基于能量流和仿真的压铸机能耗建模与评估

Energy Consumption Modeling and Evaluation of Die Casting Machine Based on Energy Flow and Simulation

针对压铸机能耗高、能量利用率低的问题,提出一种基于能量流和仿真的压铸机能耗模型,研究压铸机能耗特性与重要工艺参数对系统能耗的影响;针对压铸机能耗等级评估周期长、成本高的问题,提出一种基于能耗模型仿真测算压铸机能耗等级的新方法。分析压铸机的能量流特性,根据其能耗分布规律和能量守恒原理,构建压铸机能耗计算模型;采用AMESim与C语言联合仿真,建立压铸机液压系统能耗仿真模型,研究压铸机不同增压压力与不同快压射速度对系统能耗的影响;仿真得出压铸机能耗数据,并按相关标准评估压铸机的能效等级。研究结果显示合开模过程能效较高,有用功约占总能耗的50%;压射过程能效较低,有用功约占总能耗的21%,快速压射阶段瞬时功率非常高;增压压力与快速压射速度变化均对压射机构能耗影响较小;仿真测算出的压铸机能效等级与实测结果接近,比能耗误差为8%,显示提出模型与方法具有较好的准确性与可行性。

Aiming at the high energy consumption and low energy utilization rate of die casting machine,a model of energy con⁃sumption of die casting machine based on energy flow and simulation was proposed.The energy consumption characteristics and influ⁃ence of important process parameters on system energy consumption were studied.Aiming at the problem of long period and high cost of energy consumption evaluation of die casting machine,a new method based on energy consumption model simulation was proposed to calculate the energy consumption level of die casting machine.The energy flow characteristics of die casting machine were analyzed.According to the energy distribution law and energy conservation principle,the energy consumption calculation model of die casting machine was built;AMESim and C language were used to simulate the energy consumption of hydraulic system of die casting machine.The influences of different pressures and different rapid injection speeds on the system energy consumption were studied.The energy consumption data of die casting machine was obtained and the energy efficiency level of die casting machine was evaluated according to relevant standards.The results show that the energy efficiency of the die casting machine is high,and the useful work accounts for about 50%of the total energy consumption;the energy efficiency of the injection process is low,the useful work accounts for 21%of the total energy consumption;the instantaneous power in the rapid compression stage is very high;the influences of the pressured pressure and the rapid injection speed on the energy consumption of the press mechanism are relatively small;the energy efficiency lev⁃el of the die casting machine calculated by simulation is close to the actual result,with the specific energy consumption error of 8%.The results show that the proposed model and method are accurate and feasible.