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<h1 id="spindle-power-evaluation">Spindle Power Evaluation</h1>
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<p>For the spindle capability model itself (boundary curves, thermal envelope, and the four torque/power ratios), see <a href="spindle-capability.html">Spindle Capability</a>. This page focuses on <strong>empirical validation</strong> of HiNC's spindle-power evaluation against measured data.</p>
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<h2 id="the-role-of-spindle-power-for-energy-cost-of-milling">The role of spindle power for energy cost of Milling</h2>
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<p>The energy distribution can be referenced from Heidenhain's published measurements<a id="fnref:1" href="#fn:1" class="footnote-ref"><sup>1</sup></a>. The total machine power splits into two main flows:</p>
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<ul>
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<li><strong>External processing</strong> — Cooling lubricant and Compressed air, typically supplied by facility infrastructure.</li>
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<li><strong>Electrical power of the machine</strong> — The machine's own electrical consumption, further split into Auxiliary components and CNC control (which contains Spindle and Feed drives).</li>
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</ul>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>Case A: Mean power requirement for manufacturing a housing part — Roughing (13 kW)</strong></p>
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<pre><code class="lang-mermaid">sankey-beta
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Total power (13 kW),External processing,6.4
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External processing,Cooling lubricant,5.1
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External processing,Compressed air,1.3
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Total power (13 kW),Electrical power of the machine,6.6
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Electrical power of the machine,Auxiliary components,3.1
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Electrical power of the machine,CNC control,3.5
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CNC control,Spindle,3.25
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CNC control,Feed drives,0.25
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</code></pre>
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</div>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>Case A: Mean power requirement for manufacturing a housing part — Finishing (7.4 kW)</strong></p>
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<pre><code class="lang-mermaid">sankey-beta
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Total power (7.4 kW),External processing,2.8
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External processing,Cooling lubricant,1.5
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External processing,Compressed air,1.3
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Total power (7.4 kW),Electrical power of the machine,4.6
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Electrical power of the machine,Auxiliary components,2.8
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Electrical power of the machine,CNC control,1.8
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CNC control,Spindle,1.55
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CNC control,Feed drives,0.25
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</code></pre>
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</div>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>Case B: Mean power consumption of the drives during rough facing</strong></p>
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<p>Face-milling cutter D = 60 mm, speed 4 100 rpm, infeed depth 4 mm.</p>
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<pre><code class="lang-mermaid">xychart-beta
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title "Mean power consumption of the drives (kW)"
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x-axis ["Spindle", "Feed axes"]
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y-axis "Mean power (kW)" 0 --> 20
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bar [18.5, 0.3]
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</code></pre>
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</div>
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<p>In Case A roughing, the workpiece material seems like Al6061. CNC control (Spindle + Feed drives) takes about 27% of the total power (3.5 / 13 ≈ 26.9%).</p>
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<p>From HiNC spindle power evaluation:</p>
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<ul>
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<li>Milling S45C cost 200% energy compare to Al6061T6.</li>
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<li>Milling Inconel718 cost 800% energy compare to Al6061T6</li>
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</ul>
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<p>i.e.,</p>
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<ul>
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<li>Spindle power of milling S45C occupies 42% of total power.</li>
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<li>Spindle power of milling Inconel718 occupies 75% of total power.</li>
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</ul>
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<p>Conclusion: Spindle Power matters for not easy-working materials for computing the energy cost of milling.</p>
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<h2 id="verification-of-hinc-spindle-power-evaluation">Verification of HiNC Spindle Power Evaluation</h2>
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<p>HiNC Spindle Power Evaluation is verified by comparison of the gathering Data based on the following setting.</p>
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<h3 id="setting">Setting</h3>
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<ul>
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<li><p>Machine Tool: YCM NDV102A</p>
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</li>
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<li><p>Max Spindle Power: 22.4 kW</p>
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</li>
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<li><p>Controller: Fanuc 31i-Model A</p>
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</li>
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<li><p>Sampling: 1ms</p>
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</li>
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<li><p>Total Spindle Expended Energy: 0.412 kWh</p>
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<p>The total spindle expended energy is rearranged from Fanuc ServoGuide TCMD data.</p>
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</li>
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<li><p>Work Time: 8min 30s</p>
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</li>
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</ul>
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<h3 id="comparison">Comparison</h3>
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<p>The following figures are spindle power based on Controller and the spindle power evaluated by HiNC.</p>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>The spindle power by Fanuc ServoGuide TCMD(%) * MaxSpindlePower</strong></p>
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<p><img src="spindle-power-evaluation-img/Fanuc_Spindle_Power.png" alt="Fanuc_Spindle_Power"></p>
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</div>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>The evaluated spindle power by HiNC Milling Power * Energy Conversion Efficiency (here is 0.4)</strong></p>
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<p><img src="spindle-power-evaluation-img/HiNC_Spindle_Power.png" alt="HiNC_Spindle_Power"></p>
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</div>
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<div class="footnotes">
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<hr>
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<ol>
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<li id="fn:1">
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<p>Data summarized from Heidenhain, <em>Technical Information: Aspects of Energy Efficiency in Machine Tools</em>, November 2010.<a href="#fnref:1" class="footnote-back-ref">↩</a></p>
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</li>
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