Tool Rotational Acceleration Control for Energy Reduction
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Solution Overview
Problem
Machine tools consume excessive energy due to rapid rotational acceleration of tools before reaching the workpiece, leading to inefficient energy use and high thermal losses.
Innovation Solution
A method and control device that accelerate the tool to setpoint speed only at the end of the traversing movement, determining rotational acceleration based on the time required for the movement, allowing for constant acceleration from start to end, thereby reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the tool is rapidly accelerated to setpoint speed before reaching the workpiece, then the tool reaches machining speed quickly, but excessive energy is consumed and thermal losses increase
Solution Approach 1:
The tool is accelerated to setpoint speed in advance, during the traversing movement before machining begins. The control device calculates the required acceleration based on the traversing time, ensuring the tool reaches optimal speed just as it arrives at the workpiece, eliminating unnecessary energy consumption during idle travel time
Solution Approach 2:
The rotational acceleration of the tool is dynamically adjusted based on the traversing movement parameters. Instead of using a fixed high acceleration, the system adapts the acceleration profile to match the specific traversing time and distance, optimizing energy efficiency while ensuring the tool reaches the required speed at the correct moment
2Loss of time
If high rotational acceleration is applied to the tool, then the tool reaches setpoint speed faster, but high motor currents cause increased thermal losses and reduced motor efficiency
Solution Approach 1:
The control device changes the acceleration parameter from a fixed high value to a dynamically calculated value based on traversing time. This parameter adaptation allows the system to achieve optimal acceleration that balances speed acquisition time with energy efficiency, preventing excessive motor currents and thermal losses
Data Source
AI summary
The method involves controlling predetermined movement (12) of a tool (10) using program (2) and detecting a rotational acceleration with the tool. The tool is accelerated from beginning (X0) of predetermined movement to end (X1) of predetermined movement, such that the rotational speed of the tool corresponds to the target speed at the end of predetermined movement of tool. Independent claims are included for the following: (1) control program for controlling rotational movement of tool; and (2) control device for controlling rotational movement of tool.