Method for optimizing parameters of spindle motor of efficient and energy-saving internal meshing gear honing machine

Abstract

The invention discloses a method for optimizing parameters of a spindle motor of an efficient and energy-saving internal gearing gear honing machine. By analyzing the energy consumption characteristic and the efficiency characteristic of the main shaft system, a corresponding energy consumption model and a corresponding efficiency model are constructed, and then a multi-objective optimization model for both energy consumption minimization and efficiency maximization is established. And a multi-objective optimization algorithm is adopted for solving, and optimal spindle motor parameter configuration is obtained. According to the optimization method provided by the optimization result surface, the energy consumption of the internal meshing gear honing machine main shaft system is effectively reduced, the motor efficiency is improved, and a thought is provided for parameter selection of the internal meshing gear honing machine main shaft motor.

Description

Technical Field

[0001] The present invention relates to the technical field of machine tools, and in particular to a method for optimizing the parameters of a spindle motor of an internal meshing gear honing machine for high efficiency and energy saving. Background Art

[0002] Internal gear honing machines, as high-precision gear processing equipment, are widely used in the machining of precision transmission components in high-end manufacturing sectors such as new energy vehicles and aerospace. These machines use a motor to drive the honing wheel, efficiently and precisely machining gear tooth surfaces. The performance of the motor system is directly related to machining efficiency and energy consumption.

[0003] Therefore, this paper proposes a method for optimizing the spindle motor parameters of an internal gear honing machine for high efficiency and energy conservation. Aiming to reduce motor operating energy consumption and improve the system's overall energy efficiency, this method systematically analyzes the energy consumption characteristics of the spindle motor drive system, reveals the energy transfer patterns of the motor drive system, and then establishes an energy consumption model for the spindle motor drive system of an internal gear honing machine. Based on this, a multi-objective motor parameter optimization model for energy consumption and efficiency is constructed. A multi-objective optimization algorithm is used to solve and screen key electromechanical parameters, ultimately achieving improved energy utilization and scientific optimization of the main motor parameter configuration during the gear honing process. Summary of the Invention

[0004] The purpose of this invention is to optimize the parameters of the spindle motor of an internal gear honing machine. While meeting operational requirements, this method ensures energy-saving and efficient operation of the spindle system. The power and speed of the spindle motor are optimized, and a method for optimizing the parameters of the spindle motor of an internal gear honing machine is established.

[0005] The technical solution adopted to achieve the purpose of the present invention is as follows, namely, a method for optimizing the spindle motor parameters of an internal meshing gear honing machine for high efficiency and energy saving, comprising the following steps:

[0006] Step 1: Analyze the energy consumption characteristics of the spindle system of the internal gear honing machine and reveal the energy transfer law of the spindle system;

[0007] Step 2: According to the energy-saving design requirements, propose the internal gear honing machine spindle motor parameter optimization process;

[0008] Step 3: Construct an optimization model for the spindle motor parameters of the internal meshing gear honing machine for energy consumption and efficiency, and use a multi-objective optimization algorithm to solve and screen key electromechanical parameters.

[0009] Preferably, in step 3, a multi-objective optimization model for the spindle motor parameters of the internal meshing gear honing machine is established, and the modeling and optimization solution process is as follows: Figure 1 As shown, the specific process is:

[0010] (1) Optimization variables

[0011] Since the spindle motor power and speed have a significant impact on the spindle motor efficiency of the internal gear honing machine and the energy consumption of the spindle system, the spindle motor power and speed are coordinated and optimized to make the motor run in the high efficiency range as much as possible, thereby improving the energy efficiency ratio of the machining process, reducing the energy consumption of the spindle system, and achieving the goal of high efficiency and energy saving.

[0012] Therefore, the present invention uses the peak power P of the spindle motor max , rated power P r , Maximum speed n max , rated speed n r is the optimization variable.

[0013] (2) Objective function

[0014] 1) Energy consumption objective function

[0015] The total energy consumption of the spindle system of the internal gear honing machine can be regarded as the integration result of the input power of the spindle system over time, where the input power is the input power of the motor, which is composed of the motor loss power, mechanical transmission loss power, kinetic energy change rate of mechanical transmission components and honing power, such as Figure 2 As shown,

[0016]

[0017] Where, P m-in The input power of the spindle motor is the energy source of the entire spindle system; P m-loss is the motor loss power, which is composed of copper loss P m-loss-cu , eddy current loss P m-loss-e , hysteresis loss P m-loss-h , mechanical loss P m-loss-m and additional loss P m-loss-ad Composition; P mec is the mechanical transmission loss power, which is determined by the non-load power loss P um and additional load power loss P am Composition, P um =M me ω+B me ω 2 ;dE k / dt is the rate of change of kinetic energy of mechanical transmission components, dE k / dt=Jω m α m , J is the equivalent moment of inertia, ω m is the motor angular velocity, α m is the motor angular velocity. Since the spindle speed remains unchanged, the kinetic energy change rate is zero; P c For honing power.

[0018]

[0019] Where, P m-out is the output power of the spindle motor, P m-out =P mec +dE k / dt+P c ;n is the spindle motor speed; n r is the rated power of the spindle motor; P max is the maximum power of the spindle motor; P r is the rated power of the spindle motor; h, t, and A are the heat dissipation coefficient, temperature rise limit, and surface area of the spindle motor core, respectively.

[0020] P um =M me ω m +B me ω m 2 =2πM me n+4π 2 B me n 2

[0021] Where M me is the equivalent unloaded Coulomb friction torque; B me is the equivalent viscous friction damping coefficient.

[0022] The additional load power and the honing power approximately satisfy a quadratic function relationship, that is,

[0023]

[0024] Where a0, a1, and a2 are the additional load power coefficients.

[0025]

[0026] Where, F c is the honing force; v is the honing speed, and v=πd h n;d h is the pitch diameter of the honing wheel; k1, k2, k3 are the honing force coefficients; f z is the axial feed rate; L X is the radial feed; L Z is the axial oscillation distance.

[0027] Therefore, the energy consumption function of the spindle system of the internal gear honing machine is the integral result of the input power of the spindle system over time, that is,

[0028]

[0029] 2) Motor efficiency objective function

[0030] The efficiency of the spindle motor of an internal gear honing machine is the ratio of the spindle system's output power to its input power, where the output power is the effective power transferred to the honing wheel for actual machining, i.e., the honing power. Therefore, the efficiency function of the spindle motor of an internal gear honing machine is specifically expressed as follows:

[0031]

[0032] (3) Constraints

[0033] 1) Optimize variable constraints

[0034] Peak power P of the spindle motor of the internal gear honing machine max , rated power P r , Maximum speed n max , rated speed n r The four optimization variables should take values within the constraints, namely

[0035]

[0036] Where, P max-lower and P max-upper are the lowest and highest values of the motor peak power, P r-lower and P r-upper are the minimum and maximum values of the motor rated power, respectively, n max-lower and n max-upper is the minimum and maximum value of the motor's maximum speed, n r-lower and n r-upper The minimum and maximum values of the motor's rated speed.

[0037] 2) Honing force constraint

[0038] During the honing process, the honing force cannot exceed the maximum honing force.

[0039]

[0040] Where F c-max is the maximum honing force.

[0041] 3) Motor output power constraints

[0042] During the honing process, the spindle motor output power cannot exceed the rated power of the motor.

[0043]

[0044] (4) Establish a high-efficiency and energy-saving internal meshing gear honing machine spindle motor parameter optimization model, as follows:

[0045] minF(P max ,P r ,nmax ,n r )=(min E m ,maxη m )

[0046] BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 Internal Gear Honing Machine Spindle System Motor Parameter Optimization Process

[0048] Figure 2 Energy consumption composition of the spindle system of the internal gear honing machine

[0049] Figure 3 Pareto solution of constrained multi-objective particle swarm optimization algorithm

[0050] Figure 4 Comparison of the spindle motor efficiency of the internal meshing gear honing machine at different times before and after optimization DETAILED DESCRIPTION

[0051] The present invention will be further described below with reference to the accompanying drawings and examples, but it should not be understood that the scope of the present invention is limited to the following examples. Without departing from the above technical ideas of the present invention, various substitutions and modifications can be made according to common technical knowledge and customary means in the art, and all should be included in the scope of protection of the present invention.

[0052] This embodiment takes a certain type of internal gear honing machine tool as the research object and optimizes the spindle motor parameters. The spindle motor parameters of the machine tool are shown in Table 1.

[0053] Table 1 Spindle system motor parameters

[0054]

[0055] The commonly used cutting parameter range is determined according to the actual machining accuracy of the internal gear honing machine, the honing wheel material and the workpiece material, as shown in Table 2.

[0056] Table 2 Cutting parameter range of internal gear honing machine

[0057]

[0058] The spindle motor parameter optimization model is a complex problem involving multiple objectives and multiple constraints. The constrained multi-objective particle swarm optimization (CMOPSO) algorithm is used to solve the problem. The Pareto solution set obtained is as follows: Figure 3The final solution was selected based on the best overall performance in terms of both minimum energy consumption and maximum efficiency, as shown in Table 3. After optimization, the spindle system energy consumption was 278,732.1 J, and the motor efficiency was 88.34%. Compared to the pre-optimization results, the energy consumption decreased by 3.0% and the efficiency increased by 1.41%.

[0059] Table 3 Parameter optimization results of the spindle motor of the internal gear honing machine

[0060]

[0061] The energy consumption and motor efficiency of the internal gear honing machine tool spindle system before and after optimization were compared and analyzed using MATLAB. Figure 4 The figure shows the efficiency curves of the spindle motor at different times before and after optimization. As can be seen, the optimized spindle motor exhibits higher efficiency at most times. This demonstrates that within the set cutting parameter range, the optimization method not only improves system performance but also significantly reduces energy consumption, helping to achieve efficient and energy-saving machining goals.

Claims

1. A method for optimizing the spindle motor parameters of an internal gear honing machine for high efficiency and energy saving, characterized in that: The following steps are involved: Step 1: Analyze the energy consumption characteristics of the spindle system of the internal gear honing machine and reveal the energy transfer law of the spindle system; Step 2: According to the energy-saving design requirements, propose the internal gear honing machine spindle motor parameter optimization process; Step 3: Construct and solve the internal meshing gear honing machine spindle motor parameter optimization model for energy consumption and efficiency.

2. The method for optimizing the spindle motor parameters of an internal gear honing machine for high efficiency and energy saving according to claim 1, characterized in that: The energy consumption characteristics and energy transfer rules of the internal gear honing machine spindle system in step 1 are as follows: The energy consumption of the spindle system of the internal gear honing machine can be divided into two parts: the motor system energy consumption and the mechanical system energy consumption. Among them, the motor system energy consumption mainly includes copper loss, eddy current loss, hysteresis loss, mechanical loss and additional loss; the mechanical system energy consumption is mainly composed of mechanical transmission loss and cutting process energy consumption, specifically including non-load power loss, change in kinetic energy consumption of transmission components, additional load power loss and actual cutting energy consumption.

3. The method for optimizing the spindle motor parameters of an internal gear honing machine for high efficiency and energy saving according to claim 1, characterized in that: The process of optimizing the parameters of the spindle motor of the internal gear honing machine in step 2 is as follows: The optimization process, centered around the energy-efficient needs of the spindle system for internal gear honing machines, is divided into seven stages. First, a detailed analysis of the spindle system's energy consumption components is conducted to identify the various sources of energy consumption. Next, an in-depth analysis of the system's energy-efficient operation mechanism is conducted. Subsequently, a mathematical model for the spindle system's overall energy consumption and a motor efficiency model are constructed to quantify energy conversion and loss at each stage. Finally, a mathematical model for parameter optimization is established with energy consumption and motor efficiency as dual objectives. Then, a multi-objective optimization algorithm is introduced to solve the problem and obtain a balanced solution among different objectives; Finally, based on the optimization results, the optimal design parameters of the spindle system motor are determined to minimize energy consumption and improve efficiency while ensuring machining performance.

4. The method for optimizing the spindle motor parameters of an internal gear honing machine for high efficiency and energy saving according to claim 1, characterized in that: The process of establishing and solving the parameter optimization model of the spindle motor of the internal meshing gear honing machine for energy consumption and efficiency in step 3 is as follows: (1) Optimization variables The peak power of the spindle motor P max , rated power P r , Maximum speed n max , rated speed n r To optimize the variables, the spindle motor parameters are coordinated and optimized; (2) Objective function 1) Energy consumption objective function Where, E m is the total energy consumption of the spindle system of the internal gear honing machine, P m-in is the input power of the motor, P m-loss is the motor power loss, P mec is the mechanical transmission loss power, M me is the equivalent unloaded Coulomb friction torque, B me is the equivalent viscous friction damping coefficient, n is the spindle motor speed, a0, a1, a2 are the additional load power coefficients, P c For honing power; 2) Motor efficiency objective function Where η m The motor efficiency of the spindle system of the internal gear honing machine; (3) Constraints Where, P max-lower and P max-upper are the lowest and highest values of the motor peak power, P r-lower and P r-upper are the minimum and maximum values of the motor rated power, respectively, n max-lower and n max-upper is the minimum and maximum value of the motor's maximum speed, n r-lower and n r-upper is the minimum and maximum value of the motor’s rated speed, F c-max is the maximum honing force, P m-out is the output power of the spindle motor; (4) Establish a high-efficiency and energy-saving internal meshing gear honing machine spindle motor parameter optimization model, specifically: (5) Solution The parameter optimization model of the spindle motor of the internal gear honing machine is a complex problem with multiple objectives and multiple constraints. It is solved by the constrained multi-objective particle swarm optimization algorithm.

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