Abstract: In order to reduce the energy consumption during the use of CNC lathes, an energy-saving structural optimization design method was proposed for the spindle units in the main drive system. Firstly, the power model of the spindle units was constructed and the dynamic and static performance indicators were analyzed. Then, the size parameters that had a large impact on the energy consumption, dynamic and static performance of the spindle units were selected as optimization variables, based on the uniformity test and sensitivity analysis, and the indicators were fitted by response surface method. Thirdly, the principal unit analysis method was used to reduce the function dimension, and an optimization model for energy-saving design of the spindle unit structures was established. Finally, physical experiments were used to verify the reliability of the simulation results, and the simulated annealing-particle swarm hybrid algorithm was used to solve the optimization model. The comparative results of the harmonious response analysis and the simulation experiments of the spindles before and after optimization show that the maximum deformation of the spindles is reduced by 1.67%, the second-order frequency is increased by 6.83%, and the un-load energy consumption is reduced by 3.69%. This optimization design method reduces the spindle energy consumption, and improves the dynamic and static performances of the spindles at the same time.

Key words: energy-saving design, spindle unit, structural optimization, static and dynamic performance

摘要： 为降低数控车床使用过程中的能耗，针对主传动系统中的主轴部件提出一种面向节能的结构优化设计方法。首先构建主轴单元功率模型并分析其动静态性能指标；然后基于均匀试验和灵敏度分析，选取对主轴单元能耗和动静态性能影响较大的尺寸参数作为优化变量，再通过响应面法拟合指标函数；之后利用主成分分析法降低函数维度，建立主轴单元结构节能设计优化模型；最后采用实体实验验证仿真结果的可靠性，并使用模拟退火粒子群混合算法对该优化模型进行求解。优化前后主轴的仿真实验和谐响应分析对比结果表明：相对优化前，优化后主轴最大变形减小1.67%，二阶频率提高6.83%，空载能耗降低3.69%，该优化设计方法在降低主轴能耗的同时提高了主轴动静态性能。

关键词: 节能设计, 主轴单元, 结构优化, 动静态性能