基于能耗工步的机械加工工件能量效率精细预测方法研究

The mechanical machining systems are numerous and are used in a wide range of applications in industry, and the total amount of energy consumption by mechanical machining systems is extremely high, it usually exhibit very low energy efficiency and has great potential for energy savings and environmental emission reduction. The research on energy efficiency forecasting of mechanical machining system which is an important part of the research on the promotion of energy efficiency is of great significance. To overcome the limitation of the existing method which mainly focus on the process steps, this project will firstly study the energy sources and energy consumption characteristics of energy consumption steps systematically, and then the energy consumption model and forecasting method of each energy consumption steps shall be constructed. Secondly, the operation and energy consumption characteristics and forecasting method of random energy source will be studied, then the fine forecasting method for energy efficiency of mechanical machining systems which based on energy consumption steps is presented finally. The method which constructed based on energy consumption steps can not only improve the accuracy of the forecasting, but be a progress in the field of energy efficiency research. The energy efficiency model and the forecasting method studied above can be widely used for supporting the theoretical and application research on fine evaluation of energy efficiency, the energy-saving optimization of processing, fine management of energy efficiency, etc, and it has a good prospect for application.

机械加工系统量大面广，其能量消耗巨大，且其能量效率通常很低，节能减排潜力巨大。因此，机械加工系统能量效率提升是当代制造业亟需解决的问题。机械加工系统能量效率预测作为当前能量效率提升研究的重要内容，其研究具有十分重要的意义。本项目针对现有以工艺工步为预测单元的不足，拟以工件加工过程各个能耗环节为研究单元，对各能耗工步的能耗源构成和能耗特性进行系统地研究，进而构建出各能耗工步的能耗模型，提出其能耗预测方法；同时，对工件加工过程随机能耗源的运行特性和能耗特性以及其能耗预测方法进行研究，最终提出一种基于能耗工步的机械加工工件能量效率精细预测方法。以能耗工步为基础提出的能量效率预测方法不仅可以提高能效预测精度，在能量效率系统建模方面更是一大进展。上述模型、方法能为机械制造业能效精细评价、工艺过程节能性优化、能量效率深度管理等等一系列问题的研究和应用提供更有力的支持，具有较广阔的应用前景。

在国家自然科学基金项目资助下，项目组在前期研究的基础上，深入开展了工件加工过程能耗机理与预测方法，并系统研究了工件加工过程节能优化和管理方法。主要研究成果为：（1）基于工件加工过程的能量消耗机理，建立了能耗工步的理论模型，并综合提出了一种基于能耗工步的能量效率预测方法；（2）基于当前应用较多的数据驱动预测方法，综合提出了基于BP-Adaboost算法的切削能耗预测方法；（3）建立了面向监测的机械加工系统能量效率在线监测模型，并研究了模型参数的获取方法，建立了一套能量效率在线监测方法；（4）构建了工件加工全过程能耗切削参数模型，在此基础上提出一种面向节能优化的切削参数决策方法；建立以数控机床切削过程的能耗和生产成本为优化目标的工艺参数优化模型，对切削参数进行优化；（5）基于离散制造环境下的工件加工特点，建立了工件能耗限额指标及分类，提出了两大类能耗限额规则；提出面向任务的工件加工能耗限额制定方法并阐述了其能耗限额和指标。上述研究成果为工件加工过程能效提升提供理论依据和方法支持。

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