离散制造业产品能耗限额制定的复杂特性及制定策略

产品能耗限额对于加强产品制造过程能量消耗管理、监控和提高能量效率均十分重要。目前,钢铁、化工等流程制造行业的产品能耗限额制定已有不少成熟方法,并从国家层面制定了一些主要产品的能耗限额指标;但对于量大面广的离散制造业产品,由于其能耗规律的复杂性和动态变化性,其能耗限额制定非常困难。目前我国还没有一项国家层面的离散制造业产品能耗限额。基于离散制造业产品制造能耗特点的分析,揭示离散制造业产品能耗限额制定的分布式多数量制造系统关联性等复杂特性。在此基础上,针对规格品种繁多的一般产品即绝大多数产品,提出产品与制造系统的关联能耗限额制定策略;针对个别量大面广、能量消耗总量巨大、制造设备、工艺和制造流程相对比较成熟和确定的特定产品,提出统一能耗限额制定策略;并给出关联能耗限额制定和统一能耗限额制定的具体策略。上述特性和策略为离散制造业产品能耗限额制定这一难题提供了一种总体解决思路。     

车间生产过程的能量足迹建模与加工参数协同优化

为降低零件加工过程的生产能耗,提出一种面向节能的车间生产过程多装备加工参数协同优化方法。以包含机床与机器人的定制化生产车间为研究对象,建立了考虑刀具退化动态过程的生产车间系统能量足迹模型。考虑刀具寿命、机器人运输平稳性的成本指标函数,建立了多装备系统的加工参数协同多目标优化模型。以加工时间为约束条件,使用蜂群算法获取了最优参数。实验表明,以节能目标为主的优化方案可降低机床加工能耗17.97%,降低机器人运输能耗18.13%。     

离散制造单元生产扰动识别模型及其自适应节能控制方法

离散制造单元的生产扰动是中断设备生产、造成能耗浪费的源头，如何在复杂动态的扰动环境下实现设备节能控制策略的自适应选择和控制参数的自适应优化从而达到最优的节能控制效果是一个亟待解决的难题，为此提出了基于生产扰动识别模型的离散制造单元自适应节能控制方法。首先，基于生产扰动的模式性和不确定性，构建了一种马尔科夫逻辑网络驱动的生产扰动识别模型，实现生产扰动的精准识别。然后，以能耗浪费期望为优化目标，生产延迟时间期望为优化约束，制定了基于时间阈值的设备节能控制策略，提出了面向生产扰动自适应的节能控制方法。最后，以某压铸单元为对象进行了案例验证，结果表明生产扰动类型会对节能控制效果造成显著影响，所提出方法在尽量保证生产的前提下通过提升节能控制的自适应能力实现了更好的节能效果。     

压铸单元能效在线监测方法及监测系统

针对压铸单元能效复杂多变、难以实时有效监测的难题,通过对压铸单元能耗的构成进行分析建立了在线监测指标体系,提出了基于功率信息进行数据分析的在线监测方法。该方法通过小波变换对实时测量的压铸单元功率信息进行分析,利用极值查找法在线识别了设备的运行状态和加工件数,从而获得压铸单元的能效信息。基于C#语言开发了压铸单元能效在线监测系统。通过实验验证了所提方法和监测系统的有效性和实用性。     

Simulation based energy-resource efficient manufacturing integrated with in-process virtual management

As energy efficiency is one of the key essentials towards sustainability, the development of an energy-resource efficient manufacturing system is among the great challenges facing the current industry. Meanwhile, the availability of advanced technological innovation has created more complex manufacturing systems that involve a large variety of processes and machines serving different functions. To extend the limited knowledge on energy-efficient scheduling, the research presented in this paper attempts to model the production schedule at an operation process by considering the balance of energy consumption reduction in production, production work flow (productivity) and quality. An innovative systematic approach to manufacturing energy-resource efficiency is proposed with the virtual simulation as a predictive modelling enabler, which provides real-time manufacturing monitoring, virtual displays and decision-makings and consequentially an analytical and multidimensional correlation analysis on interdependent relationships among energy consumption, work flow and quality errors. The regression analysis results demonstrate positive relationships between the work flow and quality errors and the work flow and energy consumption. When production scheduling is controlled through optimization of work flow, quality errors and overall energy consumption, the energy-resource efficiency can be achieved in the production. Together, this proposed multidimensional modelling and analysis approach provides optimal conditions for the production scheduling at the manufacturing system by taking account of production quality, energy consumption and resource efficiency, which can lead to the key competitive advantages and sustainability of the system operations in the industry.     

[数据驱动的智能服务]数据驱动的复杂产品智能服务技术与应用

随着传感器、数据采集装置和其他具备感知能力的模块在复杂产品服务运行阶段的应用,复杂产品运维系统的数字化和智能化程度越来越高,具有实时、多源、异构、海量等特性的数据成为提高复杂产品系统可靠和低成本运行的决策依据,数字孪生技术提供了一种有效途径。介绍了数据驱动的复杂产品智能服务研究进展;分析了数据驱动的智能服务基本特征与框架模型;提出了数据驱动的复杂产品智能服务方法,主要包括面向服务的复杂产品建模与仿真方法、数据驱动的服务需求获取与精准分析预测方法、基于数字孪生的设备故障识别与动态性能预测方法、数据驱动的装备视情维修与备件库存联合多目标决策优化方法、基于数字孪生的复杂产品辅助维修技术、多要素协同的复杂装备能效精准分析预测方法、基于数据挖掘的复杂产品运行优化控制方法等;给出了智能服务系统的应用案例。所提出的框架和方法可为现代制造服务的智能化转型升级提供参考。     

压铸取件设备的优化设计

压铸取件设备不仅有利于提高生产效率,而且有助于节约大量的劳动力资源,从而降低企业的生产成本.但是,在实际的操作过程中,不可避免地存在耗时、耗器、耗材等一系列的问题.基于此,根据设备在实际的运用过程中压铸取件设备的缺点,分析了压铸取件设备的运用及工作流程,继而剖析了压铸取件设备的性能特点,提出了其优化设计的原理、方法,并对优化设计的效果进行了评价.     

On a generalized approach to manufacturing energy efficiency

Energy efficiency has become a very significant factor, requiring its inclusion in the manufacturing decision-making attributes. This paper proposes a generalized approach to manufacturing energy efficiency. The basic element of the approach is the division of energy efficiency definition and study into four manufacturing levels, namely process, machine, production line, and factory. Process-level definitions are provided for the majority of manufacturing processes. A machine-level study indicates and solves difficulties, generated by the workpiece geometry, and points out the interaction with the process level through factors, such as the process time. Moreover, machine tool peripherals are responsible for a significant portion of the consumed energy, and classification based on the dependence of their consumption on process variables is required. Studies made on the production line and factory levels show that energy efficiency, at these levels, is heavily dependent on production planning and scheduling and can be improved through the appropriate utilization of machines, with the inclusion of shutdown and eco-modes. Finally, a case study is presented, showing that many of the difficulties towards the optimization of energy efficiency can be dealt with successfully, using the proposed generalized approach.     

A quality diagnosis method for the large equipments base on quality gene similarity

The quality of the products is one of the key factors for the enterprises to increase their core competitiveness. In order to resolve the problems that the quality diagnosis with respect to manufacturing process is not effective or the low efficiency in the large equipment manufacturing enterprises, we propose a quality diagnosis approach based on the similarity of product quality gene. First, we use a product quality gene model to calculate the similarity between the organisms and the products. Second, a kind of quality gene codes is adopted to describe the complex quality information for manufacturing process. Then, string and grey relation similarity are used to evaluate whether the quality is normal or not by considering the similarity between the detected product quality gene and the case genes. Finally, we use the rotary kiln bearing body as an example to illustrate the proposed algorithm process. Experimental results have shown that the proposed approach is able to support quality diagnosis.     

[绿色制造工艺和系统]高端金属零件微铸锻铣复合超短流程绿色制造方法及其能耗分析

基于绿色设计体系结构分析了绿色设计制造理念在增材制造技术中的体现,针对高端金属零件传统制造工艺流程长与能耗高这两个瓶颈问题,提出一种金属零件微铸锻铣复合超短流程绿色制造方法,并以一航空起落架外筒零件的制造过程为例,通过理论计算比较了新方法与传统方法的能源和材料消耗。研究结果表明：制造该外筒零件,传统制造方法与微铸锻铣复合制造方法相比,前者的能耗是后者的33.3倍,前者的材料消耗为后者的6.7倍,后者的生产周期由数月缩短为数天。该方法的提出,为我国大型复杂锻件的生产提供了一种超短流程、节能省材的绿色制造新模式。     

锻造生产过程中的节能问题研究

面向锻造行业开展节能问题研究,通过分析锻造流程中能量消耗的各个环节,找出了节能设备、工艺方案、生产调度等3个能够节能的环节.在节能设备方面,给出了冷挤压及冷锻工艺、等温锻造、电液锤的改造、循环水系统的改造等方案;在工艺流程的节能优化方面,给出了高温废气的多级循环利用、连铸连锻工艺的应用、热处理工艺中余热的利用,以及节能型锻打CAPP方案等;在生产调度方面,则分别从锻件装炉中的节能优化、锻件出炉过程的节能优化、锻件锻打中的节能优化、热处理过程的节能优化等方面进行了研究.研究结果为锻造节能技术的研究及发展提供了必要的理论基础.     

面向清洁生产的磨削工艺方案多层多目标优化模型及应用

为了实现磨削过程的节能减排,提出了一种面向清洁生产的磨削工艺方案多层多目标优化模型。从清洁生产“三流（物料流、能量流、环境排放流）”的角度建立了面向清洁生产的磨削能耗与碳排放模型。从工艺路线和工序工艺参数层建立了以磨削能耗、磨削碳排放和磨削时间为目标的多层多目标优化模型,采用基于层次分析法和客观赋权法(CRITIC)法组合赋权的改进遗传算法进行优化求解。以某轴承套圈为研究对象进行磨削工艺实验,结果表明：通过算法优化得到的加工方案相较于传统的加工方案,在工艺层面节约了6.48%的加工时间、降低了42.81%的能耗、减少了8.26%的碳排放;在工序层面缩短了25%的磨削时间、降低了18.84%的能耗、减少了8.69%的碳排放。结果验证了模型和方法的有效性。最后依据上述研究结果提出了相应的节能减排策略。     

An optimal prediction model for time series prediction in manufacturing systems

Gray model GM(1, 1), a single variable first-order gray differential equation model, which is based on gray system theory, has been proposed as a prediction model to solve efficiently the prediction problems in manufacturing systems. However, the prediction accuracy of this model is unsatisfying when original data set shows great randomness. In this paper, in order to improve the prediction capability of GM(1, 1), the exponential smoothing method is integrated into GM(1, 1) through the preprocessing for original data set. Then the particle swarm optimization algorithm is employed so that the prediction power can be further enhanced. Finally, a residual compensation approach based on artificial neural network is proposed to acquire the best prediction performance.The real case of time series prediction in a product manufacturing process is used to validate the effectiveness of the proposed model.     

A Study on Development of a Die Design System for Diecasting

Diecasting is one of the forming methods for manufacturing a large number of products with short lead time and a good surface by high injection pressure of cast alloy. Die design is composed of selection of cast alloy, design of product, runner and gate design, etc. In reality, however, die design for diecasting has been performed by a trial and error method, which causes economic and time loss. This paper describes the development of the computer-aided design of product and die design. The CAD system has been written in AutoLISP on the AutoCAD with a personal computer. In this study, the die design system for the die casting process has been developed and a flowchart is presented for the automation of die design, especially of the runner–gate system. As the generation process and die design system using 3D geometry handling are integrated with the technology of process planning, die design can be automated. In addition, specific rules and equations for the runner–gate system have been presented to avoid too much trial and error with expensive equipment. It is thus possible for engineers to make automatic and efficient die design for diecasting which will result in a reduction of the required cost and time. An example of a cap-shaped product, i.e. a motor pulley, is given using the proposed flowchart.     

Development of a die design system for die casting

This paper presents a research work of a computer-aided die design system for die casting. The proposed system consists of seven distinct modules. Through these modules, the die designers are able to create a die casting die from a product part model. It is a user-friendly system that allows both experienced and novice die designers to easily accomplish the task of die design.The practical goal of this research is twofold: (1) to develop a system that integrates the different stages of die design process and (2) that at the same time facilitates the editing of die casting design during or after the course of the design process. The approach undertaken in this research includes (1) feature-based and constraint-based modelling, (2) parametric design and (3) a geometric and topological information extraction technique from a B-rep model. A prototype system has been developed using this approach and the system is able to aid the automation of the die casting die design process, thus improving the efficiency and quality of, and reducing the cost of die design for die casting.     

基于能耗的冷轧连退机组能效建模与工艺参数优化及排序建模优化

以冷轧连续退火机组能耗集中的炉区作为研究对象,根据能量流与热力学理论,建立了能耗与主要工艺参数之间的映射模型;采用MATLAB结合一种改进的量子遗传算法对能效模型进行优化,获取在保证质量的前提下能效最高的工艺参数组合;以辅助设备能耗最低、生产规格跳变平缓以及满足交货期为优化目标,建立了冷轧连退产线生产调度多目标优化模型,采用非支配排序遗传算法（NSGA-Ⅱ）进行求解,得出最优排序。结果表明,该模型和算法对生产实际有一定的指导作用。     

Energy consumption reduction technology in manufacturing — A selective review of policies, standards, and research

Research on the improvement of efficiency in the manufacturing industry is underdeveloped partly because of the ambiguous objectives of the technical development of efficiencies in terms of energy consumption reduction. Consequently, the technical development of high-efficiency techniques that consider the whole manufacturing system is rarely addressed in industrial research. For this reason, this report aims to find the patterns in, and the definitions of, the technologies that will lead to efficiency improvement in the entire manufacturing industry by thoroughly investigating the literature about energy consumption reduction strategies, energy policies, and the state-of-the-art for energy-saving methods that are being pursued currently in several major countries. Through this study, the necessity and importance of the foregoing three items have been identified, and a way of defining the productivities of an energy-saving manufacturing system distinct from those of conventional manufacturing systems was attempted. It is also shown that the development of energy-saving and energy-harvesting technologies for all industrial sectors has emerged as a herald of economic growth in the near future.     

金属型铝合金重力浇注装置及其模具设计的研究

为适应较小规模铸造企业的生产模式、有效提高铸件质苎．对铝合金重力浇注装置及其模具结构进行设计研究。在装置上采用简单的机械结构使之方便手动操作，使用完全金属型模具并使之具有倾转功能。研究发现在浇注过程中具有操作简单方便、易于维护，并且制造成本低廉、模具设计制造周期短的特点。铝合金液体在模具中的充型和排气效果良好，可减少气孔、缩孔等铸造缺陷。特别适用与中小型企业的小批量铸件的生产和产品零件的试制加工。     

高能耗企业生产能耗过程可视化建模软件设计与实现

针对企业生产能耗过程仿真优化的实际需求,依据企业生产能耗过程的物料流、能源流、信息流、排放流"四流"合一的耦合建模思想,基于面向对象的设计模式方法和ILOG图形化技术,介绍了离散制造企业生产能耗可视化建模工具的软件架构方法,及利用C#编程实现企业生产能耗耦合过程模型及生产能耗参数化设备模型的可视化方法。     

Analysis of priority mix planning for the fabrication of semiconductors under uncertainty

Because of intensive capital investment in semiconductor manufacturing, the priority mix decision plays a critical role for effective administration. The potential value of products, efficiency in the deployment of equipment, and characteristics of cash flow are inherently difficult to be precisely defined and determined by a decision maker. The main objective in this study is therefore to construct an analytical approach for dealing with the aforementioned managerial problems under subjective judgment environments. Thus, we utilized a fuzzy analytic hierarchy process method to deal with uncertainty. Of primary concern are the criteria of product, equipment efficiency, and finance, and detailed criteria are catered to the requirement for further analysis. Finally, a priority mix of strategic alternatives represented by a priority index can be evaluated. A performance ranking of priority mixes can then be generated. The results provide guidance to select strategies for accepting orders with the consideration of manufacturing efficiency and the aspects of product, equipment efficiency and finance. The model is easily understandable and can be followed by administrators to determine the most suitable priority mix for a fabrication process.