Introduction
Statement of methodological framework
Method and algorithm of carbon efficiency upgrading
Task assignment model and algorithm
Processing route optimization model and algorithm
Case study
Tab.1 Relevant information and data of parts and processing steps |
Part number | Batch task | Process step 1 | Process step 2 | Process step 3 | Process step 4 | Process step 5 | Process step 6 | Process step 7 |
---|---|---|---|---|---|---|---|---|
Tailstock spindle | 60 | Rough turning | Heat treatment | Finish turning | Slotting | Heat treatment | Finish grinding | Grinding taper hole |
Tailstock body | 80 | Heat treatment | Planing plane | Milling | Grinding | Heat treatment | – | – |
Under plate | 50 | Rough planing | Heat treatment | Finish planning | Finish milling | – | – | – |
Worktable | 50 | Rough planing | Milling plane | Finish planing | Milling step | – | – | – |
Tab.2 Relevant information and data of process units and machines |
Process unit number | Process unit name | Machine type and number | Processing capacity/(piece·time–1) |
---|---|---|---|
1 | Turning unit | CA6140 () | 1 |
CA6150 () | 1 | ||
2 | Heat treatment unit | RJX-45-9 () | 5 |
RJX-45-9 () | 5 | ||
RJX-45-9 () | 5 | ||
3 | Milling unit | TX6111D () | 1 |
4 | Grinding unit | M13328X1500 () | 1 |
C-600CNC () | 1 | ||
MA1420/500 () | 1 | ||
5 | Planing unit | BY60100C () | 1 |
BM2020 () | 1 |
Tab.3 Processing information of carbon efficiency indicator elements of |
Process step number | Process unit number | Machine number | Machining profit per time/CNY | Carbon emissions per time/(kg CO2e) | Processing time per time/s | Qualification rate/% | |
---|---|---|---|---|---|---|---|
1 | 41.0 | 0.24 | 434 | 96 | |||
40.0 | 0.23 | 421 | 96 | ||||
2 | 148.8 | 53.40 | 10980 | 98 | |||
148.8 | 53.40 | 10980 | 98 | ||||
148.8 | 53.40 | 10980 | 98 | ||||
1 | 85.0 | 1.30 | 552 | 95 | |||
87.0 | 1.20 | 533 | 95 | ||||
3 | 47.5 | 0.21 | 363 | 95 | |||
2 | 146.0 | 66.90 | 12780 | 98 | |||
146.0 | 66.90 | 12780 | 98 | ||||
146.0 | 66.90 | 12780 | 98 | ||||
4 | 48.5 | 0.65 | 325 | 95 | |||
48.8 | 0.58 | 310 | 98 | ||||
44.0 | 0.48 | 320 | 98 | ||||
4 | 51.0 | 0.68 | 344 | 98 | |||
52.0 | 0.59 | 326 | 98 | ||||
52.2 | 0.49 | 337 | 98 |
Tab.4 Processing information of carbon efficiency indicator elements of |
Process step number | Process unit number | Machine number | Machining profit per time/CNY | Carbon emissions per time/(kg CO2e) | Processing time per time/s | Qualification rate/% |
---|---|---|---|---|---|---|
2 | 82.4 | 40.90 | 7200 | 99 | ||
82.4 | 40.90 | 7200 | 99 | |||
82.4 | 40.90 | 7200 | 99 | |||
5 | 51.5 | 2.10 | 401 | 100 | ||
55.5 | 2.30 | 420 | 100 | |||
3 | 49.6 | 0.42 | 482 | 98 | ||
4 | 55.0 | 0.88 | 421 | 100 | ||
53.0 | 0.68 | 443 | 100 | |||
57.0 | 0.74 | 398 | 100 | |||
2 | 124.3 | 51.20 | 10200 | 93 | ||
124.3 | 51.20 | 10200 | 100 | |||
124.3 | 51.20 | 10200 | 100 |
Tab.5 Processing information of carbon efficiency indicator elements of |
Process step number | Process unit number | Machine number | Machining profit per time/CNY | Carbon emissions per time/(kg CO2e) | Processing time per time/s | Qualification rate/% |
---|---|---|---|---|---|---|
5 | 79.5 | 2.20 | 549 | 100 | ||
74.5 | 2.30 | 542 | 100 | |||
2 | 136.3 | 59.20 | 12600 | 99 | ||
136.3 | 59.20 | 12600 | 99 | |||
136.3 | 59.20 | 12600 | 99 | |||
5 | 82.6 | 1.90 | 552 | 100 | ||
80.0 | 1.70 | 549 | 100 | |||
3 | 42.5 | 0.64 | 325 | 98 |
Tab.6 Processing information of carbon efficiency indicator elements of |
Process step number | Process unit number | Machine number | Machining profit per time/CNY | Carbon emissions per time/(kg CO2e) | Processing time per time/s | Qualification rate/% |
---|---|---|---|---|---|---|
5 | 98.3 | 2.5 | 605 | 100 | ||
99.6 | 2.1 | 612 | 100 | |||
3 | 94.6 | 1.5 | 582 | 99 | ||
5 | 93.9 | 2.1 | 578 | 100 | ||
97.4 | 1.8 | 600 | 100 | |||
3 | 74.1 | 1.1 | 456 | 99 |
Tab.7 Task assignment of each machine with the optimal carbon efficiency |
Machine number | Process step number, processing task/piece, processing time/h | |||||||
---|---|---|---|---|---|---|---|---|
Task 1 | Task 2 | Task 3 | Task 4 | Task 5 | ||||
, 32, 3.86 | , 30, 4.60 | – | – | – | ||||
, 28, 3.27 | , 30, 4.44 | – | – | – | ||||
, 20, 12.20 | , 20, 14.20 | , 25, 10.00 | , 25, 14.10 | , 15, 10.50 | ||||
, 20, 12.20 | , 20, 14.20 | , 25, 10.00 | , 30, 17.00 | , 15, 10.50 | ||||
, 20, 12.20 | , 20, 14.20 | , 30, 12.00 | , 25, 14.10 | , 20, 14.00 | ||||
, 60, 6.05 | , 80, 10.71 | , 50, 4.51 | , 50, 8.08 | , 50, 6.33 | ||||
, 18, 1.63 | , 18, 1.72 | , 26, 3.04 | – | – | ||||
, 19, 1.64 | , 17, 1.54 | , 27, 3.32 | – | – | ||||
, 23, 2.04 | , 25, 2.34 | , 27, 2.99 | – | – | ||||
, 37, 4.12 | , 26, 3.97 | , 27, 3.37 | , 25, 4.20 | , 23, 3.69 | ||||
, 43, 5.02 | , 24, 3.61 | , 23, 4.27 | , 25, 4.25 | , 27, 4.50 |
Tab.8 Comparative analysis of carbon emissions under different objectives |
Process unit | Carbon emissions for PEO/(kg CO2e) | Carbon emissions for EBO/(kg CO2e) | Carbon emissions for CEO/(kg CO2e) | Carbon emission reduction ratio/% |
---|---|---|---|---|
Turning unit | 50.38 | 51.37 | 46.68 | 6%–9% |
Grinding unit | 138.45 | 141.32 | 129.77 | 6%–8% |
Planing unit | 637.70 | 563.10 | 595.90 | 7%–9% |
Tab.9 Specification of processing route planning |
Machine number | Processing route (process step number/divided sub-batch task) |
---|---|
P1,1/26→P1,3/6→P1,1/6→P1,3/6→P1,3/12→P1,3/6 | |
P1,1/21→P1,3/14→P1,1/7→P1,3/16 | |
P2,1/15→P1,2/10→P2,5/5→P1,2/10→P3,2/10→P2,1/10→P1,5/10→P3,2/5→P1,5/10→P2,5/20 | |
P2,1/15→P1,2/15→P3,2/10→P1,2/5→P2,5/10→P1,5/10→P3,2/5→P1,5/10→P2,1/10→P2,5/20 | |
P2,1/20→P1,2/5→P3,2/5→P1,2/5→P3,2/15→P2,5/20→P2,1/10→P1,5/5→P1,2/10→P1,5/15→P2,5/5 | |
P4,2/9→P2,3/9→P4,2/17→P1,4/6→P4,2/8→P2,3/26→P1,4/7→P4,4/8→P1,4/7→P4,4/9→P2,3/9→P4,2/8→P4,4/9→P1,4/7→P4,4/8→P3,4/5→P3,4/5→P1,4/20→P3,4/6→P4,4/8→P4,2/8→P3,4/5→P2,3/9→P1,4/6→P2,3/9→P3,4/23→P2,3/9→P4,4/8→P3,4/6→P1,4/7→P2,3/9 | |
P2,4/9→P2,4/8→P1,6/6→P1,7/6→P2,4/9→P1,6/6→P1,7/6→P1,6/6→P1,7/6 | |
P2,4/9→P1,6/7→P1,7/6→P1,6/6→P1,7/5→P1,6/6→P1,7/6→P2,4/9→P2,4/9 | |
P2,4/9→P2,4/9→P1,6/7→P1,7/8→P2,4/9→P1,6/8→P1,7/9→P1,6/8→P1,7/8 | |
P4,1/8→P2,2/9→P4,1/8→P3,1/5→P2,2/9→P3,1/16→P4,3/8→P4,1/9→P3,3/5→P3,3/11→P4,3/8→P3,3/6→P3,1/5→P3,3/5→P2,2/9→P4,3/7→P2,2/10 | |
P4,1/9→P3,1/6→P4,1/16→P2,2/26→P3,1/18→P4,3/18→P2,2/9→P4,3/9→P3,3/5→P3,3/6→P3,3/12→P2,2/8 |