Research On The Process Energy Efficiency Analysis And Energy Saving Monitoring System Of CNC Gear Hobbing Machine Tools

Machine tools are the main body of mechanical processing and manufacturing,which owns the characters like high energy consumption, high emission, low energyefficiency, etc. Therefore, energy saving and emission reduction of machine tools areattracting more and more attention throughout the world. With the wide application ofgears in various sectors of national economies, the total quantity of gear cuttingmachine keeps growing. As the most widely used gear cutting machine (about50%ofits total number), the energy related research of gear hobbing machine is an importantpart of energy saving and emission reduction strategy of machine tools. Compared toother kinds of NC machine tools and general hobbing machine tools, CNC gear hobbingmachine owns its unique energy characteristics, namely close energy correlation,complicated energy consumption regularity, multiple energy consumption components.Hence, this paper carries out a research in gear hobbing machine tools on the energyconsumption characteristics, energy flow model, practical monitoring model, andpractical monitoring system. The principal research contents are as follows:The energy consumption and energy flow characteristics of CNC gear hobbingmachine are studied. The energy flow model and the practical monitoring model areestablished. On this basis, an energy efficiency evaluation method of CNC gear hobbingmachine is analyzed.Three key technologies within an energy efficiency online acquisition and energysaving monitoring system for the gear hobbing machine process (ESGM) are studied,including an energy efficiency online acquisition technology based on basic energydatabase, an operation state online judging technology based on power sensingtechnique and machine tool PLC communication technique, and an idle state alarmingand stopping machine for energy saving technology based on the multi-idle-state onlineidentification. In this way, active power and active energy online separation, energyefficiency real-time monitoring, energy related information of work-piece onlineobtaining, and energy saving technology application are realized.The ESGM development is studied, in which the system development framework isestablished, a set of evaluation parameters used to represent the energy and operationinformation are put forward, and a hardware platform consisting of a machine tool,power sensors, and multi-function information terminals is built. On this basis, all the software modules are worked out in Qt-4software package. Lastly, a prototype systemcombined with hardware and software is worked out, which aims at energy efficiencyonline monitoring and energy saving of the gear hobbing machine process.To verify the effectiveness of the proposed system, it has been applied on theYS3118CNC5CNC gear hobbing machine tool, a production of the ChongqingMachine Tool Works. The experimental results show that the system is effective andreliable.