基于DEA的机械加工车间制造系统全要素能量效率评价与优化研究

The machining workshops in China use many machine tools, and the amount is top around the world. What is more, the machining industry is challenged by the problems of huge energy consumption and low energy efficiency. Aiming at the bad situation of machining workshops in China and the international academic frontiers, energy efficiency assessment and optimization of the manufacturing system in machining workshops are researched in this program. Firstly, based on the energy consumption features discussion and the impact analysis of non-energy input factors on energy utilization rate, the total factor energy efficiency assessing index model of manufacturing system in machining workshop is proposed under the optimal allocation scenario of production factors, so that a standardized, general energy efficiency assessing index can be gotten. After that, an assessing method based on DEA is given to get the assessing result, and the method is superior in data acquisition comparing with the assessing method based on machining experiments. And then the operation optimization of manufacturing system in machining workshop is studied based on the assessment above. Considering the influencing factors of energy efficiency, the process route energy efficiency optimization model is put forward oriented to machine tool selection, and the job sequencing energy efficiency optimization model is discussed as well oriented to utilization rate of machine tool. The optimization research can make the energy efficiency assessing results apply in practice. The models, methods and technologies discussed in the program can provide supports for the energy efficiency research, energy quota making and energy efficiency improvement of manufacturing system in the machining workshop; therefore, they have great application prospect.

本项目针对我国机械加工车间量大面广、能耗总量巨大并且能量效率低而急需提高能效的需求，并瞄准国际学科前沿热点问题，对机械加工车间制造系统能量效率评价与优化展开研究。首先基于能量消耗特性和能量利用率影响因素分析，建立最优生产要素配置下机械加工车间制造系统全要素能量效率评价指标模型，为制造系统能效评价提供标准化、通用的能效评价指标；然后，提出从车间生产日志提取信息的基于DEA的能量效率评价方法，得到归一化的全要素能效评价结果，解决了传统基于机械加工实验的能效评价方法数据获取难的问题；基于此，考虑制造系统全要素能量效率水平的主要影响因素，提出面向加工设备选择的工艺路线能效优化模型和面向设备利用率的作业排序能效优化模型，实现能效评价结果在车间制造系统优化运行中的实践应用。上述模型、方法及技术能为机械加工车间能量效率研究、能耗定额制定、能效优化等一系列问题的研究和应用提供基础支持，具有广阔的应用前景。

本项目针对我国机械加工车间量大面广、能耗总量巨大并且能量效率低而急需提高能效的需求，并瞄准国际学科前沿热点问题，对机械加工车间制造系统能量效率评价与优化展开研究。首先通过基于生产报表数据的定量分析判断包括资产、劳动力和能源的制造系统投入要素对能量利用率的影响，提出基于GRA-Tobit的制造企业车间能量效率影响因素分析模型，并建立了机械加工车间制造系统考虑非能量要素影响的全要素能量效率评价指标模型，能够在纵向的评价对象间以及横向的评价对象自身进行能效水平高低判定。然后通过从车间日报表提取评价相关数据进行能量效率评价，提出一种基于超效率DEA的机械加工车间全要素能量效率评价方法，得到各决策单元的能量效率水平，克服了基于机械加工实验的能量效率评价方法数据获取的困难。最后，基于能效水平影响因素分析建立车间制造系统运行优化模型，提出基于数据包络分析-动态规划的机械加工车间制造系统全要素能量效率优化模型，得到制造系统最优能源投入值，测算企业最优能耗，指导企业未来生产；提出一种基于递归分析和图像处理技术的流水车间和混流车间能量效率分析与状态监测方法，实现能量效率水平和异常工序状态的在线分析和识别；提出一种基于高维多目标候鸟优化算法的柔性作业车间调度方法、一种基于响应面法和人工蜂群算法的数控车削工艺参数多目标优化方法、一种考虑车间分时电价用电模式的多目标柔性作业车间调度方法，实现机械加工车间运行过程的节能优化。基于以上研究内容，实际取得如下研究成果：1）共发表和录用论文9篇，其中在《IEEE ACCESS》、《计算机集成制造系统》、《中国机械工程》SCI/EI刊源期刊发表和录用论文3篇；在《工业工程与管理》、《工业工程》、《制造业自动化》等重要刊物上发表或录用论文6篇。2）出版学术专著1部。3）申请中国发明专利2项，其中已授权1项。4）取得计算机软件著作权1项。5）项目负责人及项目组成员参加学术交流8次。6）培养硕士研究生8名。