EDM Energy Conservation Without the Effort

Published 1/25/2011

EDM Energy Conservation Without the Effort

Most machine tool energy conservation systems simply track power consumption, placing the burden of actually reducing energy use on manufacturers. GF AgieCharmilles aims to change that with the EconoWatt II, an automated system for wire EDM.

Machines
EDM

Edited by: Matt Danford

Former Senior Editor, 91��Ƶ��վ��

Taking steps to reduce machine tool energy consumption offers more than just the warm, fuzzy feeling that often comes with doing one’s part for the planet. It can also impact the bottom line. However, this more tangible benefit goes only so far with most energy-saving systems, which are typically dashboard-type units that track machine power use and leave it to manufacturers to take appropriate steps for conservation.

One system recently developed for wire EDM machines promises to relieve users of that burden. Available from GF AgieCharmilles (Lincolnshire, Illinois), the EconoWatt II is an active conservation system that automatically initiates energy-saving routines at scheduled intervals.

EconoWatt II builds on developments pioneered in the manufacturer’s previous-generation system, the EconoWatt I. Both save energy by adjusting machine peripherals—for example, switching off pumps, generators, fans, chillers, lights and other such components when the machine is idle. The EconoWatt II features all the capability of the previous model along with additional functions, including wake-up cycles, humidity holding and temperature holding. Users can also access and program the unit remotely via GF AgieCharmilles’ E-Monitoring system.

However, the most significant differences between the two systems are ease of use and scheduling capability, the manufacturer says. Unlike the EconoWatt I, which operates via special M codes that must be input into the machine program, the EconoWatt II features an additional, dedicated control screen. This screen not only provides more intuitive operation, but also enables users to specify exactly when the system will activate and deactivate machine peripherals.

For example, a shop could instruct the system to switch peripherals off every day at 5 p.m. and back on again at 6 a.m., or to switch off during the weekend and power back up on Monday. Peripherals can also be programmed to switch off at the end of a part program, if the wire breaks and in the event of a machine error. To avoid losing time waiting for the machine to warm up, wake-up cycles can be programmed to restart the peripherals, circulate the dialectric and stabilize the machine’s temperature before production starts.

The system’s humidity holding function periodically activates dielectric pumps during idle periods to automatically maintain a stable, user-specified humidity level. According to the company, keeping parts wet in this way prevents pitting or rusting when exposed to shop air overnight. Likewise, keeping machine seals, power contacts and wire-threading jet nozzles wet and clean prevents contaminants from drying on their surfaces.

Similarly, the temperature holding function periodically activates circulation and chiller pumps while the generator, control screen and other components remain off. This maintains a constant, 68-degree temperature in the dielectric tank so the machine is ready for action once the peripherals are powered up again. A shop could, for example, run roughing passes unattended at night with assurance that the machine’s temperature will be sufficiently stabilized for precision finishing passes in the morning.

The unit also enables shops to track their energy savings via the Econometer, a speedometer-like display on the control screen. Users can view the machine’s current energy consumption level in kilowatts per hour as well as its consumption history, which dates back to the day the unit was installed.

Regardless of these automated functions, the primary purpose of the EconoWatt II is saving energy. According to GF AgieCharmilles, those savings can be significant—the manufacturer estimates that a wire EDM equipped with the system consumes only 1 kilowatt per hour while sitting idle.

Related Content

High RPM Spindles: 5 Advantages for 5-axis CNC Machines

Explore five crucial ways equipping 5-axis CNC machines with Air Turbine Spindles® can achieve the speeds necessary to overcome manufacturing challenges.

Automation 11 Aug 2023

Inside the Premium Machine Shop Making Fasteners

AMPG can’t help but take risks — its management doesn’t know how to run machines. But these risks have enabled it to become a runaway success in its market.

Automation 29 Sep 2023

CNC Machine Shop Honored for Automation, Machine Monitoring

From cobots to machine monitoring, this Top Shop honoree shows that machining technology is about more than the machine tool.

Large Part Machining 4 Dec 2024

Inside a CNC-Machined Gothic Monastery in Wyoming

An inside look into the Carmelite Monks of Wyoming, who are combining centuries-old Gothic architectural principles with modern CNC machining to build a monastery in the mountains of Wyoming.

Automation

AMRs Are Moving Into Manufacturing: 4 Considerations for Implementation

AMRs can provide a flexible, easy-to-use automation platform so long as manufacturers choose a suitable task and prepare their facilities.

Economics

Last Chance! 2025 Top Shops Benchmarking Survey Still Open Through April 30

Don’t miss out! 91��Ƶ��վ��'s Top Shops Benchmarking Survey is still open — but not for long. This is your last chance to a receive free, customized benchmarking report that includes actionable feedback across several shopfloor and business metrics.

Basics

Machine Shop MBA

Making Chips and 91��Ƶ��վ�� are teaming up for a new podcast series called Machine Shop MBA—designed to help manufacturers measure their success against the industry’s best. Through the lens of the Top Shops benchmarking program, the series explores the KPIs that set high-performing shops apart, from machine utilization and first-pass yield to employee engagement and revenue per employee.

91��Ƶ��վ��

EDM Energy Conservation Without the Effort

Share

Related Content

High RPM Spindles: 5 Advantages for 5-axis CNC Machines

Inside the Premium Machine Shop Making Fasteners

CNC Machine Shop Honored for Automation, Machine Monitoring

Inside a CNC-Machined Gothic Monastery in Wyoming

Read Next

AMRs Are Moving Into Manufacturing: 4 Considerations for Implementation

Last Chance! 2025 Top Shops Benchmarking Survey Still Open Through April 30

Machine Shop MBA

Country

Industries Served

Operations Performed

Welcome to 91��Ƶ��վ��!

EDM Energy Conservation Without the Effort

Share

ZEISS Industrial Quality Solutions

Featured Content

Featured Videos

QualiChem Inc.

Featured Content

Featured Videos

CNC Engineering, Inc.

Featured Content

Featured Videos

T J Davies, Co., Inc.

Featured Content

All World Machinery Supply

Featured Content

Featured Videos

Heidenhain Corporation

Featured Content

Featured Videos

Mikron Corp.

Featured Content

Featured Videos

SMW Autoblok Corporation

Featured Content

Featured Videos

Related Content

Read Next

Country

Industries Served

Operations Performed

Welcome to 91��Ƶ��վ��!