数控机床专业英语翻译题.docx

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数控机床专业英语翻译题

JournalofCleanerProduction

Volume137,20November2016,Pages361–369

Analyticalapproachtoestablishmentofpredictivemodelsofpowerconsumptionofmachinetools'auxiliaryunits

∙MartinKolar, , 

∙JiriVyroubal, 

∙JanSmolik

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//dx.doi.org/10.1016/j.jclepro.2016.07.092

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Abstract

Simulationofpowerflowinmachinetoolsiscrucialforfuturedevelopmentofenergyefficientmachinesaswellasforenergyoptimizationofexistingmachines,productionsystemsandmanufacturingprocesses.ThispaperdescribesanalyticalapproachformodellingofenergyconsumptionofauxiliaryunitsoftheCNCmachinewithcorrespondingactivitymanagement,becausetheseunitsareusuallynotincludedincurrentmodels.Thedevelopedmodelisthencomparedwiththemeasurementofthereal3-axismachinetoprovetheaccuracyofthemodel.Resultsshowtheneedtocalibratetherealconsumptionofeachunitinsteadoftheoreticalvaluefromtheplateoftheunit.Withoutthiscalibration,modelscanbeinaccurate.

Keywords

∙Machinetool; 

∙Energymodel; 

∙Energyconsumption; 

∙Ecodesign

1.Introduction

Theissueofproductionmachineenergyconsumptionhasbeenrecentlygainingprominence,particularlyduetotheeffortsmadebythedevelopedcountriestoreducetheimpactofhumanactivityontheenvironment.Sincetheoperationofproductionmachinesisveryenergy-demanding,itisduringtheiroperationthatproductionmachinescontributetodamagingtheenvironmentthemost,asshownbypreviousstudies（CECIMO,2009）.Risingenergypricestogetherwitheffortstoreducemanufacturingcostshaveresultedinmachinetoolusersrequestforminimizingenergydemandsofmanufacturing.ThispressureonproductionmachineproducersisfurtherincreasedbytheEUdirectiveonreducingenergydemandsinallareasofhumanactivity,inparticularinindustrialproduction,whereproductionmachinesaresignificantenergyconsumers（EuropeanUnion,2009）.Inordertomeettheobjectiveofreducingproductionmachineenergydemands,itisnecessarytoconsiderpotentialenergysavingsalreadyduringthedesignstageofthesemachinesorwhenplanningproductiononthesemachines.Simulationofenergyconsumptionduringthedesignphaseofthemachineortechnologycanbeanadvantagegivinganoverviewoncostsofplannedproductionwhichisnowadaysoneofthecurrentissues.Thiscannotbeachievedwithouttheapplicationofpredictivemodelsofenergyconsumption.Alargepartofstudiesandmodelsthathavebeencarriedoutsofarfocusesinparticularonpredictingtheconsumptionofdrives.However,thecontributionofauxiliaryunitstototalenergyconsumptionissignificantandoftenhigher（Holkupet al.,2013）.Therefore,itisnecessarytodealwiththeminfurtherdevelopmentofenergyconsumptionpredictivemodelssystematicallyandtogivethemtheattentiontheydeserve.

1.1.Stateoftheart

Draganescuet al（Draganescuet al.,2003）.studiedtheinfluenceofcuttingconditionsonmachinetoolefficiencyandpowerconsumption.Theysearchedforamutualrelationshipbetweenthesetwoparametersbasedonpracticaltests.Weinertet al（Weinertet al.,2004）.focusedonthepossibilitiesofreducingtheamountofcuttingfluidusedduringmachining,whichisoneofthemethodsofreducingmanufacturingcosts.Althoughtheydidnotexaminetheeffectonenergyconsumptiondirectly,theyareoftenmentionedsincetheirresearchmadeitpossibletoincreasecuttingspeeds.Thisallowedreductioninmanufacturingtime,anessentialparameteraffectingmachinetoolconsumption.RangarajanandDornfeld（RangarajanandDornfeld,2004）werealsoawareofthesignificantroleoperatingtimesplayinreducingenergyconsumption.Theyfocusedontheoptimizationofcuttingtoolpathsduringmachining.Theyalsoinvestigatedtheinfluenceofworkpiececlampingorientationontotaltimeofmachiningplanarsurfaces.Gutowskiet al（Gutowskiet al.,2006）.werethefirsttoapplyanexergicapproachtoenergyconsumptionofmanufacturingprocesses（exergymeasuresthepotentialofmaterialstodowork）.Basedonthisapproach,Gutowskicreatedasimplemodelofmachinetoolpowerconsumption

（1）.Thismodelisbasedonthesimplisticassumptionthattheconsumptionofauxiliaryunitsisindependentofthemachiningprocess.Usingtests,healsodiscoveredthattheconsumptionoftheseunitsmayapproximatelyconstituteupto85%oftotalmachinetoolenergyconsumption.

equation

（1）

Turn MathJaxon

where E [Ws]isthetotalenergyconsumedbythemachinetool, P0 [W]istheidlepower, k[Wsm−3]isthespecificcuttingprocessenergy, 

 [m3s]isthematerialremovalrateand t[s]istotalmachiningtime.

ThisresearchwasfollowedbyDiazet al.（Diazet al.,2011）,whofocusedonidentificationofrelationshipsbetweencuttingconditionsrepresentedbymaterialremovalrate,activepowerrequirementandtotalenergyconsumption.KaraandLi（KaraandLi,2011）broughtnewinsightsintoenergyconsumptionofproductionmachines.Theyconsideredthemachineasaholisticsystem,whichisabletoinfluenceitssubsections.Therefore,itisnecessarytodealwiththerelationshipsbetweenthesesubsectionsasitisnolongerpossibletostrictlydivideenergyconsumptionbetweenthecuttingprocessandauxiliaryunitsashasbeenthepracticesofar.Moriet al（Moriet al.,2011）.focusedonthepossibilitiesofenergysavingsusingenhancedaccelerationanddecelerationcontrolwithaddedsynchronisationofthespindlewithfeedaxes.Theirimprovedmodelincludedpowerdemandforthespindletoaccelerateordecelerate.MativengaandRajemi（MativengaandRajemi,2011）focusedontheselectionofoptimumcuttingconditionswithrespecttocuttingtoollifetime.Thisinitiatedadiscussiononpowerconsumptionduringtoolexchange.LiandYan（Liet al.,2013）dealtwithmodellingmachinetoolenergyconsumptionandestablishedarefinedempiricalmodelofmachinetoolactivepower,whichachievessignificantlymoreaccurateresultsincomparisonwithpredictivemodelsoftheirpredecessors.Intheirfurtherresearch,theylookedatmulticriterialoptimizationofcuttingconditionsasasearchforacompromisebetweenmaterialremovalrate,powerconsumptionandsurfacequality（YanandLi,2013）.AvramandXirouchakis（AvramandXirouchakis,2011）focusedonpredictivemodelsofenergyconsumptionusingNCcodeanalysis.Asimilarsophisticatedmodel

（2）wasalsodevelopedbyHeet al.（Heet al.,2012）.

equation

（2）

Etotal=Espindle+Efeed+Etool+Ecool+Efix

Turn MathJaxon

where Etotal [Ws]isthetotaldirectrequirements, Espindle [Ws]isspindleenergyrequirementsforthemaincuttingmotion, Efeed [Ws]isfeedaxesrequirementsforsecondarycuttingmotions, Etool [Ws]istoolexchangeenergyrequirements, Ecool [Ws]isenergyof cuttingprocesscoolingand Efix [Ws]ismachineenergyrequirements.

Theresearchoftheabove-mentionedauthorswasfurthercontinuedbyBalogunandMativenga（BalogunandMativenga,2013）andDietmairandVerl（DietmairandVerl,2009）,whodevelopedownadvancedmodelsofenergyconsumption.Thesemodelsuseadivisionoftheentireworkingcycleaccordingtomachineregimes.Wittet al（Wittet al.,2014）.developedsimulationsoftwareforreal-timeenergyconsumptionandmanufacturingcostpredictions.Thissoftwareiscapableofprovidingvaluableinformationalreadyintheproductionplanningphase.Itusesdatafromarealcontrolsystem（hardwareintheloop）forthepredictionofenergyconsumptionofdrives.Asmanyotherauthors,theyareconfrontedwiththeissueofdeterminingtheconsumptionofasubstantialpartofauxiliaryunits,whichsignificantlycontributetothetotalconsumptionofamachinetool.

Theanalysisofexistingmachinetoolenergymodelsleadstoconclusionthatconsumptionofauxiliaryunitscanbehigherthanconsumptionofdrives.Unfortunatelynotsomanyresearchershavebeeninterestedintheprecisemodellingofenergyconsumptionofmachinetoolsauxiliaryunitsyet.Thereforethispartofthesimulationshouldbeinvestigatedinmoredetails.

1.2.Researchaimandscope

Thispaperproposesananalyticalapproachtotheestablishmentofpredictivemodelsofpowerconsumptionofmachinetools'auxiliaryunits.Anestimationofpowerconsumptionofauxiliaryunitsacquiredbythemodeldescribedbelowtogetherwiththeconsumptionofdrives.Drivescanbepredictedusingthealreadypublishedmodelsanditwillprovidemachinetooluserswithinsightsintototalenergydemandsduringproduction.Themainobjectiveofusingthisanalyticalapproachisanincreasingoftheconformitybetweentheconsumptionpredictedbythemodelandtheactualconsumptionofamachinetool.

2.Methodofmodelling

Inthischapteracreationprocessofenergymodelsofmachinetoolsespeciallyoftheirauxiliaryunitswillbedescribed.

2.1.Modelestablishment

Theevaluationoftheproposedmodel（see Fig. 1）canbedescribedinthefollowingthreesteps:

Step1.Analysisofallinstalledmachineauxiliaryunitsandtheirbehaviour.

Step2.Establishmentofsubmodelsofanalyzedauxiliaryunits.

Step3.Sumofenergyflowsofallauxiliaryunits,includingtheconsumptionofcompressedairanddrives.

Fig. 1. 

Modelofmachinetoolenergyconsumption.

Figureoptions

2.2.Coreofmodel

Thecoreoftheestablishedmodelmaybemathematicallydescribedbythreebasicequations.Theyexpresstherelationshipbetweentheactivepowerofthedeviceanditsactivity（3）,theabove-mentionedsummationofenergyflows（4）andsubsequentcalculationoftheenergyconsumed（5）.

equation（3）

Pi（t）=A（t）·Pinput

Turn MathJaxon

where Pi （t）[W]isthetimecharacteristicoftheactivepo