CN109634238A - A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method - Google Patents
A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method Download PDFInfo
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- G05B19/00—Programme-control systems
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- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention discloses a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation of Facing to Manufacturing industry energy-saving and emission-reduction and monitoring methods.This method according to numerically-controlled machine tool actual processing number of parts and processing qualified parts quantity, calculates first and obtains numerically-controlled machine tool processing quality qualification rate；Then there is rejected product in period demand and energy consumption when without rejected product by obtaining numerically-controlled machine tool, numerical-controlled machine tool machining process mass-energy efficiency is calculated.Based on numerically-controlled machine tool processing quality qualification rate obtained above and mass-energy efficiency, the relational model between NC Machine Quality-energy efficiency and processing quality qualification rate is constructed.Real-time monitoring and overload alarm and control are carried out to numerical control machine tooling procedure quality-energy efficiency based on above-mentioned assessment models.The method of the present invention assesses science to numerical control machine tooling procedure quality-energy efficiency, and can be a kind of practical and effective method by numerical-controlled machine tool machining process mass-energy control from view of profit in claimed range.
Description
Technical field
The present invention relates to the assessments of discrete manufacturing business numerically-controlled machine tool energy efficiency and energy efficiency monitoring and the field that promoted, especially
It is a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method.
Background technique
Numerically-controlled machine tool is widely used mechanized equipment in discrete manufacturing business.The research table of Massachusetts Institute Technology professor
The energy consumption of bright numerically-controlled machine tool and its indirectly caused by environmental emission be very significant.Numerically-controlled machine tool makes in China's manufacturing industry
Dosage is big and wide application, and therefore, the energy consumption total amount of numerically-controlled machine tool is very huge.Study numerical-controlled machine tool machining process matter
Amount-energy efficiency, which is assessed, and monitoring method is energy-saving for manufacturing industry is of great significance.
On the one hand numerically-controlled machine tool operational process energy efficiency is influenced by machined parameters, its processing part of still further aspect
Quality also influences numerically-controlled machine tool integral energy efficiency.The method that present analysis assesses numerical-controlled machine tool machining process energy efficiency is main
Consider the influence of machined parameters, but seldom considers influence of the processing part quality to lathe energy efficiency.Currently still lack
A kind of effectively practical the numerically-controlled machine tool energy efficiency assessment that can comprehensively consider numerically-controlled machine tool processing part quality influence and prison
Prosecutor method.The method of the present invention by comprehensively considering influence of the numerically-controlled machine tool processing quality qualification rate to numerically-controlled machine tool energy efficiency,
Construct the relational model between NC Machine Quality-energy efficiency and numerically-controlled machine tool processing quality qualification rate.Further pass through logarithm
Machine mass-energy efficiency real-time monitoring is controlled, is realized to NC Machine Quality-energy efficiency overload alarm function, thus
Make NC Machine Quality-energy efficiency control in the range of requiring.The method of the present invention considers machine tooling mass loss logarithm
The influence for controlling lathe integral energy efficiency, can effectively and accurately assess NC Machine Quality-energy efficiency, and can be to numerical control
Machine mass-energy efficiency carries out overload alarm, and making operator, targetedly control machine mass-energy efficiency exists in time
It is a kind of practical assessment of lathe energy efficiency and monitoring method in claimed range.
Summary of the invention
The purpose of the present invention is to provide one kind can be to discrete manufacturing business numerical-controlled machine tool machining process mass-energy efficiency
The method with monitoring is assessed in progress in real time, will be assessed obtained numerical-controlled machine tool machining process mass-energy efficiency and is preset
NC Machine Quality-energy efficiency lower limit value compare, to realize numerical-controlled machine tool machining process mass-energy efficiency
Overload alarm makes NC Machine Quality-energy efficiency control within the scope of requiring.
A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method, include the following steps:
Step 1, by each part install RFID (radio frequency identification) label, part after processing is completed, RFID
Reader 1 perceives part to be processed, and number of parts adds 1 automatically；Then verify that whether part is qualified product.If qualified product, then
Into qualified product storage area；If rejected product, then entering rejected product storage area, RFID reader 2 perceives rejected part,
Part rejected product quantity adds 1 automatically simultaneously；Therefore numerically-controlled machine tool actual processing number of components in available period given time
Amount (is denoted as Oactual) and numerical control machine tooling rejected product quantity (be denoted as Odefect)。
Step 2, according to numerically-controlled machine tool actual processing number of parts in obtained period demand and rejected product quantity, meter
Calculation is digitally controlled machine tooling qualified parts quantity, and calculation formula is as follows:
Oqualified=Oactual-Odefect
Wherein: OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity, OactualIndicate numerically-controlled machine tool actual processing zero
Number of packages amount, OdefectIndicate that numerically-controlled machine tool processes rejected product quantity.
Step 3, by aforementioned obtained period demand numerically-controlled machine tool processing qualified parts quantity and numerically-controlled machine tool it is practical add
Work number of parts is divided by, and numerically-controlled machine tool processing quality qualification rate is calculated, and calculation formula is as follows:
Wherein: ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, OqualifiedIndicate that numerically-controlled machine tool processes qualified parts
Quantity, OactualIndicate numerically-controlled machine tool actual processing number of parts.
Step 4, when numerically-controlled machine tool processing part is without rejected product within the given time cycle, numerically-controlled machine tool processes part
Total energy consumption is calculated by the actual consumption value of numerically-controlled machine tool actual processing number of parts and processing one-piece part and is obtained, and calculation formula is such as
Under:
Eno_defect=Oactual×Eactual
Wherein: Eno_defectNumerically-controlled machine tool energy consumption when indicating in period given time without rejected product, OactualIndicate number
Control lathe actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part.
Step 5, when numerically-controlled machine tool processing part has rejected product within the given time cycle, numerically-controlled machine tool processes part
Total energy consumption is unqualified by numerically-controlled machine tool actual processing number of parts, the actual consumption value for processing one-piece part, numerically-controlled machine tool processing
Product quantity and single-piece rejected product are done over again energy consumption calculation acquisition, and calculation formula is as follows:
Ewith_defect=Oactual×Eactual+Odefect×Erework
Wherein: Ewith_defectIndicate numerically-controlled machine tool energy consumption when having rejected product in period given time, OactualIndicate number
Control lathe actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, OdefectIndicate numerical control
Machine tooling rejected product quantity, EreworkIndicate that single-piece rejected product is done over again energy consumption.
Step 6, numerically-controlled machine tool energy consumption when will have rejected product in aforementioned obtained period demand and when without rejected product
Numerically-controlled machine tool energy consumption be divided by, numerical-controlled machine tool machining process mass-energy efficiency is calculated, calculation formula is as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, Eno_defectIndicate period given time
Numerically-controlled machine tool energy consumption when interior no rejected product, Ewith_defectIndicate numerically-controlled machine tool when having rejected product in period given time
Energy consumption.
Step 7, according to aforementioned obtained numerically-controlled machine tool processing quality qualification rate computation model and numerical-controlled machine tool machining process
Mass-energy efficiency calculation model, derivation operation is digitally controlled machine tooling procedure quality-energy efficiency and numerically-controlled machine tool is processed
Relational model between quality pass rate, relational model are expressed as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, EactualIndicate numerically-controlled machine tool work sheet
The actual consumption of part part, ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, EreworkIndicate that single-piece rejected product is done over again energy
Consumption.
Step 8, by the numerical-controlled machine tool machining process mass-energy efficiency eta in obtained period given timequality_e
With preset numerical-controlled machine tool machining process mass-energy efficiency low alarm setting valueIt is compared, is closed if meeting
It is formulaThen show that numerical-controlled machine tool machining process mass-energy efficiency is normal.If meeting relational expressionThen warning note numerical-controlled machine tool machining process mass-energy efficiency is abnormal, while the assessment is all
NC Machine Quality-energy efficiency of phase and corresponding numerically-controlled machine tool processing quality qualification rate, single-piece rejected product are done over again energy
Consumption value is shown on a display screen.
Step 9, producers carry out numerical control machine tooling procedure quality targeted according to the warning note of step 8
Adjustment and control, numerically-controlled machine tool processing quality qualification rate is improved, so that NC Machine Quality-energy efficiency is improved to wanting
Seek range.
In step 4, the actual consumption E of numerically-controlled machine tool processing one-piece partactual, by numerically-controlled machine tool air switch
Place's installation energy consumption measuring device, numerically-controlled machine tool process part using given machined parameters, and energy consumption measuring device measures zero simultaneously
The single part power consumption of polymer processing value repeatedly measured is averaging, is digitally controlled the reality of machine tooling one-piece part by part power consumption of polymer processing
Border power consumption values Eactual。
In steps of 5, single-piece rejected product is done over again energy consumption Erework, by installing energy consumption at numerically-controlled machine tool air switch
Measuring device, numerically-controlled machine tool to rejected product do over again operation when, energy consumption measuring device measures simultaneously does over again energy consumption, will be multiple
The rejected product of measurement is done over again power consumption values averaging, is obtained single-piece rejected product and is done over again energy consumption Erework。
Compared with prior art, the invention has the following beneficial effects:
The method of the present invention is by considering numerically-controlled machine tool actual processing number of parts and processing qualification zero in period given time
Number of packages amount establishes numerically-controlled machine tool processing quality qualification rate model, further considers numerically-controlled machine tool processing quality qualification rate to numerical control
The influence of lathe energy efficiency establishes numerically-controlled machine tool processing quality qualification rate and NC Machine Quality-energy efficiency relationship
Model.Further by realizing NC Machine Quality-energy efficiency to NC Machine Quality-energy efficiency real-time monitoring
Overload alarm makes operator targetedly control machine mass-energy efficiency in time in claimed range.The method of the present invention
Consider that numerically-controlled machine tool processing quality loses influence to numerically-controlled machine tool energy efficiency, can be practical and accurately evaluates numerical control machine
The mass-energy efficiency of bed, and by realizing to numerical control machine to NC Machine Quality-energy efficiency Real Time Monitoring
Bed mass-energy efficiency overload alarm, allows numerical tool operation personnel targetedly to control NC Machine Quality-energy
Amount efficiency is the effective and practical NC Machine Quality of one kind-energy efficiency assessment and monitoring method in claimed range.This hair
Bright methodological science is practical and can extend to the mass-energy efficiency evaluation and monitoring of other machinery equipment.
Detailed description of the invention
Fig. 1 is the flow diagram of the method for the present invention；
Fig. 2 is the device configuration schematic diagram of the method for the present invention.
Specific embodiment
The present invention is explained in detail now in conjunction with examples and drawings.
The present invention proposes a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method.The method of the present invention
Flow diagram as shown in Figure 1, first by the RFID label tag and RFID reader 1 being attached on part, perception obtains
Numerically-controlled machine tool actual processing number of parts in period given time.By RFID reader 2, perception obtains numerically-controlled machine tool processing not
Qualified product quantity.And then numerically-controlled machine tool in period given time is calculated and processes qualified parts quantity.Based on obtained number
Lathe actual processing number of parts and processing qualified parts quantity are controlled, numerically-controlled machine tool processing quality qualification rate is calculated.Pass through
Repeatedly measurement numerically-controlled machine tool processes the power consumption values of single part under given work parameter, averages and is digitally controlled machine tooling list
The actual consumption value of part part.Actual consumption value based on numerically-controlled machine tool actual processing number of parts and processing one-piece part, meter
Calculation obtains numerically-controlled machine tool energy consumption when no rejected product.Operation of doing over again is carried out to single rejected product by repeatedly measuring numerically-controlled machine tool
When power consumption values, average to obtain single-piece rejected product and do over again energy consumption.According to obtained numerically-controlled machine tool actual processing part
Quantity, the actual consumption value for processing one-piece part and single-piece rejected product are done over again energy consumption, and number when rejected product is calculated
Control lathe energy consumption.The further numerically-controlled machine tool energy according to numerically-controlled machine tool energy consumption when obtaining without rejected product and when having rejected product
Consumption, is calculated numerical-controlled machine tool machining process mass-energy efficiency.Based on established numerically-controlled machine tool processing quality qualification rate rate
Model and NC Machine Quality-energy efficiency model, building NC Machine Quality-energy efficiency and numerically-controlled machine tool processing quality are closed
Relational model between lattice rate.It carries out NC Machine Quality-energy efficiency real-time monitoring and realizes to transfinite based on above-mentioned relation model
Warning function makes NC Machine Quality-energy efficiency control within the scope of requiring.
Device configuration of the present invention is as shown in Fig. 2, specifically include that numerically-controlled machine tool, energy consumption measuring device, RFID read-write
Device 1 and RFID reader 2, RFID label tag, qualified product storage area, rejected product storage area, the computer for installing Sql database and
Display screen.Energy consumption measuring device is done over again power consumption values for measuring numerically-controlled machine tool processing part actual consumption value and part.RFID mark
Label are attached on part, for identifying part；The RFID label tag that RFID reader 1 is attached on part by perception, obtains
To numerically-controlled machine tool actual processing number of parts；The RFID label tag that RFID reader 2 is attached on rejected part by perception, is obtained
Obtain numerically-controlled machine tool processing rejected product quantity；Qualified product storage area is for keeping in qualified parts；Rejected product storage area is used
In temporary rejected part；The computer for installing Sql database processes number of parts for storing the numerically-controlled machine tool collected
Information and numerically-controlled machine tool energy consumption and mass-energy efficiency information；Display screen is connected with computer, for showing numerically-controlled machine tool matter
Amount-energy efficiency, processing quality qualification rate and single-piece rejected product are done over again consumption information.
For the embodiment of the present invention by taking the processing part process of CK6153i type numerically-controlled machine tool as an example, the part of processing is cylinder
Shape part is assessed and is monitored to its process mass-energy efficiency using the method for the present invention, and to CK6153i numerical control
Machine tooling procedure quality-energy efficiency overrun condition carries out warning note.In the embodiment of the present invention, to numerical control machine tooling
Journey mass-energy efficiency is primary every assessment in 1 hour.
1. obtaining numerically-controlled machine tool actual processing number of parts and processing rejected product quantity
The process mass-energy efficiency evaluation period to numerically-controlled machine tool CK6153i is 1 hour, and numerically-controlled machine tool is practical
Processing number of parts initial value is set as 0 (Oactual=0), processing rejected product quantity initial value is set as 0 (Odefect=0).Often
RFID label tag is attached on a part, part is perceived by RFID reader 1 after processing is completed, numerically-controlled machine tool actual processing number of components
The automatic cumulative 1 (O of amountactual=Oactual+1).Then verify that whether part is qualified product, if qualified product, then enters qualified product
Storage area；If rejected product, then enter rejected product storage area, RFID reader 2 perceives the RFID mark on rejected part
Label, simultaneous processing rejected product quantity add 1 (O automaticallydefect=Odefect+1).By taking morning 9:00-10:00 on October 17 as an example,
Numerically-controlled machine tool CK6153i processes part 25 altogether.RFID reader 1 perceives 25 RFID label tags, is digitally controlled lathe reality
Process number of parts Oactual=25.Inspection has 1 wherein for rejected product, and rejected product is entering rejected product storage area
When, RFID reader 2 perceives the RFID label tag of the part, obtains CK6153i and processes rejected product number within the assessment cycle
Amount is Odefect=Odefect+ 1=1.
2. obtaining numerically-controlled machine tool processes qualified parts quantity
It is O that numerically-controlled machine tool, which processes qualified parts number calculation formula,qualified=Oactual-Odefect.Wherein: OqualifiedTable
Registration control machine tooling qualified parts quantity, unit is part；OactualIndicate that numerically-controlled machine tool actual processing number of parts, unit are
Part；OdefectIndicate that numerically-controlled machine tool processes rejected product quantity, unit is part.Still by taking morning 9:00-10:00 on October 17 as an example,
Numerically-controlled machine tool actual processing number of parts is 25 (Oactual=25), numerically-controlled machine tool processing rejected product quantity is 1 (Odefect
=1).It brings above-mentioned data into formula, is calculated in the period, it is O that numerically-controlled machine tool, which processes qualified parts quantity,qualified=
Oactual-Odefect=25-1=24 part.
3. obtaining numerically-controlled machine tool processing quality qualification rate
According to obtained numerically-controlled machine tool actual processing number of parts and processing qualified parts quantity, numerical control machine is calculated
Bed processing quality qualification rate, computation model areWherein, ηqualityIndicate that numerically-controlled machine tool processing quality is closed
Lattice rate, OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity, unit is part；OactualIndicate numerically-controlled machine tool actual processing zero
Number of packages amount, unit are part.Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing in the period has been obtained
Number of parts Oactual=25, it is O that numerically-controlled machine tool, which processes qualified parts quantity,qualified=24.Above-mentioned data are substituted into public
FormulaIt calculates and obtains numerically-controlled machine tool processing quality qualification rate ηquality=96.0%.
4. numerically-controlled machine tool energy consumption when obtaining without rejected product
4.1 obtain the actual consumption of numerically-controlled machine tool processing one-piece part
Energy consumption measuring device is installed, for recording numerical control at CK6153i numerically-controlled machine tool air switch in the present embodiment
The power consumption values of machine tooling process.Repeatedly measurement CK6153i numerically-controlled machine tool processes single part under given machined parameters
The power consumption values of power consumption values, 50 times measured single part under given machined parameters are as shown in table 1.
Table 1
Average value is calculated based on 50 power consumption values obtained in above-mentioned table 1, numerically-controlled machine tool processing one-piece part can be obtained
Actual consumption value Eactual=156.3 (kJ).
Numerically-controlled machine tool energy consumption when 4.2 calculating are without rejected product
Practical energy based on obtained numerically-controlled machine tool actual processing number of parts and numerical control machine tooling one-piece part
Numerically-controlled machine tool energy consumption when no rejected product, calculation formula E is calculated in consumption valueno_defect=Oactual×Eactual.Wherein,
Eno_defectNumerically-controlled machine tool energy consumption when indicating in period given time without rejected product, unit are kilojoule (kJ)；OactualIt indicates
Numerically-controlled machine tool actual processing number of parts, unit are part；EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, it is single
Position is kilojoule (kJ).Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing zero in the period has been obtained
Number of packages amount Oactual=25, numerically-controlled machine tool processes the actual consumption value E of one-piece partactual=156.3 (kJ).By above-mentioned data
Substitute into formula Eno_defect=Oactual×Eactual, calculate numerically-controlled machine tool energy consumption E when obtaining without rejected productno_defect=
3907.5(kJ)。
5. obtaining numerically-controlled machine tool energy consumption when having rejected product
5.1 acquisition single-piece rejected products are done over again energy consumption
The energy consumption measuring device installed at CK6153i numerically-controlled machine tool air switch, while rejected product can be measured and done over again
The power consumption values of process.When CK6153i numerically-controlled machine tool does over again to rejected product, energy consumption measuring device measures single rejected product and does over again
Energy consumption.Measurement obtains power consumption values when 10 groups of rejected products are done over again altogether, as shown in table 2.
Table 2
Average value is calculated based on 10 groups of power consumption values obtained in above-mentioned table 2, single-piece rejected product can be obtained and do over again power consumption values
Erework=125.7 (kJ).
5.2 calculate numerically-controlled machine tool energy consumption when having rejected product
Based on obtained numerically-controlled machine tool actual processing number of parts, the actual consumption value for processing one-piece part, numerical control
Machine tooling rejected product quantity and single-piece rejected product energy consumption calculation of doing over again obtain numerically-controlled machine tool energy consumption when having a rejected product,
Calculation formula is Ewith_defect=Oactual×Eactual+Odefect×Erework.Wherein, Ewith_defectIndicate period given time
Inside there is numerically-controlled machine tool energy consumption when rejected product, unit is kilojoule (kJ)；OactualIndicate numerically-controlled machine tool actual processing number of components
Amount, unit is part；EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, unit is kilojoule (kJ)；OdefectIt indicates
Numerically-controlled machine tool processes rejected product quantity, and unit is part；EreworkIndicate that single-piece rejected product is done over again energy consumption, unit is kilojoule
(kJ).Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing number of parts in the period has been obtained
Oactual=25, numerically-controlled machine tool processes the actual consumption value E of one-piece partactual=156.3 (kJ), numerically-controlled machine tool processing do not conform to
Lattice product quantity Odefect=1, single-piece rejected product is done over again power consumption values Erework=125.7 (kJ).Above-mentioned data are substituted into formula
Ewith_defect=Oactual×Eactual+Odefect×Erework, calculate the numerically-controlled machine tool energy consumption obtained when having rejected product
Ewith_defect=25 × 156.3+1 × 125.7=4033.2 (kJ).
6. obtaining numerical-controlled machine tool machining process mass-energy efficiency
Numerically-controlled machine tool energy consumption when according to aforementioned obtained numerically-controlled machine tool energy consumption when having a rejected product and without rejected product,
It calculates and obtains numerical-controlled machine tool machining process mass-energy efficiency, calculation formula are as follows:Wherein,
ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, Eno_defectIt indicates in period given time without rejected product
When numerically-controlled machine tool energy consumption, unit be kilojoule (kJ)；Ewith_defectIndicate numerical control when having rejected product in period given time
Lathe energy consumption, unit are kilojoule (kJ).Still by taking morning 9:00-10:00 on October 17 as an example, obtain in the period without unqualified
Numerically-controlled machine tool energy consumption E when productno_defect=3907.5 (kJ) have numerically-controlled machine tool energy consumption E when rejected productwith_defect=
4033.2(kJ).Above-mentioned data are substituted into formulaIt calculates and obtains numerically-controlled machine tool in the time cycle
Process mass-energy efficiency is ηquality_e=96.9%.
7. obtaining NC Machine Quality-energy efficiency and quality pass rate relational model
According to aforementioned obtained numerically-controlled machine tool processing quality qualification rate computation model and numerical control machine tooling procedure quality-energy
Amount efficiency computation model, derivation operation is digitally controlled machine tooling procedure quality-energy efficiency and numerically-controlled machine tool processing quality is closed
Relational model between lattice rate, relational model areWherein, ηquality_e
Indicate numerical-controlled machine tool machining process mass-energy efficiency, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, it is single
Position is kilojoule (kJ)；ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, EreworkIndicate that single-piece rejected product is done over again energy consumption,
Unit is kilojoule (kJ).It still by taking morning 9:00-10:00 on October 17 as an example, has obtained in the time cycle, numerically-controlled machine tool processing
The actual consumption E of one-piece partactual=156.3 (kJ), single-piece rejected product are done over again energy consumption Erework=125.7 (kJ).It will be upper
It states data band to enter in relational model, then available numerical-controlled machine tool machining process mass-energy efficiency and numerically-controlled machine tool process matter
Measure the relational model between qualification rate
8. carrying out numerical-controlled machine tool machining process mass-energy efficiency monitoring and overload alarm
By the numerical-controlled machine tool machining process mass-energy efficiency eta in obtained assessment cyclequality_eWith preset
Machine tooling procedure quality-energy efficiency low alarm setting valueIt is compared.Numerically-controlled machine tool processing in the present invention
Procedure quality-energy efficiency low alarm settingIt is counted according to numerical-controlled machine tool machining process mass-energy efficiency historical data
It analyzes and combines that manager's is empirically determined.If numerical-controlled machine tool machining process load-energy efficiency low alarm setting in embodimentStill by taking morning 9:00-10:00 on October 17 as an example, the numerically-controlled machine tool processing in the time cycle has been obtained
Procedure quality-energy efficiency ηquality_e=96.9%, then meet relational expressionTable
Bright numerical-controlled machine tool machining process mass-energy efficiency is normal.Precedent is accepted, if numerical-controlled machine tool machining process mass-energy is imitated
Rate low alarm settingIt is set as 98%, then meets relational expressionAt this point, report
Alert prompt numerical-controlled machine tool machining process mass-energy efficiency is abnormal, lower than under numerical-controlled machine tool machining process mass-energy efficiency
Limit, while by the numerical-controlled machine tool machining process mass-energy efficiency (η in the assessment cyclequality_e=96.9%) and it is corresponding
Numerically-controlled machine tool processing quality qualification rate rate (ηquality=96.0%) single-piece rejected product is done over again energy and in the assessment cycle
Consumption value (Erework=125.7kJ) display is on a display screen.
9. carrying out parameter adjustment control according to warning note.
Machine operation personnel carry out numerically-controlled machine tool CK6153i machined parameters targeted according to the warning note of step 8
Adjustment so that numerical-controlled machine tool machining process mass-energy control from view of profit is in the normal range.
The method of the present invention can be used for the Scientific evaluation of numerical-controlled machine tool machining process mass-energy efficiency in discrete manufacturing business
Numerically-controlled machine tool processing is realized so that numerical-controlled machine tool machining process mass-energy control from view of profit is within the scope of requiring with monitoring
The Energy Saving Control of operational process.The method of the present invention provides effectively practical technology and methods for realization discrete manufacturing business energy-saving and emission-reduction
It supports.
Finally, it is stated that the above case study on implementation is only used to illustrate the technical scheme of the present invention and not to limit it, to the present invention
Technical solution be modified or replaced equivalently, without departing from the objective and range of the method for the present invention, should all cover this
In the scope of the claims of invention.
Claims (3)
1. a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method, which is characterized in that including walking as follows
It is rapid:
Step 1, by each part install RFID (radio frequency identification) label, part after processing is completed, RFID read-write
Device 1 perceives part to be processed, and number of parts adds 1 automatically；Then verify that whether part is qualified product.If qualified product, then enter
Qualified product storage area；If rejected product, then enter rejected product storage area, RFID reader 2 perceives rejected part, simultaneously
Part rejected product quantity adds 1 automatically；Therefore numerically-controlled machine tool actual processing number of parts (note in available period given time
For Oactual) and numerical control machine tooling rejected product quantity (be denoted as Odefect)。
Step 2, it according to numerically-controlled machine tool actual processing number of parts in obtained period demand and rejected product quantity, calculates
Qualified parts quantity is processed to numerically-controlled machine tool, calculation formula is as follows:
Oqualified=Oactual-Odefect
Wherein: OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity, OactualIndicate numerically-controlled machine tool actual processing number of components
Amount, OdefectIndicate that numerically-controlled machine tool processes rejected product quantity.
Step 3, by numerically-controlled machine tool processing qualified parts quantity and numerically-controlled machine tool actual processing zero in aforementioned obtained period demand
Number of packages amount is divided by, and numerically-controlled machine tool processing quality qualification rate is calculated, and calculation formula is as follows:
Wherein: ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity,
OactualIndicate numerically-controlled machine tool actual processing number of parts.
Step 4, when numerically-controlled machine tool processing part is without rejected product within the given time cycle, numerically-controlled machine tool processes part total energy
Consumption is calculated by the actual consumption value of numerically-controlled machine tool actual processing number of parts and processing one-piece part and is obtained, and calculation formula is as follows:
Eno_defect=Oactual×Eactual
Wherein: Eno_defectNumerically-controlled machine tool energy consumption when indicating in period given time without rejected product, OactualIndicate numerical control machine
Bed actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part.
Step 5, when numerically-controlled machine tool processing part has rejected product within the given time cycle, numerically-controlled machine tool processes part total energy
Consumption processes rejected product number by numerically-controlled machine tool actual processing number of parts, the actual consumption value for processing one-piece part, numerically-controlled machine tool
Amount and single-piece rejected product are done over again energy consumption calculation acquisition, and calculation formula is as follows:
Ewith_defect=Oactual×Eactual+Odefect×Erework
Wherein: Ewith_defectIndicate numerically-controlled machine tool energy consumption when having rejected product in period given time, OactualIndicate numerical control machine
Bed actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, OdefectIndicate numerically-controlled machine tool
Process rejected product quantity, EreworkIndicate that single-piece rejected product is done over again energy consumption.
Step 6, numerically-controlled machine tool energy consumption when will have rejected product in aforementioned obtained period demand and number when without rejected product
Control lathe energy consumption is divided by, and numerical-controlled machine tool machining process mass-energy efficiency is calculated, calculation formula is as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, Eno_defectIndicate nothing in period given time
Numerically-controlled machine tool energy consumption when rejected product, Ewith_defectIndicate numerically-controlled machine tool energy when having rejected product in period given time
Consumption.
Step 7, according to aforementioned obtained numerically-controlled machine tool processing quality qualification rate computation model and numerical control machine tooling procedure quality-
Energy efficiency computation model, derivation operation are digitally controlled machine tooling procedure quality-energy efficiency and numerically-controlled machine tool processing quality
Relational model between qualification rate, relational model are expressed as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, EactualIndicate that numerically-controlled machine tool processes single-piece zero
The actual consumption of part, ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, EreworkIndicate that single-piece rejected product is done over again energy consumption.
Step 8, by the numerical-controlled machine tool machining process mass-energy efficiency eta in obtained period given timequality_eWith it is pre-
The numerical-controlled machine tool machining process mass-energy efficiency low alarm setting value first setIt is compared, if meeting relational expressionThen show that numerical-controlled machine tool machining process mass-energy efficiency is normal.If meeting relational expressionThen warning note numerical-controlled machine tool machining process mass-energy efficiency is abnormal, while the assessment is all
NC Machine Quality-energy efficiency of phase and corresponding numerically-controlled machine tool processing quality qualification rate, single-piece rejected product are done over again energy
Consumption value is shown on a display screen.
Step 9, producers targetedly adjust numerical control machine tooling procedure quality according to the warning note of step 8
Whole and control, improves numerically-controlled machine tool processing quality qualification rate, so that NC Machine Quality-energy efficiency is improved to requiring model
It encloses.
2. a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method, feature exist as described in claim 1
In in step 4, numerically-controlled machine tool processes the actual consumption E of one-piece partactual, by being installed at numerically-controlled machine tool air switch
Energy consumption measuring device, numerically-controlled machine tool process part using given machined parameters, and energy consumption measuring device measures part processing simultaneously
The single part power consumption of polymer processing value repeatedly measured is averaging, is digitally controlled the actual consumption of machine tooling one-piece part by energy consumption
Value Eactual。
3. a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method, feature exist as described in claim 1
In in steps of 5, single-piece rejected product is done over again energy consumption Erework, by installing energy consumption measurement dress at numerically-controlled machine tool air switch
Set, numerically-controlled machine tool to rejected product do over again operation when, energy consumption measuring device measures simultaneously does over again energy consumption, by what is repeatedly measured
Rejected product is done over again power consumption values averaging, is obtained single-piece rejected product and is done over again energy consumption Erework。
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