Research On Methodology Of Shop Floor Energy Consumption Optimization And Its Application With Facility Performence Considered

As one of the most popular topic in the world, energy has been brought tothe attention of various countries and international organizations. Nowadays,how to reduce energy consumption and improve energy utilization has becomethe focus of the manufacturing enterprises, which is also one of the difficulties.In addition, the performance of facility not only affect the quality of the products,but also has a vital influence on the energy consumption of workshop. Therefore,in this paper we do the research on methodology of shop floor energyconsumption optimization and its application with facility performencsconsidered, which is instructive and meaningful to the energy efficiencymanagement of enterprises.An experimental program based on VF-2CNC, in which coated end millsand45#steel are selected as cutting tool and workpiece, is designed in order toanalyze the change of equipment facility performance through the process of toolwear. The data acquisition system for real-time collection, display and storage ofspindle vibration and power in the process of tool wear is developed both inhardware and software. An orthogonal experiment for tool wear is also designed.The result not only verify the feasibility of data acquisition system, but also helpto determin the processing parameters and tool wear experiment process.The concrete method of tool wear measurement is introduceted and based onthat, the change result of the tool wear are analyzed. At the same time, thevibration of both X and Y direction of spindle and power of facility are collectedand analyzed. Curve fitting is adopted in this paper to establish thevibration-wear function relation, with which the method of facility performanceon-line monitoring based on vibration signal is presented. The method isvalidated effective and feasible by experimental verification. The model ofprocessing power-time in the process of performance change is establishedthrough the experiment.The model of scheduling time is established based on the description ofactual job shop scheduling problem. The energy consumption model isestablished, in which the energy consumption is categorized into five parts asProcessing Energy (PE), Adjusting Energy (AE), Transport Energy (TE), WaitingEnergy (WE) and Routine Energy (RE). Genetic Algorithm (GA) andNon-dominated Sorting Genetic Algorithm (NSGA-II) are applied solve the jobshop scheduling problem. The select process, crossover and mutation operators are mentioned in the implementation of GA and NSGA-II. These two kinds ofalgorithm are applied to different actual situation, can meet the different nee ds ofenterprise in the process of workshop energy consumption optimization.A tool production workshop of Harbin is introducted to verify theeffectiveness of the method of shop floor energy consumption optimization.Fristly, the job shop model parameters is set in detail. Then the GA and NSGA-IIare appilied to solve the Job-shop energy consumption optimization schedulingproblem with facility performance considered. Simulation results demonstratethat the proposed method is effective in supporting energy efficiencymanagement in shop floor.In this paper, the method of facility performance on-line monitoring basedon vibration signal is presented by developing a data acquisition system. Usingthis method, the processing power-time model is established in the process offacility performance. By combine the power-time model to the plant energyconsumption model, the method of shop floor energy consumption optimizationwith facility performance is presented, which has some significance for thepractical application in the process of energy efficiency management in shopfloor.