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1 Framework for Energy Data Collection Prashant Lodhia Rebekah Drake.

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Presentation on theme: "1 Framework for Energy Data Collection Prashant Lodhia Rebekah Drake."— Presentation transcript:

1 1 Framework for Energy Data Collection Prashant Lodhia Rebekah Drake

2 2 Objective The objective is to provide a framework for the characterization of the energy consumption of a machine for the purpose of use in determining energy MUDA. http://www.syque.com/improvement/Muda.htm

3 3 Hierarchy of System Structure Terminology System: Group of subsystems which converts input to output (i.e. milling machine, injection molding machine, lathe) –Subsystem: Group of components acting together (i.e. spindle, coolant pump, ATC in milling/turning machine, heater, hydraulic system in injection molding machine) Component: Part of subsystem consuming power (i.e. motors in spindle/coolant pump/ATC; Heating coil in heater)

4 4 Technical Terminology Fixed Energy Consumption: Energy consumption associated with activity which consumes variable power over a fixed time duration Variable Energy Consumption: Energy consumption associated with activity which consumes constant power over a variable time duration (1) Spindle Power Analysis (2) Variable Energy Consumption Fixed Energy Consumption Variable Energy Consumption t1t1 t2t2

5 5 Technical Terminology Analyze: Divide a complex whole into its parts/elements, suggest separating or distinguishing the component parts of something so as to discover its true nature or inner relationships Correlate: To establish a mutual or reciprocal relation between Determine: To settle or decide by choice of alternatives or possibilities Focus: a center of activity, attraction, or attention; a point of concentration Set: To decide on as a time, limit, or regulation; to adjust (a device and especially a measuring device) to a desired position (Merriam-Webster Online Dictionary, 2005)

6 6 Overall Framework 0.Initialization. 1.Configure the Measuring Device 2.Capture Total System Power 3.Analyze Total System Power 4.Determine Subsystems of Primary Focus 5.Capture & Analyze Experimental Data for Each Subsystem 6.Create Model 7.Verify & Validate 8.Apply Model

7 7 Initialization Determine the bounds of the system by defining the system, subsystems, and components. Spindle (Subsystem) Coolant Pump (Subsystem) Milling machine (System) Motor (Component)

8 8 Configure the Measuring Device Connect the power measuring device & data logger to the system’s main power box Set the sampling rate per second on the power measuring device with respect to desired level of accuracy, keeping the subsystems into consideration (ex. 50 samples/sec.) Example: Power meter hooked up to power box

9 9 Capture Total System Power Create a part which captures each subsystem in a sequential order during the part run Run a trial part to collect n number of data sets while tracking the power consumption of the sequential activities in system with respect to time (ex. 5 data sets) Sample part used on CNC mill

10 10 Analyze Total System Power Plot the power data with respect to time (power plot) Correlate the sequence of activities and components of the power plot

11 11 Determine Subsystems of Primary Focus Using the power plot, analyze the subsytems based on level of significance the subsystem contributes to the total system power

12 12 Capture & Analyze Subsystem Behavior Capture the experimental data for each subsystem Analyze the subsystem’s behavior to determine fixed energy and variable energy Fixed Energy Variable Energy

13 13 Create Model Integrate the subsystems’ behavior Predict the system behavior in terms of energy Output: - Model

14 14 Verify & Validate Verify & validate the model Verification and validation procedures as deemed necessary by researcher

15 15 Apply Model Evaluate methods to minimize energy consumption of the system Implement the method Check for effect of the method Lights & Controls: 13.32 hp.sec (36%) Tip + Axis Movement: 7.92 hp.sec (21%) Coolant Pump: 3.24 hp.sec ( 9%) Spindle: 12.96 hp.sec (34%) Total Energy Consumed: 37.44 hp.sec Ex.: Milling of Al 2024 T351

16 16 Thank you.

17 17 Total Power

18 18 Machine Startup Lights & Controls Total Power

19 19 Coolant Pump Coolant Pump Startup Total Power

20 20 Coolant Pump Power-On Spike Spindle Startup Spindle Total Power

21 21 Rapid Axis Movement Total Power

22 22 Machining Startup TIP + Slow (Feed) Axis Movement Total Power


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