1 Framework for Energy Data Collection Prashant Lodhia Rebekah
Drake
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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
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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)
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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
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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)
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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
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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)
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8 Configure the Measuring Device Connect the power measuring
device & data logger to the systems 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
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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
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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
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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
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12 Capture & Analyze Subsystem Behavior Capture the
experimental data for each subsystem Analyze the subsystems
behavior to determine fixed energy and variable energy Fixed Energy
Variable Energy
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13 Create Model Integrate the subsystems behavior Predict the
system behavior in terms of energy Output: - Model
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14 Verify & Validate Verify & validate the model
Verification and validation procedures as deemed necessary by
researcher
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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
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16 Thank you.
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17 Total Power
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18 Machine Startup Lights & Controls Total Power
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19 Coolant Pump Coolant Pump Startup Total Power
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20 Coolant Pump Power-On Spike Spindle Startup Spindle Total
Power
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21 Rapid Axis Movement Total Power
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22 Machining Startup TIP + Slow (Feed) Axis Movement Total
Power