A Low-Cost Monitoring System for Energy Consumption Analysis During Machining Operation

Abstract

CNC machining is a common manufacturing process which requires significant energy consumption. The first step towards energy savings is to monitor the energy consumption of CNC machines, which are usually equipped with a three-phase electrical power supply. However, existing energy metres are costly for detailed measurements of a machine's energy consumption level. This study developed a low-cost energy measurement device based on the Arduino microcontroller-based platform to monitor energy consumption during CNC machining processes. The product development methodology includes the measurement procedure, calibration, pilot study prior to the commencement of the actual study, and results validation. A field experiment was conducted to validate the design's functionality. Preliminary energy measurements were performed on tool standby, tool changing, spindle rotation speeds, and feed rates. Results showed that the average standby power of the CNC machine is 5.15 kWh, with actual power consumption for the coolant pump motor, spindle motor, and feed motor being 0.43 kW, 0.77 kW, and 0.45 kW, respectively. Energy consumption is increased with spindle rotation speed and feed rate increments. The analysis results demonstrated the product's ability as a cost-effective solution for machining energy monitoring.