Methodology For Establishing Energy Consumption Allowance Of The Workpiece In Machining System

Product energy consumption allowance(PECA)is very important for the management and monitoring of energy consumption and the improvement of energy efficiency in product manufacturing process.A number of methods currently have been successfully used to establish the PECA for process manufacturing industry including steel,chemical industry and so on.However,as for discrete manufacturing products with great quantity,it is very difficult to establish the PECA due to the complexity and variety of their energy consumption processes.Meanwhile,Due to the insufficient of the past attention and research,the problem of the PECA establishment for discrete manufacturing products has not been solved internationally.Mechanical manufacturing industry as a one of the most typical discrete manufacturing industries,which is widely distributed and consume large amounts of energy with low efficiency,has considerable potential for reductions in energy consumption.Supported with several 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),this thesis research the methodology for establishing energy consumption allowance of the workpiece(WECA)in machining system for providing the technical supports of the WECA establishment in mechanical manufacturing industry.Firstly,the characteristics and method of the WECA in machining system are analyzed.The complex characteristic of energy consumption laws of the machining system is introduced including the multiple constitute of energy consumption,dynamic variability and multiple levels of the machining system.The level characteristic of the WECA is analyzed from the perspectives of the business management and machining process.Meanwhile,the correlated characteristic of the WECA and the technology and equipment is analyzed including correlated characteristic of the WECA and the machining system,machining equipment and processing technology.On basis of analyzing the diversity of kinds of the WECA,a variety of the WECA concepts for different production requirements and a summary of the WECA establishment are presented.Secondly,a method for establishing the WECA based on the energy consumption forecast in machining system is proposed.Through analyzing the energy consumption of machining process,the forecast model of energy consumption for the workpiece,energy consumption basic databases,energy consumption parameters and machining time parameters model are presented.On these basis,the method for establishing the WECA including the workpiece with historical machining information and the unprocessed workpiece is addressed.The application of this method in the actual machining process is verified through the case study.Thirdly,the fine energy consumption allowance of the workpiece(WFECA)and the establishment method in machining system are presented.Illustrating the connotation of the WFECA and constructing the framework of the WFECA,the establishment method and energy consumption card of the WFECA are proposed.The application of the WFECA in the actual machining process is verified through the case study.Then,the multi-objective energy consumption of workpiece(WMECA)and the establishment method in machining system are presented.Illustrating the connotation of WMECA and summarizing the establishment processes,the basic database and evaluation data model are established.On these basis,the establishment method of the WMECA through integrated assessment of TOPSIS is proposed.The application of the WMECA in the actual machining process is verified through the case study.Finally,the dynamic energy consumption of the workpiece(WDECA)and establishment method in machining system are presented.Illustrating the connotation of WDECA,a core concept of allowance rate for the WDECA and the establishment method are proposed.,including allowance rate based WDECA and allowance rate based optimized WDECA.The application of the WDECA in the actual machining process is verified through the case study.The feasibility and practicability of the above methods are preliminarily demonstrated through the practical case study of each method,providing a preliminary method for establishing the WECA in machining system and providing effective measures for the management and monitoring of energy consumption and the improvement of energy efficiency in machining process.