机床能耗基础数据建模及获取方法研究

发布时间：2018-05-13 15:20

本文选题：能耗基础数据 + 启动能耗　；参考：《重庆大学》2015年硕士论文

【摘要】：机床量大面广,能量消耗总量巨大,并且能量效率低,节能潜力很大,因此对机床能耗与能效的研究十分重要。机床能耗与能效的研究及应用均需要机床能耗基础数据的支持,为此本文在国家自然科学基金重点项目“机械加工制造系统工件能量效率的预测建模及预测方法研究”(项目编号:51375513)和国家863计划课题“机床产品机械加工制造系统能效优化提升技术及应用”(课题编号:2014AA041506)的支持下,对机床能耗基础数据建模及获取方法进行了研究。主要工作概括如下:机床能耗基础数据的构成和分析。本文首先对机床服役过程进行了时段分析,并根据时段过程分析了各时段中的能耗基础数据以及能耗基础数据涉及到的能耗部件。其中,由于待机能耗和空载能耗相对稳定,可用常数表示,因此,本文仅对机床启动过程能耗和切削加工过程能耗基础数据进行研究。机床启动能耗建模及获取方法研究。机床启动能耗的能耗规律和计算模型均十分复杂,难于获取。本文分析了启动过程的能耗特性并建立了相应的能耗模型。基于此模型,本文提出了一种启动能耗基础数据获取方法。该方法中利用启动过程功率变化特性与机床其它服役过程中功率变化的特性有较大区别这一特点,利用功率相对变化率来判定启动过程,并针对有级调速机床和无级调速机床提出了利用离散功率数据求和法和连续函数积分法两种方式来分别获取这两种机床的启动时长和启动能耗基础数据。机床切削加工系统载荷损耗系数获取方法研究。机床的切削能耗可通过已获得的机床载荷损耗系数获取,因此机床载荷损耗系数的获取便成为快捷获取机床切削能耗的关键。本文提出一种机床切削加工系统载荷损耗系数的映射测取方法。该方法选一台机床作为基准机床,通过设计基准样件、基准切削参数和采用的基准刀具,在基准机床上通过实验获取基准样件在基准切削参数下的切削功率;基于获得的切削功率均值建立切削加工系统的整体切削功率模型,将基准机床的整体切削功率模型映射到其它能够加工该基准样件的任一机床上;然后通过用相同刀具加工基准样件并检测该机床的切削加工系统总输入功率,再根据获得的切削功率模型和预先建立的待测机床的空走刀功率数据库,获取该机床切削加工系统的载荷损耗系数。该方法为机床载荷损耗系数获取十分困难的难题提供了一种解决方案。案例分析和应用前景分析表明,本文所提出的机床启动能耗和载荷损耗系数获取方法可以快捷准确地获取机床启动能耗数据和载荷损耗系数,误差较小,应用方便;再加上已有的关于机床待机能耗和空载能耗的研究,便可获得机床运行过程中所有的能耗基础数据,为机床能量消耗分析、能量效率评价、能量消耗预测和能耗定额制定等能提供数据支持,具有广阔的应用前景。
[Abstract]:The research on energy consumption and energy efficiency of machine tool is very important because of its large quantity of machine tools, huge amount of energy consumption, low energy efficiency and great potential of energy saving. The research and application of machine tool energy consumption and energy efficiency need the support of basic data of machine tool energy consumption. In this paper, the key project of National Natural Science Foundation, "Prediction Modeling and Prediction method of Machining Manufacturing system workpiece Energy efficiency" (Project No.: 513755131313) and National 863 Project "Machining and Manufacturing of Machine tool products" Technology and Application of system Energy efficiency Optimization and Promotion (Project No.: 2014AA041506), The modeling and acquisition method of basic data of machine tool energy consumption are studied. The main work is summarized as follows: structure and analysis of basic data of machine tool energy consumption. In this paper, the time period of machine tool service process is analyzed, and the basic data of energy consumption and the energy components involved in each period are analyzed according to the period process. Because the energy consumption of standby and no-load is relatively stable and can be expressed by constants, this paper only studies the basic data of the energy consumption in the starting process of machine tool and the energy consumption in cutting process. Modeling and acquisition methods of starting Energy consumption of Machine tools. The energy consumption law and calculation model of machine tool start-up energy consumption are very complex and difficult to obtain. In this paper, the energy consumption characteristics of start-up process are analyzed and the corresponding energy consumption model is established. Based on this model, this paper presents a method to obtain the basic data of starting energy consumption. In this method, the characteristics of power variation in starting process are quite different from those in other service processes of machine tools, and the relative rate of power change is used to determine the starting process. The discrete power data summation method and the continuous function integration method are used to obtain the starting time and energy consumption data of the two kinds of machine tools, respectively. Research on the method of obtaining load loss coefficient of Machine tool cutting system. The cutting energy consumption of the machine tool can be obtained by the load loss coefficient of the machine tool, so the acquisition of the load loss coefficient of the machine tool becomes the key to obtain the cutting energy consumption of the machine tool quickly. In this paper, a mapping method for measuring load loss coefficient of machine tool cutting system is presented. In this method, a machine tool is chosen as the benchmark machine tool, and the cutting power of the reference sample under the reference cutting parameters is obtained by experiments on the benchmark machine tool by designing the reference sample, the reference cutting parameters and the reference tool. Based on the obtained average cutting power, the whole cutting power model of the machining system is established, and the whole cutting power model of the reference machine tool is mapped to any other machine tool which can process the reference sample. Then by using the same cutting tool to process the reference sample and detect the total input power of the cutting system of the machine tool, then according to the obtained cutting power model and the pre-established database of the empty walking tool power of the machine tool to be tested, The load loss coefficient of the machine tool cutting system is obtained. This method provides a solution to the difficult problem of obtaining load loss coefficient of machine tools. Case analysis and application prospect analysis show that the method proposed in this paper can quickly and accurately obtain the starting energy consumption data and load loss coefficient of the machine tool. The error is small and the application is convenient. In addition to the existing research on machine tool standby energy consumption and no-load energy consumption, we can obtain all the basic energy consumption data in the process of machine tool operation, which is the analysis of machine tool energy consumption and the evaluation of energy efficiency. The prediction of energy consumption and the establishment of energy consumption quota can provide data support and have a broad application prospect.
【学位授予单位】：重庆大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG502

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