建筑陶瓷生产机械设备能耗演化机理及其低碳运行优化方法研究

Energy modeling and optimization are the core elements of green manufacturing. Many high energy intensive machines (such as ball mill machines and polishing machines) have been used in the production of ceramic tiles which consumes vast amounts of energy. The structure of these machines is complex, and there are many types of links and motions which consumes energy for the machines. In addition, the energy consumption of the machines varies with the operating status (such as the temperature of the bearings and wear of the grinding head) during the operating process of the machines. As a result, the energy modeling and optimization of the machines is very difficult. In order to solve the aforementioned problems, this project models the energy consumption of various motions of the high energy intensive ceramic machines by exploring the mechanisms of energy flow links and the relationship between the multi-dimensional parameters between the motions, transmission chains and motors. The evolution mechanisms of operating status and energy consumption of the machines during production are explored by considering the non-linear relationship between the lubricant viscous friction loss, oil viscosity and temperature as well as the wear law of the grinding head. Then experiments have been conducted and statistical analysis is used to optimize the models developed previously. Based on the proposed energy models, the method to optimize the energy consumption of the machines is developed by adopting the decomposition, coordination and feedback solution strategies and designing new algorithms. In this method, the optimized motion parameters of the machines can be obtained. The project will contribute theoretical achievements, method and technical supports for improving the energy consumption prediction accuracy and reducing the energy consumed by the ceramic production machines of our country.

能耗建模和优化是绿色制造的核心要素。建筑陶瓷生产能耗巨大，使用到球磨机、抛光机等高能耗机械设备，这些设备结构复杂、能量流环节众多，消耗能量的运动类型多样，且能耗随着设备温度、磨头磨损等运行状态的变化不断动态演化，从而导致其能耗建模和优化十分困难。针对以上问题，本项目通过研究高能耗陶瓷设备多环节能流机理和“运动-传动-电机”多维度参数映射关系，建立设备多种运动的能耗模型；根据“搅油损失-润滑油粘度-温度”非线性关联关系以及磨头磨损规律，建立设备生产过程“运行状态-能量消耗”演化模型，并通过实验研究和统计分析优化所建立的模型；进而研究设备低碳运行优化方法，应用分解-协调-反馈优化求解策略，设计算法求解得到全局能耗最低的设备运动参数。本研究能够为提高我国陶瓷生产机械设备能耗预测精度、降低设备运行能耗提供基础的理论、方法和技术支持。

节能减排是我国的基本国策，我国近期宣布了二氧化碳排放2030年达峰且2060年实现碳中和的目标。建筑陶瓷是房屋装修的必备材料，在满足人民对美好生活需要的同时，也不可避免的造成了大量的能量消耗和二氧化碳碳排放。因此，减少建筑陶瓷生产过程的能耗，是实现我国节能减排目标的必然要求。本项目围绕建筑陶瓷生产能量消耗的基础问题，分析了建筑陶瓷生产过程的物质流和能量流，针对球磨机和机床两个代表性的建筑陶瓷生产机械设备，揭示了设备能耗机理及其演化规律，进而研究了能耗预测和优化方法。在获得项目资助后，项目按计划执行，进展良好。主要研究成果包括：（1）完成了建筑陶瓷生产过程物质流和能量流的分析，得到制造过程各工序的物质和能量的输入输出及其耦合关系；（2）建立了建筑陶瓷机械设备材料加工、机械传动、电机损耗和附加载荷损耗的能耗理论模型，提出模型的基础系数特别是各环节能量传递效率的获取方法，实现建筑陶瓷生产机械设备能耗的精准预测；（3）揭示建筑陶瓷生产机械设备能耗演化机理，结合原料粒度、润滑油温、刀具磨损等设备运行状态分析设备空载和负载过程的能耗演化机理；（4）建立基于大数据分析的设备机械加工能耗以及基于长短期记忆人工神经网络的陶瓷生产过程能量流和物质流预测模型，研究通过能量流和物质流协同进行能耗优化的方法。本项目属于基础研究，能耗模型与节能方法具有较好的应用前景。研究成果发表SCI检索论文5篇，EI检索论文1篇，授权专利1项。申请者先后参加本领域学术会议3次并作学术报告1次。本项目的研究揭示了建筑陶瓷生产机械设备运行过程的能耗机理及其演化规律，以及陶瓷生产过程中物质流和能量流的协同规律，研究进展与成果在国内外产生积极的学术影响，促进建筑陶瓷工业的节能减排和绿色化转型。