Machine Tool Power Consumption Display Unit
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Solution Overview
Problem
It is challenging to identify and quantify wasteful power consumption in machine tools, as existing technologies do not effectively distinguish between necessary and unnecessary power usage during different operational states.
Innovation Solution
A power consumption display unit for machine tools that measures and visually displays power usage in machining, operation standby, and operation standby OFF modes, allowing operators to identify wasteful consumption by component, enabling targeted reduction opportunities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If power consumption is measured and displayed during non-machining states, then operators can identify wasteful power consumption, but the system complexity increases due to additional measurement and display functions
Solution Approach 1:
The power consumption measurement is segmented by operational state (machining vs. non-machining) and by component (spindle, drive shafts, pumps). This segmentation allows operators to identify specific sources of wasteful power consumption without requiring a single complex measurement system, as each component's power consumption is measured and displayed separately during non-machining states.
2Loss of energy
If power consumption in non-machining state is displayed, then operators can identify potential waste, but it cannot distinguish between necessary standby power and wasteful power consumption
Solution Approach 1:
The display dynamically changes based on the operational state of the machine tool. During non-machining states, the system displays power consumption of individual components (spindle, drive shafts, pumps) to highlight potential waste, while during machining states, it shows overall power consumption. This dynamic adaptation provides context-appropriate information without overwhelming operators with unnecessary data.
Solution Approach 2:
The system provides continuous feedback to operators about power consumption during non-machining states through the display unit. By showing real-time or accumulated power consumption data for individual components during standby periods, operators can identify which components are consuming power unnecessarily and take corrective action, creating a feedback loop for energy optimization.
3Measurement precision
If detailed power consumption data by component is displayed, then operators can pinpoint specific waste sources, but the information processing and display complexity increases
Solution Approach 1:
The measurement system is divided into separate measurement units for different power-consuming components (spindle motor, drive shafts, coolant pump, hydraulic pump, lubricant pump). Each component's power consumption is measured independently and displayed separately during non-machining states. This segmentation enables precise identification of waste sources without requiring a single complex measurement system, as each component has its own dedicated measurement and display pathway.
Data Source
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AI summary
A power consumption display unit for a machine tool includes: machining state determining means (14) for determining, when a main power switch (21) used to supply power to a machine tool is ON, whether the machine tool is in a machining state where a machining program is executed to machine a workpiece or in a non-machining state where the machining program is not executed; power consumption measuring means (15 to 17) for measuring a power consumption of the machine tool during a period where the machine tool is determined to be in the non-machining state by the machining state determining means (14); and display means (18) for displaying the power consumption measured by the power consumption measuring means (15 to 17).