刀具工件双旋转运动机床加工过程的能量效率获取方法

摘要/Abstract

摘要： 对于刀具工件双旋转运动机床，由于切削力测量仪器难以安装，同时，切削力理论模型和经验公式难以反映加工过程切削力的瞬态变化，这使得刀具工件双旋转运动机床的能量效率至今难于获取。为此，提出一种运用载荷损耗系数计算获取刀具工件双旋转运动机床能量效率的方法，该方法首先建立了刀具工件双旋转运动机床的能量效率模型，然后基于刀具、工件系统的能耗组件参数分别建立了刀具轴和工件轴的载荷损耗系数计算模型，并由此推导出刀具工件双旋转运动机床的载荷损耗能量、有效能量及能量效率的计算分析模型。实际应用时，该方法只需要安装功率传感器测取加工过程中的输入功率和空载功率，便可计算获取能量效率。实验验证表明，该方法具有较好的能量效率获取精度。应用案例表明，所提方法应用方便，可为刀具工件双旋转运动机床的能效预测、监控与管理提供技术支撑，具有较好的应用前景。

关键词: 工件刀具双旋转运动, 机床, 能量效率, 载荷损耗系数

Abstract: It is difficult to install the cutting-force measuring instruments on machine tools with both tool and workpiece axis rotating， thus the theoretical cutting force model and the empirical formulae failed to reflect the transient changes of cutting forces during the machining processes.As a result， it is still a challenge to acquire the energy efficiency of machine tools with both tool and workpiece axis rotating.Therefore， the energy efficiency models for machine tools with both tool and workpiece axis rotating were established， and the load loss coefficient models for tool and workpiece axis were developed based on their basic data respectively.Based on these model， the methods for calculating the load loss energy， efficient energy and energy efficiency for this kind of machine tools were presented.In practical applications， the proposed method may calculate the energy efficiency only need to monitor input powers and idle powers by using power sensors.Experimental verifications show that this method may obtain the energy efficiency precisely.Application cases show that the method may be effectively employed to obtain the energy efficiency for machine tools with both tool and workpiece axis rotating， without any usage of cutting-force measuring instruments.The proposed method， which may provide some technical supports for machine tool energy efficiency prediction， monitoring and management， has a wide application prospects.

Key words: both tool and workpiece axis rotating, machine tool, energy efficiency, load loss coefficient

中图分类号:

TG501

张西成;刘飞;刘培基. 刀具工件双旋转运动机床加工过程的能量效率获取方法[J]. 中国机械工程.

ZHANG Xicheng;LIU Fei;LIU Peiji. Energy Efficiency Acquisition Method for Machine Tools with Both Tool and Workpiece Axis Rotating during Machining Process[J]. China Mechanical Engineering.

参考文献

[1]刘飞，刘培基，李聪波，等.制造系统能量效率研究的现状及难点问题[J].机械工程学报，2017，53（5）：1-11.
LIU Fei，LIU Peiji，LI Congbo，et al.The Statue and Difficult Problems of Research on Energy Efficiency of Manufacturing Systems[J].Journal of Mechanical Engineering，2017，53（5）：1-11.
[2]European Commission.2030 Climate & Energy Framework[EB/OL].[2017-06-14].http：//ec.europa.eu/clima/policies/strategies/2030/index_en.htm.
[3]America Energy Department.Clean Energy Manufacturing Innovation Institute[EB/OL].[2017-06-14].http：//www.energy.gov/articles/energy-department-announces-70-million-innovation-institute-smart-manufacturing.
[4]VIJAYARAGHAVAN A，DORNFELD D.Automated Energy Monitoring of Machine Tools[J].CIRP Annals—Manufacturing Technology，2010，59（1）：21-24.
[5]ALTINTA? R S，KAHYA M，?NVER H ?.Modelling and Optimization of Energy Consumption for Feature Based Milling[J].International Journal of Advanced Manufacturing Technology，2016，86（9/12）：3345-3363.
[6]LEE J Y，SHIN Y J，KIM M S，et al.A Simplified Machine-tool Power-consumption Measurement Procedure and Methodology for Estimating Total Energy Consumption[J].Journal of Manufacturing Science & Engineering，2016，138（5）：051004-9.
[7]ABELE E，SIELAFF T，SCHIFFLER A，et al.Analyzing Energy Consumption of Machine Tool Spindle Units and Identification of Potential for Improvements of Efficiency[M]// Glocalized Solutions for Sustainabi- lity in Manufacturing.Berlin：Springer Berlin Heidelberg，2011：280-285.
[8]SAJ.JIS TS B 0024-1：2010 Machine Tools-test Methods for Electric Power Consumption—Part 1：Machining Centers[S].Japanese Standards Association，2010.
[9]ISO.ISO/WD14955-1.Environmental Evaluation of Machine Tools-Part1:Energy-saving Design Methodology for Machine Tools[S].International Organization for Standardization，2010.
[10]LENZ J，KOTSCHENREUTHER J，WESTKAEMPER E.Energy Efficiency in Machine Tool Operation by Online Energy Monitoring Capturing and Analysis [J].Procedia Cirp，2017，61：365-369.
[11]刘高君，刘飞，刘培基，等.机床多源能耗状态在线检测方法及检测系统[J].计算机集成制造系统，2016，22（6）：1550-1557.
LIU Gaojun，LIU Fei，LIU Peiji，et al.On-line Detecting Method and System of Multi-source Energy State for Machine Tools [J].Computer Integrated Manufacturing Systems，2016，22（6）：1551-1558.
[12]GUTOWSKI T G，BRANHAM M S，DAHMUS J B，et al.Thermodynamic Analysis of Resources Used in Manufacturing Processes[J].Environmental Science & Technology，2016，43（5）：1584-1590.
[13]KARA S，LI W.Unit Process Energy Consumption Models for Material Removal Processes[J].CIRP Annals—Manufacturing Technology，2011，60（1）：37-40.
[14]LIU F，WANG Q，LIU G.Content Architecture and Future Trends of Energy Efficiency Research on Machining Systems[J].Journal of Mechanical Engineering，2013，49（19）：87.
[15]HU S，LIU F，HE Y，et al.An On-line Approach for Energy Efficiency Monitoring of Machine Tools[J].Journal of Cleaner Production，2012，27（6）：133-140.
[16]VELCHEV S，KOLEV I，IVANOV K，et al.Empirical Models for Specific Energy Consumption and Optimization of Cutting Parameters for Minimizing Energy Consumption during Turning[J].Journal of Cleaner Production，2014，80：139-149.
[17]刘培基，刘霜，刘飞.数控机床主动力系统载荷能量损耗系数的计算获取方法[J].机械工程学报，2016，52（11）：121-128.
LIU Peiji，LIU Shuang，LIU Fei.Calculating Method for Additional Load Loss Coefficient of Spindle System of CNC Machine Tools [J].Journal of Mechanical Engineering，2016，52（11）：121-128.
[18]王秋莲，刘飞.数控机床多源能量流的系统数学模型[J].机械工程学报，2013，49（7）：5-12.
WANG Qiulian，LIU Fei.Mathematical Model of Multi-source Energy Flows for CNC Machine Tools [J].Journal of Mechanical Engineering，2013，49（7）：5-12.
[19]CAI W，LIU F，XIE J，et al.An Energy Management Approach for the Mechanical Manufacturing Industry through Developing a Multi-objective Energy Benchmark[J].Energy Conversion & Management，2017，132：361-371.
[20]HU S，LIU F，HE Y，et al.Characteristics of Additional Load Losses of Spindle System of Machine Tools[J].Journal of Advanced Mechanical Design Systems & Manufacturing，2010，4（7）：1221-1233.
[21]刘飞，徐宗俊，但斌，等.机械加工系统能量特性及其应用[M].北京：机械工业出版社，1995.
LIU Fei，XU Zongjun，DAN Bin et al.The Energy Characteristics of Machine Tool's System and Its Application[M].Beijing：China Machine Press，1995.
[22]邓加凌，朱劲.通用交流伺服驱动器的功耗与效率估算[J].科技创新导报，2009（35）：29-30.
DENG Jialing，ZHU Jin.Estimation of Power and Efficiency for General AC Servo Drives[J].Science and Technology Innovation Herald，2009（35）：29-30.
[23]VAVRUS V，RADVAN R，RAFAJDUS P.A Power Loss Calculation Method of IGBT SRM Converter[C]// International Conference on Electrical Drives and Power Electronics.Tatranska Lomnica， Slovakia：IEEE，2015：521-526.
[24]张明元，沈建清，李卫超，等.一种快速IGBT损耗计算方法[J].船电技术，2009，29（1）：33-36.
ZHANG Mingyuan，SHEN Jianqing，LI Weichao，et al.Calculation Method of a Fast Power Loss for IGB Tmodules[J].Marine Electric & Electronic Engineering，2009，29（1）：33-36.
[25]刘德林，赵瑞杰，代兴华，等.2MW风电变桨伺服驱动器IGBT损耗计算及散热系统设计[J].电气传动，2015，45（10）：71-75.
LIU Delin，ZHAO Ruijie，DAI Xinghua，et al.Losses Calculation of IGBT Module and Heat Dissipation System Design of Servo Driver for Pitch Control of 2MW Wind Power [J].Electric Drive，2015，45（10）：71-75.
[26]胡韶华.现代数控机床多源能耗特性研究[D].重庆：重庆大学， 2012.
HU Shaohua.Energy Consumption Characteristics of Multiple-component of Modern CNC Machine Tools[D].Chongqing：Chongqing University，2012.