机械制造系统碳排放动态特性及其碳效率评估优化方法研究
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摘要
低碳制造是一种综合考虑产品全生命周期资源消耗以及碳排放的可持续制造模式，其目标是实现产品在生产、制造、使用过程中的低资源消耗、低排放、低污染，实现制造企业经济效益、社会效益、环境效益的统一，其实质是提高制造业能源、物料等资源利用效率和创建清洁能源结构，其核心是制造业的技术创新、制度创新和发展观的转变。
我国作为制造业大国，尤其机械制造工业量大面广，其机械制造系统作为典型离散制造系统，生产过程受生产时间、产量、产值以及设备故障等因素影响，使其碳排放存在主体多样性、状态复杂性、过程动态性及随机性。本论文将结合国家自然科学基金项目“基于广义特性函数集的制造系统碳流动态模型及碳效率评估方法研究”(NO.51075415)和重庆市自然科学基金项目“机械制造系统碳排放动态特性及碳流建模理论研究”(NO.CSTC2010BB0055)等课题，对机械制造系统的碳排放动态特性建模及其碳效率评估优化方法进行研究。
首先，根据机械制造系统的分层特性及其复杂控制特性，提出碳排放源、碳流率概念，建立一种符合机械制造系统多层特点的碳流动态过程模型，系统分析各层级系统碳排放耦合输入输出特性、碳流交汇特性，并基于状态空间理论提出机械制造系统碳排放动态特性表征方法。基于生态效率(Eco-efficiency)概念，提出碳效率概念，并针对分层机械制造系统空域、时域以及复杂度的差异性，建立机械制造系统碳效率评价指标体系。
其次，针对机械制造系统典型生产设备—机床，基于生命周期评价（Life CycleAssessment, LCA）原理，对机床生命周期全过程碳排放特性进行深入研究，建立一种机床生命周期碳排放量化公式模型。着重研究机床使用过程，面向生产率、物料去除率以及经济收益率定义了三种碳效率指标，通过将机床全生命周期碳排放划分为固定碳排放与变动碳排放，基于这三种指标分别建立机床设备生命周期碳排放动态特性函数，从而实现对机床全生命周期碳排放动态特性的描述及碳效率的评估。
在此基础上，根据机械制造系统内机床设备组织特点、设备间交互特性以及设备碳排放的状态依附性，基于混合状态空间模型建立机械制造系统碳排放动态特性建模框架。并考虑扰动对系统碳排放特性的影响，基于改进混合Petri网提出一种机械制造系统碳排放动态特性及碳效率评估建模方法，综合设备状态变迁、生产扰动发生的离散过程建模以及生产与碳排放的连续过程建模，实现对机械制造系统碳排放动态特性的建模以及碳效率评估。
然后，提出一种改进甘特图将工件加工操作与碳排放动态特性进行关联，并用于分析面向生产任务分配的生产碳排放优化策略以及面向加工操作顺序的系统内设备空载无用碳排放优化策略，根据这两种优化策略的特点建立一种机械制造系统碳效率二阶优化模型，并用遗传算法分阶求解最优碳效率。
最后，应用C#+SQL server2005开发工具，开发一套适用于机械制造系统碳排放动态特性建模及碳效率评估的支持系统，并对其开发过程及应用进行说明。
Low-carbon manufacturing is a kind of sustainable manufacturing modecomprehensively considering the resources consumption and carbon emissions ofproduct life cycle, aiming at reducing the resource consumption and carbon emissionsof product production, product manufacture and its use process, for unity of enterpriseeconomic dimensions, social dimensions and environmental dimensions, and its essenceis to improve resource utilization efficiency and create clean energy structure, with thecore of manufacturing technology innovation, system innovation and development viewtransformation.
As a manufacturing power, mechanical manufacturing industry of China is featuredwith large quantity. In particular, the manufacturing sytem as a typical discretemanufacturing system is influenced by theose production factors such as productiontime, yield, output value, and equipment failures. Therefore, the carbon emissions ofmechanical manufacturing system are characterized with carbon emission bodydiversity, state complexity, process dynamics and randomness.With the support of theNational Science Foundation of China (NSFC)(NO.51075415) and the SciencFoundation of Chongqing (NO.CSTC2010BB0055), this paper will focus on themodeling of carbon emission dynamic characteristics of mechanical manufacturingsystem and the assessment and optimization approach of carbon efficiency.
Firstly, according to the hierarchical features and the complex controlcharacteristics of manufacturing system, a multi-layer carbon flow dynamic model isproposed with the definition of carbon emission source and carbon flow rate. Thus, thecoupled input-output and interchange characteristics of carbon emsissions are analyzed.The carbon emission dynamics of mechanical manufacturing system is characterizedbased on state space theory. On the basis of the analysis of carbon emission dynamics,the carbon efficiency concept is put forward based on eco-efficiency concept.Meanwhile, carbon efficiency evaluation index system is established for different layersmanufacturing system considering their difference in space domain, time domain andcomplexity.
Secondly, based on the principles of life cycle assessment (LCA), a life-cyclecarbon emissions formulation model of machie tool as the minimu organization unit ofmechanical manufacturing system is proposed. Focusing on the carbon emission dynamics of machine operation process, three carbon efficiency indicators are definedfor production rate, material removal rate and economic return rate. Then the life-cyclecarbon emissions are decomposed into two categories, fixed emissions and variedemissions which closely relates with operation performance of machine tools. Thedynamic characteristics function of life-cycle carbon emissions then will be establishedbased on the three type’s carbon efficiency indicaters respectively, for demonstrating thecarbon emission dynamcs and assessement of carbon efficiency.
As pointed out above, the carbon emissions of mechanical manufacturing system(process chains) is rather dynamic depending on the state of the machines and theirinteractions, its modeling framework is established based on hybrid state spacemodel.Considering the production disturbances, a simulation approach based on hybridPetri-nets (HPN) is proposed to display the carbon emission dynamics. This approachcan combine the discrete events such as state transition and production disturbanceswith the continuous process such as production and carbon emissions. Thus, it canmodel the carbon emission dyanics of mechanical manufacturing with the assessment ofits carbon efficiency.
Furthermore, an improved Gantt chart relating the operations of jobs with thecarbon emission dynamics of the correponsding machines is proposed. Through this tool,one carbon emission strategy for production task allocation and the other strategy foroperation sequence of workshop aiming at lower meaningless carbon emissions fromthe idle operation of machines. Thus, based on above two stragegies a two stageoptimization model for the carbon efficiency is established with genetic algorithm (GA).
Finally, a software support system is developed for the assessment and optimizationof carbon efficiency of mechanical manufacturing system with C#and SQL server2005
我国作为制造业大国，尤其机械制造工业量大面广，其机械制造系统作为典型离散制造系统，生产过程受生产时间、产量、产值以及设备故障等因素影响，使其碳排放存在主体多样性、状态复杂性、过程动态性及随机性。本论文将结合国家自然科学基金项目“基于广义特性函数集的制造系统碳流动态模型及碳效率评估方法研究”(NO.51075415)和重庆市自然科学基金项目“机械制造系统碳排放动态特性及碳流建模理论研究”(NO.CSTC2010BB0055)等课题，对机械制造系统的碳排放动态特性建模及其碳效率评估优化方法进行研究。
首先，根据机械制造系统的分层特性及其复杂控制特性，提出碳排放源、碳流率概念，建立一种符合机械制造系统多层特点的碳流动态过程模型，系统分析各层级系统碳排放耦合输入输出特性、碳流交汇特性，并基于状态空间理论提出机械制造系统碳排放动态特性表征方法。基于生态效率(Eco-efficiency)概念，提出碳效率概念，并针对分层机械制造系统空域、时域以及复杂度的差异性，建立机械制造系统碳效率评价指标体系。
其次，针对机械制造系统典型生产设备—机床，基于生命周期评价（Life CycleAssessment, LCA）原理，对机床生命周期全过程碳排放特性进行深入研究，建立一种机床生命周期碳排放量化公式模型。着重研究机床使用过程，面向生产率、物料去除率以及经济收益率定义了三种碳效率指标，通过将机床全生命周期碳排放划分为固定碳排放与变动碳排放，基于这三种指标分别建立机床设备生命周期碳排放动态特性函数，从而实现对机床全生命周期碳排放动态特性的描述及碳效率的评估。
在此基础上，根据机械制造系统内机床设备组织特点、设备间交互特性以及设备碳排放的状态依附性，基于混合状态空间模型建立机械制造系统碳排放动态特性建模框架。并考虑扰动对系统碳排放特性的影响，基于改进混合Petri网提出一种机械制造系统碳排放动态特性及碳效率评估建模方法，综合设备状态变迁、生产扰动发生的离散过程建模以及生产与碳排放的连续过程建模，实现对机械制造系统碳排放动态特性的建模以及碳效率评估。
然后，提出一种改进甘特图将工件加工操作与碳排放动态特性进行关联，并用于分析面向生产任务分配的生产碳排放优化策略以及面向加工操作顺序的系统内设备空载无用碳排放优化策略，根据这两种优化策略的特点建立一种机械制造系统碳效率二阶优化模型，并用遗传算法分阶求解最优碳效率。
最后，应用C#+SQL server2005开发工具，开发一套适用于机械制造系统碳排放动态特性建模及碳效率评估的支持系统，并对其开发过程及应用进行说明。
Low-carbon manufacturing is a kind of sustainable manufacturing modecomprehensively considering the resources consumption and carbon emissions ofproduct life cycle, aiming at reducing the resource consumption and carbon emissionsof product production, product manufacture and its use process, for unity of enterpriseeconomic dimensions, social dimensions and environmental dimensions, and its essenceis to improve resource utilization efficiency and create clean energy structure, with thecore of manufacturing technology innovation, system innovation and development viewtransformation.
As a manufacturing power, mechanical manufacturing industry of China is featuredwith large quantity. In particular, the manufacturing sytem as a typical discretemanufacturing system is influenced by theose production factors such as productiontime, yield, output value, and equipment failures. Therefore, the carbon emissions ofmechanical manufacturing system are characterized with carbon emission bodydiversity, state complexity, process dynamics and randomness.With the support of theNational Science Foundation of China (NSFC)(NO.51075415) and the SciencFoundation of Chongqing (NO.CSTC2010BB0055), this paper will focus on themodeling of carbon emission dynamic characteristics of mechanical manufacturingsystem and the assessment and optimization approach of carbon efficiency.
Firstly, according to the hierarchical features and the complex controlcharacteristics of manufacturing system, a multi-layer carbon flow dynamic model isproposed with the definition of carbon emission source and carbon flow rate. Thus, thecoupled input-output and interchange characteristics of carbon emsissions are analyzed.The carbon emission dynamics of mechanical manufacturing system is characterizedbased on state space theory. On the basis of the analysis of carbon emission dynamics,the carbon efficiency concept is put forward based on eco-efficiency concept.Meanwhile, carbon efficiency evaluation index system is established for different layersmanufacturing system considering their difference in space domain, time domain andcomplexity.
Secondly, based on the principles of life cycle assessment (LCA), a life-cyclecarbon emissions formulation model of machie tool as the minimu organization unit ofmechanical manufacturing system is proposed. Focusing on the carbon emission dynamics of machine operation process, three carbon efficiency indicators are definedfor production rate, material removal rate and economic return rate. Then the life-cyclecarbon emissions are decomposed into two categories, fixed emissions and variedemissions which closely relates with operation performance of machine tools. Thedynamic characteristics function of life-cycle carbon emissions then will be establishedbased on the three type’s carbon efficiency indicaters respectively, for demonstrating thecarbon emission dynamcs and assessement of carbon efficiency.
As pointed out above, the carbon emissions of mechanical manufacturing system(process chains) is rather dynamic depending on the state of the machines and theirinteractions, its modeling framework is established based on hybrid state spacemodel.Considering the production disturbances, a simulation approach based on hybridPetri-nets (HPN) is proposed to display the carbon emission dynamics. This approachcan combine the discrete events such as state transition and production disturbanceswith the continuous process such as production and carbon emissions. Thus, it canmodel the carbon emission dyanics of mechanical manufacturing with the assessment ofits carbon efficiency.
Furthermore, an improved Gantt chart relating the operations of jobs with thecarbon emission dynamics of the correponsding machines is proposed. Through this tool,one carbon emission strategy for production task allocation and the other strategy foroperation sequence of workshop aiming at lower meaningless carbon emissions fromthe idle operation of machines. Thus, based on above two stragegies a two stageoptimization model for the carbon efficiency is established with genetic algorithm (GA).
Finally, a software support system is developed for the assessment and optimizationof carbon efficiency of mechanical manufacturing system with C#and SQL server2005
引文
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