CN105654240A - Machine tool manufacturing system energy efficiency analysis method - Google Patents

Abstract

The invention discloses a machine tool product manufacturing system energy efficiency analysis method. The method includes the following steps that: (1) energy consumption data are acquired based on a workshop energy consumption sensing network; (2) based on the acquired energy consumption data in a manufacturing workshop, a star type model is adopted to construct a manufacturing workshop energy efficiency data warehouse; (3) a machine tool manufacturing energy efficiency evaluation index system is the established, and energy utilization situations of product production and energy management are described; (4) energy consumption integrated models are established for a step layer, a process layer, a part layer and a product layer; and (5) simulation analysis is carried out based on the established energy consumption integrated models, and the specific values of the energy efficiency evaluation indexes of each layer are obtained. According to the machine tool product manufacturing system energy efficiency analysis method of the present invention, three-level energy efficiency management evaluation indexes are established based on the energy consumption data in the manufacturing workshop acquired by the sensing network; energy consumption integrated modeling is performed for energy utilization efficiency of each level; the energy utilization ratio of the workshop is calculated based on the energy consumption integrated models; and the energy utilization situations of the whole workshop and specific production equipment can be sensed.

Description

Machine tool product manufacturing system energy efficiency analysis method for air

Technical field

The present invention relates to manufacturing system efficiency optimal control technical field of research in machine tool product manufacturing, concrete, it relates to a kind of energy efficiency analysis method for air towards machine tool product manufacturing system.

Background technology

China is as energy consumption big country, and 2008 unit GDP energy consumes are 2.4 times of world average level, is 2.4 times, 4.4 times and 1.3 times of the U.S., Japan and India respectively. In these energy, great majority are consumed by production, as the industrial machine tool-lathe of production, it ranks first in the world in the recoverable amount of China, the total rated output of machine tool equipment is equivalent to about 3 times of power station, Three Gorges total installed capacity amount, energy consumption is huge, but energy efficiency and capacity usage ratio are but very low, and investigation shows that it is lower than 30% in a large number, a large amount of energy is consumed and does without diligent. Therefore, adopting the method for science manufacturing system efficiency to carry out analysis and inspection for raising energy utilization rate, reduce enterprise investment, it is all useful for improving corporate environment etc.

Along with the development of computer technology and technology of Internet of things, the quantification utilizing the real time energy consumption data in the technical limit spacing enterprise manufacturing processedes such as sensing technology, RF identification technology and communication and inside data of enterprise to share realizes, and then to set up efficiency database be that efficiency analysis evaluation provides basic data and supports.

Summary of the invention

It is an object of the invention to for above problem, a kind of energy efficiency analysis method for air towards machine tool product manufacturing system is proposed, based on the efficiency database that the method collects by workshop energy consumption sensing network, manufacturing system efficiency is carried out objective dynamic assessment, for industry energy conservation reduction of discharging, increasing the benefit provides support with increasing economic efficiency.

In order to realize above-mentioned purpose, machine tool product manufacturing system energy efficiency analysis method for air of the present invention comprises the steps:

(1) energy consumption data is gathered based on workshop energy consumption sensing network;

(2) based on energy consumption data in the manufacturing shop gathered, star type model construction manufacturing shop efficiency data warehouse is adopted;Described star pattern type comprises main energy consumption equipment group, energy group, processing conversion unit group, conveying schedule of apportionment tuple and time group;

(3) set up machine tool product and manufacture energy efficiency evaluation index system, describe the energy utilization situation in products production and energy management;

(4) respectively layer, operation layer, part layer and gas producing formation are walked with regard to work and set up energy consumption Integrated planar schottky diode;

(5) carry out simulation analysis based on the energy consumption Integrated planar schottky diode set up, obtain the concrete value of each level efficiency evaluation index respectively.

Described machine tool product manufactures energy efficiency evaluation index system and comprises efficiency economic target, product energy efficiency indexes, energy efficiency of equipment index and flow of task energy efficiency indexes, and efficiency economic target is specialized and is decomposed into ten thousand yuan of product energy consumptions, ten thousand yuan of increased value energy consumptions; Product energy efficiency indexes is specialized and is decomposed into unit product comprehensive energy consumption, product amount of energy saving, product energy level; Energy efficiency of equipment index is specialized and is decomposed into machine tool efficiency, energy transport efficiency, energy processing translating eqipment; Flow of task energy efficiency indexes is specialized and is decomposed into production technique efficiency, resources of production scheduling efficiency.

Step 4 sets up energy consumption Integrated planar schottky diode, is respectively:

1) work step layer energy consumption Integrated planar schottky diode.

A work step can be divided into startup, standby, unloaded, processing four-stage, and gets the energy expenditure in process segment for effectively output, then have:

${\mathrm{\η}}_1=\frac{E_c}{E_1}=\frac{{\∫}_{t_c}{P}_{in}\left(t\right)dt}{{\∫}_{t_T}{P}_{in}\left(t\right)dt}$

Wherein: t_T=t_st+t_sy+t_ie+t_c, and E₁Can calculate by following formula: E₁=E_st+E_s-s+E_ie+E_c. In formula: t_TRepresent total process period, t_stRepresent lathe start time, t_syRepresent the waiting time, t_ieRepresent dead time, t_cRepresent the cutting time, E₁Work step energy consumption, E_stLathe starts energy consumption, E_s-sWork step standby energy consumption, E_ieThe unloaded energy consumption of work step, E_cRepresent and cut energy consumption.

2) operation layer energy consumption Integrated planar schottky diode.

At operation layer, the energy consumption of each operation not only comprises the energy consumption of its each work step, further comprises the part power consumption for part transport, therefore has:

$E_2=\underset{i=1}{\overset{N_1}{\Σ}}{E}_{1_i}+E_{ts}$

In formula: E₂Represent process energy consumption, N₁Represent work step number in operation, E_tsRepresent transport energy consumption.

Transport energy consumption E_tsCalculate by following formula:

$E_{ts}=\frac{P_{ts}\×t_{ts}}{Q}$

In formula: P_tsRepresent the rated output of transportation equipment, t_tsRepresenting transportation equipment working time, Q represents the part number once transporting loading.

So, operation layer efficiency represents and is:

${\mathrm{\η}}_2=\frac{\underset{i=1}{\overset{N_1}{\Σ}}{E}_{c_i}}{E_2}.$

3) part layer energy consumption Integrated planar schottky diode.

At this layer, maximum difference is to there will be, when Part supplying is not enough, the situation that lathe is forced to wait. When a front buffer zone of lathe is empty, or a rear buffer zone is for, time full, the situation being forced to wait occurs in lathe. The power that lathe is forced to etc. to bide one's time is exactly the standby power of lathe.

Simultaneously, it is contemplated that the power consumption of Cleaning of Parts and japanning, the energy consumption producing a part can represent and is:

$E_3=\underset{i=1}{\overset{N_2}{\Σ}}{E}_{2_i}+E_{pt}+E_{cn}+E_{s-p}$

In formula: E₃Represent part energy consumption, N₂Represent the process number of processing parts, E_ptRepresent japanning energy consumption, E_cnRepresent and clean energy consumption, E_s-pRepresent that machine waits energy consumption.

Corresponding efficiency calculating formula is:

${\mathrm{\η}}_3=\frac{\underset{i=1}{\overset{N_2}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ij}}}{E_3}.$

4) gas producing formation energy consumption Integrated planar schottky diode.

The power consumption of gas producing formation needs the power consumption of power consumption and the utility appliance considering Assembly of the parts. It is shown below:

$E_4=\underset{i=1}{\overset{N_3}{\Σ}}{E}_{3_i}+E_{ae}+\frac{E_{fy}}{KM}$

Wherein, E₄Represent product energy consumption, N₃Represent the part number of converted products, E_aeRepresent assembled product power consumption, E_fyUtility appliance consumes energy, K and M produces the species number of product and the number of particular types product in certain time.

So, the efficiency of this level is:

${\mathrm{\η}}_4=\frac{\underset{k=1}{\overset{N_3}{\Σ}}\underset{i=1}{\overset{N_{2_k}}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ijk}}}{E_4}.$

The present invention has following advantage:

1., based on energy consumption data in the manufacturing shop of sensing network collection, on the basis of " integrity, simplicity, importance, level, comparability " principle, based on data warehouse, set up three layers of energy efficiency management evaluation index.

2. the energy use efficiency of each level being carried out energy consumption Integrated modeling, the Energy efficiency analyzed on each level concrete in detail, to the detailed anatomy of use of the energy.

3. based on energy consumption Integrated planar schottky diode, the energy utilization rate in workshop is calculated, it is possible to the energy utilization situation of the whole workshop of perception and concrete production unit.

Accompanying drawing explanation

Fig. 1 is efficiency analysis process of the present invention.

Fig. 2 is that energy efficiency of equipment analyzes theme logical model.

Fig. 3 is that machine tool product manufactures energy efficiency management index system.

Fig. 4 is comparison diagram before and after data filtering.

Fig. 5 is energy distribution figure.

Embodiment

It is the key point that efficiency is analyzed that machine tool product manufactures energy consumption Integrated planar schottky diode. The present invention describes its energy stream feature from three levels of machine tool product manufacturing system and machine tool layer, flow of task layer and supplement production layer, sets up the energy consumption submodel of each level and the energy consumption Integrated planar schottky diode of manufacture course of products on this basis respectively. Based on the energy consumption Integrated planar schottky diode set up, obtain the concrete value of efficiency evaluation index based on certain emulation mechanisms. According to energy efficiency evaluation index system, system emulation result is assessed, after obtaining energy efficiency evaluation value, contrast with expected value, in order to obtain ideal value, can be optimized by aid decision making mechanism, and using optimum result as feedback, for improvement of the configuration of technical process, parameter and resource.

As shown in Figure 1, the overall procedure of the present invention is as follows:

(1) energy consumption data is gathered based on workshop energy consumption sensing network.

(2) based on energy consumption data in the manufacturing shop gathered, star type model construction manufacturing shop efficiency data warehouse is adopted; Described star pattern type comprises main energy consumption equipment group, energy group, processing conversion unit group, conveying schedule of apportionment tuple and time group.

Step (2) builds the efficiency data warehouse of machine tool product manufacturing shop, for storing historical data and the current data that the energy uses, the object described by data is divided into: economic data, material and product data, device data and technological process of production information etc. Efficiency data warehouse contains energy efficiency of equipment analysis, economic efficiency analysis and environment efficiency and analyzes three themes.

(3) set up machine tool product and manufacture energy efficiency evaluation index system, describe the energy utilization situation in products production and energy management.

Step (3) is set up machine tool product from Energy resources angle and is manufactured energy efficiency evaluation index system, on the basis of " integrity, simplicity, importance, level and comparability " principle, utilize master data, energy utilization statistic data, history and current production data that Analysis of Data Warehouse machine tool product manufactures, set up three layers of energy efficiency management evaluation index, describe the energy utilization situation in products production and energy management. Three layers of quantitative analysis index are divided into destination layer (A), rule layer (B) and indicator layer (C), indicator layer is that the energy consumption technologies parameter according to each equipment itself sets, and then the good technical parameter of energy according to equipment itself sorts out rule layer.

(4) respectively layer, operation layer, part layer and gas producing formation are walked with regard to work and set up energy consumption Integrated planar schottky diode.

Work step layer in step (4) is unit the most basic in production process, the part operation content completed continuously when it refers to, and finished surface is constant, cutting tool is constant, the amount of feed in cutting data and cutting speed remain unchanged substantially; Operation refers to one or one group of workman, a work point to same or carry out several workpiece processing the part technological process that completes continuously simultaneously. It also comprises quality examination and part transport; At part layer, a part completed not only needs through multiple working procedure, also will through cleaning and spray paint;Finally, at gas producing formation, multiple part is assembled into a product. Meanwhile, power consumption such as lamp, air-conditioning and so on secondary process equipment also needs to take into account.

(5) carry out simulation analysis based on the energy consumption Integrated planar schottky diode set up, obtain the concrete value of each level efficiency evaluation index respectively.

Below in conjunction with the drawings and specific embodiments, the present invention is described in further detail.

Step one: gather manufacturing shop energy consumption data based on the energy consumption sensing network set up in workshop, the hardware device of described energy consumption sensing network has sensor, RFID, communication module, central processing unit and mutual terminal etc., common composition workshop energy consumption sensing network.

Step 2: the efficiency data warehouse Example logic model being the theme with energy efficiency of equipment analysis as shown in Figure 2. Based on the manufacturing shop energy consumption data that sensing network gathers, adopt star type model construction manufacturing shop efficiency data warehouse, for storing historical data and the current data that the energy uses. Logical model as shown in Figure 2 contains five moietys that energy efficiency of equipment is analyzed, comprises main energy consumption equipment group, energy group, processing conversion unit group, conveying schedule of apportionment tuple and time group, elaborate energy efficiency of equipment situation.

Step 3: set up machine tool product from Energy resources angle and manufacture energy efficiency evaluation index system, on the basis of " integrity, simplicity, importance, level and comparability " principle, utilize master data, energy utilization statistic data, history and current production data that Analysis of Data Warehouse machine tool product manufactures, set up three layers of energy efficiency management evaluation index, describe the energy utilization situation in products production and energy management. Three layers of index the first layer of machine tool product manufacturing system efficiency are that machine tool product manufactures energy efficiency management index A, the rule layer of this index system comprises efficiency economic target B1, product energy efficiency indexes B2, energy efficiency of equipment index B3 and flow of task energy efficiency indexes B4, as shown in Figure 3, concrete, the machine tool product of above-mentioned foundation manufactures energy efficiency evaluation index specialize further and be decomposed into indicator layer, wherein, efficiency economic target B1 specializes and is decomposed into ten thousand yuan of product energy consumption C11, ten thousand yuan of increased value energy consumption C12; Product energy efficiency indexes B2 specializes and is decomposed into unit product comprehensive energy consumption C21, product amount of energy saving C22, the product horizontal C23 of energy; Energy efficiency of equipment index is specialized and is decomposed into machine tool efficiency C31, energy transport efficiency C32, energy processing translating eqipment C33; Flow of task energy efficiency indexes is specialized and is decomposed into production technique efficiency C41, resources of production scheduling efficiency C42.

Step 4: energy consumption Integrated modeling, walks layer, operation layer, part layer and gas producing formation with regard to work respectively and sets up energy consumption Integrated planar schottky diode.

1) work step layer energy consumption Integrated planar schottky diode.

A work step can be divided into startup, standby, unloaded, processing four-stage, and gets the energy expenditure in process segment for effectively output, then have:

${\mathrm{\η}}_1=\frac{E_c}{E_1}=\frac{{\∫}_{t_c}{P}_{in}\left(t\right)dt}{{\∫}_{t_T}{P}_{in}\left(t\right)dt}$

Wherein, t_T=t_st+t_sy+t_ie+t_c, and E₁Can calculate by following formula: E₁=E_st+E_s-s+E_ie+E_c. In formula: t_TRepresent total process period, t_stRepresent lathe start time, t_syRepresent the waiting time, t_ieRepresent dead time, t_cRepresent the cutting time, E₁Work step energy consumption, E_stLathe starts energy consumption, E_s-sWork step standby energy consumption, E_ieThe unloaded energy consumption of work step, E_cRepresent and cut energy consumption.

2) operation layer energy consumption Integrated planar schottky diode.

At operation layer, the energy consumption of each operation not only comprises the energy consumption of its each work step, further comprises the part power consumption for part transport, therefore has:

$E_2=\underset{i=1}{\overset{N_1}{\Σ}}{E}_{1_i}+E_{ts}$

In formula: E₂Represent process energy consumption, N₁Represent work step number in operation, E_tsRepresent transport energy consumption.

Transport energy consumption E_tsCalculate by following formula:

$E_{ts}=\frac{P_{ts}\×t_{ts}}{Q}$

In formula: P_tsRepresent the rated output of transportation equipment, t_tsRepresenting transportation equipment working time, Q represents the part number once transporting loading.

So, operation layer efficiency represents and is:

${\mathrm{\η}}_2=\frac{\underset{i=1}{\overset{N_1}{\Σ}}{E}_{c_i}}{E_2}$

3) part layer energy consumption Integrated planar schottky diode.

At this layer, maximum difference is to there will be, when Part supplying is not enough, the situation that lathe is forced to wait. When a front buffer zone of lathe is empty, or a rear buffer zone is for, time full, the situation being forced to wait occurs in lathe. The power that lathe is forced to etc. to bide one's time is exactly the standby power of lathe.

Simultaneously, it is contemplated that the power consumption of Cleaning of Parts and japanning, the energy consumption producing a part can represent and is:

$E_3=\underset{i=1}{\overset{N_2}{\Σ}}{E}_{2_i}+E_{pt}+E_{cn}+E_{s-p}$

In formula: E₃Represent part energy consumption, N₂Represent the process number of processing parts, E_ptRepresent japanning energy consumption, E_cnRepresent and clean energy consumption, E_s-pRepresent that machine waits energy consumption.

Corresponding efficiency calculating formula is:

${\mathrm{\η}}_3=\frac{\underset{i=1}{\overset{N_2}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ij}}}{E_3}$

4) gas producing formation energy consumption Integrated planar schottky diode.

The power consumption of gas producing formation needs the power consumption of power consumption and the utility appliance considering Assembly of the parts. It is shown below:

$E_4=\underset{i=1}{\overset{N_3}{\Σ}}{E}_{3_i}+E_{ae}+\frac{E_{fy}}{KM}$

Wherein, E₄Represent product energy consumption, N₃Represent the part number of converted products, E_aeRepresent assembled product power consumption, E_fyUtility appliance consumes energy, K and M produces the species number of product and the number of particular types product in certain time.

So, the efficiency of this level is:

${\mathrm{\η}}_4=\frac{\underset{k=1}{\overset{N_3}{\Σ}}\underset{i=1}{\overset{N_{2k}}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ijk}}}{E_4}$

Step 5: efficiency simulation analysis. Based on the above energy consumption Integrated planar schottky diode set up, the data gathering certain lathe enterprise production plant adopt simulation software to carry out efficiency analysis, obtain the concrete value of each level efficiency evaluation indexes such as work step layer, operation layer, part layer and gas producing formation respectively. The data obtained are carried out filtering and obtains the comparison diagram before and after the filtering shown in Fig. 4. Its energy distribution figure is as shown in Figure 5. Therefore, its efficiency is 41.31%. After obtaining assessed value, contrast with expectation index. In order to obtain ideal value, it is possible to be optimized by aid decision making mechanism, and using optimum result as feedback, for improvement of the configuration of technical process, parameter and resource.

Claims (6)

1. machine tool product manufacturing system energy efficiency analysis method for air, it is characterised in that, comprise the steps:

(1) energy consumption data is gathered based on workshop energy consumption sensing network;

(2) based on energy consumption data in the manufacturing shop gathered, star type model construction manufacturing shop efficiency data warehouse is adopted; Described star pattern type comprises main energy consumption equipment group, energy group, processing conversion unit group, conveying schedule of apportionment tuple and time group;

(3) set up machine tool product and manufacture energy efficiency evaluation index system, describe the energy utilization situation in products production and energy management;

(4) respectively layer, operation layer, part layer and gas producing formation are walked with regard to work and set up energy consumption Integrated planar schottky diode;

(5) carry out simulation analysis based on the energy consumption Integrated planar schottky diode set up, obtain the concrete value of each level efficiency evaluation index respectively.

2. machine tool product manufacturing system energy efficiency analysis method for air according to claim 1, it is characterized in that: described machine tool product manufactures energy efficiency evaluation index system and comprises efficiency economic target (B1), product energy efficiency indexes (B2), energy efficiency of equipment index (B3) and flow of task energy efficiency indexes (B4), efficiency economic target (B1) is specialized and is decomposed into ten thousand yuan of product energy consumptions (C11), ten thousand yuan of increased value energy consumptions (C12); Product energy efficiency indexes (B2) is specialized and is decomposed into unit product comprehensive energy consumption (C21), product amount of energy saving (C22), product energy level (C23); Energy efficiency of equipment index is specialized and is decomposed into machine tool efficiency (C31), energy transport efficiency (C32), energy processing translating eqipment (C33);Flow of task energy efficiency indexes is specialized and is decomposed into production technique efficiency (C41), resources of production scheduling efficiency (C42).

3. machine tool product manufacturing system energy efficiency analysis method for air according to claim 1, it is characterised in that: step (4) is set up work step layer energy consumption Integrated planar schottky diode as follows:

A work step can be divided into startup, standby, unloaded, processing four-stage, and gets the energy expenditure in process segment for effectively output, then have:

${\mathrm{\η}}_1=\frac{E_c}{E_1}=\frac{{\∫}_{t_c}{P}_{in}\left(t\right)dt}{{\∫}_{t_T}{P}_{in}\left(t\right)dt}$

Wherein, t_T=t_st+t_sy+t_ie+t_c, and E₁Calculate by following formula: E₁=E_st+E_s-s+E_ie+E_c; In formula: t_TRepresent total process period, t_stRepresent lathe start time, t_syRepresent the waiting time, t_ieRepresent dead time, t_cRepresent the cutting time, E₁Work step energy consumption, E_stLathe starts energy consumption, E_s-sWork step standby energy consumption, E_ieThe unloaded energy consumption of work step, E_cRepresent and cut energy consumption.

4. machine tool product manufacturing system energy efficiency analysis method for air according to claim 1, it is characterised in that: step (4) is set up operation layer energy consumption Integrated planar schottky diode as follows:

At operation layer, the energy consumption of each operation not only comprises the energy consumption of its each work step, further comprises the part power consumption for part transport, therefore has:

$E_2=\underset{i=1}{\overset{N_1}{\Σ}}{E}_{1_i}+E_{ts}$

In formula: E₂Represent process energy consumption, N₁Represent work step number in operation, E_tsRepresent transport energy consumption;

Transport energy consumption E_tsCalculate by following formula:

$E_{ts}=\frac{P_{ts}\×t_{ts}}{Q}$

In formula: P_tsRepresent the rated output of transportation equipment, t_tsRepresenting transportation equipment working time, Q represents the part number once transporting loading;

So, operation layer efficiency represents and is:

${\mathrm{\η}}_2=\frac{\underset{i=1}{\overset{N_1}{\Σ}}{E}_{c_i}}{E_2}.$

5. machine tool product manufacturing system energy efficiency analysis method for air according to claim 1, it is characterised in that: step (4) is set up part layer energy consumption Integrated planar schottky diode as follows:

When a front buffer zone of lathe is empty, or a rear buffer zone is for, time full, the situation being forced to wait occurs in lathe; The power that lathe is forced to etc. to bide one's time is exactly the standby power of lathe;

Simultaneously, it is contemplated that the power consumption of Cleaning of Parts and japanning, the energy consumption producing a part can represent and is:

$E_3=\underset{i=1}{\overset{N_2}{\Σ}}{E}_{2_i}+E_{pt}+E_{cn}+E_{s-p}$

In formula: E₃Represent part energy consumption, N₂Represent the process number of processing parts, E_ptRepresent japanning energy consumption, E_cnRepresent and clean energy consumption, E_s-pRepresent that machine waits energy consumption;

Corresponding efficiency calculating formula is:

${\mathrm{\η}}_3=\frac{\underset{i=1}{\overset{N_2}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ij}}}{E_3}.$

6. machine tool product manufacturing system energy efficiency analysis method for air according to claim 1, it is characterised in that: step (4) is set up gas producing formation energy consumption Integrated planar schottky diode as follows:

The power consumption of gas producing formation needs the power consumption of power consumption and the utility appliance considering Assembly of the parts, is shown below:

$E_4=\underset{i=1}{\overset{N_3}{\Σ}}{E}_{3_i}+E_{ae}+\frac{E_{fy}}{KM}$

Wherein, E₄Represent product energy consumption, N₃Represent the part number of converted products, E_aeRepresent assembled product power consumption, E_fyUtility appliance consumes energy, K and M produces the species number of product and the number of particular types product in certain time;

So, the efficiency of this level is:

${\mathrm{\η}}_4=\frac{\underset{k=1}{\overset{N_3}{\Σ}}\underset{i=1}{\overset{N_{2_k}}{\Σ}}\underset{j=1}{\overset{N_{1_i}}{\Σ}}{E}_{c_{ijk}}}{E_4}.$