| The rough development mode of manufacturing industry with high energy consumption,high pollution and high emission is a serious problem that needs to be solved urgently in the upgrading and transformation of manufacturing industry in China.With increasing penetration rate of CNC machine tools,it is urgent to explore the energy consumption characteristics and laws of mechanical processing system,which is an important part of manufacturing industry,to form a new energy efficiency promotion method or technology,and to realize green development transformation and upgrading of manufacturing industry.CNC machining system is in enormous quantity and covers a wide range of aspects,as well as,consumes great amount of energy,but energy efficiency is very low.Therefore,the research on energy efficiency of CNC machining system is developing rapidly in the world.The present research has focused on the energy efficiency in the service stage of the manufacturing system.Although a lot of research results have been achieved,however,there are few studies on reflecting and evaluating the inherent energy consumption characteristics of the CNC machining system,and the design and creation stage of the machining system also has a great impact on the energy consumption and energy efficiency in the future machining process,which is an urgent problem to be studied.To this end,combining with the projects financed by the Natural Science Foundation of China and the project financed by the National High Technology Research & Development Program of China(863 Program),the objective of this paper is to analyze the characteristics of inherent energy efficiency,which are born in the design and formation phases of the CNC machining system,as well as the inherent energy efficiency modeling and evaluation are fully studied in this paper.The research results expect to provide a new idea for studying the CNC machining system energy efficiency.The concepts of inherent energy consumption and inherent energy efficiency of CNC milling system are put forward,and this paper describes their connotations from macro and micro perspectives.Constructed an evaluation index of inherent energy consumption composed of multi-characteristic factors,and then analyses its characteristics.Furthermore,the evaluation indexes of the inherent energy utilization rate and the inherent specific energy reflecting the inherent energy efficiency characteristics are established,and the creation methods are summarized.At the end,a concrete case study is conducted.Secondly,the evaluation index system of inherent energy consumption and inherent energy efficiency of CNC milling system is further constructed,which includes four indices: inherent standby energy consumption,inherent start-up energy consumption,inherent no-load energy consumption,inherent cutting energy consumption and two comprehensive evaluation indices of inherent energy utilization and inherent specific energy,and then,the macro-micro mathematical models are established to characterize the inherent energy consumption and inherent energy efficiency of CNC milling system.Subsequently,a method framework for creating high inherent energy efficiency machining system is proposed.Based on that,the inherent energy efficiency model in the actual processing process is verified through the case study.Then,based on the research of macro-micro model of inherent energy efficiency of CNC milling system,this paper puts forward the connotation and formulation method of work-piece standard energy consumption allowance based on macro-micro model of inherent energy consumption.Furthermore,combined with macro-micro model of inherent energy efficiency,energy efficiency information card and energy efficiency label are developed,energy efficiency rating system of CNC milling system is established,and an energy efficiency rating system of CNC milling system based on energy efficiency ratio is proposed.The application of work-piece standard energy consumption allowance and energy efficiency rating system of milling machining system in actual milling process is verified through the case study.For the integrated application of the above models and approaches,a set of software system named Inherent Energy Efficiency Evaluation and Optimization Support System for Milling Machining System(IEEOMMS)was developed.The application of the system is described,combined with the actual processing data of XK714 D machining center in aluminum alloy processing enterprises.The results show that the system can realize the prediction and evaluation of inherent energy consumption and inherent energy efficiency of CNC milling system.And it also can be used to establish work-piece standard energy efficiency allowance and evaluate the energy efficiency rating of CNC milling system.In addition,the research achievements can provide theoretical and technical support to establish a high efficiency CNC machining system and promote the low energy efficiency system and also help the manufacturing enterprises to achieve energy saving and consumption reduction,as well as,have a good prospect of application. |
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