自动化生产线工业机器人的装调工艺仿真

在自动化生产线安装调试工作中,工业机器人的装调费时费力且难以迅速满足生产线工艺要求,提出了使用Process Simulate软件对自动化生产线中的工业机器人进行工艺仿真的解决方案。文章介绍了使用Process Simulate软件对自动化生产线中的工业机器人进行工艺仿真的基本方法和过程,从而实现工业机器人装调效率和自动化生产线生产效率的提高。

Theoretical analysis of hydrogen solubility in direct coal liquefaction solvents

The cyclic hydrogenation technology in a direct coal liquefaction process relies on the dissolved hydrogen of the solvent or oil participating in the hydrogenation reaction.Thus,a theoretical basis for process optimization and reactor design can be established by analyzing the solubility of hydrogen in liquefaction solvents.Experimental studies of hydrogen solubility in liquefaction solvents are challenging due to harsh reaction conditions and complex solvent compositions.In this study,the composition and content of liquefied solvents were analyzed.As model compounds,hexadecane,toluene,naphthalene,tetrahydronaphthalene,and phenanthrene were chosen to represent the liquefied solvents in chain alkanes and monocyclic,bicyclic,and tricyclic aromatic hydrocarbons.The solubility of hydrogen X(mol/mol)in pure solvent components and mixed solvents(alkanes and aromatics mixed in proportion to the chain alkanes+bicyclic aromatic hydrocarbons,bicyclic saturated aromatic hydrocarbons+bicyclic aromatic hydrocarbons,and bicyclic aromatic hydrocarbons+compounds containing het-eroatoms composed of mixed components)are determined using Aspen simulation at temperature and pressure conditions of 373–523 K and 2–10 MPa.The results demonstrated that at high temperatures and pressures,the solubility of hydrogen in the solvent increases with the increase in temperature and pressure,with the pressure having a greater impact.Further-more,the results revealed that hydrogen is more soluble in straight-chain alkanes than in other solvents,and the solubility of eicosanoids reaches a maximum of 0.296.The hydrogen solubility in aromatic ring compounds decreased gradually with an increase in the aromatic ring number.The influence of chain alkanes on the solubility of hydrogen predominates in a mixture of solvents with different mixing ratios of chain alkanes and aromatic hydrocarbons.The solubility of hydrogen in mixed aromatic solvents is less than that in the corresponding single solvents.Hydrogen is less soluble in solvent compounds containing heteroatoms than in compounds without heteroatoms.

Modeling and analysis of air combustion and steam regeneration in methanol to olefins processes

Light olefins is the incredibly important materials in chemical industry.Methanol to olefins(MTO),which provides a non-oil route for light olefins production,received considerable attention in the past decades.However,the catalyst deactivation is an inevitable feature in MTO processes,and regeneration,therefore,is one of the key steps in industrial MTO processes.Traditionally the MTO catalyst is regenerated by removing the deposited coke via air combustion,which unavoidably transforms coke into carbon dioxide and reduces the carbon utilization efficiency.Recent study shows that the coke species over MTO catalyst can be regenerated via steam,which can promote the light olefins yield as the deactivated coke species can be essentially transferred to industrially useful synthesis gas,is a promising pathway for further MTO processes development.In this work,we modelled and analyzed these two MTO regeneration methods in terms of carbon utilization efficiency and technology economics.As shown,the steam regeneration could achieve a carbon utilization efficiency of 84.31%,compared to 74.74%for air combustion regeneration.The MTO processes using steam regeneration can essentially achieve the near-zero carbon emission.In addition,light olefins production of the MTO processes using steam regeneration is 12.81%higher than that using air combustion regeneration.In this regard,steam regeneration could be considered as a potential yet promising regeneration method for further MTO processes,showing not only great environmental benefits but also competitive economic performance.

Phase equilibrium data prediction and process optimizationin butadiene extraction process

In response to the lack of reliable physical parameters in the process simulation of the butadiene extraction,a large amount of phase equilibrium data were collected in the context of the actual process of butadiene production by acetonitrile.The accuracy of five prediction methods,UNIFAC(UNIQUAC Functional-group Activity Coefficients),UNIFAC-LL,UNIFAC-LBY,UNIFAC-DMD and COSMO-RS,applied to the butadiene extraction process was verified using partial phase equilibrium data.The results showed that the UNIFAC-DMD method had the highest accuracy in predicting phase equilibrium data for the missing system.COSMO-RS-predicted multiple systems showed good accuracy,and a large number of missing phase equilibrium data were estimated using the UNIFAC-DMD method and COSMO-RS method.The predicted phase equilibrium data were checked for consistency.The NRTL-RK(non-Random Two Liquid-Redlich-Kwong Equation of State)and UNIQUAC thermodynamic models were used to correlate the phase equilibrium data.Industrial device simulations were used to verify the accuracy of the thermodynamic model applied to the butadiene extraction process.The simulation results showed that the average deviations of the simulated results using the correlated thermodynamic model from the actual values were less than 2%compared to that using the commercial simulation software,Aspen Plus and its database.The average deviation was much smaller than that of the simulations using the Aspen Plus database(>10%),indicating that the obtained phase equilibrium data are highly accurate and reliable.The best phase equilibrium data and thermodynamic model parameters for butadiene extraction are provided.This improves the accuracy and reliability of the design,optimization and control of the process,and provides a basis and guarantee for developing a more environmentally friendly and economical butadiene extraction process.

Microscale crack propagation in shale samples using focused ion beam scanning electron microscopy and three-dimensional numerical modeling

Reliable prediction of the shale fracturing process is a challenging problem in exploiting deep shale oil and gas resources.Complex fracture networks need to be artificially created to employ deep shale oil and gas reserves.Randomly distributed minerals and heterogeneities in shales significantly affect mechanical properties and fracturing behaviors in oil and gas exploitation.Describing the actual microstructure and associated heterogeneities in shales constitutes a significant challenge.The RFPA3D(rock failure process analysis parallel computing program)-based modeling approach is a promising numerical technique due to its unique capability to simulate the fracturing behavior of rocks.To improve traditional numerical technology and study crack propagation in shale on the microscopic scale,a combination of high-precision internal structure detection technology with the RFPA^(3D) numerical simulation method was developed to construct a real mineral structure-based modeling method.First,an improved digital image processing technique was developed to incorporate actual shale microstructures(focused ion beam scanning electron microscopy was used to capture shale microstructure images that reflect the distri-butions of different minerals)into the numerical model.Second,the effect of mineral inhomogeneity was considered by integrating the mineral statistical model obtained from the mineral nanoindentation experiments into the numerical model.By simulating a shale numerical model in which pyrite particles are wrapped by organic matter,the effects of shale microstructure and applied stress state on microcrack behavior and mechanical properties were investigated and analyzed.In this study,the effect of pyrite particles on fracture propagation was systematically analyzed and summarized for the first time.The results indicate that the distribution of minerals and initial defects dominated the fracture evolution and the failure mode.Cracks are generally initiated and propagated along the boundaries of hard mineral particles such as pyrite or in soft minerals such as organic matter.Locations with collections of hard minerals are more likely to produce complex fractures.This study provides a valuable method for un-derstanding the microfracture behavior of shales.

Process Simulate在综合实训系统设计中的应用

为解决传统自动化产线编程调试需根据现场实际规划反复调试的问题,借助数字孪生技术,将Process Simulate软件强大的虚实联调技术应用于自动化产线设计、安装、编程、调试、故障解决中。在现实的智能工厂中,往往都是多工作站之间配合进而实现自动化产线的连续运行。多工作站之间的配合就会涉及到通讯,以西门子1500 PLC为例详细讲解如何借助Process Simulate软件实现多站之间的PUT/GET通讯,进而完成各站的PLC程序信号交互,最终完成自动化产线的程序调试。采用Process Simulate软件实现多站之间的通讯,优势体现在:虚拟的PLC即可实现多站之间的通讯,解决无真实设备状态下的编程和通讯,进而验证Process Simulate在智能装备多工作站中的应用高效性。

基于Teamcenter Process Simulate印章定制的生产线仿真设计

基于Teamcenter Process Simulate进行了印章定制生产线仿真设计。本设计是完成印章的组装和包装工作,模拟实际生产过程。整个生产过程是由仓储供料站提供原料,运输站将其送至加工站加工,送至装配站进行组装,组装完后经过机器进行检测,然后送至包装台进行产品包装,最后由AGV小车运输至仓储放料台进行产品入库。设计以出料、运送物料、产品加工、组装、检测、包装、运送、入库等执行单元作为自动生产线的整体设计,组成了自动生产线的生产平台。系统的总控是由一台PLC承担其控制任务。结合工作中的经验,通过机电一体化设计将生产流水线设计方案嵌入到具体的Process Simulate虚拟仿真中,通过PLCSIM Advanced软件创建虚拟PLC,同时构建PLC与Process Simulate通信的桥梁,进而通过编程控制实现印章定制化生产实训系统自动化产线的仿真调试。通过仿真测试,能大大提高实际生产效率。

Research on agile space emergency launching mission planning simulation and verification method

Space emergency launching is to send a satellite into space by using a rapid responsive solid rocket in the bounded time to implement the emergency Earth observation mission.The key and difficult points mainly include the business process construction of launching mission planning,validation of the effectiveness of the launching scheme,etc.This paper pro-poses the agile space emergency launching mission planning simulation and verification method,which systematically con-structs the overall technical framework of space emergency launching mission planning with multi-field area,multi-platform and multi-task parallel under the constraint of resource schedul-ing for the first time.It supports flexible reconstruction of mis-sion planning processes such as launching target planning,tra-jectory planning,path planning,action planning and launching time analysis,and can realize on-demand assembly of operation links under different mission scenarios and different plan condi-tions,so as to quickly modify and generate launching schemes.It supports the fast solution of rocket trajectory data and the accurate analysis of multi-point salvo time window recheck and can realize the fast conflict resolution of launching missions in the dimensions of launching position and launching window sequence.It supports lightweight scenario design,modular flexi-ble simulation,based on launching style,launching platform,launching rules,etc.,can realize the independent mapping of mission planning results to two-dimensional and three-dimen-sional visual simulation models,so as to achieve a smooth con-nection between mission planning and simulation.

基于ABB机器人与Process Simulate间的虚实联调研究

无论高等院校的师生还是智能工厂的数字化工程师,在利用软件Process Simulate完成机器人工作站的虚实联调时往往会消耗大量的时间,结果还不理想,因为其用到的方法是传统的创建多个机器人子程序,或是创建一个机器人程序在程序中用到大量的等待信号去完成物理属性的机器人工作站与软件内机器人工作站的数字孪生同步运行,此方法能够实现物理属性的机器人工作站与软件内机器人工作站的同步运行即虚实联调,但是效率低同时对项目实施者要求也非常高,因此利用传统的方法完成机器人工作站的虚实联调会困难重重,效果还不理想。为了节省数字孪生项目中机器人工作站与软件间的虚实联调的完成时间和降低项目完成难度,作者通过在数字孪生实验室的大量实验研究,最终通过在真实机器人控制器中编写机器人程序读取机器人各轴位置数据,借助Profinet通讯完成机器人与PS软件间的实时位置数据交互,进而较快地完成虚实联调项目。通过与传统的方法做对比测试,作者创建的方法使项目完成的效率得到显著提高,同时降低了项目完成难度。基于以上对比测试,作者研究的方法在以后数字孪生项目中会得到很好地推广,并慢慢会取代传统的方法。

Simulation Research on the Effect of Spreading Process Parameters on the Quality of Lunar Regolith Powder Bed in Additive Manufacturing

Lunar surface additive manufacturing with lunar regolith is a key step in in-situ resource utilization.The powder spreading process is the key process,which has a major impact on the quality of the powder bed and the precision of molded parts.In this study,the discrete element method(DEM)was adopted to simulate the powder spreading process with a roller.The three powder bed quality indicators,including the molding layer offset,voidage fraction,and surface roughness,were established.Besides,the influence of the three process parameters,which are roller’s translational speed,rotational speed,and powder spreading layer thickness on the powder bed quality indicators was also analyzed.The results show that with the reduction of the powder spreading layer thickness and the increase of the rotational speed,the offset increased significantly;when the translational speed increased,the offset first increased and then decreased,which resulted in an extreme value;with the increase of the layer thickness and the decrease of the translational speed,the values for voidage fraction and surface roughness significantly reduced.The powder bed quality indicators were adopted as the optimization objective,and the multi-objective parameter optimization was carried out.The predicted optimal powder spreading parameters and powder bed quality indicators were then obtained.Moreover,the optimal values were then verified.This study can provide informative guidance for in-situ manufacturing at the moon in future deep space exploration missions.

Progress of Microbial Enhanced Oil Recovery in Laboratory Investigation

This paper describes a simple, easy process for screening microorganisms, and introduces a laboratory simulation device and process of microbial enhanced oil recovery (MEOR) , which is a necessary research step for trial in oilfields. The MEOR mechanism and the influence of adsorption, diffusion, metabolism, nutrition, porosity, and permeability are analyzed. The research indicates that different microbes have different efficiencies in EOR and that different culture types play different roles in EOR. The effect of syrup is better than that of glucose, and larger porosity is favorable to the reproduction and growth of microbes, thereby improving the oil recovery. Using crude oil as a single carbon source is more appreciable because of the decrease in cost of oil recovery. At the end of this paper, the development of polymerase chain reaction (PCR) for the future is discussed.

Photolithography Process Simulation for Integrated Circuits and Microelectromechanical System Fabrication

Simulations of photoresist etching,aerial image,exposure,and post-bake processes are integrated to obtain a photolithography process simulation for microelectromechanical system（MEMS） and integrated circuit（IC） fabrication based on three-dimensional （3D） cellular automata（CA）. The simulation results agree well with available experimental results. This indicates that the 3D dynamic CA model for the photoresist etching simulation and the 3D CA model for the post-bake simulation could be useful for the monolithic simulation of various lithography processes. This is determined to be useful for the device-sized fabrication process simulation of IC and MEMS.

Modelling and simulation of high-speed milling chatter regeneration based on MATLAB

Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for milling is developed with MAT- LAB. The simulation optimization application software of dynamics was designed using engineering simulation software Visio Basic. The chatter stability lobes for milling, which can be used as an instruction guide for the selection of process parameters, are simulated with frequency response functions （FRFs） gained by hammer test. The validation and accuracy of the simulation algorithm are verified by experiments. The simulation method has been used in a factory with an excellent application effect.

轿车侧围外板总成PLM产线规划的研究

近年来全球PLM市场持续迅速增长,PLM领域的发展速度越来越快。PLM系统在我国企业的应用已收获了初步的效果和认可,但PLM在企业中的应用仍然较低。PLM技术的发展,可以实现信息化管理企业产品和数据,主要应用在制造行业,如航天航空、医疗器械、汽车制造、电子制造和机械装备等行业。本研究内容来源于轿车企业需求,焊接质量的好坏与焊接技术的高低,是直接影响轿车侧围外板整体质量与整体外观的关键因素,因此设计了轿车侧围外板的焊接生产线,形成焊接岛(焊接工位),采用西门子Process Simulate软件实现车架焊接过程的验证,并进行仿真测试。

Ligand Size Effect on PdLn Oxidative Addition with Aryl Bromide： A DFT Study

The process and mechanism of the ligand volume controlled Pd（PR3）2 （PR3=PH3, PMe3, and PtBu3） oxidative addition with aryl bromide were investigated, using density functional theory method with the conductor-like screening model. Association pathway and dissocia-tion pathway were investigated by the comparison of several energies. The cleavage energy of Pd（PR3）2 complex was calculated, as well as the oxidative addition reaction barrier energy of Pd（PR3）n （n=1,2） with aryl bromide in N,N-dimethylformamide solvent. This study proved that the ligands volume possessed a great impact on the mechanism of oxidative addition： less bulky ligand palladium associated with aryl bromide via two donor ligands,but larger bulky ligand palladium coordinated via monoligand.

Growth Mechanism of Microcrystalline Silicon Films by Scaling Theory and Monte Carlo Simulation

Hydrogenated microcrystalline silicon （~c-Si：H） films with a high deposition rate of 1.2nm/s were prepared by hot-wire chemical vapor deposition （HWCVD）. The growth-front roughening processes of the μc-Si..H films were investi- gated by atomic force microscopy. According to the scaling theory, the growth exponent β≈0.67, the roughness exponent α≈0.80,and the dynamic exponent 1/z = 0.40 are obtained. These scaling exponents cannot be explained well by the known growth models. An attempt at Monte Carlo simulation has been made to describe the growth process of μc-Si： H film using a particle reemission model where the incident flux distribution,the type and concentration of growth radical, and sticking,reemission,shadowing mechanisms all contributed to the growing morphology.

A comparative study of MEA and DEA for post-combustion CO2 capture with different process configurations

This paper presented a comparative study of monoethanolamine （MEA） and diethanolamine （DEA） for post- combustion CO2 capture （PCC） process with different process configurations to study the interaction effect between solvent and process. The steady state process model of the conventional MEA-based PCC process was developed in Pro/II and was validated with the experimental data. Then ten different process configurations were simulated for both MEA and DEA. Their performances in energy consumption were compared in terms of reboiler duty and total equivalent work. The results show that DEA generally has better thermal performances than MEA for all these ten process configurations. Seven process configurations provide 0.38%-4.61% total energy saving compared with the conventional PCC process for MEA, and other two configurations are not favourable. For DEA, except one configuration, other process configurations have 0.27%-4.50% total energy saving. This work also analyzed the sensitivities of three key parameters （amine concentration, stripper pressure and lean solvent loading） in conventional process and five process modifications to show optimization strategy.

Computational Mass Transfer Method for Chemical Process Simulation

The recent works on the development of computational mass transfer （CMT） method and its applications in chemical process simulation are reviewed. Some development strategies and challenges in future research are also discussed.

Operation optimization of the steel manufacturing process: A brief review

Against the realistic background of excess production capacity, product structure imbalance, and high material and energy consumption in steel enterprises, the implementation of operation optimization for the steel manufacturing process is essential to reduce the production cost, increase the production or energy efficiency, and improve production management. In this study, the operation optimization problem of the steel manufacturing process, which needed to go through a complex production organization from customers' orders to workshop production, was analyzed. The existing research on the operation optimization techniques, including process simulation, production planning, production scheduling, interface scheduling, and scheduling of auxiliary equipment, was reviewed. The literature review reveals that, although considerable research has been conducted to optimize the operation of steel production, these techniques are usually independent and unsystematic.Therefore, the future work related to operation optimization of the steel manufacturing process based on the integration of multi technologies and the intersection of multi disciplines were summarized.

Process simulation and optimization of flow field in wet electrostatic precipitator

To improve the dust removal performance of the wet electrostatic precipitator(WESP), a flow field optimization scheme was proposed via CFD simulation in different scales. The simplified models of perforated and collection plates were determined firstly. Then the model parameters for the resistance of perforated and collection plates, obtained by small-scale flow simulation, were validated by medium-scale experiments. Through the comparison of the resistance and velocity distribution between simulation results and experimental data, the simplified model is proved to present the resistance characteristics of perforated and collection plates accurately. Numerical results show that after optimization, both the flow rate and the pressure drop in the upper room of electric field regions are basically equivalent to those of the lower room, and the velocity distribution in flue inlet of WESP becomes more uniform. Through the application in practice, the effectiveness and reliability of the optimization scheme are proved, which can provide valuable reference for further optimization of WESP.