机床制造业绿色制造运行模式及其特征主线研究
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摘要
绿色制造是一种综合考虑环境影响和资源消耗的现代制造模式，其目标是使得产品在整个寿命周期中对环境负面影响极小，资源利用率极高，并使企业经济效益和社会效益协调优化。作为资源消耗和环境排放严重的典型行业，机床制造业实施绿色制造是其实现可持续发展的迫切要求，对机床行业的长远发展具有重要的指导意义。
本论文结合国家重大科技专项（高档数控机床与基础制造装备）课题“模块化高速、精密、大型数控滚齿机”（2009ZX04001-081），国家自然科学基金重点项目“离散车间制造系统高效低碳运行优化理论与关键技术”（51035001）等科研项目，对机床制造业绿色制造运行模式及其特征主线进行了研究。
首先，针对我国机床制造业面临的机遇与绿色挑战，在分析机床制造业的绿色制造运行模式需求的基础上，提出了一种包括目标体系、特征主线和支撑系统等三层结构的机床制造业绿色制造运行模式，其中，目标体系包括企业战略目标与企业过程目标；特征主线包括机床产品的设计过程主线、多生命周期过程主线及物流过程主线；支撑系统包括绿色设计、清洁化生产、物能资源优化运行、管理信息、环境影响评估和质量保证等系统。
然后，对机床制造业绿色制造运行模式的三条特征主线进行阐述与分析。
（1）机床产品设计过程主线中，分析了产品设计主线的主导特性，论述了机床产品绿色设计过程框架，包括绿色设计过程、设计内容及技术体系；重点对机床总体布局设计技术、传动系统设计技术、床身及排屑系统设计、主轴及工作台主轴高速旋转的设计、刀具安装部位及工件接触部位的设计技术、安全防护设计等高速干切机床设计支持技术进行了研究。
（2）机床产品多生命周期过程主线中，分析了机床多生命周期的内涵，提出了机床多生命周期工程的概念，并对其体系结构、过程模型及特征模型进行了论述；重点研究了多生命周期过程的机床再制造环节，对其定义及特点、工艺过程、工艺技术及典型模式进行了详细论述。
（3）机床产品物流过程主线中，分析了铸造、锻造、机械加工、热处理、涂装、装配等典型工艺的环境排放及其处理方式；重点对机床产品物流过程碳排放特性进行了分析，建立了基于Petri网的机床制造过程碳排放模型，进而提出了一种机床产品物流过程碳排放量化方法。
最后，将所研究的机床制造业绿色制造运行模式应用于重庆机床集团的生产实践中，为其机床产品绿色设计以及废旧机床再制造提供了重要的理论与技术支持，取得了较好的应用效果。
Green Manufacturing (GM) is a kind of modern manufacturing mode with the fullconsideration of environmental impact and resource consumption, its goal is to makethe environmental negative impact lower, resource utilization rate higher in the wholelife cycle of product, and make the enterprise economic benefit and social benefitoptimization coordinately. As a resource consumption and environmental emissionsserious typical industry, it’s quite imperative for machine tool industry to implementGM in order to realize its sustainable development and also has important guidingsignificance to the long-term development of the machine tool industry.
With support from Major National Science&Technology Specific Projects (NO:2009ZX04001-081) and Natural Science Foundation of China (NO:51035001),Machine indutry GM operation mode and its characteristic lines are studied in the paper.
Firstly, the paper discusses the opportunity and challenge that China’s machine toolindustry is facing, and then introduces the requirements of the GM operation model ofmachine tools industry. Thereby, an overall framework of machine tool GM operationmodel, which is comprised of objective systems, characteristic lines, and supportingsystems, has been established. The objective system contains enterprise strategy goalsand enterprise process goals.The characteristic lines consist of the main lines of productdesign process, product multi-stage life cycle process, and product logistics process.The supporting system is composed of some subsystems, such as green designsupporting system, clean production supporting system, optimized operation supportingsystem of material and energy resource, management information system,environmental effect assessment system and quality assurance system.
Secondly, the three characteristic lines of GM operation model in machine toolsindustry are specified and analyzed.
The main line of product design process is centered on the dominant characteristicsand the framework of machine tool product green design, including design process,design contents and technique systems. Meanwhile, some design technologies formachine tool in general layout, transmission system, machine tool bed and automaticchip removal system, spindle and workbench spindle high speed rotating design, tooland workpiece parts installation design technology and safety protection design etc areemphatically introduced.
In view of the multi life cycle process line of machine tool products, the paperanalyses the connotation of multi-stage life cycle of machine tools and propose theconcept of multi-stage life cycle engineering of machine tool. Meanwhile, thearchitecture, process models, and characteristics models are introduced. Thenremanufacturing, one of the important parts of multi-stage life cycle engineering, hasbeen significantly introduced with the specification of the definition and characteristics,process model, process technologies and typical patterns of remanufacturing for oldmachine tools.
Regarding the logistics process line of machine tool products, the paper discussesthe environmental emissions that typical production processes, such as casting, forging,machining, heat treatment, coating and assembling, produces and the correspondingtreatments are also presented. Then the carbon emission characteristics of machine toolproducts in the logistics process are substantially analyzed and a carbon emissionmodeling and quantitative method is proposed based on Petri Net.
Finally, the GM operation model of machine tool industry that has been specifiedabove are applied into Chongqing Machine Tool (Group) Co., Ltd, which providesimportant theoretical and technological supports for the machine tool green design andold machine tools remanufacturing with a good application effect.
本论文结合国家重大科技专项（高档数控机床与基础制造装备）课题“模块化高速、精密、大型数控滚齿机”（2009ZX04001-081），国家自然科学基金重点项目“离散车间制造系统高效低碳运行优化理论与关键技术”（51035001）等科研项目，对机床制造业绿色制造运行模式及其特征主线进行了研究。
首先，针对我国机床制造业面临的机遇与绿色挑战，在分析机床制造业的绿色制造运行模式需求的基础上，提出了一种包括目标体系、特征主线和支撑系统等三层结构的机床制造业绿色制造运行模式，其中，目标体系包括企业战略目标与企业过程目标；特征主线包括机床产品的设计过程主线、多生命周期过程主线及物流过程主线；支撑系统包括绿色设计、清洁化生产、物能资源优化运行、管理信息、环境影响评估和质量保证等系统。
然后，对机床制造业绿色制造运行模式的三条特征主线进行阐述与分析。
（1）机床产品设计过程主线中，分析了产品设计主线的主导特性，论述了机床产品绿色设计过程框架，包括绿色设计过程、设计内容及技术体系；重点对机床总体布局设计技术、传动系统设计技术、床身及排屑系统设计、主轴及工作台主轴高速旋转的设计、刀具安装部位及工件接触部位的设计技术、安全防护设计等高速干切机床设计支持技术进行了研究。
（2）机床产品多生命周期过程主线中，分析了机床多生命周期的内涵，提出了机床多生命周期工程的概念，并对其体系结构、过程模型及特征模型进行了论述；重点研究了多生命周期过程的机床再制造环节，对其定义及特点、工艺过程、工艺技术及典型模式进行了详细论述。
（3）机床产品物流过程主线中，分析了铸造、锻造、机械加工、热处理、涂装、装配等典型工艺的环境排放及其处理方式；重点对机床产品物流过程碳排放特性进行了分析，建立了基于Petri网的机床制造过程碳排放模型，进而提出了一种机床产品物流过程碳排放量化方法。
最后，将所研究的机床制造业绿色制造运行模式应用于重庆机床集团的生产实践中，为其机床产品绿色设计以及废旧机床再制造提供了重要的理论与技术支持，取得了较好的应用效果。
Green Manufacturing (GM) is a kind of modern manufacturing mode with the fullconsideration of environmental impact and resource consumption, its goal is to makethe environmental negative impact lower, resource utilization rate higher in the wholelife cycle of product, and make the enterprise economic benefit and social benefitoptimization coordinately. As a resource consumption and environmental emissionsserious typical industry, it’s quite imperative for machine tool industry to implementGM in order to realize its sustainable development and also has important guidingsignificance to the long-term development of the machine tool industry.
With support from Major National Science&Technology Specific Projects (NO:2009ZX04001-081) and Natural Science Foundation of China (NO:51035001),Machine indutry GM operation mode and its characteristic lines are studied in the paper.
Firstly, the paper discusses the opportunity and challenge that China’s machine toolindustry is facing, and then introduces the requirements of the GM operation model ofmachine tools industry. Thereby, an overall framework of machine tool GM operationmodel, which is comprised of objective systems, characteristic lines, and supportingsystems, has been established. The objective system contains enterprise strategy goalsand enterprise process goals.The characteristic lines consist of the main lines of productdesign process, product multi-stage life cycle process, and product logistics process.The supporting system is composed of some subsystems, such as green designsupporting system, clean production supporting system, optimized operation supportingsystem of material and energy resource, management information system,environmental effect assessment system and quality assurance system.
Secondly, the three characteristic lines of GM operation model in machine toolsindustry are specified and analyzed.
The main line of product design process is centered on the dominant characteristicsand the framework of machine tool product green design, including design process,design contents and technique systems. Meanwhile, some design technologies formachine tool in general layout, transmission system, machine tool bed and automaticchip removal system, spindle and workbench spindle high speed rotating design, tooland workpiece parts installation design technology and safety protection design etc areemphatically introduced.
In view of the multi life cycle process line of machine tool products, the paperanalyses the connotation of multi-stage life cycle of machine tools and propose theconcept of multi-stage life cycle engineering of machine tool. Meanwhile, thearchitecture, process models, and characteristics models are introduced. Thenremanufacturing, one of the important parts of multi-stage life cycle engineering, hasbeen significantly introduced with the specification of the definition and characteristics,process model, process technologies and typical patterns of remanufacturing for oldmachine tools.
Regarding the logistics process line of machine tool products, the paper discussesthe environmental emissions that typical production processes, such as casting, forging,machining, heat treatment, coating and assembling, produces and the correspondingtreatments are also presented. Then the carbon emission characteristics of machine toolproducts in the logistics process are substantially analyzed and a carbon emissionmodeling and quantitative method is proposed based on Petri Net.
Finally, the GM operation model of machine tool industry that has been specifiedabove are applied into Chongqing Machine Tool (Group) Co., Ltd, which providesimportant theoretical and technological supports for the machine tool green design andold machine tools remanufacturing with a good application effect.
引文
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