simulationmodel of energy consumption, was programmed in Matlab/Simulink. signal transformation and expression write of simulation results 20

21 21 ) (... ) ( ) ( n n n i i j x F x F x F P P j n n j n i i j j j t ) x F (... ) x F ( ) x F ( t P t P E m nn nn n n n n m j j j m j j process t x F... x F... t x F... x F t P E E

22 Main task and content 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 22

23 M G S F T Automatic Mode NC program M03 M04 M05 Spindle on or off M06 Tool exchange; M08 M09 Coolant on or off G01 Linear interpolation; G02 Circular interpolation G33 Thread interpolation Spindle speed Feedrate Tool number CNC Machine Jog Mode Spindle on/off Coolant on/off Tool Exchange Axis Move Machine on CNC on Machining Notaus Standby Ready 23

24 Program Energy Consumption Model Energy Consumption Optimization Decode Lookahead Interpolate Classic CNC PLC Position Control Energy Consumption Monitoring Servo I/O Machine 24

25 Main task and content 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 25

26 DNC ECAT ECAT I/O 接口 WIS Diagno. HSHA SERVO SP D X Y Z n 26

27 Time Energy Optimized Cycle 27

28 Graphical interactive user-interface Up to 10% energysaving potential; (source Siemens) 28

29 J J J a. 直线加减速 b. S 曲线加减速 S-Curve Acc/Dec Lookahead Up to 5% energysaving potential; (source Siemens) 29

30 Factory, Workshop and Production Line Standardized open interface OPC UA Coffee break Lunch break Other Up to 90% energysaving potential; (source Siemens) 30

31 Thank you! 31