面向环境可持续性的数字化制造装备能耗建模及运行优化

In our country, power required for machine tools are both enormous and inefficient. From that, the prospect of increasing energy saving and resource efficiency is astounding. In order to increase the effectiveness of resource usage and energy of CNC machine tools during operation, this project targets typical cutting machine tools, to develop basic theory and key technologies about environmental sustainable energy consumption modeling and operational optimization for digital manufacturing equipment. The main research of the proposed prospect contains the following. Firstly, a multi-source energy flow model and evaluation method for digital manufacturing equipment will be established, and the energy consumption characteristics of cutting-tool and equipment wear is studied. Secondly, optimizing methods of process parameters and process planning to improve its energy efficiency, and a sustainable predictive maintenance method will be developed. Then, an energy effectiveness modeling of digital manufacturing shop floor and its evaluation methods based on multi-dimension and multi-layer will be developed. The dynamic scheduling for improved energy efficiency will be studied under an uncertain digital manufacturing shop floor. Finally, the energy efficient software-hardware integration platform of digital manufacturing shop floor will be built, and an energy efficiency control system for digital manufacturing shop floor will be developed. The results of the project will develop and advance the theory and technology of sustainable manufacturing for digital manufacturing equipment, and enhance the competitiveness and sustainable development of the Chinese manufacturing enterprises.

我国机床装备耗电总量巨大，能量利用率较低，能源节约和能效提升前景很大。为了提高数控机床使用过程中资源和能源的利用效率，本项目针对典型的切削类数控机床，开展面向环境可持续性的数字化制造装备能耗建模及运行优化的基础理论和关键技术研究。主要研究内容包括：①建立数控机床的多源能量流模型和评估方法，研究刀具磨损、设备性能衰退与能耗变化关联关系和作用规律；②研究面向能效提升的数控机床工艺参数和工艺路线优化，以及可持续预测维护技术；③研究基于多维、多层次的数字化制造车间能效模型和评估方法，以及不确定条件下数字化制造车间能量意识的动态调度优化方法；④建立面向能效的数字化制造车间软硬件一体化平台，研发数字化制造车间能效管控系统。本项目研究成果可以丰富和发展数控机床可持续制造的基础理论和技术，对于提升我国制造企业竞争力和可持续发展能力具有重要理论意义和应用价值。

我国机床装备耗电总量巨大，能量利用率较低，能源节约和能效提升前景很大。为了提高数控机床使用过程中资源与能源的利用效率，本项目开展数字化制造装备能耗建模及运行优化的基础理论和关键技术研究。结合机床加工状态的能耗特征与算法学习，提出一种通用、精确的数控车床切削过程能耗精确预测模型，设计一种改进的多目标教与学优化算法求解该模型，获得较客观的选取切削用量。为了提高刀具磨损监测的预测精度与能效性能，提出基于堆叠稀疏自动编码网络与卷积神经网络两种预测模型。依据实际制造车间生产环境，研究基于每台机器的可靠度阈值的预防性维护，建立柔性作业车间设备预防性维护与调度集成优化的数学模型。针对实际的复杂车间生产环境，分别开展了工艺参数能量效率优化、面向节能高效的柔性车间调度优化，以及工艺参数与车间调度能量效率集成优化研究。研发面向能效的数字化制造车间软硬件一体化平台，开发了数字化制造车间能效管控系统。本项目研究成果丰富和发展数控机床可持续制造的基础理论和技术，有助于提升我国制造企业竞争力和可持续发展能力。本项目在国内外权威期刊、国际会议发表论文60篇；其中SCI期刊发表论文27篇，高被引论文3篇；公开或授权国家发明专利8项；培养博士研究生4名，硕士生研究生14名。.