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Modeling the Power Consumption of a Fadal VMC20 Milling Machine

Modeling the Power Consumption of a Fadal VMC20 Milling Machine. Mark Hansen, EE Student Department of Industrial and Manufacturing Engineering Green Manufacturing Faculty Advisors: Dr. Janet Twomey, Dr. Bayram Yildirim, Dr. Lawrence Whitman, Dr. Jamal Sheikh-Ahmad

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Modeling the Power Consumption of a Fadal VMC20 Milling Machine

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  1. Modeling the Power Consumption of a Fadal VMC20 Milling Machine Mark Hansen, EE Student Department of Industrial and Manufacturing Engineering Green Manufacturing Faculty Advisors: Dr. Janet Twomey, Dr. Bayram Yildirim, Dr. Lawrence Whitman, Dr. Jamal Sheikh-Ahmad Green Manufacturing Team Members: Rebekah Drake, Prashant Lodhia Supported by NSF CAREER: DMI-973347

  2. Energy and Manufacturing • Overall Research Objective • To identify the environmental impacts of the manufacturing system so that we can mitigate their adverse impacts • My responsibilities as the E E on the team • A Problem in Manufacturing • Energy consumption impacts the environment. • By describing and predicting energy consumption, we can find ways to mitigate those impacts. • A Starting Point • Modeling the energy consumption of a single milling machine.

  3. Experimental Setup

  4. Experimental Setup • Machine: Fadal VMC20 Vertical Milling machine • Procedure: Manufacture a simple aluminum part • Data Collection: Sampling total instantaneous power consumption of the machine

  5. The Machine Lights and Controls Spindle Table Coolant Pump

  6. The Part 8mm Aluminum 2 Holes 0.25’’ in Diameter 8mm Deep Y Cut 3’’ Long 0.04’’ Deep X Cut 2.5’’ Long 0.04’’ Deep

  7. The Data Collection Device • Device Specs. • Portable device • Three-phase power measurement • Instantaneous measurement of both voltage and current • Maximum sampling rate of 250 samples per second

  8. Data Analysis

  9. Instantaneous Power Consumption

  10. Instantaneous Power Consumption Machine Startup Lights & Controls

  11. Instantaneous Power Consumption Coolant Pump Startup Coolant Pump

  12. Instantaneous Power Consumption Coolant Pump Power-On Spike Spindle Startup Spindle

  13. Instantaneous Power Consumption Rapid Axis Movement

  14. Instantaneous Power Consumption Machining Startup TIP + Slow (Feed) Axis Movement

  15. Percentage Energy Consumption Total Energy Consumed: 27,931 Joules (0.47 kWh) Tip + Axis Movement: 5,826 Joules Spindle: 9,647 Joules Coolant Pump: 2,444 Joules Lights & Controls: 10,014 Joules

  16. Goals of Future Research • Use this data to predict the energy consumption of a more complicated part, given the same machine and material, without repeating the data-collection and analysis. • Simulate production runs of many parts over time.

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