机械加工制造系统工件能量效率的预测建模及预测方法研究

Machining Manufacturing Systems(MMS) are in enormous quantity and the potentialities for energy-saving and emission-reduction to environment is great. The energy consumption of MMS has a series of features such as large number of energy sources, complicated energy flow, great dynamic changes and strong influence of random factors so that there are some difficulties for the studies on it. In recent years, a lot of studies on energy efficiency of MMS are being done on the international scene. China has the largest number of machine tools of MMS in the world and the energy efficiency is relatively very low so that how to improve the energy efficiency is urgently needed. According to the requirement, the issues about the modeling and methodology for energy efficiency forecast of workpieces in MMS will be investigated in this project. Firstly, the architecture model of the energy consumption attribute of workpieces and the energy efficiency model being geared to forecasting for total processes of workpieces in MMS are investigated And then, the method for forecasting the energy consumed by the key energy consumption components, especially the additional energy losses caused by cutting load during machining processes of workpieces, is proposed. Finally, the method for forecasting the energy efficiency of total processes of workpieces machining in MMS is given out and the forecasting system is developed. The models, methods and the system can be widely used for supporting the energy efficient investigation, the energy consumption quota formulation, energy efficient optimization, etc, and has a good prospect for application.

机械加工制造系统量大面广，其节能潜力和环境减排潜力巨大；同时其能量消耗具有能量源多、能量流程复杂、动态变化大、随机因素多等一系列特点，研究难度大；因此，近年来，对其能量效率问题研究正在国际上迅速兴起。本项目针对我国机械加工制造系统的机床拥有量世界第一、能耗总量巨大并且能量效率低而急需提高能量效率的需求，对机械加工制造系统工件能量效率的预测建模及预测方法展开研究。通过建立制造系统中工件的能量消耗属性体系结构模型和面向预测的工件加工全过程能量效率模型，提出机械加工过程载荷损耗能量等关键能耗组件的预测方法和工件能量效率超前预测的创新方法，解决工件加工全过程能量效率难以预测的难题，并在此基础上研究开发出机械加工制造系统工件能量效率预测的应用支持系统。上述模型、方法及应用系统能为机械加工制造系统能量效率研究、能耗定额制定、制造过程能效优化等一系列问题的研究和应用提供基础支持，并具有广阔的应用前景。

机械加工制造系统是一种以机床为主体的典型制造系统；量大面广，能量消耗总量巨大，并且能量效率很低，其节能潜力和环境减排潜力巨大。过去对其能量效率问题认识不够、重视不够、研究不够；但近年来，发生了根本改变，其研究正在国际上迅速兴起。本项目基于多年在机械加工制造系统能量效率领域的研究，发现了机械加工制造系统能量消耗和能量效率的可预测特性，于是对机械加工制造系统能量消耗和能量效率的预测建模及预测方法展开了研究。. 通过研究机械加工过程载荷损耗能量等关键能耗组件的预测方法，建立机械加工过程工件比能效率和能量利用率超前预测方法，并在此基础上研究开发出机械加工制造系统工件能量效率预测的应用支持系统。由于研究中发现，上述方法可为至今尚未解决的机械制造业能耗限额制定问题提供一种理论工具支持，于是我们对基于能量消耗预测的机械加工制造系统能耗限额制定方法也进行了研究。. 本项目取得了重要的研究成果： 1）揭示了机床主传动系统和机械加工制造系统能量消耗和能量效率的可预测特性，建立了机械加工过程载荷损耗能量等关键能耗组件的预测模型，提出了机械加工制造系统能量消耗和能量效率的预测方法，开发了机械加工制造系统工件能量效率预测的应用支持系统。2）提出了基于能量效率预测的机械加工系统能耗限额制定方法，可望为机械制造业这一能量消耗规律最复杂产业的能耗定额制定难题提供一种基础方法和解决思路。. 本项目共发表论文20篇：其中被SCI/EI检索19篇，SCI一区论文5篇；授权国家发明专利6项；软件著作权2项。. 本项目所建立的模型、方法及应用支持系统能为能量效率评价、工艺参数能效优化、能效优化调度、特别是至今尚未解决的机械制造业能耗限额制定问题提供一种理论工具支持，具有较大的学术价值和应用前景。