CN109784763B - Machining efficiency judging method based on energy value - Google Patents
Machining efficiency judging method based on energy value Download PDFInfo
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- 238000003754 machining Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 94
- 239000002699 waste material Substances 0.000 claims abstract description 25
- 238000005265 energy consumption Methods 0.000 claims abstract description 23
- 238000006243 chemical reaction Methods 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 21
- 238000012545 processing Methods 0.000 claims description 14
- 238000011161 development Methods 0.000 abstract description 8
- 238000011156 evaluation Methods 0.000 abstract description 8
- 230000008901 benefit Effects 0.000 abstract description 3
- 230000007613 environmental effect Effects 0.000 abstract description 2
- 238000003801 milling Methods 0.000 description 12
- 238000000227 grinding Methods 0.000 description 4
- 238000004364 calculation method Methods 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 230000010485 coping Effects 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 238000007726 management method Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000010792 warming Methods 0.000 description 2
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- 230000000694 effects Effects 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 238000012854 evaluation process Methods 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
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Abstract
The application discloses a machining efficiency judging method based on energy values, which relates to the technical field of machining, and the method comprises the steps of dividing the whole machining process into a plurality of stations by measuring the energy consumption, material consumption, service consumption, waste discharge and other accurate unified dimensions of the machining process through the energy values, dividing the production beats corresponding to each station into four stages, dividing each station energy consumption part, a production material consumption part, a production service consumption part and a waste part, correspondingly constructing an effective energy value utilization rate of a machining system on the basis of the energy consumption, and realizing the evaluation of the energy conversion efficiency of the machining system; the method explicitly quantifies the economic, social and environmental benefit scale consumed in the production process of the machining system, and provides a method and technical support for accurately measuring and optimizing the sustainable development capability of the machining system.
Description
Technical Field
The application relates to the technical field of machining, in particular to an energy-based machining efficiency judging method.
Background
The mechanical manufacturing industry is wide in range, and the total amount of energy consumption, material consumption and carbon emission is huge. Coping with global warming, increasing the ability of machining systems to sustainably develop has become a challenge for current manufacturing industries. The mechanical processing system has the characteristics of high energy consumption, low efficiency and high emission, and has great potential in sustainable development.
Machining is a main production process of the manufacturing industry, consumes a large amount of manufacturing energy and resources, and generates a large amount of wastes; the efficiency evaluation of the traditional mechanical processing system is mainly energy efficiency or resource efficiency evaluation, and the comprehensive consideration of waste efficiency is relatively less; the conversion efficiency of the machining system is the representation of the combined action of energy, materials, services and wastes in the system, and the conversion efficiency of the system is different under different view angles; however, the traditional mechanical efficiency evaluation method can bring about measurement cheating due to partial and incomplete evaluation results, so that the sustainable development capability of the mechanical processing system is difficult to accurately measure in the mechanical processing efficiency evaluation.
Disclosure of Invention
The application aims to overcome the defects of the prior art, and provides an energy-based machining efficiency judging method for solving the problems of inaccurate and incomplete efficiency evaluation and the like in the prior art.
The application is realized by the following technical scheme:
the application provides a machining efficiency judging method based on energy values, which comprises the following steps:
first, setting:
(2) The whole machining manufacturing process consists of n stations, i represents station serial numbers, i=1, 2, 3, n;
(2) Each station is not allowed to cancel or interrupt once it begins to process;
(3) Each station is a production beat from the beginning of processing to the end of processing;
(4) Each production beat is equally divided into a starting stage, a standby stage, an idle stage and a processing stage, wherein k is a specific stage in one production beat, and is a starting stage when k=1, a standby stage when k=2, an idle stage when k=3 and a processing stage when k=4;
(5) Faults in the production and manufacturing process are not considered;
(6) The total energy value generated by each production beat of each station is composed of four parts in total, namely a total energy consumption part, a total production material consumption part, a total production service consumption part and a total waste part, and the total energy value of each of four stages corresponding to the production beat of the station is composed of four parts in total, namely a part energy consumption part, a part production material consumption part, a part production service consumption part and a part waste part;
(7) The four parts are respectively formed by accumulating multiple resource or waste consumption parts, so that j represents the serial number of the resource generating energy consumption in each energy consumption part, and j=1, 2, 3, m
Step 1, obtaining the energy value MN of the total energy consumption part of the ith station in one production beat i
First,: obtaining energy MN (k) of the energy consumption part of the ith station in the kth stage in one production beat by using formula 1 i
Is the use amount of the jth resource in the energy dividing part of the ith station in the kth stage of one production beat
Is->Energy conversion rate of (2)
MN is then calculated using equation 2 i
Step 2, obtaining the energy MM of the total production material consumption part of the ith station in one production beat i
First,: obtaining the ith worker using equation 3Energy MM (k) of the consumed part of the partial production material is divided in the kth stage of a production cycle i
Is the usage amount of the j-th resource in the j-th station in the production material consumption part in the k-th stage of one production beat
Is->Energy conversion rate of (2)
MM is then calculated using equation 4 i ：
Step 3, obtaining the energy MS of the total production service consumption part of the ith procedure in one production beat i
First,: obtaining the energy MS (k) of the i-th station in the k-th stage of one tact by using equation 5 i
The i station divides the use amount of the j resource in the production service consumption part in the k stage in one production beat;
is->Energy conversion rate of (2)
MS was then calculated using equation 6 i
Step 4, obtaining total energy MW of total waste consumption part in one production beat in the ith procedure i
First,: obtaining energy MW (k) of waste consumption part of ith station in kth stage in one production beat by using formula 7 i
Is the usage amount of the jth resource in the ith station in the waste consuming part in the kth stage in one production cycle
Is->Energy conversion rate of (2)
MW was then calculated using equation 8 i
Step 5, obtaining the total effective energy value M (4) generated when k=4 in the whole machining process
Step 6, obtaining the total energy value M generated in the whole machining process
Step 7, obtaining the utilization rate Em of the effective energy value and the utilization rate Em of the effective energy value of each station in the whole machining process i
Compared with the prior art, the application has the following advantages:
1. the energy conversion efficiency evaluation of the machining system can definitely and quantitatively compensate the consumption scale of the machined product, and measure the capability of the machining system, and is the basis for making the real value (including economic value, social value and environmental value) of the product and the profit target of the system.
2. The optimizing method can improve the energy efficiency, the material utilization rate and the service value, reduce the pollutant emission, improve the comprehensive efficiency of the machining system, reduce the running cost of the system, improve the quality of products and improve the green degree and the conversion efficiency of the machining system. The method supports a sustainable development assessment model and a promotion method of a coordinated and reachable machining system, and is the basis and foundation of production management of the sustainable development of the machining system.
3. A more important and profound benefit is the availability of efficient tools for planning and controlling the sustainable development of machining systems. The method improves the green level of a machining system and operation and management staff, can easily and freely respond to demands of markets, society, laws and regulations and the like, improves the low-carbon manufacturing level of enterprises, and provides a practical theoretical and method support for coping with global climate warming, improving the sustainability of manufacturing development, further condensing and strengthening the core competitiveness of the manufacturing industry.
Detailed Description
The following describes in detail the examples of the present application, which are implemented on the premise of the technical solution of the present application, and detailed embodiments and specific operation procedures are given, but the scope of protection of the present application is not limited to the following examples.
Energy value refers to the amount of all of a certain effective energy that a product and service consume directly and indirectly in the production process. The basic method is that the energy of different forms in the biosphere is totally converted into solar energy value by adopting unified dimension, and the unit of the solar energy value is solar Joule (seJ), and the energy value conversion rate is adopted to represent the energy values of different types of energy in the energy level system because different resources, products or services have different energy values. The basic expression of energy analysis is:
EM＝UEV i ×N (13)
wherein EM represents solar energy value, UEV i Representing the energy conversion rate of different substances, N represents the input flow of different units (mass g or energy J).
Energy-monetary value (emdolar value) refers to the economic value of energy flow. The energy value-monetary value is a specific embodiment of the energy value in the economic market, and the basic expression is as follows:
EM＝V c ×U (14)
u is the monetary value of an economic system or economic production campaign, V c Representing the equivalent energy per unit of currency as an energy/currency ratio
The energy theory can convert various types of resources, energy sources, products, wastes and currencies into one unit to quantify the measure, and the energy values of different input streams and output streams can be obtained through calculation, so that the same energy value unit is used for comparing and calculating the energy flow in the machining system.
In this embodiment, taking a special axle machining workshop as an example, fifteen stations are provided in the whole process of machining the special axle, and the machining content of each station is shown in table 1
| Station number i | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 |
| Rough turning | Coarse boring | Rough milling | Drilling holes | Rough planing | Finish turning | Finish boring | Finish milling | |
| Station number i | 9 | 10 | 11 | 12 | 13 | 14 | 15 | |
| Finish planing | Reaming | Fine grinding | Optical hinge | Fine grinding | Honing machine | Polishing |
TABLE 1
In this embodiment, the middle rough milling station is selected as an object (a FANUC machine tool is adopted), and the energy consumption of the station in four periods of starting, standby, idle and machining, materials, services and wastes is measured as shown in table 2.
Table 2: energy, material, service and waste list consumed by four stages of rough milling machining station
Then the calculation is carried out according to the following steps:
step 1, obtaining the energy value MN of the total energy consumption part of the ith station in one production beat i
First,: obtaining energy MN (k) of the energy consumption part of the ith station in the kth stage in one production beat by using formula 1 i
Is the use amount of the jth resource in the energy dividing part of the ith station in the kth stage of one production beat
Is->Energy conversion rate of (2)
MN is then calculated using equation 2 i
Step 2, obtaining the energy MM of the total production material consumption part of the ith station in one production beat i
First,: obtaining the energy MM (k) of the material consuming part of the ith station in the kth stage of one production cycle by using the formula 3 i
Is the usage amount of the j-th resource in the j-th station in the production material consumption part in the k-th stage of one production beat
Is->Energy conversion rate of (2)
MM is then calculated using equation 4 i ：
Step 3, obtaining the energy MS of the total production service consumption part of the ith procedure in one production beat i
First,: obtaining the energy MS (k) of the i-th station in the k-th stage of one tact by using equation 5 i
The i station divides the use amount of the j resource in the production service consumption part in the k stage in one production beat;
is->Energy conversion rate of (2)
MS was then calculated using equation 6 i
Step 4, obtaining total energy MW of total waste consumption part in one production beat in the ith procedure i
First,: obtaining energy MW (k) of waste consumption part of ith station in kth stage in one production beat by using formula 7 i
Is the usage amount of the jth resource in the ith station in the waste consuming part in the kth stage in one production cycle
Is->Energy conversion rate of (2)
MW was then calculated using equation 8 i
The four stage energy consumption of the rough milling machining station is shown in table 3:
| start-up phase | Standby phase | No-load phase | Stage of processing | |
| Waste material | 0 | 2.54E+13 | 2.19E+13 | 1.27E+14 |
| Production material | 0 | 2.02E+13 | 2.54E+14 | 3.11E+14 |
| Energy source | 7.22E+13 | 8.82E+13 | 2.00E+14 | 2.55E+14 |
| Production service | 1.92E+14 | 2.35E+14 | 2.67E+14 | 2.87E+14 |
Table 3: energy consumption meter for four stages in one production beat of rough milling machining station
In machining, the effective operation is only the machining stage, and the ratio of the effective value of the machining system refers to the ratio of the effective value to the total value consumed by the system in the production process of the machining system. The effective energy value ratio is an index for measuring the production efficiency of the machining system, and can measure the energy value utilization efficiency of the whole system, and the higher the effective energy value ratio value is, the higher the produced output energy value is, namely the higher the production efficiency of the system is. The machining system with the effective energy value ratio has strong production activity competitiveness and is a basic condition for realizing sustainable development of the system.
The corresponding energy value amounts were calculated according to the following procedure according to Table 3
Step 5, obtaining the total effective energy value M (4) generated when k=4 in the whole machining process
MW(4) i The reason for the negative value is that waste emissions are undesirable, which negatively affects the effective energy value.
Step 6, obtaining the total energy value M generated in the whole machining process
Step 7, obtaining the utilization rate Em of the effective energy value and the utilization rate Em of the effective energy value of each station in the whole machining process i
The effective value utilization of the machining system reflects how effectively the machining system is directly used to produce the energy value, which is [0,1].
Table 4 was obtained by the above calculation.
| Station | Rough turning | Coarse boring | Rough milling | Drilling holes | Rough planing | Finish turning | Finish boring | Finish milling |
| Effective energy value ratio | 0.638 | 0.697 | 0.416 | 0.619 | 0.464 | 0.686 | 0.724 | 0.457 |
| Station | Finish planing | Reaming | Fine grinding | Optical hinge | Fine grinding | Honing machine | Polishing | Machining system |
| Effective energy value ratio | 0.651 | 0.641 | 0.508 | 0.632 | 0.659 | 0.731 | 0.469 | 0.543 |
Table 4: effective energy value ratio of machining stations
By the effective energy ratio of 15 machining stations shown in table 4, we can determine the ratio of the energy consumed by one production beat of each station to the total energy, and find that the ratio of rough milling (0.416) is the smallest, and then the energy consumed by finish milling (0.457) to explain the non-effective machining time (start, standby and idle) is higher, which is the object to be improved. Honing (0.731) is optimal, whereas the effective value ratio of the machining system is only 0.543, at a lower level.
The minimum energy conversion efficiency of the rough milling (0.416) procedure is the object of improvement.
And the station with the lowest energy conversion efficiency is found out and fed back to a technician or a system, so that the reason is found out and improved.
In the energy conversion efficiency evaluation process of the production system of the special axle machining workshop, a lot of places needing improvement are found, and the FANUC-3-2 machine tool for screening the rough milling station has long standby time, so that the energy consumption, the guide rail oil consumption is large, and the weight entropy of the spindle, the screw rod, the unstable product quality and the like is maximum.
The analysis shows that: the FANUC-3-2 machine tool needs to be warmed up for more than 2.5H every day, the spindle temperature in a natural cooling state is inconsistent with the spindle temperature when a product is processed, the spindle thermal elongation at 20-85 ℃ reaches more than 0.0397mm, the processing size is unstable, and the machine tool heating time is high.
By improving the software function of the FANUC machine tool, the natural temperature of the spindle and the thermal elongation error after high-speed operation are automatically detected, and then the compensation is automatically performed, so that the thermal elongation error is reduced or eliminated to the greatest extent.
Claims (1)
1. The machining efficiency judging method based on the energy value is characterized by comprising the following steps of:
first, setting:
(1) The whole machining manufacturing process consists of n stations, i represents station serial numbers, i=1, 2, 3, n;
(2) Each station is not allowed to cancel or interrupt once it begins to process;
(3) Each station is a production beat from the beginning of processing to the end of processing;
(4) Each production beat is equally divided into a starting stage, a standby stage, an idle stage and a processing stage, wherein k is a specific stage in one production beat, and is a starting stage when k=1, a standby stage when k=2, an idle stage when k=3 and a processing stage when k=4;
(5) Faults in the production and manufacturing process are not considered;
(6) The total energy value generated by each production beat of each station is composed of four parts in total, namely a total energy consumption part, a total production material consumption part, a total production service consumption part and a total waste part, and the total energy value of each of four stages corresponding to the production beat of the station is composed of four parts in total, namely a part energy consumption part, a part production material consumption part, a part production service consumption part and a part waste part;
(7) The four parts are respectively formed by accumulating multiple resource or waste consumption parts, so that j represents the serial number of the resource generating energy consumption in each energy consumption part, and j=1, 2, 3, m
Step 1, obtaining the energy value MN of the total energy consumption part of the ith station in one production beat i
First,: obtaining energy MN (k) of the energy consumption part of the ith station in the kth stage in one production beat by using formula 1 i
Is the use amount of the jth resource in the energy dividing part of the ith station in the kth stage of one production beat
Is->Energy conversion rate of (2)
MN is then calculated using equation 2 i
Step 2, obtaining the energy MM of the total production material consumption part of the ith station in one production beat i
First,: obtaining the energy MM (k) of the material consuming part of the ith station in the kth stage of one production cycle by using the formula 3 i
Is the usage amount of the j-th resource in the j-th station in the production material consumption part in the k-th stage of one production beat
Is->Energy conversion rate of (2)
MM is then calculated using equation 4 i ：
Step 3, obtaining the energy MS of the total production service consumption part of the ith procedure in one production beat i
First,: obtaining the energy MS (k) of the i-th station in the k-th stage of one tact by using equation 5 i
The i station divides the use amount of the j resource in the production service consumption part in the k stage in one production beat;
is->Energy conversion rate of (2)
MS was then calculated using equation 6 i
Step 4, obtaining the energy MW of the total waste consumption part of the ith procedure in one production beat i
First,: obtaining energy MW (k) of waste consumption part of ith station in kth stage in one production beat by using formula 7 i
Is the usage amount of the jth resource in the ith station in the waste consuming part in the kth stage in one production cycle
Is->Energy conversion rate of (2)
MW was then calculated using equation 8 i
Step 5, obtaining the total effective energy value M (4) generated when k=4 in the whole machining process
Step 6, obtaining the total energy value M generated in the whole machining process
Step 7, obtaining the utilization rate Em of the effective energy value and the utilization rate Em of the effective energy value of each station in the whole machining process i
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| JP5986531B2 (en) * | 2013-03-29 | 2016-09-06 | 株式会社日立製作所 | Production management system and management method |
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