CN102637014A - Method for obtaining energy efficiency of main electromechanical driving system in machining process of numerically-controlled machine tool - Google Patents

Method for obtaining energy efficiency of main electromechanical driving system in machining process of numerically-controlled machine tool Download PDF

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CN102637014A
CN102637014A CN2012101278265A CN201210127826A CN102637014A CN 102637014 A CN102637014 A CN 102637014A CN 2012101278265 A CN2012101278265 A CN 2012101278265A CN 201210127826 A CN201210127826 A CN 201210127826A CN 102637014 A CN102637014 A CN 102637014A
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rotating speed
interval
main transmission
numerically
energy efficiency
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CN102637014B (en
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刘霜
刘飞
王秋莲
谢俊
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Chongqing University
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    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
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Abstract

The invention discloses a new method for obtaining energy efficiency of a main electromechanical driving system in a machining process of a numerically-controlled machine tool. In the method, according to an energy efficiency mathematical model of the main electromechanical driving system in the machining process of a machine tool, a relation function of no-load power of the machine tool which is prepared in advance stage at one time and the rotating speed and a table function of an additional load loss factor of the machine tool with single-interval or multi-interval rotation speed, as long as input power process data or process curve of a motor of the main driving system of the machine tool in the machining process is recorded, the energy efficiency of the main electromechanical driving system in the machining process of the machine tool can be calculated out from the mathematical model. The method can be used for research and application of solution to a series of problems, such as research on energy consumption and energy efficiency and evaluation on energy efficiency in the machining process of the machine tool, and energy-saving optimization of cutting technology parameters, thereby having extensive application prospect.

Description

The method that the dynamo-electric main transmission energy efficiency of numerically-controlled machine process is obtained
Technical field
The invention belongs to the Machine-Tool Control technical field, relate in particular to the new method that the dynamo-electric main transmission energy efficiency of a kind of numerically-controlled machine process is obtained.
Background technology
It is the basis that manufacturing system reduces energy consumption, improves energy efficiency that analysis of manufacturing system power consumption state and efficiency thereof assess.The research of manufacturing system efficiency evaluation problem is risen rapidly just in the world for this reason.CN102179727A invention disclosed name is called the patent of invention of " main transmission system of machine tool process consumption information online test method "; Its disclosed scheme provides a kind of main transmission system of machine tool process consumption information online test method, seeks out the real time data of main transmission system of machine tool consumption information such as spindle motor loss power, spindle motor output power, machine driven system loss power, cutting power.CN2066162 invention disclosed name is called the utility model of " lathe energy-saving power supervising device ", discloses a kind of lathe energy-saving power supervising device, as detection signal, realizes step-down energy-conservation and power monitoring through shunt current with stator current.In September, 2009; International production engineering association (CIRP) has held the 26th international meeting (the International Manufacturing Conference that makes in Ireland; IMC ' 26); " energy efficiency and low-carbon (LC) manufacturing " as Session Topic, proposed " in order to ensure manufacturing industry innovation and development, must accurately estimate the energy consumption status of manufacture process and system ".And for example USDOE has set up with the energy efficiency that improves manufacturing enterprise's production run " industrial CELA (the Industrial Assessment Centers) " as primary goal specially.This center relies on 29 colleges and universities of the U.S., and the energy consumption status of industrial enterprise production scene is assessed and studied.During assessment, comprise each energy consumption link such as production equipment, also comprise number of motors, rated power, working time etc.But also do not relate to inner energy consumption of machine processing system and energy efficiency assessment; Its main cause is the unusual difficulty of energy consumption and energy efficiency data that the production scene obtains lathe military service process in real time.
Lathe is the equipment basis of manufacturing system, and its efficiency evaluation is the importance that the manufacturing system efficiency is estimated.Though existing document has been done many researchs to lathe energy efficiency problem,, the not fine as yet solution of the problem of obtaining of the lathe military service process energy efficient of production scene does not still have convenient practical effective ways.Its reason mainly contains 2 points: the one, and some the test data laboratory that needs obtains easily, and the production scene just obtains very difficulty; The 2nd, main transmission system of machine tool energy Flow process is complicated, and on-the-spot model parameter is difficult to confirm, thereby on-the-spot energy efficiency is difficult to obtain through model solution.
Summary of the invention
To the problems referred to above that exist in the prior art; The purpose of this invention is to provide the new method that the dynamo-electric main transmission energy efficiency of a kind of numerically-controlled machine process is obtained; Through power input process data or the conditional curve of record main transmission system of machine tool in process, can the online energy efficiency of asking for main transmission system of machine tool.
For realizing above-mentioned purpose, the present invention has adopted following technological means:
The method that the dynamo-electric main transmission energy efficiency of a kind of numerically-controlled machine process is obtained is characterized in that, comprises following content:
1) set up dynamo-electric main transmission energy efficiency model I of numerically-controlled machine process and II:
= (I)
= (II)
Wherein, the model I is applicable to single interval rotating speed numerically-controlled machine, and model is applicable to rotating speed numerically-controlled machine between multi-region.Be meant that there are a plurality of speed stages in some segmentation speed governing numerically-controlled machine between so-called multi-region, like high regime and low speed segment, each speed stage is a rotating speed interval, and the interval corresponding fixing driving-chain of rotating speed.In addition, above-mentioned energy efficiency model can also be reduced to model III and IV respectively:
= (Ⅲ)
= (Ⅳ)
2) the disposable early-stage preparations of model based function and basic coefficients specifically comprise
A. the relation function of the dynamo-electric main transmission no-load power of numerically-controlled machine process and rotating speed ; The single-relation curve that comprises single interval rotating speed main transmission system of machine tool no-load power and rotating speed , rotating speed main transmission system of machine tool no-load power between multi-region and the relation curve of rotating speed about interval number ;
The additional load loss factor of b. single interval rotating speed main transmission system of machine tool; ; ; And the additional load loss factor of rotating speed main transmission system of machine tool under each interval driving-chain between multi-region; , the table function of ;
3) only need in-site measurement numerically-controlled machine main transmission real-time power input process data or conditional curve in process during practical application, can calculate the dynamo-electric main transmission energy efficiency of machine tooling process according to above-mentioned energy efficiency model, model basic function and basic coefficients again.
Further; The acquisition methods of the no-load power of the dynamo-electric main transmission of numerically-controlled machine process and the relation function of rotating speed is: for single interval rotating speed lathe; Choose some rotating speed points; Do not cut at lathe and start lathe under the prerequisite of object and process rotating speed to this; Measure the corresponding power input of lathe; The stationary value that writes down power input under each rotating speed point simulates the relation function of no-load power and rotating speed then as the no-load power of lathe under this processing rotating speed; To rotating speed lathe between multi-region; The no-load power surveying work of the single interval rotating speed lathe of repetition under each rotating speed interval simulates no-load power and the relation function of rotating speed about interval number then.
Further; The acquisition methods of the additional load loss factor table function of main transmission system of machine tool under machining state is: to single interval rotating speed lathe; Through freely selecting rotating speed to carry out multiple different cutting experiment; Measure corresponding and carry out regretional analysis with value; Obtain one group of fixing load loss factor ; , ; For rotating speed lathe between multi-region; Through under each rotating speed interval, freely selecting rotating speed to carry out multiple different cutting experiment; Measure corresponding and carry out regretional analysis with value; Obtain load loss factor about rotating speed interval ; , table function.
Than prior art, the present invention has following beneficial effect:
1, only need the power input process data or the conditional curve of production scene main transmission system of machine tool in the record process, just can seek out the real time data of main transmission energy efficiency, its online testing process is simple to operation, and existing lathe generally is suitable for.
2, calculating the basic data that lathe process main transmission energy efficiency need obtain in advance can obtain through zero load provided by the invention and cut experiment, and its obtain manner is all very simple, has improved the operability of the inventive method; And, can continue use for its basic data of lathe of same model once obtaining then, put things right once and for all, need not to carry out the online detection of its consumption information and obtain once more before in the later stage.
3, the detected machine tooling process of the inventive method main transmission ability effective information is arranged; And the error between the machine tooling process main transmission of the reality ability effective information is no more than 20%; And mostly this error is stochastic error; Error amount has guidance, reference value preferably within the practical applications scope.
4, the inventive method can be applicable to have more wide application prospect in the researchs such as the lathe energy efficiency is obtained, the efficiency assessment of mechanical processing process.
Description of drawings
Fig. 1 turning processing work figure;
The relation function synoptic diagram of Fig. 2 embodiment no-load power and rotating speed;
Main transmission power input curve synoptic diagram in Fig. 3 engine lathe turning manuscript 1 part process;
Fig. 4 is the FB(flow block) of the inventive method.
Embodiment
Below in conjunction with accompanying drawing and embodiment technical scheme of the present invention is further described.
The present invention has announced the new method that the dynamo-electric main transmission energy efficiency of a kind of numerically-controlled machine process is obtained.This method is according to the dynamo-electric main transmission energy efficiency of machine tooling process mathematical model; With the relation function of disposable cut-and-dried main transmission system of machine tool no-load power and rotating speed, and the table function of rotating speed lathe additional load loss factor between the additional load loss factor of single interval rotating speed lathe or multi-region; Only need main transmission system of machine tool power input to a machine process data or conditional curve in the record process, just can from mathematical model, calculate the energy efficiency of the dynamo-electric main transmission of machine tooling process.
1. numerically-controlled machine main transmission energy efficiency model
= (I)
= (II)
Wherein, the model I is applicable to single interval rotating speed numerically-controlled machine, and model is applicable to rotating speed numerically-controlled machine between multi-region.Be meant that there are a plurality of speed stages in some segmentation speed governing numerically-controlled machine between so-called multi-region, like high regime and low speed segment, each speed stage is a rotating speed interval, and the interval corresponding fixing driving-chain of rotating speed.In addition, above-mentioned energy efficiency model can also be reduced to model III and IV respectively:
= (Ⅲ)
= (Ⅳ)
2. the acquisition methods of basic function and basic coefficients in the energy efficiency model
The basic function of four kinds of energy efficiency model needs is different with basic coefficients, and they are respectively:
Model (I)---no-load power function , load loss factor and ;
Model (II)---no-load power function , load loss factor table function and ;
Model (III)---no-load power function , load loss factor ;
Model (IV)---no-load power function , load loss factor table function ;
Therefore the basic function and the basic coefficients that need come to 7 kinds: i.e. no-load power function ; Load loss factor and ; Load loss factor ; No-load power function ; Load loss factor table function and , load loss factor table function .
1) the no-load power function obtains
The acquisition methods of the no-load power function of numerically-controlled machine is: to the lathe of production scene; Under every interval rotating speed, set several different rotating speed; Carry out the disposable no-load power that measures under each different rotating speeds; It is as shown in table 1 to set up the no-load power table function, and the data in the his-and-hers watches 1 carry out curve fitting and can obtain the fitting function of the no-load power of this lathe about rotating speed then:
(1)
Table 1 Machine speed range rpm under no-load power levels table function
Lathe for single interval rotating speed; There is not interval difference, so the relation function of no-load power that simulates and rotating speed is .
2) the load loss factor obtains
2.1) and the acquisition method
In the every interval rotating speed of numerically-controlled machine, freely choose rotating speed; The distinct cutting experiment of the group ( ) of carrying out ; Measure corresponding and value; Substitution formula (2) is contained the system of equations ( ) of individual equation, shown in (3).
(2)
(3)
Set up its equation of linear regression according to formula (3):
(4)
In the formula; ; ; ; , .Matrix form by formula (4) is found the solution this regression equation, can obtain:
(5)
In the following formula:
?
So get the speed range load loss coefficient , .
2.2) the obtaining of
In the every interval rotating speed of numerically-controlled machine, freely choose rotating speed; The distinct cutting experiment of the group ( ) of carrying out ; Measure corresponding and value; The system of equations of substitution formula (6) is contained ( ) individual equation is shown in (7).
(6)
(7)
Set up its equation of linear regression according to formula (7):
(8)
In the formula; ; , . finds the solution this regression equation by matrix form, can obtain:
(9)
In the following formula:
?
So get the speed range load loss coefficient .
2.3) ; , the acquisition methods of
The load loss factor and the driving-chain of same lathe is that the energy transfer chain is relevant.For the interval rotating speed lathe of the list of fixed conveyor chain; The load loss factor is a constant, i.e. =
2.4) foundation of load loss factor table function
For variable transmission chain lathes such as speed governing lathes between multi-region; is that the energy transfer chain is relevant with the corresponding driving-chain of each interval rotating speed; That is, = . can set up through table function:
Table 2 load loss factor table function
When reality is used the above table function, confirm the load loss factor according to the rotating speed interval that actual running speed is corresponding.
Embodiment:
Employing measures and calculates based on the model (II) of the power input process main transmission energy efficiency to C2-6136HK/1 lathe in machining axial workpiece (part shape and size are as shown in Figure 1) with two grades of rotating speeds (table 3).The power sensor EDA9033A that is used to measure power input is installed in main motor porch, and the data sampling cycle is 20ms.Also obtained actual energy efficient so that accuracy validation to be provided simultaneously through torque sensor TQ201 that is installed in cutting zone and the watt-hour meter that is installed in the main transmission porch.
Table 3 C2-6136HK/1 numerically controlled lathe parameter
1-1) basic function and basic coefficients obtains
Of preamble; Application model (II) is obtained the lathe energy efficiency, and the basic function and the basic coefficients that need to prepare comprise no-load power function and load loss factor table function .
According to method mentioned above; Under each interval rotating speed, choose some rotating speed points; It is as shown in Figure 2 to measure no-load power, and simulates low or first gear no-load power function and top gear no-load power function :
(10)
(11)
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 , .As stated above; Measure respectively at low or first gear and top gear how group is worth and combines above-mentioned value that measures with , the table function that simulates the additional load coefficient is following:
The additional load coefficient table function of table 4 embodiment
1-2) on-site data monitoring and energy efficiency are calculated
On the basis that obtains above-mentioned basic function and basic coefficients, begin the energy efficiency of the actual process of this workpiece is obtained.This process is used low or first gear work always, and the procedure of processing and the technological parameter of this process are as shown in table 5.
Table 5 process process parameter table
Monitor main transmission total power input in this military service process in real time, the curve synoptic diagram that obtains whole military service process is as shown in Figure 3.
Visible by Fig. 3; Have 4 processing periods in 12 periods of this military service process: (3), (5), (8), (11), i.e. .The related data of calculating these 4 total effectively energy consumptions of processing period is as shown in table 6.
Certain Machining of Shaft-type Parts sub-period efficiency data table related of table 6
With data in the table 6, and whole machining process process value substitution model (II) respectively, obtain this process main transmission system of machine tool energy efficiency is .Actual cut power and actual speed calculating through torque sensor records are obtained actual cut power and then are obtained the actual total cutting energy consumption of this military service process; Directly measure this military service process actual total energy loss through watt-hour meter, thereby obtain the actual energy efficient of this process.With efficiency measuring and calculating value and efficiency actual value contrast, the error of is .
In addition; Also can calculate the cutting energy consumption of arbitrary processing period and the ratio of this period total energy consumption, the energy efficiency of promptly processing the period through above-mentioned experimental data.Processing period energy efficiency of to use , obtaining as design factor is designated as , will be designated as through the actual energy efficient that corresponding measured value obtains.The actual efficiency of 4 processing periods in this military service process, measuring and calculating efficiency and measuring and calculating error thereof are as shown in table 7.The actual efficiency that has also comprised the whole machining process process in the table 7, measuring and calculating efficiency and measuring and calculating error.
Table 7 measuring and calculating efficiency and errors table thereof
Visible by table 7, when a certain concrete processing period energy efficiency of measuring and calculating, there is certain error in model (II); But when measuring and calculating whole machining process process energy efficient, model (II) has degree of precision.Its reason has 2 points: the one, and the precision of prediction that the various stochastic errors in the actual processing cause specifically processing the period descends; But all stochastic errors of all processing periods are cancelled out each other in whole military service process, make the efficiency estimation precision of whole military service process return to some extent; The 2nd, it is less that the total energy consumption of all processing periods accounts for the ratio of whole machining process process total energy consumption, makes that the measuring and calculating error of power consumption of polymer processing is limited to the influence of efficiency measuring and calculating error.
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 (4)

1. the method obtained of the dynamo-electric main transmission energy efficiency of numerically-controlled machine process is characterized in that, may further comprise the steps:
Set up dynamo-electric main transmission energy efficiency model I of numerically-controlled machine process and II:
= (I)
= (II)
Wherein, the model I is applicable to single interval rotating speed numerically-controlled machine, and model is applicable to rotating speed numerically-controlled machine between multi-region; Be meant that there are a plurality of speed stages in some segmentation speed governing numerically-controlled machine between so-called multi-region, like high regime and low speed segment, each speed stage is a rotating speed interval, and the interval corresponding fixing driving-chain of rotating speed;
In the formula; ; , is the load loss factor; is no-load power, and is rotating speed;
; , are the load loss factor of rotating speed interval ; is no-load power, be the rotating speed of interval number ;
The disposable early-stage preparations of model based function and basic coefficients specifically comprise:
A. the relation function of the dynamo-electric main transmission no-load power of numerically-controlled machine process and rotating speed ; The single-relation curve that comprises single interval rotating speed main transmission system of machine tool no-load power and rotating speed , rotating speed main transmission system of machine tool no-load power between multi-region and the relation curve of rotating speed about interval number ;
The additional load loss factor of b. single interval rotating speed main transmission system of machine tool; ; ; And the additional load loss factor of rotating speed main transmission system of machine tool under each interval driving-chain between multi-region; , the table function of ;
Only need in-site measurement numerically-controlled machine main transmission real-time power input process data or conditional curve in process during practical application, can calculate the dynamo-electric main transmission energy efficiency of machine tooling process according to above-mentioned energy efficiency model, model basic function and basic coefficients again.
2. the method obtained of the dynamo-electric main transmission energy efficiency of numerically-controlled machine process according to claim 1; It is characterized in that; The acquisition methods of the no-load power of the dynamo-electric main transmission of numerically-controlled machine process and the relation function of rotating speed is: for single interval rotating speed lathe; Choose some rotating speed points; Do not cut at lathe and start lathe under the prerequisite of object and process rotating speed to this; Measure the corresponding power input of lathe; The stationary value that writes down power input under each rotating speed point simulates the relation function of no-load power and rotating speed then as the no-load power of lathe under this processing rotating speed; To rotating speed lathe between multi-region; The no-load power surveying work of the single interval rotating speed lathe of repetition under each rotating speed interval simulates no-load power and the relation function of rotating speed about interval number then.
3. the method obtained of the dynamo-electric main transmission energy efficiency of numerically-controlled machine process according to claim 1; It is characterized in that; Additional load loss factor and the acquisition methods of table function thereof of main transmission system of machine tool under machining state is: to single interval rotating speed lathe; Through freely selecting rotating speed to carry out multiple different cutting experiment; Measure corresponding and carry out regretional analysis with value; Obtain one group of fixing load loss factor ; , ; For rotating speed lathe between multi-region; Through under each rotating speed interval, freely selecting rotating speed to carry out multiple different cutting experiment; Measure corresponding and carry out regretional analysis with value; Obtain load loss factor about rotating speed interval ; , table function.
4. the method obtained of the dynamo-electric main transmission energy efficiency of numerically-controlled machine process according to claim 1 is characterized in that said energy efficiency model model I and II can also be reduced to model III and IV respectively:
= (Ⅲ)
= (Ⅳ)。
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