CN102621932A - Energy consumption prediction method for use in service process of numerically-controlled machine tool - Google Patents
Energy consumption prediction method for use in service process of numerically-controlled machine tool Download PDFInfo
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Abstract
The invention provides an energy consumption prediction method for use in the service process of a numerically-controlled machine tool specific to the current situation of the lack of an energy consumption prediction method for a numerically-controlled machine tool. In the method, an energy prediction model for use in the service process of a numerically-controlled machine tool based on energy prediction of three types of sub-processes such as starting, idle load and processing on the basis of energy consumption characteristic analysis for the service process of the numerically-controlled machine tool. The energy prediction model for every type of sub-process is resolved respectively, so that an energy consumption prediction result of an entire numerically-controlled machine tool service process is obtained. According to the method, the energy consumption of a machine tool processing process can be predicted directly according to numerical control processing technic parameters.
Description
Technical field
The invention belongs to the Machine-Tool Control technical field, relate in particular to a kind of numerically-controlled machine military service process energy consumption forecast new method.
Background technology
The machining system that with the lathe is main body has a large capacity and a wide range, and it is very big that energy-saving potential and environment reduce discharging potentiality; The prediction of the energy consumption of lathe is the important component part of energy consumption problem in the machine tooling process, for energy consumption formulate by norm, a series of problems such as Cutting Process parameter energy saving optimization all have important support effect; Therefore, the research of energy consumption forecasting problem in the machine tooling process is risen rapidly in the whole world.Li, people such as W have set up a kind of energy predicting model under processing conditions, and have verified the reliability and the accuracy [3] of this model through the method for experiment; People such as Dietmair A have proposed a kind of lathe and energy for factory of formulating based on the discrete time of statistics and have consumed universal modeling method, and this method can directly be used for planning process, and [4] are predicted in the energy resource consumption of different configurations under the different scenes; But above these methods all reckon without the additional load loss power of the complicacy of lathe; People such as Gutowski have also carried out a series of analyses to the processing environment factor, have introduced the theoretical energy consumption model [5,6] of process, but he does not carry out very clear and definite definition to each parameter wherein, and do not know the value and concrete derivation of each parameter.Therefore, these methods all can not be used for the prediction to the energy consumption of numerically-controlled machine military service process more than.
Though existing document shows existing many experts and scholars lathe energy consumption forecasting problem has been done corresponding research; But the method that can be used in the energy predicting of the numerically-controlled machine military service process in the actual production does not find as yet; Its main cause is: numerically-controlled machine itself is a very complicated system; Energy Flow is very complicated in whole military service process, and various informativeization, the more important thing is that its influence factor is numerous.Therefore be difficult to find a general model to come its energy consumption is predicted.
Summary of the invention
To the problem that exists in the prior art, the purpose of this invention is to provide a kind of lathe military service process energy consumption forecast method.Can compare assessment accurately to the energy consumption of the whole military service process of lathe through this method.
For realizing above purpose, the present invention has adopted following technological means:
1. the energy consumption Forecasting Methodology of a numerically-controlled machine military service process; It is characterized by: the military service overall process is divided into start-up course, unloaded process, process; And respectively three types of subprocess are carried out the energy consumption prediction, obtain the total energy consumption prediction of the whole military service process of lathe with this.Its forecast model is:
Wherein:
representes the total energy consumption of certain military service process;
representes the number of all kinds of subprocess in this military service process; In order to sign start-up course, unloaded process, process,
representes the sequence number of each subprocess respectively for subscript
,
,
.
2. the foundation of the energy predicting function of promoter process: through a plurality of rotating speed points of prior setting; Measure lathe startup energy consumption under each rotating speed; And come measured energy consumption data is carried out match with a quadratic function about rotating speed, setting up with the rotating speed with this is the startup energy consumption function of variable:
.
3. the foundation of the power function of unloaded subprocess: measure the no-load power under a plurality of different rotating speeds in advance; And use quadratic function to come measured power data is carried out match about rotating speed, setting up with the rotating speed with this is the no-load power function of variable:
.
4. process subprocess energy consumption Forecasting Methodology: the energy predicting model of processing subprocess is:
Wherein, Said no-load power function and technology rotating speed can be confirmed
; Can confirm
according to technological parameter; Definite method of
is seen the practical implementation method.
With respect to prior art, the present invention has as follows and produces effect:
1, only need know each cutting data and the energy consumption that just can seek out the whole military service process of lathe process time of each process in the process, this method is simple, and generally suitable to existing numerically-controlled machine.
2, the lathe military service process consumption information that predicts by the inventive method; And the error in the lathe military service process between the actual consumption is no more than 10%; And mostly this error is stochastic error; And therefore error amount, has good reference value in real work within range of application.
3, the inventive method can be used for that the lathe energy efficiency is obtained, the efficiency assessment in the mechanical processing process, energy consumption monitoring, energy management, the demarcation of lathe energy consumption etc., wide application prospect is arranged in reality.
Description of drawings
Fig. 1 is a numerically-controlled machine military service process energy consumption prediction flow process rough schematic view;
Fig. 2 is case part blank figure;
Fig. 3 starts the energy consumption function curve for lathe;
Fig. 4 is a lathe no-load power function curve.
Embodiment
The present invention proposes a kind of numerically-controlled machine military service process energy Forecasting Methodology, this method is that numerically-controlled machine military service process is divided into startup, zero load, three types of subprocess of processing, and respectively every type of subprocess is carried out energy predicting.
It is following that the present invention sets up the dynamo-electric main transmission energy consumption of lathe military service process forecast model by above-mentioned thinking:
Wherein,
representes the total energy consumption of certain military service process;
representes the number of each subprocess in this military service process; In order to sign start-up course, unloaded process, process,
representes the sequence number of each subprocess respectively for subscript
,
,
.
1 basic data is obtained
1.1 Coefficient
,
access
Because what coefficient
,
embodied is the characteristic of machine tool mechanical kinematic train; Relevant with drive path, so each rotating speed shelves of numerically-controlled machine all corresponding corresponding
,
value.Obtain the value of underlying parameter
,
, need minimum two groups
,
,
.Therefore can in every grade of rotating speed of numerically-controlled machine, freely choose rotating speed; The distinct cutting experiment of the group (
) of carrying out
; Measure corresponding
and
value; And combine experiment parameter to calculate corresponding cutting power
, go out the value of underlying parameter
and
by least square fitting.
Before using the experimental
set load power
, cutting power
, processing power
establish equation:
Have by least square method:
Solve:
Thereby obtaining
,
values are:
Can be obtained based on coefficient
,
.
Its basic coefficients of lathe for same model should be identical, needn't measure accordingly and test by every lathe.
1.2 start energy consumption and no-load power Data Acquisition
At first power analyzer is installed on the lathe, is used to detect the energy consumption of lathe startup, zero load, process; Open power analyzer again; The spindle motor that starts lathe is to processing rotating speed; And workpiece processed, note promoter process energy consumption
, no-load power
, the working power
of lathe with power analyzer; Different startup rotating speeds is set, and to repeat above-mentioned experiment
inferior with the processing rotating speed; The energy consumption
of the promoter process that the group different rotating speeds that obtains
is corresponding, no-load power
.
1.2.1 the foundation of lathe promoter process energy consumption function
The startup energy consumption
and corresponding rotating speed
of utilizing above-mentioned experiment to gather; The quadratic function that in order to rotating speed is independent variable carries out match to data recorded, obtains the energy consumption function of the promoter process of numerically-controlled machine:
There are a plurality of rotating speed shelves in some numerically-controlled machines, then should set up the startup energy consumption function of each rotating speed shelves respectively, form to start the energy consumption function library.
1.2.2 the foundation of the unloaded subprocess power consumption of lathe function
The no-load power
and corresponding rotating speed
that utilize above-mentioned experiment to gather; The quadratic function that in order to rotating speed is independent variable carries out match to data recorded, obtains the power consumption function of the unloaded subprocess of numerically-controlled machine:
If there are a plurality of rotating speed shelves in measured numerically-controlled machine, then should set up the no-load power function of each rotating speed shelves respectively, form and start the energy consumption function library.
The prediction of 2 energy consumptions
2.1 promoter process energy consumption prediction
In the lathe promoter process energy consumption function that step 2 is set up, choose the energy consumption function in the corresponding rotating speed shelves according to the rotating speed shelves of choosing in the process; Bring processing rotating speed selected in the military service process into energy consumption that function can obtain promoter process under this rotating speed, this value is the prediction of energy consumption
of promoter process.
2.2 unloaded subprocess energy consumption prediction
In the unloaded subprocess power consumption of the lathe function that step 3 is set up, choose the power consumption function in the corresponding rotating speed shelves according to the rotating speed shelves of choosing in the process, bring processing rotating speed selected in the military service process into the power consumption
that arrives unloaded subprocess under this rotating speed that function gets final product.Then that's to
and the dead time
can be obtained by multiplying the predicted no-load energy consumption of sub-processes
.
2.3 processing subprocess energy consumption prediction
As the processing sub-process is determined by the energy consumption during processing load power consumption
, cutting energy consumption
and the additional load power consumption
three parts.Promptly three part power consumptions are carried out the prediction of energy consumption that integration just can obtain processing subprocess.
Wherein, no-load power can utilize the machine power consumption function of pairing rotating speed shelves to calculate according to said method; Definite method of
is as indicated above; The calculating of cutting power
is described below.
2.3.1 the calculating of cutting power
Inquiry can be known according to the metal cutting handbook; Cutting force
is obtained by computes; Wherein,
,
,
are respectively the depth of cut, speed of feed, cutting speed;
,
,
,
,
are corresponding coefficient, index, correction factor, can obtain through tabling look-up.
By the cutting force
and cutting speed
the opportunity to obtain cutting power
:
This method error is general bigger; But because the cutting energy consumption generally all is lower than 30% in total energy consumption
; Therefore, error is little to whole military service process energy consumption prediction accuracy influence.
2.3.2 the calculating of added losses power
This method uses cutting power
quadratic functions to additional load power consumption
fitting:
Can try to achieve the added losses power
in the processing subprocess through this fitting function.
The total-power loss
that can be processed subprocess by aforementioned calculation is:
Therefore, the prediction of energy consumption of processing subprocess is:
2.4 the energy consumption of numerically-controlled machine military service process prediction
On the basis of above-mentioned steps; Bring start-up course prediction of energy consumption
, unloaded course prediction energy consumption
, the process prediction of energy consumption
of prediction respectively into numerically-controlled machine military service process energy consumption forecast model, that is:
Like this, just can obtain the prediction of energy consumption
of this numerically-controlled machine military service process.
Embodiment:
On the numerically controlled lathe of C2-6136HK/1, adopt the inventive method that its military service process is carried out the energy consumption prediction, its process is following:
1) obtain the basic data of the numerically controlled lathe of C2-6136HK/1:
According to energy consumption Forecasting Methodology proposed by the invention; To predict the energy consumption of the arbitrary military service process of C2-6136HK/1 numerically controlled lathe, need to prepare start-up course energy consumption function library, unloaded process power function library in advance and find the solution underlying parameter
,
with two grades of rotating speeds (table 1).
Table 1 C2-6136HK/1 numerically controlled lathe parameter
According to the said method of the step 3 of implementation method; Choose rotating speed points at different levels; It is as shown in Figure 3 to measure the startup energy consumption, and simulates low or first gear startup energy consumption function
and top gear startup energy consumption function
:
According to the said method of the step 4 of implementation method; Choose rotating speed points at different levels; It is as shown in Figure 4 to measure no-load power, and simulates low or first gear no-load power function
and top gear no-load power function
:
Because two grades of the rotating speed of this numerically-controlled machine branch high speed and low speed; Promptly have two mechanical drive trains, so this lathe there are two groups of underlying parameter values: low or first gear underlying parameter
,
and top gear underlying parameter
,
.By the said method of implementation process step 1; Measure many groups
respectively at low or first gear and top gear and be worth and combine above-mentioned
value that measures with
, it is following to simulate two groups of underlying parameter values:
2) energy consumption prediction and error contrast
After obtaining the basic data of this lathe, can predict that what select for use is the military service process of processing part as shown in the figure to the energy consumption of the arbitrary military service process of this lathe here.The cutter and the blank material that use in this process are listed in table 2.
Table 2 blank and cutter material parameter
According to procedure of processing in this military service process and technological parameter (table 3), blank and accessory size (seeing accompanying drawing 2), the numerical control program of establishment, whole military service process is divided into 12 sub-processes, shown in table m.
Table 3 military service process parameter list
Table 4 has been listed the rotating speed and the time of each subprocess, is used for searching data and participating in the calculating that energy consumption is predicted in each function library.Because this military service process is meant in the low or first gear operation, selects the related data of low or first gear when therefore tabling look-up for use.
Table 4 military service process is shown in detail
The promoter during a speed
launch an energy function is obtained substituting
.
With the tachometer value of unloaded subprocess 2,4,6,7,9,10,12 substitution no-load power function respectively, obtain behind the corresponding no-load power that each process time substitution no-load power consumption predictor formula just can obtain
,
,
,
,
,
,
in table m.
Rotation speed n, the feeding of process 3,5,8,11 are hastened f, the depth of cut
by data substitution cutting power computing formula among the table a; Wherein
; And table look-up in the handbook in cutting and to obtain each coefficient, index, correction factor, obtain the cutting power
of each process.
With the cutting power in the following formula
; With low or first gear underlying parameter value
and
that calculates; Respectively process the energy predicting formula of subprocess time substitution process among the table m; Obtain
;
;
,
.
At last, with the energy consumption addition of all subprocess, can obtain the total power consumption of this process military service process.
And in this process; Actual the total energy consumption that records this military service process is
through watt-hour meter, and then predicated error is
.
Can find out through above-mentioned Forecasting Methodology and error analysis; It is higher by the inventive method the military service process of numerically-controlled machine to be carried out the precision that energy predicting obtains; The error of the energy consumption of the actual military service process of measuring with ammeter is basically in 10%, and mostly this error be stochastic error, and error amount is within range of application; Therefore, good reference value is arranged in real work.The inventive method can be used for that the lathe energy efficiency is obtained, the efficiency assessment in the mechanical processing process, energy consumption monitoring, energy management, the demarcation of lathe energy consumption etc., and wide application prospect is arranged in reality.
Explanation is at last; Above embodiment is only unrestricted in order to technical scheme of the present invention to be described; Although with reference to preferred embodiment the present invention is specified, those of ordinary skill in the art should be appreciated that and can make amendment or be equal to replacement technical scheme of the present invention; And not breaking away from the aim and the scope of technical scheme of the present invention, it all should be encompassed in the middle of the claim scope of the present invention.
Claims (1)
1. the energy consumption Forecasting Methodology of a numerically-controlled machine military service process; It is characterized by: the military service overall process is divided into start-up course, unloaded process, process; And respectively three types of subprocess are carried out the energy consumption prediction, obtain the total energy consumption prediction of the whole military service process of lathe with this; Its forecast model is:
Wherein:
representes the total energy consumption of certain military service process;
representes the number of all kinds of subprocess in this military service process; In order to sign start-up course, unloaded process, process,
representes the sequence number of each subprocess respectively for subscript
,
,
;
The foundation of the energy predicting function of promoter process: through a plurality of rotating speed points of prior setting; Measure lathe startup energy consumption under each rotating speed; And come measured energy consumption data is carried out match with a quadratic function about rotating speed, setting up with the rotating speed with this is the startup energy consumption function of variable:
;
The foundation of the power function of unloaded subprocess: measure the no-load power under a plurality of different rotating speeds in advance; And use quadratic function to come measured power data is carried out match about rotating speed, setting up with the rotating speed with this is the no-load power function of variable:
;
Processing subprocess energy consumption Forecasting Methodology: the energy predicting model of processing subprocess is:
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