Baseline Energy Consumption Standard

Presentation about the Baseline Energy Standard for measuring the energy consumption of machine tools.

Transcript

1. system insights © System Insights, 2012 BEC: Baseline Energy Consumption Standard Dr. Athulan Vijayaraghavan System Insights Supported by: NCDMM, General Dynamics – OTS, AMT Author Contact: athulan@systeminsights.com Friday, February 17, 12
2. system insights © System Insights, 2012 Overview Standard Overview Test Definition: Lathes Case Study Web App About System Insights Friday, February 17, 12
3. system insights © System Insights, 2012 BEC: Baseline Energy Consumption Standard methodology and metric to evaluate energy consumptions of machine tools Applications: Understand energy impact of a machine tool Compare energy usage of two machine tools Estimate relative ROI of two machine tools Assess environmental impact and embedded energy of machined parts Apply in capacity planning A pragmatic approach: Perform tests in reasonable amount of time, in standard industrial setting No special fixtures, tools, workpieces Friday, February 17, 12
4. system insights © System Insights, 2012 A Modular Test Test definition: 3 parts – Tare, Component, Cutting Scale test duration to 60 minutes, total Rationale: 50% time removing material; 25% idle; 25% exercising components Test conditions Fixed Spindle RPM: Spindle construction and design is major determinant of energy usage Fixed material properties (material scaling analysis can be applied to generalized) Apply cutting tests across range of volumetric material removal rates (MRR) Test Definition Normalized Duration Scaling Tare Usage Component Usage Cutting Tests Run machine under idle condition 15 minutes Linearly scale component tests to normalized duration Exercise major components: Axes, spindle, accessories 15 minutes Linearly scale component tests to normalized duration Material removal at fixed volumetric rates 30 minutes Using Material Removal Rate Standardized BEC Metric Total Energy Usage 60 minutes Friday, February 17, 12
5. system insights © System Insights, 2012 Scaling Past research: Power-law relationship between Energy per Volume & MRR Related to process mechanics and not process parameters Consistent relationship was seen across our tests With curve fitting and basic calculus, Average Cutting Power across a range of MRR values can be estimated using a limited set of experimental data Lower MRR Higher Specific Energy y"="1286.9x+0.85" y"="2092.4x+0.856" y"="1674.1x+0.864" 0" 10" 20" 30" 40" 50" 60" 70" 80" 90" 0.000" 100.000" 200.000" 300.000" 400.000" 500.000" 600.000" Specific'Energy'(J/mm^3)' MRR'(mm^3/sec)' "TC200"" "JobberXL"" QT100" Device A Device C Device B Source: Dahmus & Gutowski, 2004 Friday, February 17, 12
6. system insights © System Insights, 2012 Test Definition for Lathes Spindle Size X Axis Travel Range Z Axis Travel Range Material Removal Rate Range Spindle Speed ~ 7.5 kW ~ 12” ~ 14” 30 mm3/sec – 150 mm3/sec 2000 ~ 4000 RPM Type of Equipment Tare Test: Measure machine when idle for 15 minutes Component: Exercise components to their limits with Spindle in operation Cutting Test: Cutting Test can be scaled appropriately for larger Lathes Pass Feed (in/rev) Feed (in/rev) DOC (in) Length (in) Initial Radius (in) End Radius (in) Volume (in3) Cutting time (sec) MRR (in3/sec) 1 0.0016 4.0000 0.0200 4.00 0.50 0.4900 0.1244 60.00 0.0021 2 0.0016 4.0000 0.0400 4.00 0.4900 0.4700 0.2413 60.00 0.0040 3 0.0016 4.0000 0.0800 4.00 0.4700 0.4300 0.4524 60.00 0.0075 4 0.0016 4.0000 0.1200 4.00 0.4300 0.3700 0.6032 60.00 0.0101 Friday, February 17, 12
7. system insights © System Insights, 2012 Case Study: Comparing 3 Devices Specification Device A Device B Device C X Axis Travel 375 mm 350 mm 300 mm Z Axis Travel 375 mm 350 mm 400 mm Max Spindle RPM 6000 6000 3560 Machine Rated Maximum Apparent Power [kVA] 15.6 24.7 16 Rated Current Load [A] 27 31 29 Device Type 2-Axis Lathe Spindle Speed 2500 RPM Material Mild Steel Devices Specs BEC test applied to 3 devices in standard Industrial environment Each test took approximately 1 hour to run Test results computed using Web-app developed by System Insights Friday, February 17, 12
8. system insights © System Insights, 2012 Case Study: Comparative Performance Device A Device B Device C 0 1000 2000 3000 4000 3160.21 Wh 2393.96 Wh 1839.22 Wh BEC Metric Device A Device B Device C 0 800 1600 2400 3200 214 Wh 256 Wh 213 Wh 777 Wh 570 Wh 452 Wh 2169 Wh 1568 Wh 1174 Wh Cutting Factor Component Factor Tare Factor By Factor BEC Metric Friday, February 17, 12
9. system insights © System Insights, 2012 Case Study: Estimating Annual Usage BEC metric can be applied in estimating the annual energy usage In the example, Device A saves more than $800 in energy costs over a year Device A Device B Device C Estimated Annual Energy Usage (kWh) 8195.00 10854.00 14574.00 Estimated Annual Carbon Footprint (MT CO2 eq) 6.56 8.68 11.66 Estimated Annual Energy Cost ($) 1065.00 1411.00 1894.00 Device A Device B Device C 0 500 1000 1500 2000 $1,894 $1,411 $1,065 Annual Energy Usage Friday, February 17, 12
10. system insights © System Insights, 2012 Takeaways BEC Metric: First of its kind for machine tools No need for a special test part Entire test runs in under 1 hour Can quickly apply in ROI and costing analysis Can be easily scaled for other machining processes Next Steps: Work with AMT in disseminating the standard Expand to other machining processes Expand to other processes technologies: forging, casting, composite fabrication Friday, February 17, 12
11. system insights © System Insights, 2012 There is an App for that Friday, February 17, 12
12. system insights © System Insights, 2012 App: Comparing Performance Friday, February 17, 12
13. system insights © System Insights, 2012 About System Insights Products and Services Monitor à Detect à Predict Realtime Analysis of Integrated Manufacturing Systems Cloud Based Distributed Data Analysis Next Generation Manufacturing Technology vimana: Manufacturing Productivity Analysis viper: Manufacturing Energy Analysis MTConnect tools Friday, February 17, 12
14. system insights © System Insights, 2012 United States 2550 Ninth Street, Suite 204B Berkeley, CA 94710 India 235/1A & 2C, Vengaivasal Main Road Madambakkam Post, Selaiyur Chennai 600073 contact: sales@systeminsights.com Our Offices Friday, February 17, 12