Hi all, new here and seeking help.
Let's assume that cost isn't an issue for a
very hardcore enthusiast. There is a plan to create a machine shop that will be utilized part-time, working with steel and aluminium. About 20 hours per week plus perhaps a couple of hours of miscellaneous usage...
If we wanted to create a machine shop utilizing most of the basic tools - CNC, lathe, drill press, vertical/horizontal saw, vertical mill, compressor, welder, etc., along with heating and heavy computer usage...
And this shop is to be run by a massive array of solar panels and supercapacitors for energy storage. What amount of energy would need to be stored for roughly a week (20 hours of typical machine shop usage) of use?
It can be pretty ballpark with some extra energy added just in case.
We're planning on using 200 Watt-hour storage capacitors that are rated to run heavy electric transportation, figuring that this will be sufficient for the details above.
The only thing left is figuring out a ballpark estimate of how much energy storage is needed.
Any help would be appreciated - thanks!
Edit: Just realized how little those capacitors held. They discharge at over 700 KW though which is insane. Instead, we'll be using 13.5 KWh banks with 5 KW continuous discharge capability.
Look, you can do this yourself without much trouble.
1) Identify the machines the shop will use. Don't forget lighting and heating.
2) Look up the voltage and current requirements for each machine. Compute full-load Watts.
3) Estimate "duty cycle" for each machine. Equivalently, hours of use per week.
4) The next step is obvious simple arithmetic. Sum of (power times duty cycle) gives you Watt-Hours. Convert to Joules or whatever floats your supercapacitor bank boat.
What we CANNOT do for you is figure out what machines you will use, nor what their duty cycles will be. There is a huge difference in power demand between an old 1.5HP Bridgeport mill and a 20-30HP vertical milling center. There is a huge difference in duty cycle between an all manual shop where you use one machine at a time and spend more time in setup than in cutting, and a CNC production shop where you are running full shifts at nearly full load with pipelined operation through multiple machines concurrently.
You asked for a ballpark estimate, and you are entirely capable of coming up with that number yourself. We are in a poorer position than you are.
If you DON'T KNOW what machines your power system is going to be supporting, find out.
Why indeed. I'd just use the grid, but the choice isn't mine. There's nothing to showcase or anything even close to that nature, but the funding is there and it's not my decision to use it in such a way.
I'm not sure if 5 KW is even enough discharge for the applications... 1 hp is like 700-something watts yeah? The consideration was Tesla Powerwalls which have 5 KW continuous discharge. I guess if there's two independent Powerwall systems, then they could run separate machine "nodes" at 5 KW each..
Not sure what the extent of machine usage will be either - the idea this guy has is in its (very) early stages, yet he wants this power system, so my best guess would be to compare it to a machine shop's KWh monthly usage vs. hours worked per month.
So again, if anyone has any numbers for KWh monthly usage for their machine shop and lets me know what machines are being used, that would be great so I could get some grasp of comparison.
There will be around 4 part time engineers for the project/s. It will be up to the engineers to devise exactly what machinery will be needed. The problem is that the power system takes a bit of time to setup - therefore it needs to be done before the engineers are hired and working. It's a bit of a dilemma.
This is why I wanted to see if I could get some monthly KWh usage out of some machine shops; I figured it would be a decent way to at least start some kind of approximation.
Currently as it stands, the best I've come up with is 3 power nodes, each holding 27 KWh, with a max discharge of 7 KW and a continuous discharge of 5 KW. This would give us access to 3x5 KW discharge so that there would be no power bottleneck.
But again, I'd really appreciate it if anyone at a machine shop has some data to share: the monthly KWh usage, hours worked per week, and what machines typically run during work.
Thanks again, sorry for how absurd the post looks!
There will be around 4 part time engineers for the project/s. It will be up to the engineers to devise exactly what machinery will be needed. The problem is that the power system takes a bit of time to setup - therefore it needs to be done before the engineers are hired and working. It's a bit of a dilemma.
-It's not a dilemma, it's the cart being before the horse.
Sorry. No, I get it, you're trying to come up with a ballpark figure, something to work with while the plan is in development. Understandable and prudent.
The problem is it's kind of a "how long is a piece of string?" type question. Some people here might have a single mill and lathe, and may only operate during banker's hours. Others may have 25 machines running three shifts and spitting out parts by the ton.
Jaxian brings up another point- your ancillaries will be a nontrivial load as well. Most of the machines will require compressed air. A single VMC and small lathe can get by with a home-shop 60 or 80 gallon upright. 25 machines running flat out will need closer to a 60HP setup- and the power draw will be even greater if you add in a refrigerated air dryer.
Lights- a small shop with three machines will need less lighting than a high-bay warehouse with thirty machines. Air conditioning- if you want accurate parts, you can't just open the doors and let the breeze blow through on a hot day. Again, five machines in a 600 square foot room won't take up anywhere near as much power as 25 machines in a square foot space.
I think you'd be better off getting some individual machine numbers- typically straight from the manufacturer- so you can "build a number" as needed. Oh, you only think we need two machines? Well, here's the draw for one, so we just double that. Oh, the plan changed and now we need eight machines? We take that single-machine number and multiply it by eight. Etcetera.
That would probably do you better than asking a guy in a different state, with a different number of different machines, running them all on utility power, on a different schedule, and using his numbers to estimate what you need.
Doc.
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