What Part of the Machine Tool Consumes the Most Power? Machine Tool Energy Savings

The Importance of Energy Saving and the Role of Machine Tools

In recent years, our society has faced serious problems with the advance of climate change and depleting natural resources. Against this backdrop, the Japanese government has progressed in its efforts to reduce greenhouse gas emissions, setting a goal of a 46% reduction from 2013 levels by 2030. Currently, companies and offices account for more than 60% of all power consumption in Japan, of which the manufacturing industry accounts for half. Thus, progress made on energy saving across the manufacturing industry will contribute to the reduction of Japan's greenhouse gas emissions overall.

How exactly can manufacturers reduce their power consumption? According to statistics from the Agency for Natural Resources and Energy, production equipment accounts for more than 80% of the power consumed by the manufacturing industry. This means that the most efficient thing for manufacturers to consider is how to reduce power consumption in the production process.

Parts of Machine Tools That Consume the Most Power

In manufacturing, machine tools are an indispensable part of the production line. However, in exchange for their high production capacity, these machines consume large amounts of power. Specifically, power is used in the following parts:

Spindle motor: The central part of the machine tool that rotates to enable cutting and grinding. It consumes a particularly large amount of power during machining and during start-up and stopping.

Servos: The motors and amplifiers that precisely control the movement of each axis. Continuous power supply is required for fine movement control.

Coolant: The liquid and oil used to cool the heat generated when cutting. Parts such as the pumps for pumping up the coolant consume power.

Air compressor: Equipment for feeding compressed gas within the machine tool. Plays such important roles as tool attachment and removal and air blowing chips. Maintaining constant air pressure consumes a lot of power.

Operation panel: With their touch panels, sensors, and communication functions, modern operation panels consume power at all times. While not consuming as much power as the drive system, the cumulative power consumption cannot be ignored on production lines that operate 24-7.

Power consumption will vary depending on the size and type of machine tools used, but power is mostly consumed in the main parts above. In addition, standby power consumed outside of machining should not be overlooked. Even when not cutting, machine tools consume power to maintain their internal temperature and condition, and if it has lights, power is also used for lighting.

How to Reduce Power Consumption of Machine Tools

Machine tools account for much of the power consumed by the manufacturing industry. Next up are some ways to reduce the power consumption of machine tools.

Shorten Machining Time

Completing machining operations quickly leads directly to a reduction in power consumption. Specifically, wasted action can be eliminated by reviewing the cutting conditions and tools by workpiece, or by revising the production process. Shortening the time to machine each workpiece even by a few seconds can add up to produce a significant reduction effect.

Optimize Configuration and Machine

In some cases, optimizing the operation settings and range of machine tools can reduce wasted movement and, as a result, power consumption. Fully understand machine performance and workpiece characteristics, and adjust settings such as the cutting speed, feed rate, and cutting depth. In addition, as using larger equipment than necessary will waste power, it can also be effective to consider downsizing your machinery according to production volume and machining details.

Reduce Standby Power

Even when not machining, machine tools consume a certain amount of power in standby. To reduce wasteful standby power, save power by turning the machinery off or switching to low consumption mode when not in operation.

Reduce Air Consumption

Power consumption can also be reduced by optimizing air purges, air blowing, and other air compressor operations to reduce air consumption. Regular inspections and maintenance to prevent air leaks are also effective.

Deploy Efficient Equipment

The latest machine tools are more energy efficient, greatly reducing power consumption over older machinery. Although efficient machinery does require an initial cost, it consumes less power and shortens machining time. The shortened work hours can also be expected to reduce power consumption from air conditioning and lighting equipment.

Benefits of Energy-Efficient Machine Tools

Energy saving is a recent trend in machine tools. The benefits of adopting energy-efficient machine tools include the following. Manufacturers using aging machinery or considering replacing their machine tools are encouraged to refer to this list.

Cost Reduction

Energy-efficient machine tools can greatly reduce power consumption. For example, the "SPEEDIO" series (spindle size: BT30) developed by Brother Industries has excellent environmental performance and allows for faster, more efficient machining. When replacing a common BT40 spindle machining center, it can be expected to reduce power consumption by 80%.

Corporate Image Improvement

With the advent of the term ESG investment, reducing CO2 emissions will directly impact corporate profits and funding. Deploying energy-efficient machine tools will help in reducing environmental impact, consequentially improving your company's reputation and image.

Productivity Improvement

In the past, it was common to perform each step by hand one at a time using universal machine tools. Today, however, computer-controlled CNC machining centers are the mainstream. These machine tools can be automatically operated by programming the cutting conditions, greatly streamlining the machining process. Particularly, as energy-efficient machine tools often incorporate high-efficiency operations and advanced technologies, their introduction will lead to productivity improvements.

Introducing Machine Tools With High Environmental Performance to Reduce Power Consumption

Working to reduce power consumption in machine tools helps in terms of reducing both environmental impact and costs. Consider whether you can reduce power consumption in your current production process by reviewing your work processes and cutting conditions, or by optimizing your air consumption. In many cases, power consumption can be greatly reduced simply by replacing old equipment with energy-efficient machine tools. Consider investing in energy-efficient machine tools, as they also provide benefits such as improved production efficiency and reduced maintenance costs.