机械加工制造过程能耗优化方法研究

发布时间：2019-04-29 08:33

【摘要】：制造业在将资源转变为产品或服务的过程中消耗了大量能量。机械加工作为制造业的主要生产过程,机床是机械加工制造过程的重要耗能制造资源。为应对全球气候变暖,提高制造业发展的可持续性,针对机械产品零件的机械加工制造过程能耗进行优化对于节约能源,实现低碳制造具有重要意义。为此,本文提出了通过集成工艺规划与生产调度进行机械加工制造过程能耗优化的方法,着重研究了机床设备资源状态建模与量化评估、机械加工制造过程能耗的定量计算、面向低碳制造的工艺规划与生产调度集成等内容。针对机床设备资源状态建模与量化评估问题,首先讨论了资源能力与状态的区别,对机床设备状态进行了形式化的建模描述;然后建立了机床设备状态量化评价指标体系;结合建立的机床状态模型和评价指标体系,利用基于层次分析法的二级模糊综合评判法实现了机床设备状态量化分析,得到了机床设备状态总评分数,从而支持工艺规划资源决策。针对机械加工制造过程能耗的定量计算问题,在界定的研究范围内,通过合理假设,利用基于动素的机床能耗模型,建立了机械产品零件的机械加工制造过程能耗计算模型。针对面向低碳制造的工艺规划与生产调度集成问题,本文基于非线性工艺规划这一典型的工艺规划与生产调度集成模型开展研究。首先分析了非线性工艺规划的特点,结合AOS树理论介绍了表达它的AOS树建立过程和如何基于非线性工艺规划AOS树获得零件可选工艺路线。然后,借鉴现有柔性作业车间调度研究,通过合理假设,建立了以全部加工任务选择机床的综合平均状态、总完工时间以及机械加工制造过程能耗为优化目标,面向低碳制造的工艺规划与生产调度集成模型,给出了其数学表达。采用了基于智能算法的工艺规划与生产调度集成实现方法,利用染色体分层编码遗传算法求解建立的集成模型。当通过非线性工艺规划为每个零件生成的可选工艺方案给定时,该集成模型能权衡优化目标,决策出适合各零件的工艺路线、机床选择方案和相应的生产调度方案。为验证本文提出的机械加工制造过程能耗优化方法节能效果,进行了案例研究。以某制造企业为背景,通过对比某批次机械产品零件在工艺规划与生产调度集成模式和传统串行工作模式下的机械加工制造过程能耗,验证了所提节能方法的有效性。使用基准实例测试验证了基于染色体分层编码遗传算法实现工艺规划与生产调度集成的可行性。最后,对全文的主要研究内容和创新点进行了归纳总结,并对后续研究方向进行了展望和探讨。
[Abstract]:Manufacturing consumes a lot of energy in the process of transforming resources into products or services. As the main production process of manufacturing industry, machine tool is an important energy-consuming resource in the process of machining and manufacturing. In order to deal with global warming and improve the sustainability of manufacturing development, it is of great significance to optimize the energy consumption of mechanical manufacturing process for mechanical parts to save energy and realize low carbon manufacturing. In this paper, an integrated process planning and production scheduling method for optimization of energy consumption in machining manufacturing process is proposed. The modeling and quantitative evaluation of machine tool equipment resource state and the quantitative calculation of energy consumption in machining manufacturing process are emphatically studied, and the energy consumption of machining manufacturing process is optimized by means of integrated process planning and production scheduling. Integration of process planning and production scheduling for low carbon manufacturing. In view of the modeling and quantitative evaluation of machine tool equipment resource state, the difference between resource capability and state is discussed, and the formalized modeling description of machine tool equipment state is given, and then the quantitative evaluation index system of machine tool equipment state is established. Combined with the established machine tool state model and evaluation index system, the quantitative analysis of machine tool equipment state is realized by using the two-stage fuzzy comprehensive evaluation method based on analytic hierarchy process (AHP), and the total evaluation score of machine tool equipment state is obtained. Thus supporting process planning resource decision-making. Aiming at the problem of quantitative calculation of energy consumption in machining and manufacturing process, the energy consumption model of mechanical parts in machining process is established by means of reasonable assumption and dynamic element-based energy consumption model of machine tool. Aiming at the integration of process planning and production scheduling for low carbon manufacturing, this paper studies the integration model of process planning and production scheduling based on nonlinear process planning. Firstly, the characteristics of nonlinear process planning are analyzed. Combined with the theory of AOS tree, the process of establishing AOS tree to express it and how to obtain the optional process route of parts based on AOS tree of nonlinear process planning are introduced. Then, referring to the existing research on flexible job shop scheduling, through reasonable assumptions, the optimization objectives of selecting the comprehensive average state of machine tool, the total completion time and the energy consumption of machining manufacturing process with all machining tasks are established. The integrated model of process planning and production scheduling for low carbon manufacturing is presented, and its mathematical expression is given. The integration method of process planning and production scheduling based on intelligent algorithm is adopted. The integration model is solved by using the genetic algorithm of chromosome hierarchical coding. When the optional process plan generated for each part is timed by nonlinear process planning, the integrated model can weigh the optimization objective and decide the process route, machine tool selection scheme and corresponding production scheduling scheme suitable for each part. In order to verify the energy saving effect of the optimization method of energy consumption in machining manufacturing process, a case study was carried out. Based on the background of a manufacturing enterprise, the effectiveness of the proposed energy-saving method is verified by comparing the energy consumption of a batch of mechanical parts under the integration mode of process planning and production scheduling and the traditional serial working mode. The feasibility of integration of process planning and production scheduling based on chromosome hierarchical coding genetic algorithm is verified by benchmark examples. Finally, the main research contents and innovation points are summarized, and the future research direction is prospected and discussed.
【学位授予单位】：浙江大学
【学位级别】：博士
【学位授予年份】：2016
【分类号】：TH186

【参考文献】