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<p>The existing machine tool energy consumption (EC) modeling mainly focuses on the total EC or cutting EC of the machine tool, while limited research exists on modeling the inherent EC of mechanical drive components in the spindle system. Therefore, this study adopts bond graph (BG) theory, and under comprehensive consideration of the influence of multiple rotational speeds, a BG model of a belt-type spindle system is established. Then, the output power of the system and the EC characteristics of the key components are obtained through derivation and simulation calculation. The output power of the EC model is used to predict the start-up EC through the peak power mapping method. The feasibility and practicability of the model are verified through experiments. The adjusted R<sup>2</sup> value of the damping coefficient of the pulley reaches 0.9998. Experimental results show that the average relative errors of the BG model and the start-up EC prediction model are 2.29 % and 5.94 %, respectively, and the minimum relative errors are 0.34 % and 0.9 %, respectively. The model proposed in this paper provides theoretical support and a new evaluation index for the optimal design of spindle systems.</p>

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Modeling and prediction method for inherent energy consumption of CNC machine tool spindle systems

  • 期刊论文

  • 发表日期：

    2025年6月26日

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  • Xuanyi Wang,
  • Hongyi Wu,
  • Junshou Yang,
  • Xiaolei Deng,
  • Zhongyu Piao,
  • Xinhua Yao

摘要

The existing machine tool energy consumption (EC) modeling mainly focuses on the total EC or cutting EC of the machine tool, while limited research exists on modeling the inherent EC of mechanical drive components in the spindle system. Therefore, this study adopts bond graph (BG) theory, and under comprehensive consideration of the influence of multiple rotational speeds, a BG model of a belt-type spindle system is established. Then, the output power of the system and the EC characteristics of the key components are obtained through derivation and simulation calculation. The output power of the EC model is used to predict the start-up EC through the peak power mapping method. The feasibility and practicability of the model are verified through experiments. The adjusted R2 value of the damping coefficient of the pulley reaches 0.9998. Experimental results show that the average relative errors of the BG model and the start-up EC prediction model are 2.29 % and 5.94 %, respectively, and the minimum relative errors are 0.34 % and 0.9 %, respectively. The model proposed in this paper provides theoretical support and a new evaluation index for the optimal design of spindle systems.