Method Research And System Development Of Energy Efficiency Evaluation And Optimization In Die Casting Workshop

Manufacturing industry is widely distributed and consumes massive energy consumption with low energy efficiency.Promoting energy conservation and energy efficiency improvement is a key field in the green transformation development of the manufacturing industry,which has been widely concerned by academia and industry at home and abroad.Die casting is the mainstream manufacturing process for automobile,ship,communication,and other industrial parts,but it is an energy-intensive manufacturing process,and the energy consumption cost accounts for more than 25% of the total production cost.Moreover,die casting has the characteristics of different energy structures,numerous energy consumption components,and the disturbed production environment,and its energy consumption and energy efficiency law are complex.With the green manufacturing system integration project of the Ministry of Industry and Information Technology(No.201756298),this research takes die casting workshop as the research object,considering product parameters,equipment information,mold parameters,process parameters,and production scheduling,and carries out method research and system development of energy efficiency evaluation and optimization.Firstly,the system boundary and energy consumption characteristics of the die casting workshop are analyzed in detail.A product parameter-driven energy consumption model of the die casting machine considering the product information,mold parameters,equipment information,and process parameters is established.On this basis,case studies are conducted to validate the generality and reliability of the proposed energy consumption prediction approach.Secondly,the energy efficiency evaluation index system of the die casting workshop is proposed.The models for energy efficiency index acquisition and evaluation of the equipment level are established through clustering analysis,extreme point identification,and data envelopment analysis methods.Meanwhile,an energy efficiency evaluation approach for the workshop level is proposed based on the quota ratio.The effectiveness of the proposed energy efficiency evaluation method for the die casting workshop is verified by practical cases.Then,the multi-objective optimization model of the equipment level in the die casting workshop is established with the consideration of energy efficiency,productivity,and production cost to control die opening force,die closing force,plunger forward pressure,molten metal temperature,mold temperature,solidification pressure,pressure and average velocity of the plunger backward.At the workshop level,by considering the maximum production efficiency and minimum energy consumption as the optimization targets,a multi-objective optimization model is also established with the scheduling plan of melting furnace and die casting machine.The relevant algorithms are also given.The effectiveness of the proposed energy efficiency optimization approach for the die casting workshop is verified by practical cases.Finally,aiming at the real-time and dynamic requirements of energy efficiency evaluation and optimization of the die casting workshop,a system architecture of energy efficiency evaluation and optimization is proposed based on cloud-fog computing,and the corresponding system is developed.An application case of the proposed system in the die casting enterprise in Chongqing is used to verify its stability and practicability.