The Method For Acquiring The Key Energy-Efficiency Factors In A Service Period Of Gear Machining Machines

The mechanical manufacturing industry,which is mainly based on machine tools,has huge energy consumption,low energy utilization rate,and high potential for energy saving.Therefore,in recent years,researchers have been actively paying great effort into the the energy efficiency and its evaluation of the machine tool industry at home and abroad.However,gear machining machines known as “King of Machine Tools”,with comparatively large energy consumption,complex machine structure,multi-motion coordinates,strong motion association,complex energy consumption law.Moreover,the gear machining machine has a unique motion feature of both tool and workpiece axis rotating motion.As a result,it is difficult to install the cutting force measuring instruments,and some factors of energy efficiency is difficult to obtain.therefore,the energy efficiency prediction and evaluation in a service period of gear machining machines have not been implemented at home and abroad.Based on this,this paper studied the acquisition method of key energy efficiency factors in a service period of gear machining machines.Firstly,the characteristics of energy efficiency in a service period of machine tools are summarized,and the special energy efficiency characteristic of gear machining machines during a service period are analyzed.based on this,the energy efficiency factors in a service period of machine tool are analyzed,three key factors for the energy efficiency in a service period of gear machining machines are presented,including idle power function,additional load loss function,effective energy.and the difficulties in obtaining the key factors are analyzed.Then,the function models and acquisition methods for the idle power factor are studied.The idle power of main transmission system during a service period of gear machining machines is divided into two parts: the idle power of the tool axis transmission system and the idle power of the workpiece axis transmission system.The idle power function model of each part is established.Based on this,presented a method for calculating the idle power function in a service period of gear machining machines.Secondly,the function models and acquisition methods for the additional load loss factor are studied.Based on the energy components of the main drive system,an additional load loss model and an additional load loss coefficient model are established in a service period of gear machining machines.Based on this,a method for calculating the additional load loss coefficient and additional load loss function of gear machining machines during a service period which was based on the basic data of the drive system of the machine tools is obtained.Finally,the function model and the acquisition method of the effective energy factor are studied.Based on the energy efficiency characteristics of gear machining machines,the effective energy composition in a service period of gear machining machines is studied,and an effective energy model related to the additional load loss coefficient is established;based on this,a method which based on the additional load loss coefficient of the gear machining machine is obtained to acquire the effective energy in a service period of gear machining machines.The above methods have been verified in laboratories and production sites.The verification results show that these methods have good accuracy and maneuverability.