CN110262392A - A kind of intrinsic efficiency property measurement System and method for of lathe based on virtual exemplar - Google Patents
A kind of intrinsic efficiency property measurement System and method for of lathe based on virtual exemplar Download PDFInfo
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- CN110262392A CN110262392A CN201910616144.2A CN201910616144A CN110262392A CN 110262392 A CN110262392 A CN 110262392A CN 201910616144 A CN201910616144 A CN 201910616144A CN 110262392 A CN110262392 A CN 110262392A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
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Abstract
The invention discloses a kind of intrinsic efficiency property measurement System and method for of lathe based on virtual exemplar, measuring system includes the intrinsic efficiency attribute test index system of lathe, energy consumption data measuring system, virtual exemplar simulation system and the intrinsic efficiency attribute test indication computing system of lathe.Measurement method includes, step 1: measuring the energy consumption data under lathe non-cutting state to be measured；Step 2: according to the energy consumption data of the function model and step 1 of intrinsic energy consumption characteristic index and equivalent energy consumption index, calculating lathe intrinsic energy consumption characteristic index group and equivalent energy consumption index group；Step 3: creating virtual exemplar, simulate the energy consuming process of the virtual exemplar of machine tooling to be measured, calculate according to analog result inherently than energy efficiency.The present invention, which solves the problems, such as to rely on entity exemplar and measures existing energy consumption characters, to be covered incomplete, not only can be measured lathe self-operating energy consumption attribute but also had been capable of measuring lathe to be measured in the following military service stage comprehensive energy efficiency potentiality.
Description
Technical field
The invention belongs to be machined manufacturing technology field more particularly to a kind of lathe intrinsic efficiency property measurement measurement system
System and measurement method.
Background technique
Equipment body and energy consumption main body of the lathe as machinery manufacturing industry, have a large capacity and a wide range, energy consumption total amount is huge, energy
Utilization rate is very low, and potential of energy efficiency improvement is very big；Therefore, lathe efficiency research significance is great.Existing lathe efficiency research mainly collects
In in the research of machine tooling Process Energy efficiency (also known as lathe operation energy efficiency), achieved lot of research；
But characteristic research that is intrinsic on lathe itself, influencing machine tooling Process Energy efficiency is not enough, some is caused important to ask
Topic not yet solves, for this purpose, the intrinsic energetic efficiency characteristic of lathe itself has become a key areas of lathe energy saving research in the world,
The especially measurement of the intrinsic energetic efficiency characteristic of lathe itself.
Domestic scholars have carried out certain research to the measurement of lathe energy efficiency in recent years.Published patent of invention " one
The configurable energy consumption on-line monitoring method and system of kind lathe polyergic source " (CN103941081A) uses multiple power sensors
The measurement for carrying out the various energy sources of lathe realizes lathe without the real-time power consumption monitoring of energy source.Utility model patent
" real-time energy consumption monitoring system of numerical control machine " (ZL201120320637.0) discloses a kind of numerically-controlled machine tool real time energy consumption monitoring system
System, the system are made of Flexible transformer, single-chip microcontroller, host computer etc., are realized by increasing current supply circuit current transformers at different levels
The input power real-time measurements of lathe transmission mechanisms at different levels." the lathe work step based on least-squares iteration algorithm authorized
Energy-consumption monitoring method " (CN105955198A) discloses a kind of by measuring machine tool chief axis realtime power to be measured and combining lathe
The power balance equation of main transmission complete machine cut energy consumption estimation on line, and then realize lathe work step energy consumption
Line real-time monitoring.Patent of invention " acquisition and control method of numerically-controlled machine tool fast forwarding and fast rewinding power and energy consumption "
(ZL201410083510.X) disclose it is a kind of according to feed motion power, feeding acceleration, feeding deceleration, feeding it is critical away from
The method for calculating fast forwarding and fast rewinding energy consumption from parameters such as, feeding distances.These lathe energy consumptions or energy efficiency online or
Person's off-line measurement is in the specific process energy efficiency towards the system of processing constituted with lathe, cutter, workpiece.
It is obtained towards the intrinsic energy efficiency of lathe itself, some scholars have also carried out certain research.Nippon Standard association
" Machine tools e test methods for electric power consumption " has been formulated in meeting (JIA)
(JIS TS B 0024-1:2010) standard, by integrating accessory power consumption measurement module, kinematic system power consumption
Measurement module and exemplar processing power consumption measurement module three parts realize in numerical control machining center, numerically controlled lathe and turning
The efficiency measurement and assessment of the various types lathe such as the heart, cylindrical grinder；Wherein, different types of lathe needs to design different ginsengs
Exemplar is examined, and test result is often depending on designed reference exemplar, rather than just lathe itself energy consumption feature.It is international
The standardization committee (ISO) has formulated " Methods for measuring energy supplied to machine
Tools and machine tool components " (14955-2:2018), the standard disclose lathe energy consumption testing
In-site measurement boundary, measurement target, measuring device and measurement method etc., and describe the test of each component power consumption in detail
The calculation method of method and total power consumption.Document " Behrendt T, Zein A, Min S.Development of an
energy consumption monitoring procedure for machine tools[J].CIRP annals,
2012,61 (1): 43-46. " set forth a kind of lathe method for testing energy consumption, to the reference in JIS TS B 0024-1:2010
Exemplar method has carried out perfect, establishes a kind of master body for covering 16 kinds of machining features, this method be applicable in can complete it is a variety of
Lathe itself energy consumption testing of (including at least 16 kinds of master body) machining feature.However, itself self-energy of these lathes
There is also deficiencies, i.e. entity exemplar energy consumption characters can not cover all energy consumption features of lathe for the test method of efficiency, and
Test result dependent on master body rather than only lathe itself, so be easy to cause dispute and preciseness is inadequate.
In conclusion the measurement method of existing lathe energy efficiency is concentrated mainly on and is made of lathe, cutter, workpiece etc.
In certain specific process of machining system, measurement result show as lathe during one's term of military service in a certain specific process
Energy consumption and capacity usage ratio；Some scholars are studied towards lathe itself, the energetic efficiency characteristic intrinsic to lathe itself,
But there is problems: 1) lathe self-energy efficiency attributes describe that method is fuzzy, and descriptive model is indefinite；2) it is currently used for
The entity exemplar energy consumption characters of test lathe self-energy efficiency attributes are covered not entirely, and its cutting experiment process is cumbersome；3) it surveys
Test result easily depends on master body rather than lathe itself, so preciseness is inadequate, easily causes dispute.
Summary of the invention
In view of the above shortcomings of the prior art, the present invention provides a kind of intrinsic efficiency attribute survey of the lathe based on virtual exemplar
Measure System and method for, with solves the problems, such as rely on entity exemplar measure existing for energy consumption characters cover it is incomplete；The present invention is not
It only can be measured lathe self-operating energy consumption attribute, moreover it is possible to measure lathe in the following military service stage comprehensive energy efficiency potentiality.
In order to solve the above technical problems, technical scheme is as follows: a kind of lathe intrinsic energy based on virtual exemplar
Imitate property measurement system, including the simulation of the intrinsic efficiency attribute test index system of lathe, energy consumption data measuring system, virtual exemplar
System and the intrinsic efficiency attribute test indication computing system of lathe；
The intrinsic efficiency attribute test index system of lathe: including the intrinsic energy for characterizing lathe self-operating energy consumption attribute
Consume characteristic index group, the equivalent energy consumption index group for characterizing lathe future process comprehensive energy consumption characteristic and for characterizing machine
The intrinsic ratio energy efficiency of the following process comprehensive energy efficiency attribute of bed, and intrinsic energy consumption characteristic index group, equivalent energy consumption index
Group and the intrinsic function model than energy efficiency；
Energy consumption data measuring system: for measuring the energy consumption data under lathe non-cutting state to be measured, including lathe to be measured
The starting energy consumption and zero load function under all speeds of mainshaft in standby power, the lathe range of speeds to be measured under all standby situations
The feed power under all feed speeds in rate, machine tool feed velocity interval to be measured, wherein all feed speeds include all
Fast feed speed and all work feed speeds under multiplying power；
Virtual exemplar simulation system: for creating virtual exemplar and according to the energy consumption data under lathe non-cutting state to be measured
The energy consuming process of the virtual exemplar of machine tooling to be measured is simulated with the investigational data of lathe user service condition to be measured；Wherein,
Virtual exemplar be in order to reflect lathe future is on active service stage all possible processing tasks and its probability distribution is proposed concept, it is empty
Quasi- exemplar is by lathe military service stage and the associated all possible lathe operating statuses of workpiece energy consumption and corresponding operation
The aggregate that the operation duration of state is constituted；
The intrinsic efficiency attribute test indication computing system of lathe: for according to the energy measured under lathe non-cutting state to be measured
It consumes data and calculates intrinsic energy consumption characteristic index group and equivalent energy consumption index group, and according to the simulation virtual exemplar of machine tooling to be measured
Energy consuming process data obtained calculate inherently than energy efficiency.
Further, virtual exemplar includes following process feature:
Feature a: the revolving speed of virtual exemplar process covers all speeds of mainshaft in the lathe range of speeds to be measured；
Feature b: the process of virtual exemplar contains start-up course and zero load under all ranges of speeds of lathe to be measured
Process；
Feature c: the process of virtual exemplar contains the load under all revolving speeds of lathe to be measured, negative under every kind of revolving speed
It carries and contains 0 load for arriving maximum load under the revolving speed again；
Feature d: the process time of various revolving speeds is that the revolving speed is always transported using probability with main shaft in virtual exemplar process
Turn the product of time；When the load time of various load is total load under the probability and the revolving speed that the load occurs under various revolving speeds
Long product.
Further, all speeds of mainshaft in the lathe range of speeds to be measured indicate as follows:
When the speed of mainshaft of lathe to be measured is step speed regulation, using the set expression machine to be measured of every grade of speed of mainshaft composition
All speeds of mainshaft in the bed range of speeds；
When the speed of mainshaft of lathe to be measured is stepless speed regulation, composed set is represented using several discrete revolving speeds
To characterize all speeds of mainshaft in the lathe range of speeds to be measured；
All feed speeds in machine tool feed velocity interval to be measured indicate as follows:
When the feed speed of lathe to be measured is step speed regulation, using composed by the fast feed speed under every kind of multiplying power
Gather and gathers all feed speeds indicated in machine tool feed velocity interval to be measured together composed by every grade of work feed speed；
When the feed speed of lathe to be measured is stepless speed regulation, collect using composed by fast feed speed under every kind of multiplying power
Close and several work feed speeds represent composition set come together to characterize in machine tool feed velocity interval to be measured it is all into
To speed.
Further, under type processing such as is taken in the load suggestion in feature c: the load distribution use pair under every kind of revolving speed
Load carries out interval division, then selects load power to represent and characterizes with load distribution probability, and the load in each section selects one
A load power represents to characterize, the appearance that the total probability that each load occurs in each load on section is represented as the load power
Probability；It is characterized alternatively, the load distribution under every kind of revolving speed directlys adopt normal distribution.
Further, the process of virtual exemplar also includes following characteristics:
Feature e: the process processing of virtual exemplar contains all feed speeds of lathe to be measured, including all multiplying powers
Under fast feed speed and machine tool feed velocity interval in all work feed speeds；
Feature f: the process of virtual exemplar contains all standby situations of lathe to be measured；
Further, intrinsic energy consumption characteristic index group includes standby power function Psb, starting energy consumption function Est(n), unloaded
Power function Pu(n) with additional load loss factor function alpha (n)；Equivalent energy consumption index group includes equivalent standby power EPsb, when
Amount starting energy consumption EEst, equivalent no-load power EPu, equivalent additional load loss factor E α.Their function model difference is as follows:
(1) standby power function PsbRefer to the set of the lathe standby power under various standby situations:
Psb={ Psb,1,...,Psb,i,...,Psb,S}；
In formula, Psb,iIndicate the standby power under i-th kind of standby situation；S indicates standby situation sum.
(2) start energy consumption function Est(n) for indicating the functional relation of machine tool chief axis starting energy consumption and the speed of mainshaft:
In formula, n indicates machine spindle speed；A, B, C are fitting coefficient, Est(ni) indicate i-th kind of revolving speed niUnder open
Kinetic energy consumption, N indicate machine spindle speed quantity.
(3) no-load power function Pu(n) functional relation of lathe no-load power and revolving speed is indicated:
In formula, n indicates machine spindle speed, fu(n) no-load power fitting function, P are indicatedu(ni) indicate i-th kind of revolving speed ni
Under no-load power；N indicates machine spindle speed quantity.
(4) additional load loss factor function alpha (n) indicates the functional relation of lathe additional load loss factor and revolving speed:
In formula, n indicates machine spindle speed, fα(n) additional load loss factor fitting function, α (n are indicatedi) indicate i-th
Kind revolving speed niUnder additional load loss factor；N indicates machine spindle speed quantity.
(5) it is standby that standby power obtained from carrying out the standby power under each standby situation of lathe averagely is known as equivalent
Power EPsb:
In formula, Psb,iIndicate that the standby power under i-th kind of standby situation, S indicate total standby situation quantity.
(6) the starting energy consumption that energy consumption averagely obtain will be started under each revolving speed of lathe and is known as equivalent starting energy consumption EEst:
In formula, Est(ni) indicate revolving speed niUnder starting energy consumption, N indicate machine spindle speed quantity.
(7) power that the no-load power under each revolving speed of lathe averagely obtain is known as equivalent no-load power EPu:
In formula, Pu(ni) indicate revolving speed niUnder no-load power；N is machine spindle speed quantity.
(8) coefficient obtained from carrying out the additional load loss factor under each revolving speed of lathe averagely is known as the additional load of equivalent
Lotus loss factor E α:
In formula, α (ni) indicate revolving speed niUnder load loss factor, N be machine spindle speed quantity.
Further, intrinsic to refer to that lathe completes energy consumed by virtual exemplar process, letter than energy efficiency EE
Exponential model is as follows:
When requiring approximate calculation, for the cutting period energy for having ignored feed system energy consumption in virtual exemplar cutting process
Consumption:
EE≈EMS=Eu+Emr+Ea；
In formula, EMSIt indicates not including the machine cut period energy consumption that feed system can be time-consuming；EuIt indicates in the cutting period
No-load power consumption, EmrIndicate that the spindle material in the cutting period removes energy consumption, EaIndicate the main shaft additional load loss of cutting period；
It is all non-cutting and cutting process energy consumptions of virtual exemplar process when computational accuracy requires higher:
EE=ESB+EST+EU+EF+EM；
In formula, ESBIndicate total standby interval energy consumption, ESTIndicate total starting period energy consumption, EUIndicate total unloaded period energy consumption,
EFIndicate total feed period energy consumption, EMIndicate total cutting period energy consumption comprising feed system energy consumption.
The present invention also provides a kind of intrinsic efficiency property measurements of lathe based on virtual exemplar, using base of the invention
In the intrinsic efficiency property measurement system of the lathe of virtual exemplar, comprising the following steps:
Step 1: measuring the energy consumption data under lathe non-cutting state to be measured: including under all standby situations of lathe to be measured
The starting energy consumption and no-load power, machine tool feed to be measured under all speeds of mainshaft in standby power, the lathe range of speeds to be measured
The feed power under all feed speeds in velocity interval, wherein all feed speeds include all multiplying powers under it is quick into
To with work feed speeds all within the scope of feed speed；
Step 2: according to the function model of intrinsic energy consumption characteristic index and equivalent energy consumption index, and the lathe that measurement obtains
Energy consumption data under non-cutting state calculates and obtains the intrinsic energy consumption characteristic index group of lathe and equivalent energy consumption index group；
Step 3: create virtual exemplar, and according to measured under lathe non-cutting state energy consumption data, lathe user to be measured
The investigational data of service condition simulates the energy consuming process of the virtual exemplar of machine tooling to be measured, and then according to simulation machine to be measured
The analog result that bed processes the energy consuming process of virtual exemplar calculates inherently ratio can efficiency；Lathe user service condition to be measured
Investigational data includes the duration of runs of the load energy consumption data and load time data and each revolving speed under all speeds of mainshaft.
Further, the energy consumption data in step 1 under lathe non-cutting state to be measured is using published patent of invention " number
The intrinsic efficiency element function acquisition methods of control lathe and system " (CN109753017A) measures.
Further, it is calculated in step 2 and obtains the intrinsic energy consumption characteristic index group of lathe and equivalent energy consumption index group, comprising:
Firstly, the no-load power under the different rotating speeds measured is combined, using a kind of published patent of invention " machine cut system of processing
Additional load loss factor acquisition methods " (CN104669057A) are realized that additional load loss factor calculates and are obtained；Then, it ties
Close energy consumption measured under intrinsic energy consumption characteristic index group and equivalent energy consumption index group function model, lathe non-cutting state to be measured
Data and the additional load loss factor for calculating acquisition, the intrinsic energy consumption characteristic index group of completion lathe and equivalent energy consumption index group's
It calculates and obtains.
Further, the energy consuming process in virtual exemplar process is indicated using power curve in step 3, in turn
Lathe, which is calculated, according to power curve inherently compares energy efficiency.When simulation, the simulating cutting time of each revolving speed is that the revolving speed uses probability
The product of duration is always operated with main shaft；The fictitious load time of various load is the probability and be somebody's turn to do that the load occurs under various revolving speeds
The product of total load duration under revolving speed；Different rotating speeds are represented and are carried using the load of probability, lathe to be measured under different rotating speeds
Lotus distribution probability is obtained by investigating the service condition of lathe user to be measured.When carrying out inherently than energy efficiency calculation, do
Following processing:
When the intrinsic efficiency requirements approximate calculation than energy, lathe is inherently to ignore in virtual exemplar cutting process than energy efficiency
The cutting period energy consumption of feed system energy consumption, at this point, the lathe in conjunction with attached drawing 1 is virtual under certain feed speed of certain revolving speed
The power curve of the complete machining process of workpiece, the intrinsic approximate calculation function model than energy efficiency are further refined such as following formula institute
Show:
EE≈Eu+Emr+Ea
=∑ PuTmr+∑PmrTmr+∑PaTmr
In formula, EE is represented inherently than energy efficiency, EuIndicate the no-load power consumption in the cutting period, EmrIt indicates in the cutting period
Spindle material removes energy consumption, EaIndicate the main shaft additional load loss of cutting period, PuIndicate no-load power, PmrIndicate that material is gone
Except power, PaIndicate additional load loss power, TmrIndicate cutting period duration.
From attached drawing 1 it is found that when approximate calculation, standby, starting, unloaded and feeding period duration are had ignored；So at this point, cutting
The summation of period duration, that is, cutting period total operation duration are cut, is the virtual manufacture time；The cutting period under different rotating speeds
The Shi Changwei revolving speed uses the product of probability and virtual manufacture time；A length of load when the cutting of different loads under different rotating speeds
The product of the probability of appearance and revolving speed cutting period duration.
When computational accuracy requires higher, lathe inherently than can efficiency be that virtual exemplar process is all non-cutting and cut
Process energy consumption is cut, in conjunction with the power graph of attached drawing 1, the intrinsic approximate calculation function model than energy efficiency further refines as follows
Shown in formula:
EE=ESB+EST+EU+EF+EM
=∑ PsbTsb+∑Est+∑PuTu+∑(Pu+Pfeed)Tf+∑(Pu+Pfeed+Pmr+Pa)Tmr+
In formula, EE is represented inherently than energy efficiency, ESBIndicate total standby interval energy consumption, ESTIndicate total starting period energy consumption, EU
Indicate total unloaded period energy consumption, EFIndicate total feed period energy consumption, EMIndicate total cutting period energy consumption comprising feed system, Psb
Indicate standby power, EstIndicate starting energy consumption, PuIndicate no-load power, PfeedIndicate feed system power, PmrIndicate that material is gone
Except power, PaIndicate additional load loss power；TsbIndicate standby interval duration, TuIndicate unloaded period duration, TfIndicate feeding
Period duration, TmrIndicate cutting period duration.
Further, when accurately calculating lathe self-energy efficiency, the investigation of lathe user service condition to be measured in step 3
Data further include lathe it is standby, it is unloaded, feeding, the cutting time；When simulation, standby, idle operation, feeding process, cutting
The time parameter of process can be handled according to finding Uniform provisions, or as follows:
It is interior for a period of time (usually 1 day) to investigate lathe to be measured, lathe stand-by time, idle time, feeding time, cutting
Time accounts for the standby probability of different stand situation in the ratio and standby of lathe total run time, in idle operation not
With the frequency of use of the speed of mainshaft, the frequency of use of different feed speeds in the process, the different speeds of mainshaft in cutting process are fed
Frequency of use.When simulating cutting, the time parameter of simulation is handled are as follows: total standby time, total unloaded duration, total feed duration,
Total cutting duration is respectively to investigate the product of the respective proportion and virtual manufacture time that obtain；It is standby under each standby situation
Time is the standby probability of each standby situation and the product of total standby time, in when zero load under different rotating speeds a length of idle operation
The product using probability and total unloaded duration of each revolving speed, each feeding during a length of feeding of when feeding under different feed speeds
The product using probability and total feed duration of speed；When cutting under different rotating speeds in a length of cutting process each revolving speed use
The product of probability and total cutting duration.
Compared with prior art, the invention has the following advantages:
1, a kind of measurement method of intrinsic efficiency attribute of lathe is provided.This method is established based on virtual exemplar,
It efficiently avoids based on the deficiencies of cumbersome present in entity exemplar method of testing, test result is easily disputed on.
2, the intrinsic efficiency ATTRIBUTE INDEX system of a set of lathe is established.The index system can systematically reflect that lathe itself is transported
Row energy consumption characteristics and comprehensive energy consumption characteristic in the following process are carried out the intrinsic efficiency evaluating characteristics of lathe itself for enterprise and are mentioned
Important references are supplied.
3, a kind of exemplar that can be used for testing lathe intrinsic energy effect attribute, i.e., virtual exemplar are proposed.Virtual exemplar adds
Work process contains the energy consumption feature of the following all processing situations of lathe, and in other words, which overcomes conventional entity exemplar
Present in energy consumption characters cover the deficiencies of not comprehensive.
Detailed description of the invention
Fig. 1 is power curve schematic diagram during machine tooling；
Fig. 2 is the flow chart of the intrinsic efficiency property measurements of lathe based on virtual exemplar.
Specific embodiment
Using the intrinsic efficiency property measurement System and method for of lathe proposed by the invention, to certain three shaft vertical CNC milling machine
Intrinsic efficiency attribute be tested, measurement procedure is with reference to shown in Fig. 2；When test, intrinsic efficiency attribute test index includes
Standby power function, starting energy consumption function, no-load power function, additional load loss factor function, equivalent standby power, equivalent
Start energy consumption, equivalent no-load power, equivalent additional load loss factor, inherently ratio energy efficiency, wherein intrinsic than energy efficiency use
Approximate calculation obtains；Measurement process is as follows:
(1) energy consumption data under lathe non-cutting state to be measured is measured
The standby situation of lathe to be measured includes two classes, i.e. two kinds of machine body unlatching, machine body+hydraulic pressure opening standby feelings
Shape；Through measuring, their corresponding standby powers are respectively 323W, 425W.
Having chosen 600,1000,1400,1800,2200,2600,3000,3400r/min, totally 8 revolving speed representatives are surveyed
Amount, which is to choose as follows: the lathe range of speeds being divided into 8 revolving speed sections, according to making for revolving speed
Respective revolving speed representative (such as revolving speed 3400 represents [3200,4000]) or direct is selected from different rotating speeds section with probability
It selects the intermediate speed in the section to be used as and represents revolving speed (such as revolving speed 600,1000,1400,1800,2200,2600,3000).Through
Measurement, starting energy consumption and no-load power of the milling machine under these revolving speeds are as shown in table 1 below:
Starting energy consumption and no-load power under 1 different rotating speeds of table
Using published patent of invention " a kind of machine cut system of processing additional load loss factor acquisition methods "
(CN104669057A) acquisition methods of additional load loss factor carry out additional load of the lathe in above-mentioned 8 under revolving speed
The acquisition of loss factor, the results are shown in Table 2:
Additional load loss factor under 2 different rotating speeds of table
(2) according to the function model and lathe non-cutting state to be measured of intrinsic energy consumption characteristic index and equivalent energy consumption index
Under energy consumption data, calculate lathe intrinsic energy consumption characteristic index group and equivalent energy consumption index group
1. standby power function
According to formula standby power function PsbFunction model, the standby power function of the lathe is Psb,i={ 323,415 }
2. starting energy consumption function
Since lathe to be measured is stepless speed regulation, according to table 1 and starting energy consumption function Est(n), the data of starting energy consumption are carried out
Fitting obtains starting energy consumption function result and is shown below
Est(ni)=5.19 × 10-6n2+8.02×10-3N+2.52, n ∈ [200,4000]
Fit interval n ∈ [200,4000] herein includes that 8 revolving speeds represent, and in the fit interval revolving speed it is total
Using probability it is larger (90% or more).
Fit interval can select according to actual needs, and the principle of selection is to represent comprising all revolving speeds, and use probability
It is larger, it can select using probability 80% or more, 85% with first-class, be chosen in conjunction with actual demand.
3. no-load power function
Since lathe to be measured is stepless speed regulation, according to table 1 and no-load power function Pu(n) function model carries out unloaded
The data of power are fitted, and are obtained no-load power function result and are shown below
Piecewise fitting is carried out herein, has fitted two straight lines, is the separation of two fitting a straight lines at 2200, and only
Fitting straight line is compared, more accurately.
4. additional load loss factor function
According to the function model of additional load loss factor function alpha (n), additional load of the lathe under surveyed revolving speed is obtained
Lotus loss factor function is as follows
α (n)=3.14-1.0 × 10-2n+1.2×10-5n2-6.8×10-9n3+1.7×10-12n4-1.7×10-16n5n∈
[200,4000]
5. equivalent standby power
The equivalent standby power of the lathe is
6. equivalent starts energy consumption
The equivalent of the lathe starts energy consumption
7. equivalent no-load power
The equivalent no-load power of the lathe is
8. equivalent additional load loss factor
The equivalent additional load loss factor of the lathe is
(3) virtual exemplar is created, the energy consuming process of the virtual exemplar of machine tooling to be measured is simulated, is disappeared according to analog energy
The analog result that consumption process obtains calculates inherently than energy efficiency
When simulating the processing of virtual exemplar, the processing revolving speed of virtual exemplar includes 600,1000,1400,1800,2200,
Totally 8 revolving speeds represent 2600,3000,3400r/min.8 revolving speed representatives are to choose as follows: by the lathe range of speeds
8 revolving speed sections are divided into, respective revolving speed representative is selected using probability from different rotating speeds section according to revolving speed.
In simulation process, the load of virtual exemplar is obtained and investigating the service condition of lathe user, present case
By accessing the operator of lathe to be measured, approximation is carried out it is assumed that the results are shown in Table 3 to the load of above-mentioned 8 revolving speeds.Wherein, different
Loading condition under revolving speed is represented using low load power and top load power represents and its probability of occurrence is characterized, specific to grasp
Two sections are divided into as by the load power bracket under every kind of revolving speed；The load in each section selects a load power generation
Table characterizes, the probability that the total probability that each load occurs in each load on section is represented as load power.The lathe of consideration is real
Border service condition, what top load power represented (i.e. 3/5 maximum load) in present case represents section as 1/5~1 times of maximum load；
Low load power representative (i.e. 1/10 maximum load) represents section as 0~1/5 times of maximum load.
Load distribution under 3 different rotating speeds of table
When simulation, the virtual manufacture time of virtual exemplar process assumes to be unit 1, since present case uses approximation
Calculation method obtains lathe and inherently compares energy efficiency, thus, total operation duration of the cutting period in virtual exemplar process
For unit 1；From attached drawing 2 it is found that when ignoring standby, starting, zero load, feeding period, the cutting period duration under different rotating speeds is
For the operating duration of different rotating speeds.Based on this, the rotation speed operation time provided with this patent and load time calculation method are obtained
It must cut that load time is obtained under period duration and different loads is as shown in table 4 in virtual exemplar process under different rotating speeds.
The runing time of cutting period duration and load under 4 different rotating speeds of table
When calculating lathe inherently compares energy efficiency, case has selected approximate function model to carry out the calculating inherently than energy efficiency,
Be shown below #
EE≈Eu+Emr+Ea=∑ PuTmr+∑PmrTmr+∑PaTmr；
In formula, EE is represented inherently than energy efficiency, EuIndicate the no-load power consumption in the cutting period, EmrIt indicates in the cutting period
Spindle material removes energy consumption, EaIndicate the main shaft additional load loss of cutting period；PuIndicate no-load power, PmrIndicate that material is gone
Except power, PaIndicate additional load loss power, TmrIndicate cutting period duration.
Cutting period duration T under the different rotating speeds provided according to table 4mr, no-load power under different rotating speeds under table 1
Pu, obtain no-load power consumption EuAs a result as follows:
Eu=∑ PuTmr=566 (J)
Load power under the different rotating speeds provided according to table 3 represents (top loadAnd low load) and table 4 mention
Cutting period duration T under the different rotating speeds of confessionmrWith load time (the top load load time of different loadsWith low load
Lotus load time), obtain spindle material removal energy consumption EmrResult it is as follows:
According to additional load loss power Pa, additional load loss factor α and material remove power PmrRelationship, i.e. Pa=
αPmr；And the additional load loss factor α (n under the different rotating speeds of the offer of table 2i), table 3 provide different rotating speeds under load
The different loads that power represents, table 4 provides divide load time, obtain main shaft additional load loss EaAs a result as follows:
So lathe is inherently as follows than energy efficiency calculations:
EE ≈=∑ PuTmr+∑PmrTmr+∑PaTmr=566+1157+157=1880J
Integrate above-mentioned calculated result, the surveyed lathe of case is shown in test result is as follows:
The present invention solves relies on the technical issues of entity exemplar measures in the prior art, can reduce measurement process
Cumbersome property, improve the preciseness of measurement result, not only can be measured lathe self-operating energy consumption attribute, but also introducing can be passed through
Lathe to be measured is measured in the following military service stage comprehensive energy efficiency attribute using probability.
Claims (8)
1. a kind of intrinsic efficiency property measurement system of lathe based on virtual exemplar, which is characterized in that including the intrinsic efficiency of lathe
Attribute test index system, energy consumption data measuring system, virtual exemplar simulation system and the intrinsic efficiency attribute test index of lathe
Computing system；
The intrinsic efficiency attribute test index system of lathe: special including the intrinsic energy consumption for characterizing lathe self-operating energy consumption attribute
Levy index group, the equivalent energy consumption index group for characterizing lathe future process comprehensive energy consumption characteristic and for characterizing lathe not
Come process comprehensive energy efficiency attribute it is intrinsic than can efficiency, and intrinsic energy consumption characteristic index group, equivalent energy consumption index group with
The intrinsic function model than energy efficiency；
Energy consumption data measuring system: for measuring the energy consumption data under lathe non-cutting state to be measured, including lathe to be measured is all
Starting energy consumption under all speeds of mainshaft in standby power, the lathe range of speeds to be measured and no-load power under standby situation,
The feed power under all feed speeds in machine tool feed velocity interval to be measured, wherein all feed speeds include all times
Fast feed speed and all work feed speeds under rate；
Virtual exemplar simulation system: for create virtual exemplar and according under lathe non-cutting state to be measured energy consumption data with to
The investigational data for surveying lathe user service condition simulates the energy consuming process of the virtual exemplar of machine tooling to be measured；Wherein, virtually
Exemplar is to reflect lathe future is on active service stage all possible processing tasks and its probability distribution is proposed concept, virtual sample
Part is by lathe military service stage and the associated all possible lathe operating statuses of workpiece energy consumption and corresponding operating status
The aggregate that is constituted of operation duration；
The intrinsic efficiency attribute test indication computing system of lathe: for according to the energy consumption number measured under lathe non-cutting state to be measured
According to the intrinsic energy consumption characteristic index group of calculating and equivalent energy consumption index group, and according to the energy for simulating the virtual exemplar of machine tooling to be measured
Consumption process data obtained calculate inherently than energy efficiency.
2. the intrinsic efficiency property measurement system of the lathe according to claim 1 based on virtual exemplar, which is characterized in that empty
Quasi- exemplar includes following process feature:
Feature a: the revolving speed of virtual exemplar process covers all speeds of mainshaft in the lathe range of speeds to be measured；
Feature b: the process of virtual exemplar contains start-up course and idle operation under all ranges of speeds of lathe to be measured；
Feature c: the process of virtual exemplar contains the load under all revolving speeds of lathe to be measured, and the load under every kind of revolving speed is again
Contain 0 load for arriving maximum load under the revolving speed；
Feature d: when the process time of various revolving speeds is that the revolving speed is always operated using probability and main shaft in virtual exemplar process
Between product；The load time of various load is total load duration under the probability and the revolving speed that the load occurs under various revolving speeds
Product.
3. the intrinsic efficiency property measurement system of the lathe according to claim 2 based on virtual exemplar, which is characterized in that
All speeds of mainshaft in the lathe range of speeds to be measured indicate as follows:
When the speed of mainshaft of lathe to be measured is step speed regulation, the set expression lathe to be measured using every grade of speed of mainshaft composition turns
All speeds of mainshaft in fast range；
When the speed of mainshaft of lathe to be measured is stepless speed regulation, composed set is represented come table using several discrete revolving speeds
Levy all speeds of mainshaft in the lathe range of speeds to be measured；
All feed speeds in machine tool feed velocity interval to be measured indicate as follows:
When the feed speed of lathe to be measured is step speed regulation, gather using composed by the fast feed speed under every kind of multiplying power
With gather all feeding revolving speeds indicated in machine tool feed velocity interval to be measured together composed by every grade of work feed speed；
When the feed speed of lathe to be measured is stepless speed regulation, gather using composed by the fast feed speed under every kind of multiplying power
And several work feed speeds represent the set formed and come together to characterize all feedings in machine tool feed velocity interval to be measured
Speed.
4. the intrinsic efficiency property measurement system of the lathe according to claim 3 based on virtual exemplar, which is characterized in that Gu
Having energy consumption characters index group includes standby power function Psb, starting energy consumption function Est(n), no-load power function Pu(n) and it is additional
Load loss coefficient function α (n)；Standby power function PsbThe set for referring to the lathe standby power under various standby situations, is opened
Kinetic energy consumes function Est(n) for indicating the functional relation of machine tool chief axis starting energy consumption and the speed of mainshaft, no-load power function Pu(n)
Indicate that the functional relation of lathe no-load power and revolving speed, additional load loss factor function alpha (n) indicate the loss of lathe additional load
The functional relation of coefficient and revolving speed, their function model difference are as follows:
Standby power function Psb:
Psb={ Psb,1,...,Psb,i,...,Psb,S}；
In formula, Psb,iIndicate the standby power under i-th kind of standby situation；S indicates standby situation sum；
Start energy consumption function Est(n):
In formula, n indicates machine spindle speed；A, B, C are fitting coefficient, Est(ni) indicate i-th kind of revolving speed niUnder starting energy
Consumption；N indicates machine spindle speed quantity；
No-load power function Pu(n):
In formula, n indicates machine spindle speed, fu(n) no-load power fitting function, P are indicatedu(ni) indicate i-th kind of revolving speed niUnder
No-load power；
Additional load loss factor function alpha (n):
In formula, n indicates machine spindle speed, fα(n) additional load loss factor fitting function, α (n are indicatedi) indicate that i-th kind turns
Fast niUnder additional load loss factor；N indicates machine spindle speed quantity.
5. the intrinsic efficiency property measurement system of the lathe according to claim 3 based on virtual exemplar, which is characterized in that when
Measuring energy consumption index group includes equivalent standby power EPsb, equivalent start energy consumption EEst, equivalent no-load power EPu, equivalent additional load
Loss factor E α；Standby power obtained from standby power under various standby situations is carried out averagely is known as the standby function of equivalent
Rate EPsb, the starting energy consumption under each revolving speed of lathe is subjected to starting energy consumption that is average and obtaining and is known as equivalent starting energy consumption EEst, will
No-load power under each revolving speed of lathe carries out power that is average and obtaining and is known as equivalent no-load power EPu, will be under each revolving speed of lathe
Additional load loss factor carry out it is average obtained from coefficient be known as equivalent additional load loss factor E α, their Function Modules
Type difference is as follows:
Equivalent standby power EPsb:
In formula, Psb,iIndicate that the standby power under i-th kind of standby situation, S indicate total standby situation quantity；
Equivalent starts energy consumption EEst:
In formula, Est(ni) indicate revolving speed niUnder starting energy consumption, N indicate machine spindle speed quantity；
Equivalent no-load power EPu:
In formula, Pu(ni) indicate revolving speed niUnder no-load power；N indicates machine spindle speed quantity；
Equivalent additional load loss factor E α:
In formula, α (ni) indicate revolving speed niUnder additional load loss factor, N indicate machine spindle speed quantity.
6. the intrinsic efficiency property measurement system of the lathe according to claim 1 based on virtual exemplar, which is characterized in that Gu
Have and refer to that lathe completes energy consumed by virtual exemplar process than energy efficiency EE, function model is as follows:
It is the cutting period energy consumption that feed system energy consumption is had ignored in virtual exemplar cutting process when requiring approximate calculation:
EE≈EMS=Eu+Emr+Ea；
In formula, EMSIt indicates not including the machine cut period energy consumption that feed system can be time-consuming, EuIndicate the zero load in the cutting period
Energy consumption, EmrIndicate that the spindle material in the cutting period removes energy consumption, EaIndicate the main shaft additional load loss of cutting period；
It is all non-cutting and cutting process energy consumptions of virtual exemplar process when computational accuracy requires higher:
EE=ESB+EST+EU+EF+EM；
In formula, ESBIndicate total standby interval energy consumption, ESTIndicate total starting period energy consumption, EUIndicate total unloaded period energy consumption, EFTable
Show total feed period energy consumption, EMIndicate total cutting period energy consumption comprising feed system.
7. a kind of intrinsic efficiency property measurements of lathe based on virtual exemplar, which is characterized in that using as claim 1 to
Any intrinsic efficiency property measurement system of the lathe based on virtual exemplar in 6, comprising the following steps:
Step 1: measuring the energy consumption data under lathe non-cutting state to be measured: including standby under all standby situations of lathe to be measured
The starting energy consumption and no-load power, machine tool feed speed to be measured under all speeds of mainshaft in power, the lathe range of speeds to be measured
The feed power under all feed speeds in range, wherein all feed speeds include all multiplying powers under fast feed and
All feed speeds within the scope of feed speed；
Step 2: according to the function model of intrinsic energy consumption characteristic index and equivalent energy consumption index, and the lathe that obtains of measurement is non-cuts
The energy consumption data under state is cut, calculates and obtains the intrinsic energy consumption characteristic index group of lathe and equivalent energy consumption index group；
Step 3: creating virtual exemplar, and used according to the energy consumption data that is measured under lathe non-cutting state, lathe user to be measured
The investigational data of situation is simulated the energy consuming process of the virtual exemplar of machine tooling to be measured, and then is added according to lathe to be measured is simulated
The analog result of the energy consuming process of the virtual exemplar of work calculates inherently than energy efficiency；The investigation of lathe user service condition to be measured
Data include the duration of runs of the load energy consumption data and load time data and each revolving speed under all speeds of mainshaft.
8. the intrinsic efficiency property measurements of the lathe according to claim 7 based on virtual exemplar, which is characterized in that step
The energy consuming process in virtual exemplar process is indicated using power curve in rapid 3, and then according to power curve computer
Bed is inherently than energy efficiency.
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