Green Machine

Green Machine-what is a green machine?

Machine tools in use not only energy consumption, there will be a solid, liquid and gas waste, the work environment and the natural environment directly or indirectly caused by pollution. From the entire life cycle of the machine look, how to reduce the environmental impact of the green machine has become a research focus. Green machine should have the following characteristics:

1) The main machine components made ​​of recycled materials.

2) the machine's weight and size reduction of 50% or more.

3) by reducing the moving mass, reduced empty running power and other measures to reduce the power consumption of 30 to 40%.

4) the process of using a variety of waste reduced by 50 to 60%, to ensure no contamination of the basic work environment.

5) After the machine scrap material 100% recyclable.

2.1 weight saving

According to statistics, machine tool, the process used to remove metal only about 25% power, a variety of loss accounts for most. Green machine first measure is a significant reduction in machine weight and reduce the power required to build eco-efficient machine (Eco-efficient Machine). Green machine presents a new concept: a substantial reduction of the weight of the machine, saving materials; while reducing energy consumption when using the machine.

Traditional machine design philosophy is "just enough stiffness to ensure accuracy, improve the stiffness must increase the weight of the machine." Thus, 80% of the weight of the existing machine tools for the "guarantee" the stiffness of the machine, while only 20% to meet the needs of machine tool kinematics. So plenty of room for optimization of machine tool structure. To achieve this goal is through the use of new structures and new materials are two aspects.

2.2 MQL reduction
Machine using the process of lubricating coolant is harmful emissions, particularly when used in emulsion grinding on the environment and health of workers are very harmful. Therefore, the substantial reduction in coolant use and emissions are the basic characteristics of green machine. Way to achieve this goal the following two aspects:
1) dry cutting without using coolant. Need to have sufficient machine rigidity and sharp knives, only relatively simple processing of certain shapes milling and turning operations.
2) micro-lubrication (MQL). MQL broader scope of application can be used for a variety of processing methods, but it requires special equipment to provide aerosol or cold air (cold air), and specialized lubricants.
2.3 tool efficiency
The productivity of the machine to tip on. The use of advanced tools, choose the right tool geometry and cutting parameters, machining can significantly improve efficiency and reduce the power required cutting process, extend tool life, so as to achieve with less resource consumption for a larger output purposes.
2.4 and then added
Metal cutting chip is the main tool used in the process of solid waste. The traditional method is to sell it as scrap to the recycling units, waste recycling into the community. Jiangsu Province, Yang Li Group in the house each year thousands of tons of scrap iron and steel scrap after sorting, briquetting, ingredients, melting of high quality ductile iron casting, turning waste into wealth, the press made such as the crankshaft and other key parts.
3 smart machining systems
If the green machine vision is environmentally friendly, then the goal of intelligent machines is user-friendly. "User friendly" meaning that significantly improve work efficiency and more comfort and safety. This requires the machine to self-manage their own, can automatically identify the processing task and processing status, with little or no need for manual intervention, and timely communication with the operator, are "smart" up, open up a new era of CNC machine tools.
Machine in the process will inevitably produce a variety of errors, we need a modern monitoring and compensation techniques to further improve machine performance and communication capabilities. In 2005, the U.S. National Institute of Standards and Technology that "smart processing system" (Smart Machining System) research program.
Intelligent processing system of the five objectives are:
1) dynamic optimization system. Related processes and equipment will be integrated after the model of knowledge, the system dynamic performance optimization.
2) characteristics of the device. Development characteristics of the measurement methods, models and standards, and in the running state of the machine performance measurement and communications.
3) using the next generation of numerical control system. And STEP-NC compliant interfaces and data formats, so that the machine control based on the CAD model can be run seamlessly.
4) condition monitoring and reliability, development of measurement, sensing and analysis.
5) In the process tool wear and workpiece directly measure the accuracy of the method.
The essence of intelligent processing systems, intelligent manufacturing systems and networking.
3.1 advanced process control system
Advanced Process Systems (Advanced Process System) to monitor the content of the work spindle status. Because CNC machine spindle is the heart of the state is directly related to its processing accuracy and processing efficiency. The principle is the spindle front bearing housing in the vicinity of the acceleration sensor is installed so that the vibration of the milling process can produce acceleration "g loading" value in the form of display.
Intelligent Temperature Control System 3.2
Thermal deformation of machine tools are the main factors affecting the accuracy of processing. Thermal deformation of many factors, mainly from the machine tool and machine working environment within the heat-affected:
1) environmental impact. Such as plant and the temperature distribution and temperature of air convection; sunlight, heating and other heat sources close to the impact of machine tools; and heat transfer from the machine base.
2) the impact of the internal machine. Machine components such as heat (bearings, screws, rails, motors, gears, hydraulic systems, etc.), the heat generated by the cutting process of heating and cooling systems.
The heat affected the structure of the machine is a complex heat input, and over time it changes the working state machine is unpredictable, and ultimately resulting in the size of the thermal deformation of machine tools and machine parts also depends on the thermal properties of structural materials that the thermal expansion coefficient, thermal conductivity and thermal capacity of the machine design, that is part shape, quality and distribution of heat.
4. E-machine
In the high-speed machining of complex three-dimensional contours, we often encounter how to optimize the three interrelated values: speed, accuracy and surface finish. For example, when the rough mold, it should first consider the speed; in finishing small precision electrodes, the accuracy has become the most important; and in the finishing mold, but it is the pursuit of the surface finish. How different circumstances, the rational allocation and performance optimization tools to achieve the goal, is a complex issue. Because it involves hundreds of CNC parameters, such as motion control algorithm, servo-loop gain, feed-forward, smoothing filters.