CN109634238B - Quality-energy efficiency assessment and monitoring method for machining process of numerical control machine tool - Google Patents
Quality-energy efficiency assessment and monitoring method for machining process of numerical control machine tool Download PDFInfo
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Abstract
The invention discloses a numerical control machine tool machining process quality-energy efficiency assessment and monitoring method for energy conservation and emission reduction in manufacturing industry. Firstly, calculating to obtain the qualified rate of the machining quality of the numerical control machine tool according to the actual number of machined parts and the number of qualified machined parts of the numerical control machine tool; and then calculating to obtain the quality-energy efficiency of the numerical control machine tool in the machining process by obtaining the energy consumption of the numerical control machine tool when unqualified products exist and unqualified products do not exist in a given period. And constructing a relation model between the quality-energy efficiency and the machining quality qualification rate of the numerical control machine tool based on the obtained machining quality qualification rate and the quality-energy efficiency of the numerical control machine tool. And (4) carrying out real-time monitoring and overrun alarming and controlling on the quality-energy efficiency of the machining process of the numerical control machine tool based on the evaluation model. The method is scientific in quality-energy efficiency evaluation of the numerical control machine tool machining process, can control the quality-energy efficiency of the numerical control machine tool machining process within a required range, and is a practical and effective method.
Description
Technical Field
The invention relates to the field of numerical control machine tool energy efficiency assessment and energy efficiency monitoring and improvement in the discrete manufacturing industry, in particular to a numerical control machine tool machining process quality-energy efficiency assessment and monitoring method.
Background
Numerically controlled machine tools are mechanical equipment widely used in the discrete manufacturing industry. The study of professor of the american college of labor and technology of massachusetts states that the energy consumption of numerically controlled machines and their indirect environmental emissions are very significant. The numerical control machine tool in the manufacturing industry of China is large in usage amount and wide in application range, so that the total energy consumption of the numerical control machine tool is huge. The method for evaluating and monitoring the quality-energy efficiency of the numerical control machine tool in the machining process has important significance for energy conservation and consumption reduction in the manufacturing industry.
The energy efficiency of the numerical control machine tool in the operation process is influenced by the processing parameters on one hand, and the quality of the processing parts of the numerical control machine tool also influences the overall energy efficiency of the numerical control machine tool on the other hand. The current method for analyzing and evaluating the energy efficiency of the machining process of the numerical control machine tool mainly considers the influence of machining parameters, but rarely considers the influence of the quality of machined parts on the energy efficiency of the machine tool. Currently, an effective and practical numerical control machine tool energy efficiency assessment and monitoring method capable of comprehensively considering the quality influence of the machined parts of the numerical control machine tool is still lacked. The method constructs a relation model between the numerical control machine tool quality-energy efficiency and the numerical control machine tool machining quality qualification rate by comprehensively considering the influence of the numerical control machine tool machining quality qualification rate on the numerical control machine tool energy efficiency. And further, the numerical control machine quality-energy efficiency is monitored in real time, so that the over-limit alarm function of the numerical control machine quality-energy efficiency is realized, and the numerical control machine quality-energy efficiency is controlled within a required range. The method of the invention considers the influence of the machine tool processing quality loss on the integral energy efficiency of the numerical control machine tool, can effectively and accurately evaluate the quality-energy efficiency of the numerical control machine tool, and can carry out overrun alarm on the quality-energy efficiency of the numerical control machine tool, so that an operator can timely and pertinently control the quality-energy efficiency of the machine tool to be within a required range, thereby being a practical machine tool energy efficiency evaluation and monitoring method.
Disclosure of Invention
The invention aims to provide a method for evaluating and monitoring the quality-energy efficiency of a numerical control machine tool in the discrete manufacturing industry in real time, which compares the quality-energy efficiency of the numerical control machine tool in the evaluation with a preset lower limit value of the quality-energy efficiency of the numerical control machine tool, thereby realizing the alarm of the quality-energy efficiency of the numerical control machine tool in the process of exceeding the limit and controlling the quality-energy efficiency of the numerical control machine tool in a required range.
A quality-energy efficiency evaluation and monitoring method for a numerical control machine tool machining process comprises the following steps:
step 1, installing an RFID (radio frequency identification) tag on each part, sensing the part to be processed by an RFID reader-writer 1 after the part is processed, and automatically adding 1 to the number of the parts; and then checking whether the part is qualified. If the qualified product is qualified, entering a qualified product storage area; if the parts are unqualified products, the parts enter an unqualified product storage area, the RFID reader-writer 2 senses the unqualified parts, and meanwhile, the quantity of the unqualified parts is automatically increased by 1; therefore, the actual number of machined parts (marked as O) of the numerical control machine tool in a given time period can be obtainedactual) And the number of unqualified products machined by the numerical control machine tool (recorded as O)defect)。
Step 2, calculating to obtain the number of the parts which are processed by the numerical control machine tool and qualified according to the obtained number of the parts which are actually processed by the numerical control machine tool in the given period and the obtained number of the unqualified products, wherein the calculation formula is as follows:
Oqualified＝Oactual-Odefect
wherein: o isqualifiedIndicates the number of parts qualified in the numerical control machine tool, OactualIndicating the number of parts actually machined by the numerical control machine, OdefectAnd indicating the number of unqualified products machined by the numerical control machine tool.
And 3, dividing the obtained number of the parts qualified in the numerical control machine tool machining in the given period by the number of the parts actually machined by the numerical control machine tool, and calculating to obtain the qualified rate of the machining quality of the numerical control machine tool, wherein the calculation formula is as follows:
wherein: etaqualityIndicates the qualified rate of the processing quality of the numerical control machine tool, OqualifiedIndicates the number of parts qualified in the numerical control machine tool, OactualAnd the number of the actually processed parts of the numerical control machine tool is shown.
Step 4, when the numerically-controlled machine tool machined part has no unqualified product in a given time period, the total energy consumption of the numerically-controlled machine tool machined part is obtained by calculating the actual machined part number of the numerically-controlled machine tool and the actual energy consumption value of the machined single part, and the calculation formula is as follows:
Eno_defect＝Oactual×Eactual
wherein: eno_defectRepresenting the energy consumption of the numerical control machine tool, O, when no non-conforming article is present in a given time periodactualIndicating the number of parts actually machined by the numerical control machine, EactualRepresenting the actual energy consumption of the numerical control machine for machining a single part.
Step 5, when the numerically-controlled machine tool machining parts have unqualified products in a given time period, the total energy consumption of the numerically-controlled machine tool machining parts is obtained by calculating the actual machining part number of the numerically-controlled machine tool, the actual energy consumption value of machining single parts, the number of the numerically-controlled machine tool machining unqualified products and the rework energy consumption of the single unqualified products, and the calculation formula is as follows:
Ewith_defect＝Oactual×Eactual+Odefect×Erework
wherein: ewith_defectIndicating numerically controlled machine tool energy consumption, O, when defective products are present in a given time periodactualIndicating the number of parts actually machined by the numerical control machine, EactualRepresenting the actual energy consumption of the numerically controlled machine for machining a single part, OdefectIndicating the number of defective parts machined by the numerical control machine, EreworkAnd indicating the rework energy consumption of the single unqualified product.
Step 6, dividing the obtained numerical control machine tool energy consumption when unqualified products exist in the given period with the numerical control machine tool energy consumption when unqualified products do not exist, and calculating to obtain the quality-energy efficiency of the numerical control machine tool in the machining process, wherein the calculation formula is as follows:
wherein: etaquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, Eno_defectRepresenting the energy consumption of the numerical control machine tool in the absence of non-conforming articles within a given time period, Ewith_defectRepresenting the numerically controlled machine tool energy consumption when defective products exist in a given time period.
And 7, according to the obtained numerical control machine tool machining quality qualification rate calculation model and the numerical control machine tool machining process quality-energy efficiency calculation model, carrying out derivation operation to obtain a relation model between the numerical control machine tool machining process quality-energy efficiency and the numerical control machine tool machining quality qualification rate, wherein the relation model is expressed as follows:
wherein: etaquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, EactualRepresenting the actual energy consumption, eta, of the numerically controlled machine tool for machining a single partqualityRepresenting the qualification rate of the machining quality of the numerical control machine tool, EreworkAnd indicating the rework energy consumption of the single unqualified product.
Step 8, obtaining the quality-energy efficiency eta of the numerical control machine tool processing process in a given time periodquality_eCompared with the preset numerical control machine tool machining process quality-energy efficiency alarm lower limit value
Comparing, if the relation formula is satisfied
The quality-energy efficiency of the numerical control machine tool in the machining process is normal. If the relational expression is satisfied
And alarming to prompt the quality-energy efficiency abnormity of the machining process of the numerical control machine tool, and simultaneously displaying the quality-energy efficiency of the numerical control machine tool in the evaluation period, the corresponding machining quality qualification rate of the numerical control machine tool and the rework energy consumption value of the single unqualified product on a display screen.
And 9, according to the alarm prompt in the step 8, the production personnel pertinently adjust and control the quality of the machining process of the numerical control machine tool, and the qualified rate of the machining quality of the numerical control machine tool is improved, so that the quality-energy efficiency of the numerical control machine tool is improved to a required range.
In step 4, the actual energy consumption E of the numerical control machine for machining the single-piece partactualThe energy consumption measuring device is installed at the air switch of the numerical control machine tool, the numerical control machine tool processes parts by using given processing parameters, the energy consumption measuring device simultaneously measures the part processing energy consumption, and the multiple measured single part processing energy consumption values are averaged to obtain the actual energy consumption value E of the numerical control machine tool for processing single partsactual。
In step 5, the energy consumption E for reworking the single unqualified productreworkAnd by installing the energy consumption measuring device at the air switch of the numerical control machine tool, when the numerical control machine tool carries out rework operation on the unqualified product, the energy consumption measuring device simultaneously measures the rework energy consumption, and the rework energy consumption values of the unqualified product measured for multiple times are averaged to obtain the rework energy consumption E of the single unqualified productrework。
Compared with the prior art, the invention has the following beneficial effects:
the method establishes a numerical control machine tool machining quality qualification rate model by considering the actual machining part number and the machining qualified part number of the numerical control machine tool in a given time period, further considers the influence of the numerical control machine tool machining quality qualification rate on the numerical control machine tool energy efficiency, and establishes a numerical control machine tool machining quality qualification rate and a numerical control machine tool quality-energy efficiency relation model. Further, the numerical control machine tool quality-energy efficiency is monitored in real time, so that the numerical control machine tool quality-energy efficiency overrun alarm is realized, and an operator can timely and pertinently control the machine tool quality-energy efficiency within a required range. The method of the invention considers the influence of the processing quality loss of the numerical control machine tool on the energy efficiency of the numerical control machine tool, can evaluate the quality-energy efficiency of the numerical control machine tool practically and accurately, and can realize the over-limit alarm of the quality-energy efficiency of the numerical control machine tool through the real-time monitoring and analysis of the quality-energy efficiency of the numerical control machine tool, so that the operator of the numerical control machine tool can control the quality-energy efficiency of the numerical control machine tool in a required range in a targeted manner, thereby being an effective and practical method for evaluating and monitoring the quality-energy efficiency of the numerical control machine tool. The method is scientific and practical and can be popularized to quality-energy efficiency assessment and monitoring of other mechanical equipment.
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FIG. 1 is a schematic flow diagram of the process of the present invention;
FIG. 2 is a schematic diagram of the apparatus configuration of the method of the present invention.
Detailed Description
The present invention will now be explained in detail with reference to the embodiments and the accompanying drawings.
The invention provides a quality-energy efficiency evaluation and monitoring method for a machining process of a numerical control machine tool. The flow diagram of the method of the invention is shown in fig. 1, firstly, the number of the parts actually processed by the numerical control machine tool in a given time period is sensed and obtained by means of the RFID label attached to the parts and the RFID reader-writer 1. And sensing and acquiring the quantity of unqualified numerical control machine tool machining products by means of the RFID reader-writer 2. And then calculating to obtain the number of the parts qualified in the numerical control machine tool in a given time period. And calculating to obtain the qualified rate of the machining quality of the numerical control machine tool based on the obtained actual number of machined parts and the obtained qualified number of machined parts of the numerical control machine tool. And measuring the energy consumption value of the numerical control machine tool for processing the single part under the given working parameters for multiple times, and averaging to obtain the actual energy consumption value of the numerical control machine tool for processing the single part. And calculating to obtain the energy consumption of the numerical control machine tool without unqualified products based on the actual number of machined parts of the numerical control machine tool and the actual energy consumption value of machined single parts. And measuring the energy consumption value of the numerical control machine tool in the process of performing rework operation on a single unqualified product for multiple times, and averaging to obtain the rework energy consumption of the single unqualified product. And calculating to obtain the energy consumption of the numerical control machine tool when unqualified products exist according to the obtained actual number of parts processed by the numerical control machine tool, the actual energy consumption value of processing single parts and the rework energy consumption of the single unqualified products. And further calculating to obtain the quality-energy efficiency of the numerical control machine tool in the machining process according to the obtained numerical control machine tool energy consumption when no unqualified product exists and the numerical control machine tool energy consumption when an unqualified product exists. And constructing a relation model between the quality-energy efficiency of the numerical control machine tool and the machining quality qualification rate of the numerical control machine tool based on the established numerical control machine tool machining quality qualification rate model and the numerical control machine tool quality-energy efficiency model. And (4) carrying out real-time monitoring on the quality-energy efficiency of the numerical control machine tool based on the relation model and realizing an overrun alarm function, so that the quality-energy efficiency of the numerical control machine tool is controlled within a required range.
The device configuration related to the present invention is shown in fig. 2, and mainly includes: the system comprises a numerical control machine tool, an energy consumption measuring device, an RFID reader-writer 1, an RFID reader-writer 2, an RFID label, a qualified product storage area, a unqualified product storage area, a computer provided with an Sql database and a display screen. The energy consumption measuring device is used for measuring the actual energy consumption value of the parts machined by the numerical control machine tool and the rework energy consumption value of the parts. The RFID label is attached to the part and used for identifying the part; the RFID reader-writer 1 acquires the number of the actually processed parts of the numerical control machine tool by sensing the RFID tags attached to the parts; the RFID reader-writer 2 acquires the number of unqualified products processed by the numerical control machine tool by sensing the RFID tags attached to the unqualified parts; the qualified product storage area is used for temporarily storing qualified parts; the unqualified product storage area is used for temporarily storing unqualified parts; the computer is provided with a Sql database and is used for storing the acquired numerical control machine tool machining part number information and numerical control machine tool energy consumption and quality-energy efficiency information; and the display screen is connected with the computer and is used for displaying the numerical control machine tool quality-energy efficiency, the machining quality qualification rate and the single unqualified product reworking energy consumption information.
The embodiment of the invention takes the part processing process of a CK6153i numerical control machine tool as an example, the processed part is a cylindrical part, the quality-energy efficiency of the processing process is evaluated and monitored by adopting the method, and the alarm prompt is carried out on the condition that the quality-energy efficiency of the processing process of the CK6153i numerical control machine tool is out of limit. In the embodiment of the invention, the quality-energy efficiency of the numerical control machine tool machining process is evaluated once every 1 hour.
1. Acquiring the actual processing part number and the processing unqualified product number of the numerical control machine tool
The evaluation period of the quality-energy efficiency of the processing process of the numerical control machine CK6153i is 1 hour, and the initial value of the number of the actually processed parts of the numerical control machine is set to be 0 (O)actual0), the initial value of the number of defective products is set to 0 (O)defect0). Each part is attached with an RFID label, the parts are sensed by an RFID reader-writer 1 after being processed, and the number of the actually processed parts of the numerical control machine tool is automatically accumulated by 1 (O)actual＝Oactual+1). Then, whether the parts are qualified products is checked, and if the parts are qualified products, the parts enter a qualified product storage area; if the part is unqualified, the part enters an unqualified product storage area, an RFID reader-writer 2 senses RFID labels on unqualified parts, and the quantity of processed unqualified products is automatically increased by 1 (O)defect＝Odefect+1). Taking 10 months and 17 am at 9:00-10:00 in the morning as an example, 25 parts are co-processed by the numerical control machine CK6153 i. The RFID reader-writer 1 senses 25 RFID labels to obtain the actual processing part number O of the numerical control machine toolactual25 pieces. When 1 defective product is detected, and the defective product enters the defective product storage area, the RFID reader-writer 2 senses the RFID label of the part, and the number of processed defective products in the evaluation period is O, namely CK6153idefect＝Odefect+1＝1。
2. Obtaining the number of parts qualified in the machining of the numerical control machine tool
The numerical formula of the number of the qualified parts processed by the numerical control machine tool is Oqualified＝Oactual-Odefect. Wherein: o isqualifiedThe number of the parts qualified in the numerical control machine tool machining is represented, and the unit is a part; o isactualThe number of the actually processed parts of the numerical control machine tool is represented, and the unit is a part; o isdefectThe number of unqualified products machined by the numerical control machine tool is shown, and the unit is a piece. Still taking 10 months and 17 days in the morning of 9:00-10:00 as an example, the number of actually processed parts of the numerical control machine tool is 25 (O)actual25), the number of unqualified products processed by the numerical control machine tool is 1 (O)defect1). Substituting the data into a formula, and calculating to obtain the number of the parts qualified in the numerical control machine tool machining in the period as Oqualified＝Oactual-Odefect25-1-24 pieces.
3. Obtaining the qualified rate of the processing quality of the numerical control machine tool
According to the obtained actual processing part number and the processing qualified part number of the numerical control machine tool, the processing quality qualified rate of the numerical control machine tool is obtained by calculation, and the calculation model is
Wherein eta isqualityIndicates the qualified rate of the processing quality of the numerical control machine tool, OqualifiedThe number of the parts qualified in the numerical control machine tool machining is represented, and the unit is a part; o isactualThe number of the actually processed parts of the numerical control machine tool is shown, and the unit is a part. Taking the 9:00-10:00 am of 17 days of 10 months as an example, the actual machining part number O of the numerical control machine tool in the period is obtainedactualThe number of the parts processed by the numerical control machine tool is Oqualified24 pieces. Substituting the above data into formula
Calculating to obtain the qualified rate eta of the processing quality of the numerical control machine toolquality＝96.0％。
4. Obtaining numerical control machine tool energy consumption without unqualified products
4.1 obtaining actual energy consumption of numerically controlled machine tool for machining single-piece parts
In the embodiment, an energy consumption measuring device is installed at an air switch of the CK6153i numerical control machine tool and is used for recording an energy consumption value of the machining process of the numerical control machine tool. The energy consumption value of the CK6153i numerical control machine tool for processing a single part under the given processing parameter is measured for multiple times, and the measured energy consumption value of the single part under the given processing parameter for 50 times is shown in Table 1.
TABLE 1
Based on the 50 energy consumption values obtained in the table 1, the average value is calculated, and the actual energy consumption value E of the numerically-controlled machine tool for processing the single-piece part can be obtainedactual＝156.3(kJ)。
4.2 calculate the numerical control machine tool energy consumption without unqualified products
Calculating the numerical control machine tool energy consumption when no unqualified product is obtained based on the obtained actual machining part number of the numerical control machine tool and the actual energy consumption value of the numerical control machine tool machining single-piece part, wherein the calculation formula is Eno_defect＝Oactual×Eactual. Wherein E isno_defectRepresenting the energy consumption of the numerical control machine tool when no unqualified product exists in a given time period, and the unit is kilojoule (kJ); o isactualThe number of the actually processed parts of the numerical control machine tool is represented, and the unit is a part; eactualThe actual energy consumption of the numerically-controlled machine tool for machining a single part is shown, and the unit is kilojoule (kJ). Taking the 9:00-10:00 am of 17 days of 10 months as an example, the actual machining part number O of the numerical control machine tool in the period is obtainedactualActual energy consumption value E of numerically controlled machine tool for machining single-piece partsactual156.3 (kJ). Substituting the above data into formula Eno_defect＝Oactual×EactualAnd calculating the energy consumption E of the numerical control machine tool when no unqualified product is obtainedno_defect＝3907.5(kJ)。
5. Obtaining numerical control machine tool energy consumption when unqualified products exist
5.1 obtaining rework energy consumption of single unqualified product
The energy consumption measuring device arranged at the air switch of the CK6153i numerical control machine tool can measure the energy consumption value of the unqualified product reworking process. When the CK6153i numerical control machine tool returns unqualified products, the energy consumption measuring device measures the energy consumption of the single unqualified product for rework. The energy consumption values of 10 sets of defective product returning hours are obtained by measurement in total, and are shown in table 2.
TABLE 2
Calculating the average value based on the 10 groups of energy consumption values obtained in the table 2 to obtain the rework energy consumption value E of the single unqualified productrework＝125.7(kJ)。
5.2 calculate the numerically controlled machine tool energy consumption when there is a defective product
Calculating the energy consumption of the numerical control machine tool when unqualified products are obtained based on the obtained actual number of parts processed by the numerical control machine tool, the actual energy consumption value of processing single parts, the number of unqualified products processed by the numerical control machine tool and the rework energy consumption of the single unqualified products, wherein the calculation formula is Ewith_defect＝Oactual×Eactual+Odefect×Erework. Wherein E iswith_defectRepresenting the energy consumption of the numerical control machine tool when unqualified products exist in a given time period, and the unit is kilojoule (kJ); o isactualThe number of the actually processed parts of the numerical control machine tool is represented, and the unit is a part; eactualThe actual energy consumption of the numerically-controlled machine tool for processing a single part is expressed in kilojoule (kJ); o isdefectThe number of unqualified products machined by the numerical control machine tool is represented, and the unit is a piece; ereworkAnd the unit of the reworking energy consumption of the single unqualified product is kilojoule (kJ). Taking the 9:00-10:00 am of 17 days of 10 months as an example, the actual machining part number O of the numerical control machine tool in the period is obtainedactualActual energy consumption value E of numerically controlled machine tool for machining single-piece partsactual156.3(kJ), the number O of unqualified products processed by the numerical control machine tooldefect1, rework energy consumption value E of single unqualified productrework125.7 (kJ). Substituting the above data into formula Ewith_defect＝Oactual×Eactual+Odefect×EreworkAnd calculating the energy consumption E of the numerical control machine tool when unqualified products are obtainedwith_defect＝25×156.3+1×125.7＝4033.2(kJ)。
6. Obtaining quality-energy efficiency of numerical control machine tool machining process
According to the obtained numerical control machine tool energy consumption when unqualified products exist and the numerical control machine tool energy consumption when unqualified products do not exist, the numerical control machine tool machining process quality-energy efficiency is obtained through calculation, and the calculation formula is as follows:
wherein eta isquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, Eno_defectRepresenting the energy consumption of the numerical control machine tool when no unqualified product exists in a given time period, and the unit is kilojoule (kJ); ewith_defectAnd the unit of the numerical control machine tool energy consumption is kilojoule (kJ) when unqualified products exist in a given time period. Taking the 9:00-10:00 am of 17 th of 10 months as an example, the energy consumption E of the numerical control machine tool when no unqualified product exists in the period is obtainedno_defect3907.5(kJ), energy consumption E of NC machine tool when there is defective productwith_defect4033.2 (kJ). Substituting the above data into formula
The quality-energy efficiency of the numerical control machine tool in the time period is calculated to be etaquality_e＝96.9％。
7. Obtaining a numerical control machine tool quality-energy efficiency and quality qualification rate relation model
According to the obtained numerical control machine tool machining quality qualification rate calculation model and the numerical control machine tool machining process quality-energy efficiency calculation model, a relation model between the numerical control machine tool machining process quality-energy efficiency and the numerical control machine tool machining quality qualification rate is obtained through derivation operation, and the relation model is
Wherein eta isquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, EactualThe actual energy consumption of the numerically-controlled machine tool for processing a single part is expressed in kilojoule (kJ); etaqualityRepresenting the qualification rate of the machining quality of the numerical control machine tool, EreworkAnd the unit of the reworking energy consumption of the single unqualified product is kilojoule (kJ). Still taking 10 months and 17 days at 9:00-10:00 am as an example, the actual energy consumption E of the numerical control machine tool for processing the single part in the time period is obtainedactual156.3(kJ), rework energy consumption E of single unqualified productrework125.7 (kJ). The data are substituted into the relation model, so that the relation model between the quality-energy efficiency of the numerical control machine tool machining process and the machining quality qualification rate of the numerical control machine tool can be obtained
8. Monitoring the quality-energy efficiency of the numerical control machine tool machining process and alarming for overrun
The obtained quality-energy efficiency eta of the numerical control machine tool processing process in the evaluation periodquality_eThe preset lower limit value of the machine tool processing quality-energy efficiency alarm
A comparison is made. The numerical control machine tool processing process quality-energy efficiency alarm lower limit in the invention
The method is determined according to statistical analysis of historical data of quality-energy efficiency of the numerical control machine tool machining process and by combining with the experience of a manager. If the embodiment is used for alarming the lower limit of the load-energy efficiency in the processing process of the numerical control machine tool
Taking the 9:00-10:00 am of 17 days in 10 months as an example, the numerical control machine tool processing quality-energy efficiency eta in the time period is obtainedquality_e96.9%, the relational expression is satisfied
The numerical control machine tool has normal quality-energy efficiency in the machining process. Taking the former example, if the quality-energy efficiency alarm lower limit of the numerical control machine tool machining process is set
Set to 98%, the relational expression is satisfied
At this time, the alarm prompts the quality-energy efficiency abnormity of the numerical control machine tool machining process to be lower than the lower limit of the quality-energy efficiency of the numerical control machine tool machining process, and simultaneously the quality-energy efficiency (eta) of the numerical control machine tool machining process in the evaluation period is evaluatedquality_e96.9%) and the corresponding numerical control machine tool machining quality qualification rate (eta)quality96.0%) and the rework energy consumption value (E) of a single reject during the evaluation periodrework125.7kJ) is displayed on the display screen.
9. And adjusting and controlling parameters according to the alarm prompt.
And (4) carrying out targeted adjustment on the machining parameters of the numerical control machine CK6153i by a machine tool operator according to the alarm prompt in the step 8, so that the quality-energy efficiency of the machining process of the numerical control machine is controlled within a normal range.
The method can be used for scientific evaluation and monitoring of the quality-energy efficiency of the machining process of the numerical control machine tool in the discrete manufacturing industry, so that the quality-energy efficiency of the machining process of the numerical control machine tool is controlled within a required range, and the energy-saving control of the machining operation process of the numerical control machine tool is realized. The method provides effective and practical technology and method support for realizing energy conservation and emission reduction of the discrete manufacturing industry.
Finally, the above embodiments are only used for illustrating the technical solutions of the present invention and not for limiting, and modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the method of the present invention, which shall be covered by the claims of the present invention.
Claims (3)
1. A method for evaluating and monitoring the quality-energy efficiency of a numerical control machine tool machining process is characterized by comprising the following steps:
step 1, installing an RFID (radio frequency identification) tag on each part, sensing the part to be processed by an RFID reader-writer 1 after the part is processed, and automatically adding 1 to the number of the parts; then, whether the part is a qualified product is checked; if the qualified product is qualified, entering a qualified product storage area; if the parts are unqualified products, the parts enter an unqualified product storage area, the RFID reader-writer 2 senses the unqualified parts, and meanwhile, the quantity of the unqualified parts is automatically increased by 1; therefore, the actual number O of the parts processed by the numerical control machine tool in a given time period can be obtainedactualAnd the number O of unqualified products machined by a numerical control machine tooldefect；
Step 2, calculating to obtain the number of the parts which are processed by the numerical control machine tool and qualified according to the obtained number of the parts which are actually processed by the numerical control machine tool in the given period and the obtained number of the unqualified products, wherein the calculation formula is as follows:
Oqualified＝Oactual-Odefect
wherein: o isqualifiedIndicates the number of parts qualified in the numerical control machine tool, OactualIndicating the number of parts actually machined by the numerical control machine, OdefectIndicating the number of unqualified products machined by the numerical control machine tool;
and 3, dividing the obtained number of the parts qualified in the numerical control machine tool machining in the given period by the number of the parts actually machined by the numerical control machine tool, and calculating to obtain the qualified rate of the machining quality of the numerical control machine tool, wherein the calculation formula is as follows:
wherein: etaqualityIndicates the qualified rate of the processing quality of the numerical control machine tool, OqualifiedIndicates the number of parts qualified in the numerical control machine tool, OactualRepresenting the number of actually processed parts of the numerical control machine tool;
step 4, when the numerically-controlled machine tool machined part has no unqualified product in a given time period, the total energy consumption of the numerically-controlled machine tool machined part is obtained by calculating the actual machined part number of the numerically-controlled machine tool and the actual energy consumption value of the machined single part, and the calculation formula is as follows:
Eno_defect＝Oactual×Eactual
wherein: eno_defectRepresenting the energy consumption of the numerical control machine tool, O, when no non-conforming article is present in a given time periodactualIndicating the number of parts actually machined by the numerical control machine, EactualRepresenting the actual energy consumption of the numerical control machine tool for processing a single part;
step 5, when the numerically-controlled machine tool machining parts have unqualified products in a given time period, the total energy consumption of the numerically-controlled machine tool machining parts is obtained by calculating the actual machining part number of the numerically-controlled machine tool, the actual energy consumption value of machining single parts, the number of the numerically-controlled machine tool machining unqualified products and the rework energy consumption of the single unqualified products, and the calculation formula is as follows:
Ewith_defect＝Oactual×Eactual+Odefect×Erework
wherein: ewith_defectIndicating numerically controlled machine tool energy consumption, O, when defective products are present in a given time periodactualIndicating the number of parts actually machined by the numerical control machine, EactualRepresenting the actual energy consumption of the numerically controlled machine for machining a single part, OdefectIndicating the number of defective parts machined by the numerical control machine, EreworkRepresenting the rework energy consumption of the single unqualified product;
step 6, dividing the obtained numerical control machine tool energy consumption when unqualified products exist in the given period with the numerical control machine tool energy consumption when unqualified products do not exist, and calculating to obtain the quality-energy efficiency of the numerical control machine tool in the machining process, wherein the calculation formula is as follows:
wherein: etaquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, Eno_defectRepresenting the energy consumption of the numerical control machine tool in the absence of non-conforming articles within a given time period, Ewith_defectRepresenting the energy consumption of the numerical control machine tool when unqualified products exist in a given time period;
and 7, according to the obtained numerical control machine tool machining quality qualification rate calculation model and the numerical control machine tool machining process quality-energy efficiency calculation model, carrying out derivation operation to obtain a relation model between the numerical control machine tool machining process quality-energy efficiency and the numerical control machine tool machining quality qualification rate, wherein the relation model is expressed as follows:
wherein: etaquality_eRepresenting the quality-energy efficiency of the machining process of a numerically controlled machine tool, EactualRepresenting the actual energy consumption, eta, of the numerically controlled machine tool for machining a single partqualityRepresenting the qualification rate of the machining quality of the numerical control machine tool, EreworkRepresenting the rework energy consumption of the single unqualified product;
step 8, obtaining the quality-energy efficiency eta of the numerical control machine tool processing process in a given time periodquality_eCompared with the preset numerical control machine tool machining process quality-energy efficiency alarm lower limit value
Comparing, if the relation formula is satisfied
The quality-energy efficiency of the numerical control machine tool in the machining process is normal; if the relational expression is satisfied
Alarming to prompt the quality-energy efficiency abnormity of the numerical control machine tool in the processing process, and simultaneously displaying the numerical control machine tool quality-energy efficiency of the evaluation period, the corresponding numerical control machine tool processing quality qualification rate and the single unqualified product reworking energy consumption value on a display screen;
and 9, according to the alarm prompt in the step 8, the production personnel pertinently adjust and control the quality of the machining process of the numerical control machine tool, and the qualified rate of the machining quality of the numerical control machine tool is improved, so that the quality-energy efficiency of the numerical control machine tool is improved to a required range.
2. The method as claimed in claim 1, wherein in step 4, the actual energy consumption E of the numerically controlled machine tool for machining the single-piece part is determinedactualThe energy consumption measuring device is installed at the air switch of the numerical control machine tool, the numerical control machine tool processes parts by using given processing parameters, the energy consumption measuring device simultaneously measures the part processing energy consumption, and the multiple measured single part processing energy consumption values are averaged to obtain the actual energy consumption value E of the numerical control machine tool for processing single partsactual。
3. The method as claimed in claim 1, wherein in step 5, the rework energy consumption E of the single rejected product is increasedreworkAnd by installing the energy consumption measuring device at the air switch of the numerical control machine tool, when the numerical control machine tool carries out rework operation on the unqualified product, the energy consumption measuring device simultaneously measures the rework energy consumption, and the rework energy consumption values of the unqualified product measured for multiple times are averaged to obtain the rework energy consumption E of the single unqualified productrework。
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