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CN109634238A - A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method - Google Patents

A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method Download PDF

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CN109634238A
CN109634238A CN201811559025.XA CN201811559025A CN109634238A CN 109634238 A CN109634238 A CN 109634238A CN 201811559025 A CN201811559025 A CN 201811559025A CN 109634238 A CN109634238 A CN 109634238A
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machine tool
cnc machine
actual
quality
energy consumption
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CN109634238B (en
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贾顺
蔡维
袁清和
李美燕
王志强
马晓原
王海洋
张利
姚文喜
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Southwest University
Shandong University of Science and Technology
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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
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
    • 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
    • G05B2219/32—Operator till task planning
    • G05B2219/32368—Quality control
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Numerical Control (AREA)

Abstract

本发明公开了一种面向制造业节能减排的数控机床加工过程质量‑能量效率评估与监控方法。该方法首先根据数控机床实际加工零件数量和加工合格零件数量，计算获得数控机床加工质量合格率；接着通过获得数控机床在给定周期内有不合格品和无不合格品时的能耗，计算得到数控机床加工过程质量‑能量效率。基于上述得到的数控机床加工质量合格率和质量‑能量效率，构建数控机床质量‑能量效率与加工质量合格率间的关系模型。基于上述评估模型对数控机床加工过程质量‑能量效率进行实时监测和超限报警与控制。本发明方法对数控机床加工过程质量‑能量效率评估科学，且能够将数控机床加工过程质量‑能量效率控制在要求范围内，是一种实用有效的方法。

The invention discloses a numerical control machine tool processing quality-energy efficiency evaluation and monitoring method for energy saving and emission reduction in the manufacturing industry. The method firstly calculates and obtains the qualified rate of CNC machine tool processing quality according to the actual number of parts processed by the CNC machine tool and the number of qualified parts; CNC machining process quality-energy efficiency. Based on the above obtained CNC machine tool machining quality pass rate and quality-energy efficiency, a relationship model between CNC machine tool quality-energy efficiency and machining quality pass rate was constructed. Based on the above evaluation model, real-time monitoring and over-limit alarm and control of the quality-energy efficiency of the CNC machine tool processing process are carried out. The method of the invention scientifically evaluates the quality-energy efficiency of the machining process of the CNC machine tool, and can control the quality-energy efficiency of the machining process of the CNC machine tool within the required range, which is a practical and effective method.

Description

A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method
Technical field
The present invention relates to the assessments of discrete manufacturing business numerically-controlled machine tool energy efficiency and energy efficiency monitoring and the field that promoted, especially It is a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method.
Background technique
Numerically-controlled machine tool is widely used mechanized equipment in discrete manufacturing business.The research table of Massachusetts Institute Technology professor The energy consumption of bright numerically-controlled machine tool and its indirectly caused by environmental emission be very significant.Numerically-controlled machine tool makes in China's manufacturing industry Dosage is big and wide application, and therefore, the energy consumption total amount of numerically-controlled machine tool is very huge.Study numerical-controlled machine tool machining process matter Amount-energy efficiency, which is assessed, and monitoring method is energy-saving for manufacturing industry is of great significance.
On the one hand numerically-controlled machine tool operational process energy efficiency is influenced by machined parameters, its processing part of still further aspect Quality also influences numerically-controlled machine tool integral energy efficiency.The method that present analysis assesses numerical-controlled machine tool machining process energy efficiency is main Consider the influence of machined parameters, but seldom considers influence of the processing part quality to lathe energy efficiency.Currently still lack A kind of effectively practical the numerically-controlled machine tool energy efficiency assessment that can comprehensively consider numerically-controlled machine tool processing part quality influence and prison Prosecutor method.The method of the present invention by comprehensively considering influence of the numerically-controlled machine tool processing quality qualification rate to numerically-controlled machine tool energy efficiency, Construct the relational model between NC Machine Quality-energy efficiency and numerically-controlled machine tool processing quality qualification rate.Further pass through logarithm Machine mass-energy efficiency real-time monitoring is controlled, is realized to NC Machine Quality-energy efficiency overload alarm function, thus Make NC Machine Quality-energy efficiency control in the range of requiring.The method of the present invention considers machine tooling mass loss logarithm The influence for controlling lathe integral energy efficiency, can effectively and accurately assess NC Machine Quality-energy efficiency, and can be to numerical control Machine mass-energy efficiency carries out overload alarm, and making operator, targetedly control machine mass-energy efficiency exists in time It is a kind of practical assessment of lathe energy efficiency and monitoring method in claimed range.
Summary of the invention
The purpose of the present invention is to provide one kind can be to discrete manufacturing business numerical-controlled machine tool machining process mass-energy efficiency The method with monitoring is assessed in progress in real time, will be assessed obtained numerical-controlled machine tool machining process mass-energy efficiency and is preset NC Machine Quality-energy efficiency lower limit value compare, to realize numerical-controlled machine tool machining process mass-energy efficiency Overload alarm makes NC Machine Quality-energy efficiency control within the scope of requiring.
A kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method, include the following steps:
Step 1, by each part install RFID (radio frequency identification) label, part after processing is completed, RFID Reader 1 perceives part to be processed, and number of parts adds 1 automatically；Then verify that whether part is qualified product.If qualified product, then Into qualified product storage area；If rejected product, then entering rejected product storage area, RFID reader 2 perceives rejected part, Part rejected product quantity adds 1 automatically simultaneously；Therefore numerically-controlled machine tool actual processing number of components in available period given time Amount (is denoted as Oactual) and numerical control machine tooling rejected product quantity (be denoted as Odefect)。
Step 2, according to numerically-controlled machine tool actual processing number of parts in obtained period demand and rejected product quantity, meter Calculation is digitally controlled machine tooling qualified parts quantity, and calculation formula is as follows:
Oqualified=Oactual-Odefect
Wherein: OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity, OactualIndicate numerically-controlled machine tool actual processing zero Number of packages amount, OdefectIndicate that numerically-controlled machine tool processes rejected product quantity.
Step 3, by aforementioned obtained period demand numerically-controlled machine tool processing qualified parts quantity and numerically-controlled machine tool it is practical add Work number of parts is divided by, and numerically-controlled machine tool processing quality qualification rate is calculated, and calculation formula is as follows:
Wherein: ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, OqualifiedIndicate that numerically-controlled machine tool processes qualified parts Quantity, OactualIndicate numerically-controlled machine tool actual processing number of parts.
Step 4, when numerically-controlled machine tool processing part is without rejected product within the given time cycle, numerically-controlled machine tool processes part Total energy consumption is calculated by the actual consumption value of numerically-controlled machine tool actual processing number of parts and processing one-piece part and is obtained, and calculation formula is such as Under:
Eno_defect=Oactual×Eactual
Wherein: Eno_defectNumerically-controlled machine tool energy consumption when indicating in period given time without rejected product, OactualIndicate number Control lathe actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part.
Step 5, when numerically-controlled machine tool processing part has rejected product within the given time cycle, numerically-controlled machine tool processes part Total energy consumption is unqualified by numerically-controlled machine tool actual processing number of parts, the actual consumption value for processing one-piece part, numerically-controlled machine tool processing Product quantity and single-piece rejected product are done over again energy consumption calculation acquisition, and calculation formula is as follows:
Ewith_defect=Oactual×Eactual+Odefect×Erework
Wherein: Ewith_defectIndicate numerically-controlled machine tool energy consumption when having rejected product in period given time, OactualIndicate number Control lathe actual processing number of parts, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, OdefectIndicate numerical control Machine tooling rejected product quantity, EreworkIndicate that single-piece rejected product is done over again energy consumption.
Step 6, numerically-controlled machine tool energy consumption when will have rejected product in aforementioned obtained period demand and when without rejected product Numerically-controlled machine tool energy consumption be divided by, numerical-controlled machine tool machining process mass-energy efficiency is calculated, calculation formula is as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, Eno_defectIndicate period given time Numerically-controlled machine tool energy consumption when interior no rejected product, Ewith_defectIndicate numerically-controlled machine tool when having rejected product in period given time Energy consumption.
Step 7, according to aforementioned obtained numerically-controlled machine tool processing quality qualification rate computation model and numerical-controlled machine tool machining process Mass-energy efficiency calculation model, derivation operation is digitally controlled machine tooling procedure quality-energy efficiency and numerically-controlled machine tool is processed Relational model between quality pass rate, relational model are expressed as follows:
Wherein: ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, EactualIndicate numerically-controlled machine tool work sheet The actual consumption of part part, ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, EreworkIndicate that single-piece rejected product is done over again energy Consumption.
Step 8, by the numerical-controlled machine tool machining process mass-energy efficiency eta in obtained period given timequality_e With preset numerical-controlled machine tool machining process mass-energy efficiency low alarm setting valueIt is compared, is closed if meeting It is formulaThen show that numerical-controlled machine tool machining process mass-energy efficiency is normal.If meeting relational expressionThen warning note numerical-controlled machine tool machining process mass-energy efficiency is abnormal, while the assessment is all NC Machine Quality-energy efficiency of phase and corresponding numerically-controlled machine tool processing quality qualification rate, single-piece rejected product are done over again energy Consumption value is shown on a display screen.
Step 9, producers carry out numerical control machine tooling procedure quality targeted according to the warning note of step 8 Adjustment and control, numerically-controlled machine tool processing quality qualification rate is improved, so that NC Machine Quality-energy efficiency is improved to wanting Seek range.
In step 4, the actual consumption E of numerically-controlled machine tool processing one-piece partactual, by numerically-controlled machine tool air switch Place's installation energy consumption measuring device, numerically-controlled machine tool process part using given machined parameters, and energy consumption measuring device measures zero simultaneously The single part power consumption of polymer processing value repeatedly measured is averaging, is digitally controlled the reality of machine tooling one-piece part by part power consumption of polymer processing Border power consumption values Eactual。
In steps of 5, single-piece rejected product is done over again energy consumption Erework, by installing energy consumption at numerically-controlled machine tool air switch Measuring device, numerically-controlled machine tool to rejected product do over again operation when, energy consumption measuring device measures simultaneously does over again energy consumption, will be multiple The rejected product of measurement is done over again power consumption values averaging, is obtained single-piece rejected product and is done over again energy consumption Erework。
Compared with prior art, the invention has the following beneficial effects:
The method of the present invention is by considering numerically-controlled machine tool actual processing number of parts and processing qualification zero in period given time Number of packages amount establishes numerically-controlled machine tool processing quality qualification rate model, further considers numerically-controlled machine tool processing quality qualification rate to numerical control The influence of lathe energy efficiency establishes numerically-controlled machine tool processing quality qualification rate and NC Machine Quality-energy efficiency relationship Model.Further by realizing NC Machine Quality-energy efficiency to NC Machine Quality-energy efficiency real-time monitoring Overload alarm makes operator targetedly control machine mass-energy efficiency in time in claimed range.The method of the present invention Consider that numerically-controlled machine tool processing quality loses influence to numerically-controlled machine tool energy efficiency, can be practical and accurately evaluates numerical control machine The mass-energy efficiency of bed, and by realizing to numerical control machine to NC Machine Quality-energy efficiency Real Time Monitoring Bed mass-energy efficiency overload alarm, allows numerical tool operation personnel targetedly to control NC Machine Quality-energy Amount efficiency is the effective and practical NC Machine Quality of one kind-energy efficiency assessment and monitoring method in claimed range.This hair Bright methodological science is practical and can extend to the mass-energy efficiency evaluation and monitoring of other machinery equipment.
Detailed description of the invention
Fig. 1 is the flow diagram of the method for the present invention；
Fig. 2 is the device configuration schematic diagram of the method for the present invention.
Specific embodiment
The present invention is explained in detail now in conjunction with examples and drawings.
The present invention proposes a kind of numerical-controlled machine tool machining process mass-energy efficiency evaluation and monitoring method.The method of the present invention Flow diagram as shown in Figure 1, first by the RFID label tag and RFID reader 1 being attached on part, perception obtains Numerically-controlled machine tool actual processing number of parts in period given time.By RFID reader 2, perception obtains numerically-controlled machine tool processing not Qualified product quantity.And then numerically-controlled machine tool in period given time is calculated and processes qualified parts quantity.Based on obtained number Lathe actual processing number of parts and processing qualified parts quantity are controlled, numerically-controlled machine tool processing quality qualification rate is calculated.Pass through Repeatedly measurement numerically-controlled machine tool processes the power consumption values of single part under given work parameter, averages and is digitally controlled machine tooling list The actual consumption value of part part.Actual consumption value based on numerically-controlled machine tool actual processing number of parts and processing one-piece part, meter Calculation obtains numerically-controlled machine tool energy consumption when no rejected product.Operation of doing over again is carried out to single rejected product by repeatedly measuring numerically-controlled machine tool When power consumption values, average to obtain single-piece rejected product and do over again energy consumption.According to obtained numerically-controlled machine tool actual processing part Quantity, the actual consumption value for processing one-piece part and single-piece rejected product are done over again energy consumption, and number when rejected product is calculated Control lathe energy consumption.The further numerically-controlled machine tool energy according to numerically-controlled machine tool energy consumption when obtaining without rejected product and when having rejected product Consumption, is calculated numerical-controlled machine tool machining process mass-energy efficiency.Based on established numerically-controlled machine tool processing quality qualification rate rate Model and NC Machine Quality-energy efficiency model, building NC Machine Quality-energy efficiency and numerically-controlled machine tool processing quality are closed Relational model between lattice rate.It carries out NC Machine Quality-energy efficiency real-time monitoring and realizes to transfinite based on above-mentioned relation model Warning function makes NC Machine Quality-energy efficiency control within the scope of requiring.
Device configuration of the present invention is as shown in Fig. 2, specifically include that numerically-controlled machine tool, energy consumption measuring device, RFID read-write Device 1 and RFID reader 2, RFID label tag, qualified product storage area, rejected product storage area, the computer for installing Sql database and Display screen.Energy consumption measuring device is done over again power consumption values for measuring numerically-controlled machine tool processing part actual consumption value and part.RFID mark Label are attached on part, for identifying part；The RFID label tag that RFID reader 1 is attached on part by perception, obtains To numerically-controlled machine tool actual processing number of parts；The RFID label tag that RFID reader 2 is attached on rejected part by perception, is obtained Obtain numerically-controlled machine tool processing rejected product quantity；Qualified product storage area is for keeping in qualified parts；Rejected product storage area is used In temporary rejected part；The computer for installing Sql database processes number of parts for storing the numerically-controlled machine tool collected Information and numerically-controlled machine tool energy consumption and mass-energy efficiency information；Display screen is connected with computer, for showing numerically-controlled machine tool matter Amount-energy efficiency, processing quality qualification rate and single-piece rejected product are done over again consumption information.
For the embodiment of the present invention by taking the processing part process of CK6153i type numerically-controlled machine tool as an example, the part of processing is cylinder Shape part is assessed and is monitored to its process mass-energy efficiency using the method for the present invention, and to CK6153i numerical control Machine tooling procedure quality-energy efficiency overrun condition carries out warning note.In the embodiment of the present invention, to numerical control machine tooling Journey mass-energy efficiency is primary every assessment in 1 hour.
1. obtaining numerically-controlled machine tool actual processing number of parts and processing rejected product quantity
The process mass-energy efficiency evaluation period to numerically-controlled machine tool CK6153i is 1 hour, and numerically-controlled machine tool is practical Processing number of parts initial value is set as 0 (Oactual=0), processing rejected product quantity initial value is set as 0 (Odefect=0).Often RFID label tag is attached on a part, part is perceived by RFID reader 1 after processing is completed, numerically-controlled machine tool actual processing number of components The automatic cumulative 1 (O of amountactual=Oactual+1).Then verify that whether part is qualified product, if qualified product, then enters qualified product Storage area；If rejected product, then enter rejected product storage area, RFID reader 2 perceives the RFID mark on rejected part Label, simultaneous processing rejected product quantity add 1 (O automaticallydefect=Odefect+1).By taking morning 9:00-10:00 on October 17 as an example, Numerically-controlled machine tool CK6153i processes part 25 altogether.RFID reader 1 perceives 25 RFID label tags, is digitally controlled lathe reality Process number of parts Oactual=25.Inspection has 1 wherein for rejected product, and rejected product is entering rejected product storage area When, RFID reader 2 perceives the RFID label tag of the part, obtains CK6153i and processes rejected product number within the assessment cycle Amount is Odefect=Odefect+ 1=1.
2. obtaining numerically-controlled machine tool processes qualified parts quantity
It is O that numerically-controlled machine tool, which processes qualified parts number calculation formula,qualified=Oactual-Odefect.Wherein: OqualifiedTable Registration control machine tooling qualified parts quantity, unit is part；OactualIndicate that numerically-controlled machine tool actual processing number of parts, unit are Part；OdefectIndicate that numerically-controlled machine tool processes rejected product quantity, unit is part.Still by taking morning 9:00-10:00 on October 17 as an example, Numerically-controlled machine tool actual processing number of parts is 25 (Oactual=25), numerically-controlled machine tool processing rejected product quantity is 1 (Odefect =1).It brings above-mentioned data into formula, is calculated in the period, it is O that numerically-controlled machine tool, which processes qualified parts quantity,qualified= Oactual-Odefect=25-1=24 part.
3. obtaining numerically-controlled machine tool processing quality qualification rate
According to obtained numerically-controlled machine tool actual processing number of parts and processing qualified parts quantity, numerical control machine is calculated Bed processing quality qualification rate, computation model areWherein, ηqualityIndicate that numerically-controlled machine tool processing quality is closed Lattice rate, OqualifiedIndicate that numerically-controlled machine tool processes qualified parts quantity, unit is part；OactualIndicate numerically-controlled machine tool actual processing zero Number of packages amount, unit are part.Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing in the period has been obtained Number of parts Oactual=25, it is O that numerically-controlled machine tool, which processes qualified parts quantity,qualified=24.Above-mentioned data are substituted into public FormulaIt calculates and obtains numerically-controlled machine tool processing quality qualification rate ηquality=96.0%.
4. numerically-controlled machine tool energy consumption when obtaining without rejected product
4.1 obtain the actual consumption of numerically-controlled machine tool processing one-piece part
Energy consumption measuring device is installed, for recording numerical control at CK6153i numerically-controlled machine tool air switch in the present embodiment The power consumption values of machine tooling process.Repeatedly measurement CK6153i numerically-controlled machine tool processes single part under given machined parameters The power consumption values of power consumption values, 50 times measured single part under given machined parameters are as shown in table 1.
Table 1
Average value is calculated based on 50 power consumption values obtained in above-mentioned table 1, numerically-controlled machine tool processing one-piece part can be obtained Actual consumption value Eactual=156.3 (kJ).
Numerically-controlled machine tool energy consumption when 4.2 calculating are without rejected product
Practical energy based on obtained numerically-controlled machine tool actual processing number of parts and numerical control machine tooling one-piece part Numerically-controlled machine tool energy consumption when no rejected product, calculation formula E is calculated in consumption valueno_defect=Oactual×Eactual.Wherein, Eno_defectNumerically-controlled machine tool energy consumption when indicating in period given time without rejected product, unit are kilojoule (kJ)；OactualIt indicates Numerically-controlled machine tool actual processing number of parts, unit are part；EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, it is single Position is kilojoule (kJ).Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing zero in the period has been obtained Number of packages amount Oactual=25, numerically-controlled machine tool processes the actual consumption value E of one-piece partactual=156.3 (kJ).By above-mentioned data Substitute into formula Eno_defect=Oactual×Eactual, calculate numerically-controlled machine tool energy consumption E when obtaining without rejected productno_defect= 3907.5(kJ)。
5. obtaining numerically-controlled machine tool energy consumption when having rejected product
5.1 acquisition single-piece rejected products are done over again energy consumption
The energy consumption measuring device installed at CK6153i numerically-controlled machine tool air switch, while rejected product can be measured and done over again The power consumption values of process.When CK6153i numerically-controlled machine tool does over again to rejected product, energy consumption measuring device measures single rejected product and does over again Energy consumption.Measurement obtains power consumption values when 10 groups of rejected products are done over again altogether, as shown in table 2.
Table 2
Average value is calculated based on 10 groups of power consumption values obtained in above-mentioned table 2, single-piece rejected product can be obtained and do over again power consumption values Erework=125.7 (kJ).
5.2 calculate numerically-controlled machine tool energy consumption when having rejected product
Based on obtained numerically-controlled machine tool actual processing number of parts, the actual consumption value for processing one-piece part, numerical control Machine tooling rejected product quantity and single-piece rejected product energy consumption calculation of doing over again obtain numerically-controlled machine tool energy consumption when having a rejected product, Calculation formula is Ewith_defect=Oactual×Eactual+Odefect×Erework.Wherein, Ewith_defectIndicate period given time Inside there is numerically-controlled machine tool energy consumption when rejected product, unit is kilojoule (kJ)；OactualIndicate numerically-controlled machine tool actual processing number of components Amount, unit is part；EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, unit is kilojoule (kJ)；OdefectIt indicates Numerically-controlled machine tool processes rejected product quantity, and unit is part；EreworkIndicate that single-piece rejected product is done over again energy consumption, unit is kilojoule (kJ).Still by taking morning 9:00-10:00 on October 17 as an example, numerically-controlled machine tool actual processing number of parts in the period has been obtained Oactual=25, numerically-controlled machine tool processes the actual consumption value E of one-piece partactual=156.3 (kJ), numerically-controlled machine tool processing do not conform to Lattice product quantity Odefect=1, single-piece rejected product is done over again power consumption values Erework=125.7 (kJ).Above-mentioned data are substituted into formula Ewith_defect=Oactual×Eactual+Odefect×Erework, calculate the numerically-controlled machine tool energy consumption obtained when having rejected product Ewith_defect=25 × 156.3+1 × 125.7=4033.2 (kJ).
6. obtaining numerical-controlled machine tool machining process mass-energy efficiency
Numerically-controlled machine tool energy consumption when according to aforementioned obtained numerically-controlled machine tool energy consumption when having a rejected product and without rejected product, It calculates and obtains numerical-controlled machine tool machining process mass-energy efficiency, calculation formula are as follows:Wherein, ηquality_eIndicate numerical-controlled machine tool machining process mass-energy efficiency, Eno_defectIt indicates in period given time without rejected product When numerically-controlled machine tool energy consumption, unit be kilojoule (kJ)；Ewith_defectIndicate numerical control when having rejected product in period given time Lathe energy consumption, unit are kilojoule (kJ).Still by taking morning 9:00-10:00 on October 17 as an example, obtain in the period without unqualified Numerically-controlled machine tool energy consumption E when productno_defect=3907.5 (kJ) have numerically-controlled machine tool energy consumption E when rejected productwith_defect= 4033.2(kJ).Above-mentioned data are substituted into formulaIt calculates and obtains numerically-controlled machine tool in the time cycle Process mass-energy efficiency is ηquality_e=96.9%.
7. obtaining NC Machine Quality-energy efficiency and quality pass rate relational model
According to aforementioned obtained numerically-controlled machine tool processing quality qualification rate computation model and numerical control machine tooling procedure quality-energy Amount efficiency computation model, derivation operation is digitally controlled machine tooling procedure quality-energy efficiency and numerically-controlled machine tool processing quality is closed Relational model between lattice rate, relational model areWherein, ηquality_e Indicate numerical-controlled machine tool machining process mass-energy efficiency, EactualIndicate the actual consumption of numerically-controlled machine tool processing one-piece part, it is single Position is kilojoule (kJ)；ηqualityIndicate numerically-controlled machine tool processing quality qualification rate, EreworkIndicate that single-piece rejected product is done over again energy consumption, Unit is kilojoule (kJ).It still by taking morning 9:00-10:00 on October 17 as an example, has obtained in the time cycle, numerically-controlled machine tool processing The actual consumption E of one-piece partactual=156.3 (kJ), single-piece rejected product are done over again energy consumption Erework=125.7 (kJ).It will be upper It states data band to enter in relational model, then available numerical-controlled machine tool machining process mass-energy efficiency and numerically-controlled machine tool process matter Measure the relational model between qualification rate
8. carrying out numerical-controlled machine tool machining process mass-energy efficiency monitoring and overload alarm
By the numerical-controlled machine tool machining process mass-energy efficiency eta in obtained assessment cyclequality_eWith preset Machine tooling procedure quality-energy efficiency low alarm setting valueIt is compared.Numerically-controlled machine tool processing in the present invention Procedure quality-energy efficiency low alarm settingIt is counted according to numerical-controlled machine tool machining process mass-energy efficiency historical data It analyzes and combines that manager's is empirically determined.If numerical-controlled machine tool machining process load-energy efficiency low alarm setting in embodimentStill by taking morning 9:00-10:00 on October 17 as an example, the numerically-controlled machine tool processing in the time cycle has been obtained Procedure quality-energy efficiency ηquality_e=96.9%, then meet relational expressionTable Bright numerical-controlled machine tool machining process mass-energy efficiency is normal.Precedent is accepted, if numerical-controlled machine tool machining process mass-energy is imitated Rate low alarm settingIt is set as 98%, then meets relational expressionAt this point, report Alert prompt numerical-controlled machine tool machining process mass-energy efficiency is abnormal, lower than under numerical-controlled machine tool machining process mass-energy efficiency Limit, while by the numerical-controlled machine tool machining process mass-energy efficiency (η in the assessment cyclequality_e=96.9%) and it is corresponding Numerically-controlled machine tool processing quality qualification rate rate (ηquality=96.0%) single-piece rejected product is done over again energy and in the assessment cycle Consumption value (Erework=125.7kJ) display is on a display screen.
9. carrying out parameter adjustment control according to warning note.
Machine operation personnel carry out numerically-controlled machine tool CK6153i machined parameters targeted according to the warning note of step 8 Adjustment so that numerical-controlled machine tool machining process mass-energy control from view of profit is in the normal range.
The method of the present invention can be used for the Scientific evaluation of numerical-controlled machine tool machining process mass-energy efficiency in discrete manufacturing business Numerically-controlled machine tool processing is realized so that numerical-controlled machine tool machining process mass-energy control from view of profit is within the scope of requiring with monitoring The Energy Saving Control of operational process.The method of the present invention provides effectively practical technology and methods for realization discrete manufacturing business energy-saving and emission-reduction It supports.
Finally, it is stated that the above case study on implementation is only used to illustrate the technical scheme of the present invention and not to limit it, to the present invention Technical solution be modified or replaced equivalently, without departing from the objective and range of the method for the present invention, should all cover this In the scope of the claims of invention.

Claims (3)

1.一种数控机床加工过程质量-能量效率评估与监控方法，其特征在于，包括如下步骤：1. a numerical control machine tool processing quality-energy efficiency evaluation and monitoring method, is characterized in that, comprises the steps: 步骤1，通过在每个零件上安装RFID(无线射频识别)标签，零件加工完成后，RFID读写器1感知被加工零件，零件数量自动加1；接着检验零件是否为合格品。若为合格品，则进入合格品存放区；若为不合格品，则进入不合格品存放区，RFID读写器2感知不合格零件，同时零件不合格品数量自动加1；因此可以得到给定时间周期内数控机床实际加工零件数量(记为Oactual)和数控机床加工不合格品数量(记为Odefect)。Step 1, by installing an RFID (Radio Frequency Identification) tag on each part, after the part is processed, the RFID reader 1 senses the processed part, and the number of parts is automatically increased by 1; then it is checked whether the part is a qualified product. If it is a qualified product, it will enter the qualified product storage area; if it is an unqualified product, it will enter the unqualified product storage area. The actual number of parts processed by the CNC machine tool (denoted as O actual ) and the number of non-conforming products processed by the CNC machine tool (denoted as O defect ) within a certain period of time. 步骤2，根据所得到的给定周期内数控机床实际加工零件数量和不合格品数量，计算得到数控机床加工合格零件数量，计算公式如下：Step 2: Calculate the number of qualified parts processed by the CNC machine tool according to the actual number of parts processed by the CNC machine tool and the number of unqualified products in a given period. The calculation formula is as follows: Oqualified＝Oactual-Odefect O qualified =O actual -O defect 其中：Oqualified表示数控机床加工合格零件数量，Oactual表示数控机床实际加工零件数量，Odefect表示数控机床加工不合格品数量。Among them: O qualified represents the number of qualified parts processed by the CNC machine tool, O actual represents the actual number of parts processed by the CNC machine tool, and O defect represents the number of unqualified products processed by the CNC machine tool. 步骤3，将前述得到的给定周期内数控机床加工合格零件数量和数控机床实际加工零件数量相除，计算得到数控机床加工质量合格率，计算公式如下：Step 3: Divide the number of qualified parts processed by the CNC machine tool in the given period obtained above and the actual number of parts processed by the CNC machine tool to calculate the qualified rate of CNC machine tool processing. The calculation formula is as follows: 其中：ηquality表示数控机床加工质量合格率，Oqualified表示数控机床加工合格零件数量，Oactual表示数控机床实际加工零件数量。Among them: η quality represents the qualified rate of CNC machine tool processing quality, O qualified represents the number of qualified parts processed by the CNC machine tool, and O actual represents the actual number of parts processed by the CNC machine tool. 步骤4，在给定的时间周期内数控机床加工零件无不合格品时，数控机床加工零件总能耗由数控机床实际加工零件数量和加工单件零件的实际能耗值计算获得，计算公式如下：Step 4: When there are no defective parts processed by the CNC machine tool within a given time period, the total energy consumption of the CNC machine tool processed parts is calculated from the actual number of parts processed by the CNC machine tool and the actual energy consumption value of processing a single part, and the calculation formula is as follows: Eno_defect＝Oactual×Eactual E no_defect =O actual ×E actual 其中：Eno_defect表示给定时间周期内无不合格品时的数控机床能耗，Oactual表示数控机床实际加工零件数量，Eactual表示数控机床加工单件零件的实际能耗。Among them: E no_defect represents the energy consumption of the CNC machine tool when there are no defective products in a given time period, O actual represents the actual number of parts processed by the CNC machine tool, and E actual represents the actual energy consumption of the CNC machine tool processing a single part. 步骤5，在给定的时间周期内数控机床加工零件有不合格品时，数控机床加工零件总能耗由数控机床实际加工零件数量、加工单件零件的实际能耗值、数控机床加工不合格品数量和单件不合格品返工能耗计算获得，计算公式如下：Step 5: When there are unqualified parts in CNC machine tool processing parts within a given time period, the total energy consumption of CNC machine tool processing parts is determined by the actual number of CNC machine tool processing parts, the actual energy consumption value of processing a single part, and the CNC machine tool processing unqualified products. The number of products and the energy consumption for rework of a single non-conforming product are calculated, and the calculation formula is as follows: Ewith_defect＝Oactual×Eactual+Odefect×Erework E with_defect =O actual ×E actual +O defect ×E rework 其中：Ewith_defect表示给定时间周期内有不合格品时的数控机床能耗，Oactual表示数控机床实际加工零件数量，Eactual表示数控机床加工单件零件的实际能耗，Odefect表示数控机床加工不合格品数量，Erework表示单件不合格品返工能耗。Among them: E with_defect represents the energy consumption of the CNC machine tool when there are defective products in a given time period, O actual represents the actual number of parts processed by the CNC machine tool, E actual represents the actual energy consumption of a single part processed by the CNC machine tool, and O defect represents the CNC machine tool. The number of unqualified products processed, E rework represents the energy consumption for rework of a single piece of unqualified product. 步骤6，将前述得到的给定周期内有不合格品时的数控机床能耗和无不合格品时的数控机床能耗相除，计算得到数控机床加工过程质量-能量效率，计算公式如下：Step 6: Divide the energy consumption of the CNC machine tool when there are substandard products and the energy consumption of the CNC machine tool when there are no substandard products in the given cycle obtained above, and calculate the quality-energy efficiency of the CNC machine tool processing process. The calculation formula is as follows: 其中：ηquality_e表示数控机床加工过程质量-能量效率，Eno_defect表示给定时间周期内无不合格品时的数控机床能耗，Ewith_defect表示给定时间周期内有不合格品时的数控机床能耗。Among them: η quality_e represents the quality-energy efficiency of the CNC machine tool processing process, E no_defect represents the energy consumption of the CNC machine tool when there are no defective products in a given time period, and E with_defect represents the energy consumption of the CNC machine tool when there are defective products in a given time period . 步骤7，根据前述得到的数控机床加工质量合格率计算模型和数控机床加工过程质量-能量效率计算模型，推导运算得到数控机床加工过程质量-能量效率与数控机床加工质量合格率间的关系模型，其关系模型表达如下：Step 7, according to the numerical control machine tool processing quality qualification rate calculation model and the numerical control machine tool processing quality-energy efficiency calculation model obtained above, the relationship model between the numerical control machine tool processing quality-energy efficiency and the numerical control machine tool processing quality qualification rate is obtained by deduction operation, Its relational model is expressed as follows: 其中：ηquality_e表示数控机床加工过程质量-能量效率，Eactual表示数控机床加工单件零件的实际能耗，ηquality表示数控机床加工质量合格率，Erework表示单件不合格品返工能耗。Among them: η quality_e represents the quality-energy efficiency of the CNC machine tool processing process, E actual represents the actual energy consumption of the CNC machine tool processing a single part, η quality represents the CNC machine tool processing quality pass rate, and E rework represents the rework energy consumption of a single unqualified product. 步骤8，将所得到的给定时间周期内的数控机床加工过程质量-能量效率ηquality_e与预先设定的数控机床加工过程质量-能量效率报警下限值进行比较，若满足关系式则表明数控机床加工过程质量-能量效率正常。若满足关系式则报警提示数控机床加工过程质量-能量效率异常，同时将该评估周期的数控机床质量-能量效率以及对应的数控机床加工质量合格率、单件不合格品返工能耗值显示在显示屏上。Step 8: Compare the obtained CNC machine tool processing quality-energy efficiency η quality_e within a given time period with the preset CNC machine tool processing quality-energy efficiency alarm lower limit Compare, if the relation is satisfied It shows that the quality-energy efficiency of the CNC machine tool processing process is normal. If the relationship is satisfied Then the alarm will prompt that the quality-energy efficiency of the CNC machine tool processing process is abnormal, and at the same time, the CNC machine tool quality-energy efficiency of the evaluation cycle, the corresponding CNC machine tool processing quality pass rate, and the energy consumption value of a single piece of unqualified product rework will be displayed on the display screen. 步骤9，生产人员根据步骤8的报警提示，对数控机床加工过程质量进行有针对性的调整和控制，提高数控机床加工质量合格率，从而使得数控机床质量-能量效率提高至要求范围。In step 9, according to the alarm prompt in step 8, the production personnel make targeted adjustments and control on the quality of the CNC machine tool processing process, so as to improve the qualified rate of CNC machine tool processing quality, so that the quality-energy efficiency of the CNC machine tool can be improved to the required range. 2.如权利要求1所述一种数控机床加工过程质量-能量效率评估与监控方法，其特征在于，在步骤4中，数控机床加工单件零件的实际能耗Eactual，通过在数控机床空气开关处安装能耗测量装置，数控机床使用给定的加工参数加工零件，能耗测量装置同时测量零件加工能耗，将多次测量的单个零件加工能耗值求平均，得到数控机床加工单件零件的实际能耗值Eactual。2. a kind of numerical control machine tool machining process quality-energy efficiency evaluation and monitoring method as claimed in claim 1, is characterized in that, in step 4, the actual energy consumption E actual of numerical control machine tool processing single piece part, by in numerical control machine tool air The energy consumption measuring device is installed at the switch, and the CNC machine tool uses the given processing parameters to process the part. The energy consumption measuring device simultaneously measures the energy consumption of the part processing, and averages the processing energy consumption values of a single part measured multiple times to obtain a single piece processed by the CNC machine tool. The actual energy consumption value E actual of the part. 3.如权利要求1所述一种数控机床加工过程质量-能量效率评估与监控方法，其特征在于，在步骤5中，单件不合格品返工能耗Erework，通过在数控机床空气开关处安装能耗测量装置，数控机床对不合格品进行返工作业时，能耗测量装置同时测量返工能耗，将多次测量的不合格品返工能耗值求平均，得到单件不合格品返工能耗Erework。3. a kind of numerical control machine tool machining process quality-energy efficiency evaluation and monitoring method as claimed in claim 1, is characterized in that, in step 5, single piece of substandard product rework energy consumption E rework , by at the numerical control machine tool air switch place Install the energy consumption measurement device. When the CNC machine tool reworks the unqualified products, the energy consumption measurement device simultaneously measures the rework energy consumption, and averages the rework energy consumption values of the unqualified products measured several times to obtain the rework energy of a single piece of unqualified products. Consume E rework .
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