Load-energy efficiency evaluation and monitoring method for achieving energy conservation and emission reduction of numerical control machine tool

A load-energy efficiency evaluation and monitoring method for achieving energy conservation and emission reduction of a numerical control machine tool, comprising the following steps:

• at step 1, after each part provided with a radio frequency identification, RFID, tag is processed, automatically perceiving, by an RFID reader, the processed part and automatically increasing the umber of the parts by 1 to obtain an actual part processing number, denoted as Oactual, of the numerical control machine tool within a given time period;
• at step 2, calculating a theoretical part processing number of the numerical control machine tool based on an available time of the numerical control machine tool within the given time period and a single-part ideal part processing time, wherein the calculation model thereof is as follows:
• O
• theory
• =
• T
• available
• T
• ideal
• -
• C
• ⁢
• T
• ;
• in the above model, Otheory refers to the theoretical part processing number of the numerical control machine tool within the given time period, Tavailable refers to the available time of the numerical control machine tool within the given time period, and Tideal-CT refers to the single-part ideal processing time;
• at step 3, calculating a loading performance of the numerical control machine tool based on the obtained actual part processing number of the numerical control machine tool within the given time period and the obtained theoretical part processing number of the numerical control machine tool within the given time period, wherein the calculation model thereof is as follows:
• η
• performanc
• ⁢
• e
• =
• O
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• O
• theory
• ;
• in the above model, ηperformance refers to the loading performance of the numerical control machine tool, Oactual refers to the actual part processing number of the numerical control machine tool within the given time period, and Otheory refers to the theoretical part processing number of the numerical control machine tool within the given time period;
• at step 4, measuring a single-part processing energy consumption value of the numerical control machine tool under given ideal processing parameters several times by using an energy consumption measuring device mounted at an air switch of the numerical control machine tool and performing averaging for the Obtained energy consumption values, so as to obtain a single-part ideal processing energy consumption value denoted as Eideal;
• at step 5, calculating a waste energy value of the numerical control machine tool within the given time period based on a waste time of the numerical control machine tool within the given time period and a standby power value of the numerical control machine tool, wherein the calculation model is as follows:
• Ewaste=Twaste×Pstandby;
• in the above model, Ewaste refers to the waste energy value of the numerical control machine tool within the given time period, Twaste refers to the waste time of the numerical control machine tool within the given time period, and Pstandby refers to the standby power value of the numerical control machine tool;
• at step 6, obtaining a single-part actual processing energy consumption value according to the obtained waste energy value of the numerical control machine tool within the given time period in combination with the actual part processing number of the numerical control machine tool within the given time period, wherein the calculation formula is as follows:
• E
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• =
• O
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• ×
• E
• ideal
• +
• E
• w
• ⁢
• a
• ⁢
• s
• ⁢
• t
• ⁢
• e
• O
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• ;
• in the above formula, Eactual refers to the single-part actual processing energy consumption value, Oactual refers to the actual part processing number of the numerical control machine tool within the given time period, Eideal refers to the single-part ideal processing energy consumption value, and Ewaste refers to the waste energy value of the numerical control machine tool within the given time period;
• at step 7, calculating a load-energy efficiency of the numerical control machine tool based on the obtained single-part ideal processing energy consumption value and the single-part actual processing energy consumption value, wherein the calculation model thereof is as follows:
• η
• performance_e
• =
• E
• ideal
• E
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• ;
• in the above model, ηperformance_e refers to the load-energy efficiency of the numerical control machine tool, Eideal refers to the single-part ideal processing energy consumption value, and Eactual refers to the single-part actual processing energy consumption value;
• at step 8, obtaining a relationship model between the load-energy efficiency of the numerical control machine tool and the loading performance of the numerical control machine tool through derivation operation based on the obtained calculation model of the loading performance of the numerical control machine tool and the obtained calculation model of the load-energy efficiency of the numerical control machine tool, wherein the relationship model is expressed as follows:
• η
• performance_e
• =
• O
• a
• ⁢
• c
• ⁢
• t
• ⁢
• u
• ⁢
• a
• ⁢
• l
• ×
• E
• ideal
• ×
• T
• available
• -
• 1
• O
• actual
• ×
• E
• ideal
• ×
• T
• available
• -
• 1
• +
• (
• 1
• -
• η
• performanc
• ⁢
• e
• )
• ×
• P
• s
• ⁢
• t
• ⁢
• a
• ⁢
• n
• ⁢
• d
• ⁢
• b
• ⁢
• y
• ;
• in the above formula, ηperformance_e refers to the load-energy efficiency of the numerical control machine tool, Oactual refers to the actual part processing number of the numerical control machine tool within the given time period, Eideal refers to the single-part ideal processing energy consumption value, Tavailable refers to the available time of the numerical control machine tool within the given time period, ηperformance refers to the loading performance of the numerical control machine tool, and Pstandby refers to the standby power value of the numerical control machine tool;
• at step 9, comparing the obtained load-energy efficiency ηperformance_e of the numerical control machine tool within the given time period with a preset alarming lower limit value ηperformance_eL of the load-energy efficiency of the numerical control machine tool;
• if the expression ηperformance_e>ηperformance_eL is satisfied, the load-energy efficiency of the numerical control machine tool being normal;
• if the expression ηperformance_e≤ηperformance_eL is satisfied, prompting by alarming that the load-energy efficiency of the numerical control machine tool is abnormal, and displaying the load-energy efficiency of the numerical control machine tool, the corresponding loading performance of the numerical control machine tool and the waste energy value of the numerical control machine tool within the given time period on a display screen at the same time;
• at step 10, according to the alarming prompt at step 9, making , by production personnel, specific adjustment to a part processing procedure of the numerical control machine tool to reduce the waste energy value of the numerical control machine tool so as to increase the load-energy efficiency of the numerical control machine tool to a normal range.