US 2020/0019135 A1 · METHOD OF ACCURATELY PREDICTING ENERGY CONSUMPTION OF AUTOMATIC TOOL CHANGE FOR MULTI-POSITION ROTARY TOOL HOLDER OF NUMERICAL CONTROL MACHINE

Abstract

Disclosed is a method of accurately predicting energy consumption of an automatic tool change process of a multi-position rotary tool holder of a numerical control machine. In this method, automatic tool change durations at a plurality of groups of rotary tool position numbers are firstly measured and a calculation model of the automatic tool change duration is obtained by fitting. A basic module power of machine is obtained by collection and operation and a basic module energy consumption of machine is obtained by calculation based on the basic module power of machine and the automatic tool change duration. A steady state power of tool changer is obtained by collection and operation and further a steady state energy consumption of tool changer is calculated. A transient state energy consumption of tool changer is obtained by accumulating energy consumptions caused by all power peaks in the automatic tool change process of the numerical control machine. An energy consumption prediction model of the automatic tool change process is obtained according to the obtained basic module energy consumption of machine, the obtained steady state energy consumption of tool changer, the obtained transient state energy consumption of tool changer, thereby accurately predicting the energy consumption of the automatic tool change process of the numerical control machine and providing basic module support to the energy-saving optimization of machine.

A method of accurately predicting energy consumption of an automatic tool change process of a multi-position rotary tool holder of a numerical control machine, comprising the following steps:

at step 1, determining a rotary tool position number according to a current tool position number and a target tool position number of the multi-position rotary tool holder of the numerical control machine, wherein the multi-position rotary tool holder of the numerical control machine generally adopts a unidirectional sequential rotation manner and therefore the rotary tool position number is calculated according to the following formula:
Δ
=
{
T
t
-
T
i
,
T
t
≥
T
i
T
p
-

T
t
-
T
i

,
T
t
<
T
i
in the formula, Δ refers to the rotary tool position number of the rotary tool holder, t refers to the target tool position number of the rotary tool holder, Ti refers to the current tool position number of the rotary tool holder and TP refers to the total tool position number of the rotary tool holder;
at step 2, measuring automatic tool change duration values (ttc1, ttc2, . . . ttcN) at different rotary tool position numbers (Δ1, Δ2, . . . ΔN) of the numerical control machine, wherein ΔN refers to the N-th rotary tool position number and ttcN refers to the automatic tool change duration value at the N-th rotary tool position number;
at step 3, performing data fitting with the rotary tool position number A as an independent variable and the automatic tool change duration ttc as a response variable according to the obtained automatic tool change durations at a plurality of groups of different rotary tool position numbers and establishing a calculation model of the automatic tool change duration with the model expressed as:
t
tc
=
α


Δ
1
+
β


Δ
wherein ttc refers to the automatic tool change duration, Δ refers to the rotary tool position number of the rotary tool holder and α and β refer to coefficients of the formula;
at step 4, obtaining a basic module power of machine by collecting a plurality of basic module powers of machine and obtaining an average value, wherein a power calculation formula is expressed as:
P
basic
=
∑
i
=
1
N
b

P
basic_i
/
N
b
wherein Pbasic refers refers to basic module power of machine, Pbasic_i refers to the i-th measured value of the basic module power of machine, and Nb refers to the total number of the measured values of the basic module power of machine;
at step 5, a basic module energy consumption of machine in the automatic tool change process of the numerical control machine is calculated according to the obtained basic module power of machine and the obtained automatic tool change duration, wherein a calculation formula is expressed as:
Ebasic=Pbasic×ttc
wherein Ebasic refers to the basic module energy consumption of machine in automatic tool change process of the numerical control machine, Pbasic refers to the basic module power of machine and ttc refers to the automatic tool change duration;
at step 6, obtaining a steady state power of tool changer in the automatic tool change process of the numerical control machine by collecting a plurality of steady state powers of tool changer and obtaining an average value, wherein a calculation formula is expressed as:
P
m


s
=
∑
j
=
1
N
s


Δ

P
m


s
,
Δ_

j
/
N
s


Δ
wherein Pms refers to the steady state power of tool changer, Pms,Δ_j refers to the j-th measured value of the steady state power of tool changer when the rotary tool position number of the rotary tool holder is Δ, and NsΔ refers to the total number of the measured values of the steady state powers of tool changer when the rotary tool position number of the rotary tool holder is Δ;
at step 7, obtaining a steady state energy consumption of tool changer in the automatic tool change process of the numerical control machine according to the obtained steady state power of tool changer and the obtained automatic tool change duration, wherein a calculation formula is expressed as:
Ems=Pms×ttc
wherein Ems refers to the steady state energy consumption of tool changer in the automatic tool change process of the numerical control machine, Pms refers to the steady state power of tool changer, and ttc refers to the automatic tool change duration;
at step 8, obtaining a transient state energy consumption of tool changer by accumulating energy consumptions caused by all power peaks in the automatic tool change process of the numerical control machine, wherein a calculation formula is expressed as:
E
mt
=
∑
u
=
1
N
Δ

E
mt
,
Δ_

u
wherein Emt refers to the transient state energy consumption of tool changer in the automatic tool change process of the numerical control machine, Δ refers to the rotary tool position number of the rotary tool holder, Emt,Δ_u refers to the energy consumption caused by the u-th power peak when the rotary tool position number of the rotary tool holder is Δ and NΔ refers to the total number of the power peaks when the rotary tool position number of the rotary tool holder is Δ;
at step 9, calculating the energy consumption of the automatic tool change process according to the obtained basic module energy consumption of machine, the obtained steady state energy consumption of tool changer, and the obtained transient state energy consumption of tool changer in the automatic tool change process of the numerical control machine, wherein a calculation formula is expressed as:
Etc=Ebasic+Ems+Emt
wherein Etc refers to energy consumption of the automatic tool change process of the multi-position rotary tool holder of the numerical control machine, Ebasic refers to the basic module energy consumption of machine in the automatic tool change process of the numerical control machine, Ems refers to the steady state energy consumption of tool changer in the automatic tool change process of the numerical control machine and Emt refers to the transient state energy consumption of tool changer in the automatic tool change process of the numerical control machine.

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Method of accurately predicting energy consumption of automatic tool change for multi-position rotary tool holder of numerical control machine

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Method of accurately predicting energy consumption of automatic tool change for multi-position rotary tool holder of numerical control machine

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Abstract

Claims3