CN1517821A - Energy-saving noise-lowering method for mechanical processing system - Google Patents

Abstract

An energy-saving and noise-lowering method for mechanical processing system includes such steps as measuring the idle noise and idle pwoder of each machine-tool in the system at different rotation speeds, creating rotation speed-idle noise and rotation speed-idle power database, determining the rotation speed and processing time for machining each workpiece according to its technological document, calculating the idle energy consumption array and equivalent continuous idle noise array of workpiece-mechine-tool, and optimizing the processing schence according to the mathematical model of optimal scheduling and arrangement.

Description

A kind of machining system energy-saving and noise-reducing method

It is purpose with conserve energy and reduction noise that technical field the present invention relates to a kind of, and machining system is carried out the method that the production task scheduling is arranged, and is specifically related to a kind of machining system energy-saving and noise-reducing method.

The background technology human development enters 21st century, and the strategy of sustainable development becomes themes of the times.For the machinery manufacturing industry that has a large capacity and a wide range, original is that the extensive mode of production of cost has caused unprecedented environmental disruption to the earth with a large amount of consumption of natural resource and contaminated environment, does not meet the requirement of sustainable development.How to save the resource consumption (supplies consumption and energy resource consumption) in the machine-building process and reduce environmental impact (dischargings of waste gas, waste liquid, solid waste and noise etc.) and be subjected to extensive concern.In recent years, a series of standard, rules etc., the progressively environment friendly of modular product manufacture process have been released around this problem both at home and abroad.As ISO14000 environmental management series standard, clean the strategy of producing, green manufacturing, green product authentication marks or the like.Machining system is one of elementary cell of machinery manufacturing industry, has a large capacity and a wide range in the development of the national economy, and none can leave mechanical processing process as industries such as lathe, automobile, household electrical appliances.For mechanical processing process, energy consumption and noise pollution are that it influences one of main forms of environment.

Machining system is a kind of system of the enforcement machining function based on lathe, is made up of a series of lathe, anchor clamps, cutter and workpiece etc., and wherein lathe (comprising machine tool and numerically-controlled machine) is the chief component of machining system.Can be divided into unit bed system of processing and multimachine bed system of processing to machining system again according to what difference of the lathe quantity in the system.The practical manifestation form of machining system can be a machine tool, a manufacturing cell, a workshop or a production line etc.Energy consumption and noise are two kinds of basic physical phenomenons following machining.As long as processing tasks begins to produce a large amount of consumption that just mean energy, also produce the pollution of noise simultaneously to the shopwork environment, influence the communication in workman's physical and mental health and the production.Lathe is the main source of energy consumption in the machining system, noise pollution.Existing production system scheduling research document and patent (as, United States Patent (USP): Production scheduling management system, and method of managing production scheduling, US6438436, authorize in August, 2002, Deng) in, mainly be optimized scheduling as objective function, and do not consider energy consumption and noise pollution problem in the process of manufacture with delivery date or production cost.The research of existing, noise reduction energy-conservation about machining system (as, the plan machine noise is opened by mechanical noise seminar of University Of Tianjin---and principle and control Tianjin: the Tianjin science and technology is published; Controller for driving motor of machine tools, China, CN89104006.4 etc.) mainly with single lathe as object, improve the energy consumption and the noiseproof feature of lathe.Improve the energy and the noiseproof feature of machining system if desired, must improve design or buy new lathe, increase production cost lathe.In the actual production, the energy consumption of machining system and noise also have following two characteristics: the first, and the machining system energy consumption is not only relevant with lathe with noise, and relevant with the technological requirement of workpiece to be processed; On the other hand, machining system often is made up of many lathes, and production task also often comprises various workpieces.Therefore this system should consider between difference between getting in touch between lathe and the workpiece, lathe and the lathe and the different workpieces factors such as technological requirement.

Find after research and testing, take all factors into consideration, also can reach the purpose of whole machining system energy consumption of remarkable reduction and noise by the rational management arrangement between workpiece and the lathe from the angle of system.Be illustrated below by two simplified example.

Example 1: there are two gear hobbing lathe: YKB3120 and Y3150H in certain factory workshop.Existing two kinds of gears of first, second need processing: during the A gear rolling cut, rotating speed is 125 commentaries on classics, requires 300 to change during the second gear hobbing.Now these two kinds of gears to be arranged in hobbing machine YKB3120 and Y3150H respectively and go up processing, two kinds of different arrangement option A and B are arranged:

A: A gear is positioned on YKB3120 and goes up processing, and the second gear is positioned on Y3150H and goes up processing.

B: the second gear is positioned on YKB3120 and goes up processing, and A gear is positioned on Y3150H and goes up processing.

Survey:

YKB3120: when n=300rpm, machine noise is 81.3db; When n=125rpm, machine noise is 80.6db;

Y3150H: when n=300rpm, machine noise is 83.7db; When n=125rpm, machine noise is 80.2db.

According to above processing noise data can calculate (its decibel mean value calculation formula:

For the A scheme, the noise decibel mean value of two lathes is 82.42db; For the B scheme, the noise decibel mean value of two lathes is 80.78db.From noise decibel mean value as can be seen, the B scheme is better than the A scheme.

Example 2: certain workshop has No. 01 and No. 02 two horizontal lathes.Existing the first and second two batches of workpiece need size.Owing to technologic reason, during the turning of first workpiece, the speed of mainshaft should be 600rpm, and the second workpiece should be 185rpm.The turning time all is 15 minutes.During two a pair of workpiece of each turning of lathe (first, each one of second workpiece), survey to such an extent that be with no-load power corresponding under the rotating speed:

01 lathe: when n=600rpm, no-load power P _u=2260 watts;

When n=185rpm, no-load power P _u=1280 watts.

02 lathe: when n=600rpm; No-load power P _u=1320 watts;

When n=185rpm, no-load power P _u=900 watts.

Existing two kinds of different scheduling scheme A: the first workpiece is positioned on lathe No. 01, and the second workpiece is positioned on lathe No. 02; Or option b: the second workpiece is positioned on lathe No. 01, and the first workpiece is positioned on lathe No. 02.For two kinds of schemes, cutting energy and added losses energy can be regarded as constant substantially, so the saving of no-load power consumption can regard the saving amount of gross energy as, can be calculated by above data:

To dispatching option A: unloaded total energy consumption E _UA=0.790 degree.

To dispatching option b: unloaded total energy consumption E _UB=0.650 degree.

This shows that when adopting option b, a pair of workpiece of every processing just can economize on electricity and 0.14 spend.If produce by batch, every day, class Three cut 20 hours, then option b than scheme A every year (working 300 days) can economize on electricity 3360 the degree.Option b is exactly the energy saving scheduling arrangement scheme that will seek.

In the actual production workshop, normally many on lathe, workpiece to be processed be more than 2, but many.For the machining system of many a plurality of workpiece of lathe, the energy-saving and noise-reducing effect is more remarkable usually, but because scheduling scheme is a lot, preferred process is more complicated also.As, certain machining system has 10 lathes, and 12 kinds of workpiece etc. are to be processed, and if do not consider constraint condition, each workpiece has 10 kinds of possible lathes to arrange scheme, and then all feasible processing schemes of system are 10 ¹²Kind, from so numerous schemes, optimize very difficulty of optimum energy-saving and noise-reducing scheme.

The deficiency that summary of the invention exists at prior art, the invention provides a kind of is the machining system energy-saving and noise-reducing method that purpose is dispatched with the energy-saving and noise-reducing towards multimachine bed, multiplex's part machining system.

The object of the present invention is achieved like this: 1) measure idle operator lamp, the no-load power of lathe under different rotating speeds in the machining system, set up rotating speed-idle operator lamp, the rotating speed-no-load power database of lathe; 2), determine the processing rotating speed and the corresponding process time of each workpiece according to the technical papers of workpiece; 3) the continuous idle operator lamp matrix of the no-load power consumption matrix of calculating workpiece-lathe and equivalence; 4) arrange mathematical model according to Optimization Dispatching, processing scheme is carried out preferably, draw optimum energy-conservation, noise reduction scheduling arrangement scheme.

This method adopts the unloaded energy consumption of lathe to replace the energy consumption of lathe in reality processing to dispatch arrangement.Workpiece i is arranged on the lathe j and adds man-hour, and its no-load power consumption computing formula is as follows:

$E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{P}_{\mathrm{ul}}{t}_l$ Or $E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{P}_{\mathrm{ul}}\left(t\right)\mathrm{dt}$

This method adopts the lathe idle operator lamp to replace the actual processing of lathe noise to dispatch arrangement.Adopt lathe idle operator lamp and the equivalent idle operator lamp continuously of the long-pending conduct of corresponding process time under the corresponding rotating speed of each different process of workpiece.Workpiece i is arranged on the lathe j and adds man-hour, and the idle operator lamp computing formula is as follows continuously in its equivalence:

$L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=0}{\overset{N_i}{\mathrm{\Σ}}}{L}_{\mathrm{ul}}{t}_l\right)$ Or $L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=0}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{L}_{\mathrm{ul}}\left(t\right)\mathrm{dt}\right)$

This method has been set up mathematical model scheduling arrangement scheme has been carried out preferably, and mathematical model is as follows:

$\min E\left(X\right)=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{E}_L(i,j)x_{\mathrm{ij}}$

$\min L\left(X\right)=101g\left(\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{10}^{\frac{L_{\mathrm{eq}}(i,j)x_{\mathrm{ij}}}{10}}\right)-101\mathrm{gm}$

$\max F\left(X\right)=w_1\stackrel{\·\·}{E}\left(X\right)+w_2\stackrel{\·\·}{L}\left(X\right)$

One class constraint condition:

Or

Two class constraint conditions:

Characteristics of the present invention are, enterprise need not carry out hardware investment, angle from system, difference according to each lathe energy consumption characteristic and noisiness, and the difference of various workpieces technological requirement in the production task, by rational management between lathe and the workpiece and arrangement, provide the optimum combination scheme, just can obtain the obvious energy saving effect and the noise reduction of whole machining system.

The present invention is suitable for machining system very general, that have following characteristics in the reality:

(1) each lathe has identical process principle or similar working ability.

(2) same workpiece adds man-hour on different lathes, processes by the Process Plans of formulating, and does not change processing conditionss such as machined parameters and frock.

The theoretical foundation of technical solution of the present invention and specific implementation method are as follows:

If m workpiece, n platform lathe are arranged in a certain machining system, the numbering of workpiece and lathe is respectively: 1,2 ..., m, 1,2 ..., n.The ENERGY E that workpiece i consumes in the process on lathe j _L(i j) is:

$E_L(i,j)={\∫}_0^T{P}_i\left(t\right)\mathrm{dt}={\∫}_0^T{P}_u\left(t\right)\mathrm{dt}+{\∫}_0^T{P}_a\left(t\right)\mathrm{dt}+{\∫}_0^T{P}_c\left(t\right)\mathrm{dt}---\left(1\right)$

Wherein: P _t---the lathe power input;

P _u---no-load power;

P _a---secondary power;

P _c---cutting power;

T---processing continues T.T..

The energy consumption E of whole machining system then _LFor:

$E_L=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ij}}\left(t\right)\mathrm{dt}=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ui}}\left(t\right)\mathrm{dt}+\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ai}}\left(t\right)\mathrm{dt}+\underset{c=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ci}}\left(t\right)\mathrm{dt}---\left(2\right)$

Reduce the energy loss of system, promptly should make:

$E_L=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ui}}\left(t\right)\mathrm{dt}+\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ai}}\left(t\right)\mathrm{dt}+\underset{c=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{\mathrm{Ti}}{P}_{\mathrm{ci}}\left(t\right)\mathrm{dt}\→\min ---\left(3\right)$

If m workpiece, n platform lathe are arranged in a certain machining system, the numbering of workpiece and lathe is respectively: 1,2 ..., m, 1,2 ..., n.Workpiece i processes on lathe j, and its equivalent continuing noise is:

$L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T}{\∫}_0^T{10}^{0.1L_{\mathrm{eq}}\left(t\right)}\mathrm{dt}\right)---\left(4\right)$

In the formula: T---processing continues T.T.;

L _A(t)---t machine noise constantly;

L _Eq(i, j)---the equivalent continuing noise of all process.

The global noise of whole system of processing, the equivalent continuing noise decibel mean value in the time of can be with m workpiece processing is estimated as evaluation function:

$L=101g\left(\underset{i=0}{\overset{m}{\mathrm{\Σ}}}{10}^{\frac{L_{\mathrm{eq}}\left(i\right)}{10}}\right)-101\mathrm{gm}\→\min ---\left(5\right)$

Introduce 0,1 variable x _Ij, order:

Therefore the arrangement relation (or being called the arrangement scheme) of workpiece and lathe can be used 0-1 matrix [X] in the machining system _{M * n}Expression.

${\left[X\right]}_{m\×n}=\left[\begin{array}{cccc}{x}_{11}& x_{12}& ...& x_{1n}\\ x_{21}& x_{22}& ...& x_{2n}\\ & & x_{\mathrm{ij}}& \\ x_{m1}& x_{m2}& ...& x_{\mathrm{mn}}\end{array}\right]---\left(6\right)$

At matrix [X] _{M * n}In, the behavior workpiece is classified lathe as.x _Ij=1 expression workpiece i is arranged on the lathe j and processes; x _Ij=0 expression workpiece i is not arranged on the lathe j and processes.

All workpiece add power in man-hour, noise and process time in the machining system on different lathes by measuring, and can obtain energy consumption and noise figure according to formula (1), (4), constitute corresponding to scheme matrix [X] _{M * n}Energy consumption matrix [E] _{M * n}With processing noise matrix [L] _{M * n}:

${\left[E\right]}_{m\×n}=\left[\begin{array}{cccc}{E}_L\left(\mathrm{1,1}\right)& E_L\left(\mathrm{1,2}\right)& ...& E_L(1,n)\\ E_L\left(\mathrm{2,1}\right)& E_L\left(\mathrm{2,2}\right)& ...& E_L(2,n)\\ & & E_L(i,j)& \\ E_L(m,1)& E_L(m,2)& ...& E_L(m,n)\end{array}\right]---\left(7\right)$

${\left[L\right]}_{m\×n}=\left[\begin{array}{cccc}{L}_{\mathrm{eq}}\left(\mathrm{1,1}\right)& L_{\mathrm{eq}}\left(\mathrm{1,2}\right)& ...& L_{\mathrm{eq}}(1,n)\\ L_{\mathrm{eq}}\left(\mathrm{2,1}\right)& L_{\mathrm{eq}}\left(\mathrm{2,2}\right)& ...& L_{\mathrm{eq}}(2,n)\\ & & L_{\mathrm{eq}}(i,j)& \\ L_{\mathrm{eq}}(m,1)& L_{\mathrm{eq}}(m,2)& ...& L_{\mathrm{eq}}(m,n)\end{array}\right]---\left(8\right)$

E wherein _L(i, j) and L _Eq(i j) represents that respectively the i workpiece is arranged in energy consumption and the equivalent continuing noise that adds man-hour on the j lathe.

If certain lathe can't be processed certain workpiece, then suppose its energy consumption and equivalent continuing noise for infinitely great, can not be arranged into as h kind workpiece and process on the k lathe, then:

E _L(h，k)＝∞?????????????????????(9)

L _eq(h，k)＝∞????????????????????(10)

Can be according to energy consumption matrix [E] _{M * n}With processing noise matrix [L] _{M * n}, scheduling scheme is carried out preferably.At first should determine the objective function that Optimization Dispatching is arranged.According to scheme matrix [X] _{M * n}, energy consumption matrix [E] _{M * n}, noise matrix [L] _{M * n}, can determine that energy-saving Optimization Dispatching arranges objective function to be in the machining system:

$\min E\left(X\right)=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{E}_L(i,j)x_{\mathrm{ij}}---\left(11\right)$

The noise reducing type Optimization Dispatching arranges objective function to be:

$\min L\left(X\right)=101g\left(\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{10}^{\frac{L_{\mathrm{eq}}(i,j)x_{\mathrm{ij}}}{10}}\right)-101\mathrm{gm}---\left(12\right)$

For energy-conservation and noise reduction are carried out synthesis optimizing and scheduling, also need to provide synthesis energy saving noise reducing type multiple-objection optimization regulation goal function.Be that target is carried out preferably scheduling arrangement scheme with energy-conservation and noise reduction respectively, can obtain the maximum energy consumption value E of machining system _Max, least energy consumption value E _Min, maximum noise value L _Max, minimal noise value L _MinSo can obtain energy consumption and the noise nondimensionalization relative size value of any scheme X.

$\stackrel{\·\·}{E}\left(X\right)=\frac{E_{\max }-E\left(X\right)}{E_{\max }-E_{\min }}---\left(13\right)$

$\stackrel{\·\·}{L}\left(X\right)=\frac{L_{\max }-L\left(X\right)}{L_{\max }-L_{\min }}---\left(14\right)$

If energy-conservation and weight noise reduction is respectively w ₁, w ₂, then synthesis optimizing and scheduling arranges objective function to be expressed as:

$\max F\left(X\right)=w_1\stackrel{\·\·}{E}\left(X\right)+w_2\stackrel{\·\·}{L}\left(X\right)---\left(15\right)$

In reality processing, for equilibrium and the usage ratio of equipment that guarantees processing tasks, the general requirement is less than or equal to the workpiece number when the lathe number, and then every lathe is processed a workpiece at least; When the lathe number is counted greater than workpiece, allow unnecessary lathe not arrange production task.Arrange mathematical model so can set up energy-conservation, the noise reducing type scheduling of machining system:

Objective function:

$\min E\left(X\right)=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{E}_L(i,j)x_{\mathrm{ij}}$

$\min L\left(X\right)=101g\left(\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{10}^{\frac{L_{\mathrm{eq}}(i,j)x_{\mathrm{ij}}}{10}}\right)-101\mathrm{gm}$

$\max F\left(X\right)=w_1\stackrel{\·\·}{E}\left(X\right)+w_2\stackrel{\·\·}{L}\left(X\right)$

One class constraint condition:

Or

Two class constraint conditions:

Above-mentioned model has been found the solution several different methods.For the machining system of a plurality of workpiece, separate unit lathe, the arrangement scheme has only one; For the machining system of single workpiece, many lathes and a small amount of workpiece, a small amount of lathe (referring generally to be no more than 3 on a small quantity), generally also can adopt the method for exhaustive arrangement scheme, can obtain the optimal scheduling scheme soon.In multimachine bed multiplex (MUX) part machining system, be that to be optimized that scheduling arranges be a complicated problems to target with energy-conservation, noise reduction.Therefore generally need adopt methods such as Hungary's algorithm or genetic algorithm that above-mentioned model is found the solution for multimachine bed multiplex (MUX) part machining system.Its concrete solution procedure can be with reference to relevant document.

For the ease of calculating and practical operation, the present invention adopts no-load power to replace actual working power, idle operator lamp to replace actual processing noise, facts have proved it is feasible.Be analyzed as follows:

Test and theoretical analysis all show in a large number, for the arrangement scheme of different workpiece and lathe, $\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ci}}\left(t\right)\mathrm{dt}$ With $\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ai}}\left(t\right)\mathrm{dt}$ Difference very little, these difference with respect to $\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ui}}\left(t\right)\mathrm{dt}$ Difference can ignore, that is:

$\mathrm{\Δ}{E}_L\≈\mathrm{\Δ}{E}_u=\mathrm{\Δ}\left(\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ui}}\left(t\right)\mathrm{dt}\right)---\left(19\right)$

E _uBe unloaded total energy consumption.So formula (3) can replace with following formula:

$E_u=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}{\∫}_0^{T_i}{P}_{\mathrm{ul}}\left(t\right)\mathrm{dt}\→\min ---\left(20\right)$

In cutting parameter, lathe no-load power P _uMain relevant with rotating speed.If workpiece i processes, need N on lathe j _iIndividual process, the corresponding a kind of processing rotating speed of each process l, the time of each process is respectively t _lSo the no-load power consumption of these all process of workpiece can be expressed as:

$E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{P}_{\mathrm{ul}}{t}_l---\left(21\right)$

Then formula (20) can further be reduced to:

$E_u=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{P}_{\mathrm{ul}}{t}_l\→\min ---\left(22\right)$

Therefore when setting up lathe energy consumption matrix, can replace formula (1) to carry out energy loss with formula (21) and calculate.

Change if consider the no-load power under each rotating speed, then:

$E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{P}_{\mathrm{ul}}\left(t\right)\mathrm{dt}---\left(23\right)$

The machine tooling noise mainly is the synthetic of construct noise and cutting noise.Construct noise is relevant with lathe itself, as gear, bearing, casing etc.; The cutting noise mainly by cutter, be cut material and smear metal three and produce, the power that is consumed is directly proportional, and with dynamic cutting force extremely strong correlativity is arranged.In machining system, if processing conditionss such as the machined parameters of assurance workpiece, frock are constant, cutting power loss, dynamic cutting force and cutting noise can be considered as approximately equal, and the difference of processing noise is mainly derived from construct noise, is determined by lathe itself.The lathe idle operator lamp is one of important evaluation index of reflection machine tool structure noisiness and machine mass, in the countries concerned's standard, all require under the dry run condition, to carry out as machine noise mensuration among GB/T 16769-1997 " Metal Cutting Machine Tool noise sound measuring method " and the GB/T 4215-1984 " mensuration of Metal Cutting Machine Tool noise sound power level ".

Given this, based on idle operator lamp formula (4) is simplified.If workpiece i processes, need N on lathe j _iIndividual process, the corresponding a kind of processing rotating speed of each process, and each process is continuous, then all process with the continuous idle operator lamp of the equivalence rotating speed under are:

$L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{L}_{\mathrm{ul}}(i,j)t_l\right)---\left(24\right)$

In the formula: t _l---operation (machine tool running) time of l process;

L _Ul(i, j)---with the idle operator lamp of l process with rotating speed;

N _i---the required process number of workpiece i;

T _i---the processing T.T. of workpiece i;

L _Eq(i, j)---the continuous idle operator lamp of equivalence of all process.

If consider the variation of idle operator lamp under each rotating speed, then:

$L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=0}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{L}_{\mathrm{ul}}\left(t\right)\mathrm{dt}\right)---\left(25\right)$

According to above analysis, can carry out energy-saving and noise-reducing type scheduling arrangement to machining system based on no-load power consumption and idle operator lamp.By measuring, can obtain idle operator lamp, the no-load power of lathe under different rotating speeds in the machining system easily, thereby set up rotating speed-idle operator lamp, the rotating speed-no-load power database of lathe.Because lathe no-load power, idle operator lamp are relevant with the performance of lathe own, irrelevant with workpiece, so this database is in case set up, can be used as basic data supports the energy-saving and noise-reducing type scheduling of all workpiece processing to arrange, thereby simplified the scheduling scheduling processes greatly, improved the present invention's operability in actual applications.

The invention will be further described below in conjunction with embodiment for embodiment:

Production practical problems with certain machining factory Gear Processing workshop is an example.

This workshop has 5 kinds of different gear workpiece to need processing in a collection of production task, and existing 4 lathes can be arranged for scheduling.

After measured, the relation of the rotating speed-no-load power of 4 gear hobbing lathes and rotating speed-idle operator lamp is as follows:

1) lathe 1 hobbing machine

This hobbing machine is semi-automatic chain digital control gear hobbing machine, and its no-load power performance data is as follows:

Rotating speed (n/min)	????125	??160	????200	????250	????330	????400
							No-load power (kw)	????2.65	??2.72	????2.88	????3.2	????3.84	????4.48
Idle operator lamp (db)	????74.2	??75.0	????78.6	????79.2	????82.6	????81.9

2) lathe 2 hobbing machines

This hobbing machine is efficient numerically controlled hobbing machine, and its no-load power performance data is as follows:

Rotating speed (n/min)	??125	??160	??200	??250	??300	??350	??400	??450	??500
										No-load power (kw)	??2.5	??2.8	??3.25	??3.9	??4.4	??5.2	??5.9	??6.7	??7.6
Idle operator lamp (db)	??73.7	??76.2	??75.3	??77.3	??79.3	??77.6	??80.0	??80.6	??86.3

3) lathe 3 hobbing machines

This hobbing machine is a semi-automatic gear hobbing machine, and its no-load power performance data is as follows:

Rotating speed (n/min)	??130	??160	??200	??250	??330	??400
							No-load power (kw)	??2.88	??3.04	??3.26	??3.68	??4.48	??5.44
Idle operator lamp (db)	??78.4	??80.4	??80.2	??80.5	??81.2	??83.8

4) lathe 4 hobbing machines

This hobbing machine is semi-automatic chain digital control gear hobbing machine, and its no-load power performance data is as follows:

Rotating speed (n/min)	??100	??125	??150	??200	??250	??300	??350	??400	??500
										No-load power (kw)	??4.8	??5.2	??5.6	??5.6	??6.0	??6.0	??6.0	??6.1	??6.1

Idle operator lamp (db)

79.5

?79.6

?79.8

??80

??79

??78

?78.5

????79

????79

Can set up the rotating speed-idle operator lamp and the rotating speed-no-load power consumption database of lathe according to above data.

According to technical papers, determine feed number of times, processing rotating speed and the corresponding process time thereof of various workpiece.The process data such as the table 5 of 5 kinds of workpiece.

The process data of table 5 workpiece

The workpiece figure number	Rolling cut for the first time		Rolling cut for the second time
					Rotating speed (n/min)	Time (min)	Rotating speed (n/min)	Time (min)
	Workpiece 1	????125	????22.39	????200					????13.99
Workpiece 2					????200	????8.39	????250	????4.03
	Workpiece 3	????250	????17.12	????300					????14.26
Workpiece 4					????200	????10.82	????300	????4.33
	Workpiece 5	????160	????28.10	????200					????22.48

According to the data of table 5,, and, can draw the no-load power consumption matrix [E] that this scheduling is arranged according to formula (21,24) calculating by rotating speed-idle operator lamp and the rotating speed-no-load power database of inquiring about 4 optional lathes _{5 * 4}With the continuous idle operator lamp matrix of equivalence [L] _{5 * 4}(the behavior workpiece is classified lathe as):

${\left[E\right]}_{5\×4}=\left[\begin{array}{cccc}1.66& 1.84& 1.17& 2.43\\ 0.62& 0.70& 0.72& 1.18\\ 1.75& 1.98& 2.10& 3.14\\ 0.77& 1.61& 0.90& 1.44\\ 2.35& 2.65& 2.53& 4.72\end{array}\right]{\left[L\right]}_{5\×4}=\left[\begin{array}{cccc}76.44& 79.18& 74.39& 79.76\\ 78.80& 80.30& 76.05& 77.63\\ 80.06& 80.23& 79.99& 78.57\\ 79.39& 79.39& 76.85& 79.36\\ 77.48& 80.31& 75.82& 79.89\end{array}\right]$

Can be respectively dispatch arrangement with energy-conservation, noise reduction and three kinds of modes of energy-saving and noise-reducing.Mathematical model is arranged in the scheduling of setting up according to the present invention, can work out out auxiliary calculating of scheduling scheduling of three kinds of different purposes.Scheduling arranges result of calculation as follows:

(1) with energy-conservation be purpose:

Maximum no-load power consumption is 11.85kwh, and minimum no-load power consumption is 7.41kwh, and pairing model solution is:

$X_{\max }=\left[\begin{array}{cccc}1& 0& 0& 0\\ 0& 0& 1& 0\\ 0& 0& 0& 1\\ 0& 1& 0& 0\\ 0& 0& 0& 1\end{array}\right];X_{\min }=\left[\begin{array}{cccc}0& 0& 1& 0\\ 0& 1& 0& 0\\ 1& 0& 0& 0\\ 0& 0& 0& 1\\ 1& 0& 0& 0\end{array}\right]$

The difference of minimum and maximum value is: 4.45kwh.Be that scheduling scheme is:

Workpiece	??1	??2	??3	??4	??5	Unloaded total energy consumption	Difference
								The MAX scheme	Lathe 1	Lathe 3	Lathe 4	Lathe 2	Lathe 4	11.85kwh	4.44

The MIN scheme

Lathe 3

Lathe 2

Lathe 1

Lathe 4

Lathe 1

??7.41kwh

??kwh

(2) with the noise reduction be purpose:

Maximum noise decibel mean value is 79.96, and minimal noise decibel mean value is 77.50, and pairing model solution is:

$X_{\max }=\left[\begin{array}{cccc}0& 0& 0& 1\\ 0& 1& 0& 0\\ 0& 0& 1& 0\\ 1& 0& 0& 0\\ 0& 1& 0& 0\end{array}\right];X_{\min }=\left[\begin{array}{cccc}1& 0& 0& 0\\ 0& 0& 1& 0\\ 0& 0& 0& 1\\ 0& 1& 0& 0\\ 0& 0& 1& 0\end{array}\right]$

The difference of minimum and maximum value is 2.46 decibels.Be that scheduling scheme is:

Workpiece	??1	??2	??3	??4	??5	Noise	Difference
								The MAX scheme	Lathe 4	Lathe 2	Lathe 3	Lathe 1	Lathe 2	?79.96db	?2.46 ?db
The MIN scheme	Lathe 1	Lathe 3	Lathe 4	Lathe 2	Lathe 3	?77.50db

(3) with the energy-saving and noise-reducing be purpose

Energy-conservation and weights noise reduction all are taken as 0.5.The integrated dispatch value of optimal case is 0.9367, and the integrated dispatch model solution is:

$X^{*}=\left[\begin{array}{cccc}0& 0& 1& 0\\ 0& 0& 0& 1\\ 0& 1& 0& 0\\ 0& 0& 1& 0\\ 1& 0& 0& 0\end{array}\right]$

Corresponding no-load power consumption value is 7.58kwh, and noise decibel mean value is 77.71.Be that scheduling scheme is:

Workpiece	??1	??2	??3	??4	??5	Total energy consumption	Noise mean value
								Integration scenario	Lathe 3	Lathe 4	Lathe 2	Lathe 3	Lathe 1	??7.58 ??kwh	????77.71 ????db

More than the comparative analysis of scheduling arrangement result shows, energy-saving and noise-reducing type scheduling arrangement method of the present invention is effectively, can reduce system's power consumption of polymer processing and noise significantly, obtains tangible economic benefit.

Claims (4)

1, a kind of machining system energy-saving and noise-reducing method is characterized in that may further comprise the steps:

1) measures idle operator lamp, the no-load power of lathe under different rotating speeds in the machining system, set up rotating speed-idle operator lamp, the rotating speed-no-load power database of lathe;

2), determine the processing rotating speed and the corresponding process time of each workpiece according to the technical papers of workpiece;

3) the continuous idle operator lamp matrix of the no-load power consumption matrix of calculating workpiece-lathe and equivalence;

4) arrange mathematical model according to Optimization Dispatching, processing scheme is carried out preferably, draw optimum energy-conservation, noise reduction scheduling arrangement scheme.

2, energy-saving and noise-reducing method according to claim 1 is characterized in that this method adopts the unloaded energy consumption of lathe to replace the energy consumption of lathe in reality processing to dispatch arrangement; Workpiece i is arranged on the lathe j and adds man-hour, and its no-load power consumption computing formula is as follows:

$E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{P}_{\mathrm{ul}}{t}_l$ Or $E_u(i,j)=\underset{l=1}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{P}_{\mathrm{ul}}\left(t\right)\mathrm{dt}$

3, energy-saving and noise-reducing method according to claim 1 is characterized in that this method adopts the lathe idle operator lamp to replace the actual processing of lathe noise to dispatch arrangement; Adopt lathe idle operator lamp and the equivalent idle operator lamp continuously of the long-pending conduct of corresponding process time under the corresponding rotating speed of each different process of workpiece; Workpiece i is arranged on the lathe j and adds man-hour, and the idle operator lamp computing formula is as follows continuously in its equivalence:

$L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=0}{\overset{N_i}{\mathrm{\Σ}}}{L}_{\mathrm{ul}}{t}_l\right)$ Or $L_{\mathrm{eq}}(i,j)=101g\left(\frac{1}{T_i}\underset{l=0}{\overset{N_i}{\mathrm{\Σ}}}{\∫}_0^i{L}_{\mathrm{ul}}\left(t\right)\mathrm{dt}\right)$

4, energy-saving and noise-reducing method according to claim 1 is characterized in that this method set up mathematical model scheduling arrangement scheme is carried out preferably, and mathematical model is as follows:

$\min E\left(X\right)=\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{E}_L(i,j)x_{\mathrm{ij}}$

$\min L\left(X\right)=101g\left(\underset{i=1}{\overset{m}{\mathrm{\Σ}}}\underset{j=1}{\overset{n}{\mathrm{\Σ}}}{10}^{\frac{L_{\mathrm{eq}}(i,j)x_{\mathrm{ij}}}{10}}\right)-101\mathrm{gm}$

$\max F\left(X\right)=w_1\stackrel{\·\·}{E}\left(X\right)+w_2\stackrel{\·\·}{L}\left(X\right)$

One class constraint condition:

Or

Two class constraint conditions: