CN104820899A - Method and system for acquiring energy efficiency of discrete machining equipment based on IOT (Internet of Things) - Google Patents

Method and system for acquiring energy efficiency of discrete machining equipment based on IOT (Internet of Things) Download PDF

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CN104820899A
CN104820899A CN201510246894.7A CN201510246894A CN104820899A CN 104820899 A CN104820899 A CN 104820899A CN 201510246894 A CN201510246894 A CN 201510246894A CN 104820899 A CN104820899 A CN 104820899A
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process equipment
equipment
things
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internet
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王艳
高云
纪志成
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Jiangnan University
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Jiangnan University
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Abstract

The invention proposes a method and system for acquiring the energy efficiency of discrete machining equipment based on the IOT (Internet of Things). The method mainly comprises the steps: building an energy efficiency model of the discrete machining equipment; building a workshop IOT sensing platform, defining an energy efficiency base database tabular form, and building and using an energy efficiency database. Through the above scheme of the invention, the real-time energy efficiency of the discrete machining equipment on a workshop site can be calculated based on machining parts, and can be stored in a background database, thereby achieving the sharing of energy efficiency information of a production management system and the discrete machining equipment.

Description

Based on discrete mechanical process equipment efficiency acquisition methods and the system of Internet of Things
Technical field
The present invention relates to administrative skill between intelligent vehicle, be specifically related to a kind of discrete mechanical process equipment efficiency acquisition methods based on Internet of Things and system.
Background technology
Since entering 21 century, industry is developed fast, especially the fast development of infotech and popularization and application, information-basedly merges with industrialization the new change constantly leading the mode of production, just become a kind of innovative resources employment methods, become the forever motive force of social development.Especially Modern Information based green is produced, carry out energy-conservation scheduling and optimize to produce having become the important developing direction of manufacturing activities one.Wherein, the efficiency of Real-time Obtaining discrete mechanical process equipment is have great significance for analytical equipment working ability and then resource distribution.But relative to flow manufacturing, the production run of discrete manufacture is quite complicated, produce real-time follow-up difficulty greatly, equipment automatization level is low, and production data is numerous and diverse.These features all hinder the Real-time Obtaining of discrete mechanical process equipment efficiency.The how efficiency of Real-time Obtaining discrete mechanical process equipment and then reasonably scheduling, reducing enterprise's production cost is good problem to study.
Summary of the invention
The object of the invention is to for the problems referred to above, a kind of discrete mechanical process equipment efficiency acquisition methods based on Internet of Things and system are proposed, the real-time energy efficiency of the discrete mechanical process equipment of plant site based on processing parts is calculated and be stored in the database on backstage, realizes sharing of production management system and discrete mechanical process equipment energy effective information.
Technical scheme of the present invention is as follows: the present invention establishes the energy model of main transmission according to process equipment military service Track character:
E in＝E S+E U+E M+E B
E infor in part process, the input energy of equipment main transmission, E sfor starting the energy ezpenditure of period, E uthe energy ezpenditure of unloaded period, E mfor the energy ezpenditure of part processing period, E bfor an energy ezpenditure for stopping time section;
Wherein
 
E B＝0，
A 1the load coefficient of first order processing the period in military service process, a 2the load quadratic coefficients of processing the period in military service process, P ufor the no-load power of equipment, P int () is the power processing the period in certain military service process, its expression formula is: t mfor equipment processes the time of certain part, t ufor equipment idle time.
The efficiency computing formula on process equipment same day is can be expressed as further:
  
Wherein Q sfor the number of starts on the lathe same day, Q ufor the unloaded number of times on the lathe same day, Q mfor the processing parts number on the lathe same day;
The working (machining) efficiency of single part operation
Wherein P ct () is obtained by the torque sensor be arranged in machine spindle: m z(t) moment of torsion for recording, n is the speed of mainshaft;
For load coefficient of first order a 1with load quadratic coefficients a 2acquisition set up equation of linear regression by workshop Internet of Things information architecture, under the identical speed of mainshaft, formulate multiple processing schemes that cutting data is different, measure and organize P more in(t) and P ct () value sets up the system of equations containing k equation:
And then set up equation of linear regression
Wherein, x 1=P c, P c=(P c1..., P ck) t, therefore Y=X β, wherein
By formula β=(X ' X) -1x ' Y solves, and obtains the loading factor a under this speed of mainshaft 1and a 2, simultaneously under other speeds of mainshaft, obtain corresponding loading factor, and carry out matching and obtain a 1(n i), a 2(n i), wherein n ithat machine spindle regulates the rotating speed of gear number when being i.
Accordingly, the present invention has built a discrete mechanical process equipment efficiency based on Internet of Things and has obtained system, it comprises: RFID label tag, hand-held label reader, serial server, industrial switch, control desk computing machine, torque sensor, intelligent torque gauge, zigbee node, zigbee repeater, zigbee telegon; Described industrial switch connects serial server, control desk computing machine, database server and application server respectively, composition LAN (Local Area Network);
Described RFID label tag adopts passive magnet-type anti-metal tag, is adsorbed on part to be processed, and each process equipment configures a hand-held label reader, and has exclusive IP address; When part is transported to process equipment board, operating personnel read the RFID label tag on part with hand-held label reader, and send information to database server and application server with WIFI form, and then change the machining information of part in database;
At the electric power incoming line place of every platform process equipment, an intelligent electric meter is installed, intelligent electric meter adopts Modbus communication protocol, control desk computing machine is as main website, intelligent electric meter is as slave station, all communication instructions send by main website, slave station receives communication instruction, issues oneself, then make corresponding response if judge; Intelligent electric meter is by RS485 twisted pair line connection serial server, and serial server is with ICP/IP protocol access to LAN;
The cutting power of every platform process equipment mounting torque sensor measurement process equipment main shaft, torque sensor connects intelligent torque gauge and connects Zigbee node again, the measurement data of torque sensor passes through Zigbee node-node transmission to Zigbee repeater after intelligent torque gauge process, pass to control desk computing machine after converging arrangement by the data of Zigbee telegon to torque sensor again, and then upload in database.
Control desk computing machine wherein as main website can communicate with the intelligent electric meter as slave station separately, also can with broadcast mode and all slave station communications; If communicated separately, slave station returns a message as response, if inquire about with broadcast mode, then do not do any response.
Concrete, the tables of data of described intelligent electric meter comprises: the system time when identification number of intelligent electric meter, the identification number of process equipment, image data, process equipment voltage U, process equipment electric current I; First the no-load power P of process equipment is measured u, by low speed at a high speed, add up the data of intelligent electric meter step by step, in the unloaded state, equipment general power P inbe similar to and think no-load power P u; According to the process equipment voltage U in the intelligent electric meter tables of data in database and process equipment electric current I, by P u=PI calculates P u(n 1), P u(n 2) ... P u(n i), wherein P u(n i) represent in the speed of mainshaft to be n itime equipment no-load power, will as the average no-load power of process equipment
The tables of data of described torque sensor comprises: the speed of mainshaft that the current main-shaft torque of the system time when identification number of sensor, the identification number of process equipment, image data, process equipment, process equipment are current; The current output power P of process equipment is obtained according to main-shaft torque and the speed of mainshaft c(t), the i.e. cutting power of machine spindle.
The tables of data of described hand held readers comprises: system time when tag recognition that the identification number of reader, the identification number of process equipment, part adsorb number, part identification number, image data, the machine direction of part, the machine direction of described part represents with odd number and starts processing, represents machine with even number.
Identification number and the IP address binding of reader get up, and the data of reading are transferred to server by wireless WIFI mode, and system is by resolving IP address, and judgement is the data which reader sends, and then judge it is which platform process equipment.
In the preparation process segment, the identification number of operation and process equipment bound in a database, the identification number according to part identification number and process equipment can judge the ongoing operation of this part.
T process time is calculated process time with end process time according to the beginning of part on certain process equipment m, the beginning simultaneously terminating process time and current part according to a upper part operation calculates equipment t idle time process time u.
The present invention compared with prior art has the following advantages:
1, automaticity is high: the present invention is the Real-time Obtaining realizing the parameter relevant to efficiency based on technology of Internet of things, with RFID technique, ZIGBEE technology, industrial Ethernet technology etc. realize the automatic record of production process for relying on, and then equipment real-time energy efficiency, eliminate workload and inconvenience that complicate statistics brings, decrease the monitoring burden of workshop teams and groups.
2, accuracy is high: with equipment such as sensor, industrial computer, efficiency servers for supporting, computational accuracy is higher, and real-time is stronger.Avoid the data error situation because staff's negligence brings.
3, stability is high: due to the complicacy of workshop condition, and when carrying out various data communication, the communication process of links very likely produces interruption because of external influence.Workshop thing connection aware platform in this method has more outstanding fault-tolerance, can avoid the impact that extraneous interference produces efficiency basic data acquisition process.
Accompanying drawing explanation
Fig. 1 is the workshop thing connection aware platform schematic diagram that the present invention sets up.
Fig. 2 is that reader reads setting procedure figure.
Fig. 3 is the discrete mechanical process equipment efficiency acquisition process flow diagram based on Internet of Things.
Embodiment
Below in conjunction with drawings and Examples, the present invention will be further described.
As shown in Figure 3, enforcement of the present invention mainly comprises following several part.
1: the foundation of the energy efficiency model of discrete mechanical process equipment.
For in actual process, the military service process of machining equipment by one or more unloading phase, unloaded stage, process segment and to stop the 4 class periods such as stage and form; The different periods correspond to different energy models, and different energy transfer chains not only brings the difference of energy ezpenditure, and brings the change of multiple model parameter in energy.The energy model of main transmission is set up according to process equipment military service Track character:
E in＝E S+E U+E M+E B
E infor in part process, the input energy of equipment main transmission, E sfor starting the energy ezpenditure of period, E uthe energy ezpenditure of unloaded period, E mfor the energy ezpenditure of part processing period, E bfor an energy ezpenditure for stopping time section.
Wherein
E B＝0。
A 1the load coefficient of first order processing the period in military service process, a 2the load quadratic coefficients of processing the period in military service process, P ufor the no-load power of equipment, P int () is the power processing the period in certain military service process, its expression formula is: t mfor equipment processes the time of certain part, t ufor equipment idle time.
The efficiency computing formula on process equipment same day is can be expressed as further:
Wherein Q sfor the number of starts on the lathe same day, Q ufor the unloaded number of times on the lathe same day, Q mfor the processing parts number on the lathe same day.
The working (machining) efficiency of single part operation
Wherein P ct () can be obtained by the torque sensor be arranged in machine spindle: m zt () moment of torsion for recording, n is the speed of mainshaft.
For load coefficient of first order a 1with load quadratic coefficients a 2acquisition obtain relevant operational factor by workshop Internet of Things information architecture and set up equation of linear regression, under the identical speed of mainshaft, formulate multiple processing schemes that cutting data is different, measure and organize P more in(t) and P ct () value sets up the system of equations containing k equation
And then set up equation of linear regression
Wherein, x 1=P c, P c=(P c1..., P ck) t, therefore Y=X β, wherein
By formula β=(X ' X) -1x ' Y solves, and obtains the loading factor a under this speed of mainshaft 1and a 2.Simultaneously under other speeds of mainshaft, obtain corresponding loading factor, and carry out matching and obtain a 1(n i), a 2(n i), wherein n ithat machine spindle regulates the rotating speed of gear number when being i.In conjunction with above-mentioned, the efficiency obtaining final discrete mechanical process equipment needs t process time learning part m, because t idle time produced is changed in part processing u, the output power P of equipment ct (), processes the load coefficient of first order a of period in military service process 1with quadratic coefficients a 2etc. efficiency basic data.
2: building of workshop thing connection aware platform.
In order to the processing site in work under bad environment obtains efficiency basic data, the workshop thing can built as shown in Figure 1 joins aware platform to obtain related data, platform mainly comprises process equipment, RFID label tag, hand-held label reader, RS485 cable, serial server, industrial switch, Ethernet cable, torque sensor, the compositions such as intelligent torque gauge, zigbee node, zigbee repeater, zigbee telegon.RFID label tag adopts passive magnet-type anti-metal tag to be adsorbed on part to be processed, each process equipment configures a hand-held label reader, and be connected with database server by WLAN (wireless local area network) with exclusive IP address, be deposited in prevent on-the-spot part and cause together reading interference, the reading distance of hand-held label reader is set to 20cm, when a certain part is transported to process equipment board, operating personnel read the label on part with reader, the antenna of label receives the specific electromagnetic wave signal that reader sends, coil can produce induction current, thus label is started working the content in label is sent in reader, after reader is integrated the information received, feed back to host computer with WIFI form, application software in host computer and then change the machining information of the part in database.In order to obtain process equipment power consumption condition, each process equipment installs an intelligent electric meter at electric power incoming line place, and the working current for equipment reality selects electric current than suitable current transformer, mutual inductor open type, avoids installing the situation of taking out stitches caused.Intelligent electric meter adopts Modbus communication protocol, and control desk computing machine is as main website, and intelligent electric meter is as slave station, and all communication instructions send by main website, and slave station receives communication instruction, issues oneself, then make corresponding response if judge.Main website can separately and slave station communication, also can with broadcast mode and all slave station communications.If communicated separately, slave station returns a message as response, if inquire about with broadcast mode, then do not do any response.Intelligent electric meter is by RS485 twisted pair line connection Multi-serial port server, and the serial server other end is linked in Industrial Ethernet with ICP/IP protocol.The cutting power of every platform process equipment mounting torque sensor measurement process equipment main shaft, the measurement data of torque sensor passes through Zigbee node-node transmission to Zigbee repeater after intelligent torque gauge process, pass to control desk computing machine after converging arrangement finally by the data of Zigbee telegon to torque sensor, and then upload in database.Configuration and the management of network be also responsible for by Zigbee telegon simultaneously, and comprise definition communication channel, network identifier, configuration network file, responsive node adds request and the bind request of network, strengthens Zigbee ad hoc capability.
3: the acquisition of efficiency basic data.
Table 1: intelligent electric meter tables of data form
First the no-load power P of sensing equipment u.In order to make experimental data stablize, first equipment normally being dallied a period of time, then measuring.By low speed at a high speed, add up the data of intelligent electric meter step by step, in the unloaded state, equipment general power P incan be similar to and think no-load power P u.According to the equipment voltage U in the intelligent electric meter tables of data in database and device current I value, by P u=PI calculates P u(n 1), P u(n 2) ... P u(n i), wherein P u(n i) represent in the speed of mainshaft to be n itime equipment no-load power.Relative to output power P in load conditions c(t), P u(n i) between otherness little, can be by as the average no-load power of process equipment
The collection period of torque sensor is set as that 5s gathers once, and the torque signal of collection is frequency signal.After intelligent torque gauge process, frequency signal changes into electric signal, and the amplifier through its inside delivers to A/D converter after amplifying, and converts final moment of torsion frequency signal to digital signal.By Zigbee node transmitter module, be sent to control desk computing machine.According to Zigbe node address and sensor ID and process equipment binding table, treatment classification is carried out to data.Torque sensor data sheet format in final data storehouse is as follows: final according to machine spindle torque M zthe current output power P of equipment is obtained with machine spindle rotating speed n c(t) (i.e. cutting power of machine spindle).
Table 2: torque sensor data sheet format
Table 3: hand held readers tables of data form
Hand held readers ID and IP address binding get up, and the data of reading are transferred to server by wireless WIFI mode, and by resolving IP address, judgement is the data which reader sends, and then judge it is which platform process equipment.Simultaneously in order to determine the manufacturing procedure that part carries out at process equipment, in the preparation process segment, in a database operation and device id are bound, because a part can not exceed once at often kind of process equipment processing number of times in a work flow.So the ongoing operation of this part can be judged according to Part No. and device id number.In order to calculate t process time of each part m, the Operation system setting as Fig. 2 is carried out to reader.Such background server is according to the beginning process time t of part on certain process equipment 1with end t process time 2(the system time t from data record) calculates t process time m, terminate t process time according to a part operation on equipment simultaneously 3t is counted process time with the beginning of current part 4calculate equipment t idle time u.
4: the structure in energy efficiency of equipment storehouse and part efficiency storehouse.
Efficiency data and part processing efficiency data were processed the same day for the lathe got set up corresponding form and be stored in database, so that managerial personnel's real time inspection, and carry out optimizing scheduling according to efficiency situation.Lathe efficiency spreadsheet format is as shown in table 4:
Table 4: process equipment efficiency tables of data form
Field name Data type Implication
Process equipment ID Number The identification number of process equipment
Date Date Lathe efficiency record date
The same day efficiency ψ d Number Lathe efficiency on the same day
Remarks Char Remarks
Simultaneously in order to analyze part energy effective information, the operation efficiency spreadsheet format setting up part is as shown in table 5:
Table 5: part efficiency tables of data form
Managerial personnel check the efficiency tables of data of lathe and part by database background application, and automatically to transfinite or the efficiency data of exception give the alarm to managerial personnel, efficiency data can be customized to figure or curve form is convenient compares the efficiency data of lathe and part and follow the tracks of according to demand.And on this basis, set up efficiency database, carry out optimization processing arrangement according to the efficiency situation of part and lathe in managerial personnel's processing scheduling afterwards.

Claims (10)

1., based on the discrete mechanical process equipment efficiency acquisition methods of Internet of Things, it is characterized in that: the energy model setting up main transmission according to process equipment military service Track character:
E in＝E S+E U+E M+E B
E infor in part process, the input energy of equipment main transmission, E sfor starting the energy ezpenditure of period, E uthe energy ezpenditure of unloaded period, E mfor the energy ezpenditure of part processing period, E bfor an energy ezpenditure for stopping time section;
Wherein E S = ∫ 0 t s P in ( t ) dt ;
E U = ∫ 0 t U P in ( t ) dt = P U × t U ;
E M = P U × t M + a 1 ∫ 0 t M P c ( t ) dt + a 2 ∫ 0 t M P c 2 ( t ) dt = P in ( t ) × t M ;
E B＝0，
A 1the load coefficient of first order processing the period in military service process, a 2the load quadratic coefficients of processing the period in military service process, P ufor the no-load power of equipment, P int () is the power processing the period in certain military service process, its expression formula is: t mfor equipment processes the time of certain part, t ufor equipment idle time.
2., as claimed in claim 1 based on the discrete mechanical process equipment efficiency acquisition methods of Internet of Things, it is characterized in that:
The efficiency computing formula on process equipment same day is can be expressed as:
ψ d = Σ i = 1 Q M ∫ 0 t M P c ( t ) dt Σ i = 1 Q S E Si + Σ i = 1 Q U ( P Ui × t Ui ) + Σ i = 1 Q M [ P Ui × t Mi + a 1 ∫ 0 t Mi P c ( t ) dt + a 2 ∫ 0 t Mi P c 2 ( t ) dt ]
Wherein Q sfor the number of starts on the lathe same day, Q ufor the unloaded number of times on the lathe same day, Q mfor the processing parts number on the lathe same day;
The working (machining) efficiency of single part operation ψ e = ∫ 0 t M P c ( t ) dt P U × t M + a 1 ∫ 0 t M P c ( t ) dt + a 2 ∫ 0 t M P c 2 ( t ) dt + P U × t U
Wherein P ct () is obtained by the torque sensor be arranged in machine spindle: m z(t) moment of torsion for recording, n is the speed of mainshaft;
For load coefficient of first order a 1with load quadratic coefficients a 2acquisition set up equation of linear regression by workshop Internet of Things information architecture, under the identical speed of mainshaft, formulate multiple processing schemes that cutting data is different, measure and organize P more in(t) and P ct () value sets up the system of equations containing k equation
P in 1 - P U = a 1 P c 1 + a 2 P c 1 2 . . . P ink - P U = a 1 P ck + a 2 P ck 2
And then set up equation of linear regression
y ^ = β ^ 1 x 1 + β ^ 2 x 2
Wherein, y ^ = P in - P U , β ^ 1 = a 1 , x 1＝P c，P c＝(P c1，…，P ck) T， β 2 ^ = a 2 , x 1 = P c 2 , P c 2 = ( P c 1 2 , . . . , P ck 2 ) T , Therefore Y=X β, wherein Y = P in 1 - P U . . . P ink - P U , X = P c 1 P c 1 2 . . . . . . P ck P ck 2 , β = a 1 a 2 ,
By formula β=(X ' X) -1x ' Y solves, and obtains the loading factor a under this speed of mainshaft 1and a 2, simultaneously under other speeds of mainshaft, obtain corresponding loading factor, and carry out matching and obtain a 1(n i), a 2(n i), wherein n ithat machine spindle regulates the rotating speed of gear number when being i.
3. the discrete mechanical process equipment efficiency based on Internet of Things obtains system, it is characterized in that, comprise: RFID label tag, hand-held label reader, serial server, industrial switch, control desk computing machine, torque sensor, intelligent torque gauge, zigbee node, zigbee repeater, zigbee telegon; Described industrial switch connects serial server, control desk computing machine, database server and application server respectively, composition LAN (Local Area Network); Described RFID label tag adopts passive magnet-type anti-metal tag, is adsorbed on part to be processed, and each process equipment configures a hand-held label reader, and has exclusive IP address; When part is transported to process equipment board, operating personnel read the RFID label tag on part with hand-held label reader, and send information to database server and application server with WIFI form, and then change the machining information of part in database;
At the electric power incoming line place of every platform process equipment, an intelligent electric meter is installed, intelligent electric meter adopts Modbus communication protocol, control desk computing machine is as main website, intelligent electric meter is as slave station, all communication instructions send by main website, slave station receives communication instruction, issues oneself, then make corresponding response if judge; Intelligent electric meter is by RS485 twisted pair line connection serial server, and serial server is with ICP/IP protocol access to LAN;
The cutting power of every platform process equipment mounting torque sensor measurement process equipment main shaft, torque sensor connects intelligent torque gauge and connects Zigbee node again, the measurement data of torque sensor passes through Zigbee node-node transmission to Zigbee repeater after intelligent torque gauge process, pass to control desk computing machine after converging arrangement by the data of Zigbee telegon to torque sensor again, and then upload in database.
4. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 3, it is characterized in that: the control desk computing machine as main website can communicate with the intelligent electric meter as slave station separately, also can with broadcast mode and all slave station communications; If communicated separately, slave station returns a message as response, if inquire about with broadcast mode, then do not do any response.
5. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 3, it is characterized in that: the tables of data of described intelligent electric meter comprises: the system time when identification number of intelligent electric meter, the identification number of process equipment, image data, process equipment voltage U, process equipment electric current I; First the no-load power P of process equipment is measured u, by low speed at a high speed, add up the data of intelligent electric meter step by step, in the unloaded state, equipment general power P nbe similar to and think no-load power P u; According to the process equipment voltage U in the intelligent electric meter tables of data in database and process equipment electric current I value, by P u=PI calculates P u(n 1), P u(n 2) ... P u(n i), wherein P u(n i) represent in the speed of mainshaft to be n itime equipment no-load power, will as the average no-load power of process equipment
6. as claimed in claim 3 obtain system based on the discrete mechanical process equipment efficiency of Internet of Things, it is characterized in that: the tables of data of described torque sensor comprises: the speed of mainshaft that the current main-shaft torque of the system time when identification number of sensor, the identification number of process equipment, image data, process equipment, process equipment are current; The current output power P of process equipment is obtained according to main-shaft torque and the speed of mainshaft c(t), the i.e. cutting power of machine spindle.
7. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 3, it is characterized in that: the tables of data of described hand held readers comprises: system time when tag recognition that the identification number of reader, the identification number of process equipment, part adsorb number, part identification number, image data, the machine direction of part, the machine direction of described part represents with odd number and starts processing, represents machine with even number.
8. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 7, it is characterized in that: the identification number of reader and IP address binding, the data of reading are transferred to database server and application server by wireless WIFI mode, by resolving IP address, judgement is the data which reader sends, and then judges it is which platform process equipment.
9. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 7, it is characterized in that: in the preparation process segment, the identification number of operation and process equipment bound in a database, the identification number according to part identification number and process equipment can judge the ongoing operation of this part.
10. obtain system based on the discrete mechanical process equipment efficiency of Internet of Things as claimed in claim 7, it is characterized in that: calculate t process time process time with end process time according to the beginning of part on certain process equipment m, the beginning simultaneously terminating process time and current part according to a upper part operation calculates equipment t idle time process time u.
CN201510246894.7A 2015-05-14 2015-05-14 Method and system for acquiring energy efficiency of discrete machining equipment based on IOT (Internet of Things) Pending CN104820899A (en)

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Application publication date: 20150805