Research On Energy-saving Design And Optimization Of Feed System For CNC Gear Hobbing Machine

Machine tool is the working master in the mechanical manufacturing industry,and consumes a large amount of energy,but its energy utilization rate is relatively low.At present,the research on computer numerical control(CNC)machine tools focuses on reducing energy consumption and improving energy efficiency by optimizing the process parameters of machine tools during operation stage.This method has a certain significance for reducing the energy consumption of machine tools,but it does not solve the problem of energy consumption of CNC machine tools from the root,which restricts the improvement of energy efficiency of CNC machine tools.How to reduce the energy consumption and improve the energy efficiency of CNC machine tools from the design stage is a problem worthy of further study.Based on this,this paper takes CNC gear hobbing machine which is widely used in manufacturing industry as the research object.The feed system is is an important energy-consuming component,and the energy consumption characteristics and energy-saving potential of the feed system are studied.An optimization method of energy-saving design for the feed system of CNC gear hobbing machine is proposed.The energy consumption of the machine tool in the operation stage is considered from the design stage,in order to improve the energy efficiency of CNC gear hobbing machine.Firstly,the energy consumption characteristics of the feed system of CNC gear hobbing machine is analyzed,and the energy consumption model of feed system is formulated.On this basis,the influence of the electromechanical transmission unit,moving component and servo control unit on the energy consumption of the feed system are studied.Then,the energy-saving design mechanism of the electromechanical transmission unit,moving part and servo control unit are analyzed.The integrated optimization method of servo motor parameters and mechanical transmission parameters is proposed,and the integrated optimization method of moving component structural parameters and servo control parameters is presented.Secondly,considering the influence of the servo motor parameters and mechanical transmission parameters on the energy consumption of electromechanical transmission unit,this paper proposes a flow framework of design optimization of the electromechanical transmission unit for energy saving.The energy consumption and cost models of electromechanical transmission unit are firstly put forward.Based on the common gear process parameters of CNC gear hobbing machine,the peak power,rated power,rated speed of servo motor,and worm gear ratio are takes as the optimization variables.The multi-objective optimization model of the minimum energy consumption and cost of the electromechanical transmission unit is established,and is solved via the improved teaching-learning based optimization algorithm(ITLBO).The optimal design parameters of the electromechanical transmission unit are obtained.Thirdly,considering the influence of the moving component structure and servo control system on the energy consumption of the feed system,the energy-saving design and optimization method of the moving component and servo control unit is proposed.Based on the power flow equation of the feed system,the servo sliding mode controller is designed and the simulation model of the steady-state error of the angular displacement of the servo motor is established.The parameters that have significant influence on the energy consumption and the steady-state error are selected as the optimization variables through the orthogonal experiment and analysis of variance.The optimization model is established for minimizing the energy consumption and minimizing the steady-state error,and is solved via the whale optimization algorithm(WOA).Finally,Matlab/Simulink is used to establish the simulation model of the energy consumption and control performance of CNC gear hobbing machine.Taking the actual hobbing parameters as the input condition,the energy consumption of the feed system before and after the optimization is obtained through simulation analysis.Moreover,the control performance of the feed drive system after design optimization is simulated and analyzed to ensure the machining accuracy of the CNC gear hobbing machine.