#GROB4Efficiency OPTIMIZATION OF THE ENERGY EFFICIENCY OF MACHINING CENTERS

Pioneering technologies for a sustainable world

THE FUTURE OF ENERGY EFFICIENCY

In today's world, where resourcemanagement and sustainabilityaremore important than ever, energyefcieny has become a key factor in both business competitiveness and environmental responsibility. That's why we're committed to tackling this critical issue—improving energy eficiency in machining center—-and offering in-depth insights andpractical solutions tohelp you optimizeyourproductionprocesses.

Machining centers are the backbone of modern manufacturing.Using energy wisely can significantly reduce operatingcostsandminimizeyourenvironmentalfootprint.

Explore the world of energy effciency and discoverhow cutting-edge technologies can not only enhance your production workflows but also help you make a meaningful contribution to environmental protection.

ENERGYCONSUMPTION AT A GLANCE

Inamachningcent,thatualcuingpresstyicallysn't thebiggest energycnumerstead,its theaxilia systems—-especially cooling and cutting fluid/lubrication systemsthat account for the majority of energy use.

Theenergyefficiencyofmachiningcenters canbeimprovedthroughtwotargetedstrategies:

Optimizationofthemachine

①Using high-efficiency components Switch off during idle state

Optimizing the machining strategy

①Reduction of non-machining times
①Reduction of machining times

Sustainable solutions for maximum performance ENERGY EFFICIENCY MEASURES IN GROB MACHINING CENTERS

SUSTAINABLESOLUTIONSFORMAXIMUMPERFORMANCE

GROB's development engineers are constantly reviewing whether the use of new technologies can improve energy efficiency.For instance, an entire porfolio of measures to increase the energyefficiency of the machiningcentershasbeendeveloped.

The majority of these measures are now included in the standard machine configuration at no extra cost toourcustomers.Additional measuresareavailableasoptional features.

STANDARD:

Needs-based selection of the motorized spindle according to process requirements

Hydraulicpowerunitwithneeds-basedintermittentoperation

Highly efficient drives

LED work area lighting

Efficient cooling

W Regenerative frequency converter

Z0 neg Frequency-controlledworkareaexhaustsystem

Sustainable solutions for maximum performance

ENERGY EFFICIENCY MEASURES IN GROB MACHINING CENTERS

REGENERATIVEFREQUENCYCONVERTER

Did you know that modern frequency converters can even help recover energy?Whenspindles orfeed axes decelerate, the motorfunctions ikea generator and produces electricalenergy.his recovered energy isstored in the intermedite circuit of the frequency converterWithregenerative frequencyconverter, anyexcessbraking energy canalsobefd back into the power grid when thecapacity of the intermediate circuit capacitor is exceeded—such aswhen decelerating from high rotational speeds.

Byusing regenerativefrequencyconverters, thebraking energynourmachining centerisutlized toitsfullpotential increasing energyefciency throughout your production process.That's why GROB has long relied on regenerative frequencycovertersformtorizedspindles andfeeddrives.Regenerativefrequenyconvertersareespeciallybenefial in tasks involving high spindle speeds and frequent toolchanges.naluminummachining tasks,forexamplepto 3% of the consumed electrical energy can be fed back into the grid.

HYDRAULICPOWERUNITWITHNEEDS-BASEDINTERMITTENTOPERATION

Machining centers experience fluctuating demands forhydraulic power—for example, during tool changes or when actuating clamping hydraulics. Tomeet this need eficiently GROB machining centers come standard withhigh-efficieny hydraulic units featuring accumulator charging and intermittent operation.

Compared to conventional continuous operation with unpressurized circulation,this approachoffers a significant reduction inenergyconsumtion.Another benefit is reduced oilheating.Infact, accumulator charging with intemittent operation is typically evenmore efficient thanspeed-controlled systems withfrequency converters.

EFFICIENTCOOLING

When designing our machines, we prioritize maximum efficiency.That's why we offer multiple cooling system options—-allowing you to choose the solution that best meets your specific needs.

Water-to-water heat exchanger(without refrigeration compressor)

0 With central supply of cold water <16°C
Wasteheat isconducted out of thehallbywater, thusreducing theload onthehallairconditioning system
+ Utilization of (water-bound) waste heat or use of eficient fre cooling systems (e.g., cooling towers) optional
+ No noise pollution from ventilator; no filter mat replacement; nopreventive maintenance ofarefrigerationcompressor

Water-to-waterheat exchanger(withrefrigeration compressor)

0 With central supply of cooling water >16°C
Wasteheat is conductedout of the hallbywater, thusreducing the load on thehallairconditioning system
+ Utilization of (water-bound) waste heat or use of efficient fre cooling systems (e.g., cooling towers) optional
+ No noise pollution from ventilator; no filter mat replacement
+ Regularpreventive maintenance of therefrigeration compressor

Water-to-airheatexchanger(withrefrigerationcompressor)

For decentralized refrigeration
①Lowerinstallationeffortcomparedtocentralcoolingsystems
+ Waste heat is released into the hall air, therefore increased air conditioning requirements and possible influence on machine accuracy
+ Noise pollution from ventilator;regular replacement of filter mats; regularpreventivemaintenanceoftherefrigerationcompressor

In therefrigerationcompressors, theuseof child watertosupportcooling enablesefficient andlow-losscooling (especiallyduring the frequentlyoccuring partiaload operation).Compared tohot gasbypass control, which is inherently less efficient, this approach delivers significant energy savings.

Sustainable solutions for maximum performance

ENERGY EFFICIENCY MEASURES IN GROB MACHINING CENTERS

FREQUENCY-CONTROLLEDWORKAREAEXHAUSTSYSTEM

In manymachining tasks, itsnot ecessary toperate exhaust systemsat fulflowrate allthe timeTpiclly highe flow rate is only needed during specific moments—such as just before opening the machine door or when changing parts—toeffectively remove cuting fluid mist from thework area.By adjusting the exhaust flow toactual demand, energyconsumtioncanbesinificantlyreduced,helpinglwerperatingcosts.hissmartadjustmentnotonlycut energy use,bt alosupports a more sustainable and effcient peformance from ourmachining centers.That's whyall GROBmachining centers come standard withaspeed-contrldwork areaexhaust system.Forcentralied exhaust system a motorized throttle valve is also available as an option.

0Average exhaustvolume flowWITHouT demand-based control \mathbf{Q}_{\mathsf{m e a n}}=4,000\ \mathsf{m}^{3}/\mathsf{h}
AverageexhaustvolumeflowWiTHdemand-basedcontrol \mathbf{Q}_{\mathfrak{m e a n}}=2.560~\mathfrak{m}^{3}/\mathfrak{h}

CONSUMPTIONMONITORINGFOROPTIMUMTRANSPARENCY

GROB machining centers can optionalybe equipped with comprehensive monitoring systemsfor tracking resource consumptionThese systems don't just measure electricityusage,theyalomonitor compressed air, cutting fluid, and cooling water consumption.

Thislevelofdetaild datacollectionprovidesvaluable transparency and helps youbeteunderstandandoptimize you energy usage.Withthese insights,youcanimplement targeted strategiesforreducing operating costs and promoting efficient energy management.

INTELLIGENTCUTTINGFLUIDCIRCULATION

Tomaintaintheng-tmqualityf cutingfluid rgulairulatioessentiWithout it, thecuttingfluid canrad and becmeusableweverkeping themachinruing sollfrcutin fluidirculationis ineficient andret unnecessary base load consumption.Byadding a compact control unit, cuing fluid circulationcan be automated—even when the machine is tured off. This not only preserves cuing fluid quality bt alsoleads to significant energy saving.

EXAMPLE:AUTOMATEDCUTTINGFLUIDCIRCULATIONOVERTHEWEEKEND

0Average power consumption WITHouT intelligent cutting fluid circulation {±b{\mathsf{P}}}_{\mathsf{m e a n}}=7.3 kW
OAveragepowerconsumptionWiTHintelligentcuttingfluidcirculation Pmean = 0.3 kW

Sustainable solutions for maximum performance

ENERGY EFFICIENCY MEASURES IN GROB MACHINING CENTERS

SWITCH-OFFFUNCTIONDURINGMACHINESTANDSTILL

GROB machining centers can optionaly be equipped with six customizable energy-saving profiles ESP)designed to selectively shut down machine components during idle periods.These energy-saving profiles are activated aftea user-defined standstiltimeandcanreduce power consumption tonearly zerowatts when themachine is inidle stat. Theresult:significant energy savings andlower operating costs.

Actual savings depend on the machinesusage paterns and idle time.For processs requiring high thermal stabilty, theESPsettingscanbefine-tuned accordingly

FREQUENCY-CONTROLLEDHIGH-PRESSURECOOLANTPUMP

Our machines can also be equipped with an optional speed-controlled high-pressure coolant pump. Compared to conventional fixed-speed pumps with bypass regulation, this system delivers substantial energy savings.

Choosing the right coolant pump has a significant impact on the energy efciency of your production processes. Whiletraditionalbpass-contrledpumpsalwayrunatfulrotationaleedwithexcesscoolantflwreiretd throughabypass valve, speed-contrlled pumps work muchmore efficiently.Incontrast, avariable speed pump adjusts its output preciselytomatch demand,minimizing energylossand improving overall efficiency.

OPTIMIZEDPERFORMANCEWITHMINIMALWASTE

Thebenefitsof thistechnologyareespeciallynoticeablewhenusinglong,slendertoosuchasdee-holedrillthat only requiremalcolantflrateathighpressureWithayas-controlldpum,thisreults nsinificant energs Aspeed-contrlhig-ressure colant pum,hwever, tailrperformance tactualnds, redcing ecesay.

YOUR BENEFITS

Significant energy savings
Cost reduction
+ Environmental protection
① Less foaming due to reduced coolant circulation Lessheatingofthecoolantduetoreducedcirculation

Optimized Processes for Maximum Results EFFICIENTMACHINING STRATEGIES

HOWMATERIALREMOVALRATEIMPACTSENERGYCONSUMPTION

As the material removal rate increases, so does the power consumption of the machining center.However, the specificenergyconsumption perunit of material removed actuallydereases. Inotherwords,highermaterial removal rates not only speed up production but also reduce the energy consumed per part.This makes energy-efcient manufacturing synonymous with time-effcient manufacturing.y optimizing your machining strategy, you can significantly shorten production times and reduce energyusageakeyadvantage inan era of rising energy costs and growing environmental demands.

ATAGLANCE

OReduced energy consumption perpart Higher chip removal rates reduce the specific energy consumption per machined volume
Fastermachining Increasedchipremovalratesresultinshorterproductiontimes
Eco-friendly Energy-efficient manufacturing helps reduce your environmental footprint

Powerconsumptionofmachiningcenter

Spec.energypermachinedvolume

CYCLETIMEREDUCTION-OPTIMIZEDPATHPLANNING

GROB Path Optimization(GPO)significantlyreduces non-machining time during tool repositioning.Traditional programming often results in"angular" tool paths that require the machine to stop at each change of direction. GPO takes a smarter approach, generating "round," spline-based trajectories that eliminate unnecessary axis stops. This ptimizationisepeciallyvaluableforpartswithnumerousholeor threads that require frequentrepositioning of the tools. A practical example of this is hydraulic valve blocks, where GPO can deliver substantial time savings.

Conventional vs.optimized drilling

Savings in percent: 16.0%

Conventional vs.optimized tapping

Optimized Processes for Maximum Results EFFICIENTMACHINING STRATEGIES

CYCLETIMEREDUCTION-ADAPTIVEFEEDCONTROL

Adaptivefeedcontrolsignificantlyreducesmachining timebymaking themost of yourmain pindle's available powerThe goalof thistechnologyistooptimize spindleutilization,leadingtoanoticeableboost inoverall production efficiency.

ENHANCEDEFFICIENCYTHROUGHADAPTIVEFEEDCONTROL

Adaptivefeedcontroloperatesonasimpleyethighlyeffectiveprinciplespindlepoweriscontinuouslymonitored and thefeed rate is automaticalyadjusted inresponse.When the mainspindle in't running at full apacity, the systm automaticlly increases the feed rate (within predefined limits) speeding up the machining processwithout compromising qualityaddition,adaptivefdcontrolcanreduce thefeedrateduringperidsfexceiv spineloadhpint protect both the machine and the tools.

YOURBENEFITS

①Shortermachining times Fasterthroughputwithconsistentprecision
Maximumefficiency Optimaluseofmachinecapacities
OReduced energy consumption per part Higher chip removal rates reduce energy consumption per part

WITHOuTadaptivefeedcontrol

Cycle time:29s Time[s]

At a glance!

OVERVIEW OF THE FULL SAVINGS POTENTIAL

MAXIMUMENERGYEFFICIENCYTHROUGH TARGETEDOPTIMIZATION

By strategically optimizing both the machine and the machining process, impressive energy savings can be achieved. Compared to a completely unoptimized setup, energy consumption canbe reduced by up to37%.This significant reduction not only lowers operating costs but also plays a key role in promoting sustainable manufacturing.

CUSTOMIZEDSAVINGSPOTENTIALTAILOREDSOLUTIONSFORMAXIMUMEFFICIENCY

The actual savings potential varies and depends on a number of factors, including the type of part, the specific machining strategy, and the machine configuration. However, experience shows that thoughtful optimization consistently delivers significant benefits andhelps you unlockthefull potential of your production.

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GROB-WERKE GmbH & Co.KG

Pioneers in designing and building highly innovative production and automation systems for almost 100 years.

#MachiningTechnology#UniversalMachiningCenters #AssemblyPlants#Electromobility#Automation #AdditiveManufacturing #Digitalization #NewAndQualityCheckedUsedMachines#Service

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