INGENIERÍA E INVESTIGACIÓN VOL. xx No.

x, xxxx - xxxx (xx-xx)

DOI: http://dx.doi.org/10.15446/ing.investig.vxxnx.xxxx

111Equation Chapter 1 Section 1 Electrical energy analysis consumption

of a CNC lathe
machine using mobile average filter
Análisis de consumo de energía eléctrica de una máquina de torno CNC usando un filtro
promedio móvil

ABSTRACT
The importance of the consumption of electric energy is substantial for any activity, in the manufacturing process excessive consumption of electrical energy has been
identified and in the profitable industry the income should not exceed the expenses. Data acquisition and monitoring of manufacturing process in machine tools with
CNC is common in the industry, a feature problematic with measurements is all real energy signals contain noise. The interest of the study is aimed at identifying the
energy consumption of a CNC lathe machine using numerical tools.

The industry is interested in doing innovative things, in outdoing their competitors and very often uses the numeric tools for solutions problems of energy saving. The
energy consumption of a CNC machine cutting is largely determined by the tool condition, in this work, the electrical energy consumed by a CNC machine is mea-
sured using mobile average filter. In conventional energy measurements of a CNC there are some undesirable signal noises that can modify the result. The aim of this
paper is to analyze, study and filter the pure signal energy consumption of the CNC machine cutting tool for a machining routine of a three-axial CNC milling ma-
chine using classic mobile average filter. The proposed methodology can be used for tool life analysis, choose a viable cooling and machine speed control.

Keywords: Electrical consumption analysis, electrical noise measurements, mobile average filter, CNC lathe machine.

RESUMEN
La importancia del consumo de energía eléctrica es sustancial para cualquier actividad, en el proceso de fabricación se ha identificado un consumo excesivo de
energía eléctrica lo que propicia una industria no rentable ya que los gastos no deben superar los ingresos. La adquisición de datos y el monitoreo del proceso de fa -
bricación en máquinas herramienta con CNC es común en la industria, un problema identifcado en las mediciones registradas, es que todas las señales de energía real
contienen ruido. El interés del estudio apunta a identificar el consumo de energía de una máquina de torno CNC utilizando herramientas numéricas.

La industria está interesada en hacer cosas innovadoras, en superar a sus competidores y muy a menudo usa las herramientas numéricas para solucionar problemas de
ahorro de energía. El consumo de energía de una máquina de corte CNC está determinado en gran medida por la condición de la herramienta, en este trabajo, la
energía eléctrica consumida por una máquina CNC se mide utilizando un filtro promedio móvil. En las mediciones de energía convencionales de un CNC hay algunos
ruidos de señal indeseables que pueden modificar el resultado. El objetivo de este trabajo es analizar, estudiar y filtrar el consumo de energía de señal pura de la herra-
mienta de corte de máquina CNC para una rutina de mecanizado de una fresadora CNC de tres ejes que utiliza un filtro promedio móvil clásico. La metodología pro -
puesta se puede utilizar para el análisis de la vida útil de la herramienta, elegir un enfriamiento viable y control de velocidad de la máquina.

Palabras clave: Análisis de consumo eléctrico, mediciones de ruido eléctrico, filtro promedio móvil, máquina de torno CNC.
Received: January __th 20xx
Accepted: January __th 20xx

Introduction gorithms is to extract the pure signal of electrical consumption of

a CNC lathe machine.
Highly reliable control systems are demanded for supervision,
control and optimization of technical processes in energy saving In the manufacturing industry different investigations have been
(Sirodz et al., 2017). The study of energy saving in industrial pro- carried out in order to maximize the use of resources, such as
cesses in any manufacturing sector has become a priority because monitoring the operation of the machines while performing a ma-
industrial sector uses more energy than other end-use sectors. chining process, such as spindle speed, cutting advances, change
of cutting tool. The life of a cutting tool will also depend on the
Machining processes cause rising in the energy consumption of amount of material that is renewed (Qian, 2016).
the industrial electrical circuit. It has been shown that enhancing
energy efficiency of machine tools increases the environmental In industrial processes the machines have variables that increase
performance of machining systems (Shaohua Hu, 2012). As a re- the energy expenditure, this additional consume affects the econ-
sult, a reliable and precise estimation model of energy consump- omy of the company, there are cases in which they have studied
tion that can reflect the principal dynamic parameters of the elec- why so high expenses have become, being a clear example the en-
trical energy is required (Jiang et al., 2019). ergy consumption generated by a tool in a machining center, in
which its variables such as speed, cutting shape, tool wear or cur-
rent consumed (Pradeep Kumar, 2016).
The main difference between the current studies and this work is In the industry, the electrical system overload has numerous detri-
the use of moving average filter. The goal of signal processing al- mental effects, among which the following stand out: The in-

1
Electrical energy analysis consumption of a CNC lathe ma-chine using mobile average filter

crease in power losses in the cables, in the transformers and in the

generators of the network. C. Filtering and Eliminating Noise

The reduction in electricity consumption during mass production Results D. Electrical Energy Consumption
carried is attractive for any company that seek to reduce polluting Analysis
emissions and production costs. Many efforts have been made to
develop heuristic algorithms to define cutting parameters that de-
Figure 1. Flowchart of the study.
crease energy consumption during manufacturing (Marín et al.,
2018) and (Liu et al., 2015). Carried out the previous procedure, the electrical current of the
tool is analyzed, and the signal is filtered to eliminate unwanted
The moving average filter, develop by Steven W. Smith, is used
information, the result of this methodology is a pure signal of the
to minimize noise level from temporal data series as well as act-
energy consumed during the manufacturing process.
ing as a low pass filter, smoothing the numerical data of the real
signal. Mathematically, it is similar to convolution in signal pro- A. Data Acquisition of the Current
cessing, thus due to its simplicity is used for time domain encoded
signals. An electronic circuit that measures the current consumption of a
CNC is described and analyzed. In order to convert the current
The average mobile filter is often used to reduce the magnitude of signal to analog signal a commercial sensor is used, the ACS712
the noise that may be present in a signal. To see how this is possi - current sensor has been used to measure both small laboratory and
ble, assume that the input x [ n ] is given in the form x [ n ] = large industrial type devices.
s [ n ] + e [ n ], where s [ n ] is the soft part of x [ n ], and e [ n ] is The ACS712 current sensor is a hall effect current sensor, which
the erratic or noisy part of x [ n ]. This filter has different applica- provides an economical and accurate solution for measuring AC
tions to obtain real information of numerical data applied to engi- alternating current or DC direct current. This Sensor works by
neering, electrical circuits, finance, prices in the basic caste, popu- transforming a magnetic field arising from the passage of current
lation censuses, advanced statistics, etc. (Congbo et al., 2017). through an internal copper wire in the sensor, and converting this
field into a variable voltage, the sensor has three pins, two of
In addition, there are many works about the importance of the them supply and the third is the output which measures the flow
working speed of the machining machines through theoretical of current (Ballesteros, 2004) and (Liuping Wang, 2014).
concepts, experience and laboratory experiments. Due to the in-
herent simplicity of this model, there exist techniques to form es-
timates of the parameters of the CNC current, with a numerical
model during a specific work routine, however, these techniques
do not have filters to reduce noise.
Electrical signals mostly contain noise caused by artifacts, addi-
tional device, interference from the network or wiring, which can
hardly be eliminated by conventional analog filters. The digital
filters have had great reception, but unfortunately, they induce
distortions in these signals (Ballesteros, 2004).
In this paper a relatively new technique is presented for the filter-
ing of signals with the minimum distortion and the maximum
amount of noise eliminated using the discrete wavelet transform.

Methodology Figure 2. Physical connection of the sensor with the CNC.

Next section describes the data acquisition, filtering The current sensor is in series with power supply of the tool spin-
method and the test system developed for its validation. dle (see figure 2). For the validation of the proposed method, data
readings are considered which were carried out during a machin-
Figure 1 shows the steps of the proposed process, followed ing routine of 1400 milliseconds and 1350 data. The numerical
by result section. data obtained are processed in MATLAB using Mobile Average
Filter.

A. Data Acquisition of the Current

B. Mobile Average Filter

2
INGENIERÍA E INVESTIGACIÓN VOL. xx No. x, xxxxx - xxxx (xx-xx)
The industrial applications of electrical drive control have sources
that generate high frequency noises, namely an appropriate filter
in the control will be beneficial to reduce the errors caused by the
noise.
B. Mobile Average Filter
In the dynamic systems noise injection can occur anywhere, this
limitation makes it difficult for any filtering method to minimize
the error between the filtered signal and the original signal
(Klipec, 1967).
Noise is defined as everything in a set of data, signal, image or in-
formation in general, which
 It is not of interest. M: Number of pints in the middle and smoothing signal
 Degrades or distorts the signal. In the figure 3, shows the variation of a moving average filter ac-
 Prevents or limits the study or use of the information. cording to the average.
Signal noise in an industrial network can cause havoc with
Figure 3. Variation of a moving average filter according to the average (Alonso,
process control systems. There may be noise in (Klipec, 1967) 2013).
and (Rojas, 2018.
 The sensor, transducer or actuator with which the signal Given a positive integer N, the moving average filter at point N
interacts. is a discrete time system given by the input / output.

 Poor wiring practices, the channel or in the interface 1

measuring and sensor, and between each stage. γ [ n ]= ( x [n]+ x [ n−1 ] + x [ n−2 ] +…+ x [ n−N +1 ] )
N
 The misinterpretation of a signal, in the method of analy- (2)
sis and modeling.
 Contamination effects on electronic products
Where x [ n ]the input is applied to the filter, and γ [ n ]is the re-
sulting output response. For example, if N=3, the moving aver-
 Long wire leads picking up radio frequency or proximity age filter at point 3 is given by the input / output.
to other electrical equipment.
1
Even certain processing and analysis methods can introduce some y [ n ] = (x [n]+ x [ n−1 ] + x [ n−2 ] ) (3)
noise, disturbance or collateral modification, although it may be 3
the cost of obtaining other benefits. This noise varies depending
Thus, the term "point N" refers to the number of input values used
on the circuit and may occur due to different effects, such as ther-
when calculating the filter output. The filter is known as the
mal noise, trigger noise and manufacturing quality (Santamaría,
"moving average filter", because we calculate the following value
2012). The moving average filter is a more common filter in digi-
tal signal processing that can smooth high frequency fluctuations and n-1] of the output, moving the time point interval over which
in the data or eliminate periodic trends of a specific frequency of the filter output is calculated.
the data, the filter operates by averaging a number of points of the The moving average filter modifies the simulation program in
input signal to produce each point of the output signal (Alonso, which your filtered data is implemented, this filter can use the sig-
2013). nal values to calculate the average. The filtering characteristics
The filter was mathematically expressed as: are not affected, the only drawback being that the filtered signal is
slightly delayed. This filter can be implemented as a single point
M −1 filter function that receives an unfiltered value and returns its fil-
1
γ [ n ]= ∑ x [ n+k ]=
M 1 + M 2 +1 K =− M 1
tered version. Such a function is implemented in MATLAB to fil-

1
¿…..
M 1 + M 2 +1
+x [n ] + x [n -1] +…. x [ n+ M 2 ] ¿
(1)

ter signals (Kendall et al., 1983).

Where: Figure 4 shows an input sequence plotted as a function of a
γn: Input signal dummy index k and samples involved in the computation of the
output sample γn for n=7, M 1=0, M 2=5 ,the output sam-
xk : Output signal ple γ [ 7 ] is equal to one-sixth of the sum of call the samples

INGENIERÍA E INVESTIGACIÓN VOL. xx No. x, xxxx - xxxx (xx-xx) 3

Electrical energy analysis consumption of a CNC lathe ma-chine using mobile average filter

between the vertical dotted lines. To compute γ [ 8 ] , both dotted An important parameter in signal processing to analyze perfor-
lines would move one sample to the right. mance is the Signal to Noise Ratio (SNR). It relates and calculates
the average powers of both the signal and the noise, where mathe-
Figure 4. Sequence values involved in computing a casual moving average filter matically it is represented as follows (Proakis, 1996).
(Oppenheim, 1998).

∑ f (n)
2
The following figure 5 shows the representation of an improved
signal after applying a mobile average filter, after that it is noted
SNR=10 log 2 (4)
that the noise was eliminated (unwanted information). ∑ e (n)
2 2
Where ∑f ( n )∧∑ e (n) are the powers of the signal and
noise averages. Graph 2 shows the total noise of the real signal
marked in green and the signal filtered using Mobile average fil-

Figure 5. Representation of a signal (Left) with its respective moving average

filter (Right) (Klipec, 1967).

Results
The results section is divided in two sub-sections, where the first
describes the filtering technique of the current consumption. The
second sub-section presents the electrical energy consumption
analysis using a numerical method. In order to test the accuracy of
the technique a specific CNC machine routine is evaluated using
well stablished techniques.
C. Filtering and Eliminating Noise
Graph 1 represent the current consumption for a specific machin-
ing of process in CNC which last 1300 ms (M), material is re-
moved for a solid block using a cutting tool to produce a part ter in red.
based on G-code. As shown in green color in graph 1 the current Graph 2. Total noise of the Current over time and the filtered current signal.
consumption of the tool at the time of the machining routine is af-
fected by unwanted information (noise) which presents unstable D. Electrical Energy Consumption Analysis
positions within the real signal, this is due to that there are inter-
Elemental analysis and observation of graph 2 indicates high fre-
nal components of the system that cause the signal to be affected
quency reduction when filtering technique is applied. As a result
when doing the numerical survey of the current flow.
of this technique, the Electrical energy consumption analysis can
be assessed using numerical method.
A direct way of estimating the electrical energy consumption is
developed in this research through the use of the integration of the
filtered current signal of the graph 1.
∞
E=∫ |f (t)| dt
2
(5)
0

Where f ( t ) is the filtered current signal. Equation (5) can be used

in the following way which calculates the area under the curve of
a signal in a range of 0 to M (1300 ms).
M

∫|f (t )| dt
2
(6)
Graph 1. Signal with noise of energy consumption during machining process
0
and the filtered pure signal.

The red signal in graph 1 shows the same signal as the green, but
now the moving average filter that eliminates the noise is applied,
resulting in the pure signal of the power consumption of the tool.
The Filtered current signal was calculated using equation 1, 2 and
3.

4
INGENIERÍA E INVESTIGACIÓN VOL. xx No. x, xxxxx - xxxx (xx-xx)
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Shaohua Hu, Fei Liu, Yan He, Tong Hu (2012). An on-line approach for en-
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tion. Elsevier. https://doi.org/10.1016/j.jclepro.2012.01.013

Jiang, Z., Gao, D., Lu, Y. et al. (2019). Electrical energy consumption of CNC
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Qian Qian Zhong, R. T. (2016).Evaluation on models of calculating energy

consumption in metal. Int J Adv Manufacturing Techno, pp. 2087–2099.

Pradeep Kumar Patil, A. I. (2016).Measurement and analysis of cutting

forces”. International Journal of Structural, 359-369.

Marín, R, Juárez, C y Martínez, Irma. (2018). Análisis del consumo energético

Graph 3. Electrical energy consumption of the filtered current signal. a través de la medición de corriente para determinar la vida útil de la he -
rramienta de corte de un torno usando integración numérica. Revista de In-
geniería Eléctrica Vol.2 No.5, pp. 10-17.
Graph 3 shows the electrical energy consumption for a specific
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under the signal Matlab toolboox is used. tion modelling based on cutting power: a milling case, Journal of Cleaner
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parameters in multi-pass face milling for máximum energy efficiency and
The above numerical implementation of the method can be used minimum production cost, Journal of Cleaner Production, 140:1805-18.
for optimization cutting conditions of the routines of a material,
Ballesteros L; Dora M. (2004). Aplicación de la transformada wavelet discreta
tool life, choose a viable cooling system and optimize the energy
en el filtrado de señales bioeléctricas Umbral Científico, núm. 5, diciem-
expenditure of the numerical control machine. The proposed bre, pp. 92-98 Universidad Manuela Beltrán Bogotá, Colombia.
method can be replicated in other analysis of energy consumption,
that use an electronic device monitor system with undesirable Liuping Wang, Shan Chai, Dae Yoo, Lu Gan, Ki Ng. (2014).PID and Predict-
ive Control of Electrical Drives and Power Converters using MATLAB /
noise. Simulink”, IEEE Press, Wiley, ,116-126.
Conclusion Klipec, Bruce E. (1967). Reducing Electrical Noise in Instrument Circuits,
IEEE Trans. Ind. Gen. Appl., vol. IGA-3, no. 2, March/April.
The paper proposes to combine conventional energy consumption
analysis of a CNC machine with a low-pass filter, to assess the Rojas, H.E., C.A. Cortés y M.C. Forero. (2018).Local polynomial approxima-
contribution and impact of the research a specific CNC machine tion and intersection of confident intervals for removing noise of lightning
routine is evaluated. The results showed the effectiveness of this electric field measurements, 85(205) ,264-273, doi: 10.15446/dyn-
a.v85n205.64151, DYNA.
method in the high frequency noise reduction.
Santamaría, F; Cortés, C y Román, F. (2012). Uso de la Transformada de On-
The mobile media filter for signal filtering is an effective tool for deletas (Wavelet Transform) en la Reducción de Ruidos en las Señales de
engineering and research, as well as for various applications such Campo Eléctrico producidas por Rayos”, Bogotá – Colombia Vol. 23(1),
as industrial energy consumption. Many recent investigations 65-78. doi: 10.4067/S0718-07642012000100008.
have examined the electrical consumption, this interest arises A, Alonso, N.GilNegrete, J, Nieto; J.G.Giménez. (2013). Development of rub-
from an electric energy saving measure nevertheless, the signal ber component model suitable for being implemented in railway dinamic
noisy is a common problem of the actual techniques. In this arti- simulation programs, Journal of Sound and Vibration ,332,3032-3048.
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dres: Macmillan.
The basic procedure is examined by analyzing the filtering char-
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graph 1 shows how noise was eliminated as unwanted informa- ing, Upper Saddle River, Nueva Jersey, Prentice Hall.
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trol machines integrated into its manufacturing processes, the Prentice Hall, 36-39. 1.
present method can be applied, future research will be carried out
to determine best practice and energy saving conditions of the
CNC in manufacturing processes.

Acknowledgment
The most sincere thanks to the Autonomous University of the
State of Mexico with the postgraduate degree in computer science
and to Conacyt for the financial support granted through the
scholarships during the preparation of this work.
References

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