An Energy Consumption Estimation Method for the Tool Setting Process in CNC Milling Based on the Modular Arrangement of Predetermined Time Standards

Abstract

Modeling and estimating the energy consumption of computer numerical control (CNC) milling systems have been recognized as essential ways to realize lean energy consumption management and improve energy efficiency performance. As the preparatory phase, considerable time and energy are consumed in the tool setting process. However, research on the tool setting process mainly focuses on accuracy and operational efficiency, and the energy consumption is usually ignored or simplified. Accurately estimating the energy consumption of the tool setting process is thus indispensable for reducing the energy consumption of CNC milling systems and improving their energy efficiency. To bridge this gap, an energy consumption estimation method for the tool setting process in CNC milling based on the modular arrangement of predetermined time standards (MODAPTS) is presented. It includes three steps: (i) operations decomposition and determination of the MODAPTS codes for the tool setting process, (ii) power modeling of the basic action elements of the machine tool, and (iii) energy consumption modeling of the tool setting process. Finally, a case study was conducted to illustrate the practicability of the proposed method via energy consumption modeling of the tool setting process using an XH714D CNC machine center with a square workpiece, in which the estimation values of the operating time and the energy consumption for the tool setting process were 210.786 s and 140,681.68 J, respectively. The proposed method can increase the transparency of energy consumption and help establish labor-hour quotas and energy consumption allowances in the tool setting process.