| An automatic production line is a complex dynamic system with multiple machines, buffers and controlling systems, which is applied in machining process widely due to its high productivity and high automaticity. However, the energy efficiency of the production line in machining process is generally low. Research on energy saving and efficiency increasing of production line has great signification for promoting energy-saving and emission reduction and the construction of ecological civilization duo to the shortage of energy and serious environment pollution. Analysis of energy efficiency is the basis of developing potential energy saving strategies. This paper is based on car special seed fund project of basic scientific research in central colleges and universities named “performance analysis and optimization of automatic production line for transmission gears”(CDJZR13110071). This paper focuses on energy efficiency analysis of serial production line with unreliable machines aiming to provide a quantitative analysis method and analyze influence factor of energy efficiency in production line, which provides theoretical basis for improving energy efficiency.Firstly, production system modeling method, the equipment energy consumption states and energy efficiency are described systematically. Power profile of machine in multi-step process and mass production is analyzed deeply. The relationship between operation state and energy state of machine is established.Secondly, energy efficiency analysis method for two stage production system is researched. Energy consumption states of two stage production line are analyzed, energy consumption states transition model and energy efficiency analysis model are established. The probabilities of the system in steady are obtained by state transition equations. The simulation model is established with the software e M-Plant. Experiments are performed to verify the effectiveness of energy efficiency analysis model.Then, energy efficiency analysis method for multistage serial production system is researched. The line is decomposed into several two stage lines with Gershwin decomposition method. And main parameters are obtained with DDX algorithm. The probabilities of the system in steady are obtained indirectly by analyzing the buffer state. Simulated analysis is performed to verify the effectiveness of energy efficiency analysis model for multistage serial production line. The effects of some parameters on the average energy efficiency are analyzed.Finally, energy efficiency analysis of two automatic production lines for car transmission gears is carried out. Energy efficiency is obtained and reasons are analyzed. |
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