Abstract
Sustainability has become a major concern in many countries and is leading to strict regulations regarding the impact of products and services during their manufacturing, use, and disposal. Power consumption monitoring in manufacturing companies can lead to a reduction of machine tools energy wastes and consequently to lower expenses. To this end, a complete transparency of energy usage among the entire manufacturing facilities is required. Despite the small volume of material processed, micro manufacturing processes are energy intensive and the optimization of energy usage becomes critical for manufacturing sustainability. Electrical discharge machining (EDM) is considered an attractive solution for the manufacturing of microcomponents. In this paper, a low cost and modular data acquisition system, based on open-hardware and open-source software, for online energy consumption monitoring, is presented. The system described is applied for energy efficiency analysis of the micro EDM milling process by using a state of the art commercial machine tool. A number of sensors is connected to the data acquisition system to measure the energy consumption of the main sub-systems of the machine tool, data is recorded through a microcontroller, and sent to the main computer via Wi-Fi for data storage and analysis. Results show that the process efficiency depends on machine parameters but it is always far below 0.01 %. Solutions are suggested to improve the energy efficiency of the machine tool considered in this work.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Anastas P, Eghbali N (2010) Green chemistry: Principles and practice. Chem Soc Rev 39(1):301–312
Behrendt T, Zein A, Min S (2012) Development of an energy consumption monitoring procedure for machine tools. CIRP Ann - Manuf Technol 61(1):43–46. doi:10.1016/j.cirp.2012.03.103
Bissacco G, Hansen H, Tristo G, Valentincic J (2011) Feasibility of wear compensation in micro edm milling based on discharge counting and discharge population characterization. CIRP Ann - Manuf Technol 60(1):231–234. doi:10.1016/j.cirp.2011.03.064
Diaz N, Redelsheimer E, Dornfeld D (2011) Energy consumption characterization and reduction strategies for milling machine tool use. In: Hesselbach J, Herrmann C (eds) Glocalized Solutions for Sustainability in Manufacturing. Springer Berlin Heidelberg, Berlin, Heidelberg, pp 263–267
Draganescu F, Gheorghe M, Doicin CV (2003) Models of machine tool efficiency and specific consumed energy. J Mater Process Technol 141(2002):9–15
Duflou JR, Sutherland JW, Dornfeld D, Herrmann C, Jeswiet J, Kara S, Hauschild M, Kellens K (2012) Towards energy and resource efficient manufacturing: a processes and systems approach. CIRP Ann - Manuf Technol 61(2):587–609. doi:10.1016/j.cirp.2012.05.002
Gunasekaran A, Spalanzani A (2012) Sustainability of manufacturing and services: Investigations for research and applications. Int J Prod Econ 140(1):35–47. doi:10.1016/j.ijpe.2011.05.011
Gutowski T, Dahmus J , Thiriez A (2006) Electrical energy requirements for manufacturing processes. In: 13th CIRP International Conference on Life Cycle Engineering, vol 31
Haapala KR, Zhao F, Camelio J, Sutherland JW, Skerlos SJ, Da Dornfeld, Jawahir IS, Clarens AF, Rickli JL (2013) A review of engineering research in sustainable manufacturing. J Manuf Sci Eng 135(4):041013. doi:10.1115/1.4024040
Herrmann C, Thiede S, Kara S, Hesselbach J (2011) Energy oriented simulation of manufacturing systems concept and application. CIRP Ann - Manuf Technol 60(1):45–48. doi:10.1016/j.cirp.2011.03.127
Hu S, Liu F, He Y, Hu T (2012) An on-line approach for energy efficiency monitoring of machine tools. J Clean Prod 27:133–140. doi:10.1016/j.jclepro.2012.01.013
Kara S, Li W (2011) Unit process energy consumption models for material removal processes. CIRP Ann - Manuf Technol 60(1):37–40. doi:10.1016/j.cirp.2011.03.018
Renaldi KK, Dewulf W , Duflou JR (2011) Preliminary environmental assessment of electrical discharge machining. In: Glocalized Solutions for Sustainability in Manufacturing, pp 377–382
Kojima A, Natsu W, Kunieda M (2008) Spectroscopic measurement of arc plasma diameter in edm. CIRP Ann - Manuf Technol 57(1):203–207. doi:10.1016/j.cirp.2008.03.097
Kunieda M, Lauwers B, Rajurkar K, Schumacher B (2005) Advancing edm through fundamental insight into the process. CIRP Ann - Manuf Technol 54(2):64–87. doi:10.1016/S0007-8506(07)60020-1
Lebar A, Selak L, Vrabič R, Butala P (2012) Online monitoring, analysis, and remote recording of welding parameters to the welding diary. Strojniški vestnik - J Mech Eng 58(7–8):444–452
Liow J (2009) Mechanical micromachining: a sustainable micro-device manufacturing approach J Clean Prod 17(7):662–667. doi:10.1016/j.jclepro.2008.11.012
O’Driscoll E , O’Donnell GE (2012) Industrial power and energy metering a state of the art review. J Clean Prod. doi:10.1016/j.jclepro.2012.09.046
Rajurkar K, Levy G , Malshe A, Sundaram M , McGeough J , Hu X , Resnick R , DeSilva A (2006) Micro and Nano Machining by Electro-Physical and Chemical Processes. CIRP Ann - Manuf Technol 55(2):643–666. doi:10.1016/j.cirp.2006.10.002
Seow Y, Rahimifard S (2011) A framework for modelling energy consumption within manufacturing systems. CIRP J Manuf Sci Technol 4(3):258–264. doi:10.1016/j.cirpj.2011.03.007
Vijayaraghavan A, Dornfeld D (2010) Automated energy monitoring of machine tools. CIRP Ann - Manuf Technol 59(1):21–24. doi:10.1016/j.cirp.2010.03.042
Yu ZY, Fujino M (1998). Micro-EDM for Three-Dimensional Cavities - Development of Uniform Wear Method - 47:169–172
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Tristo, G., Bissacco, G., Lebar, A. et al. Real time power consumption monitoring for energy efficiency analysis in micro EDM milling. Int J Adv Manuf Technol 78, 1511–1521 (2015). https://doi.org/10.1007/s00170-014-6725-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6725-3