CN111665812A - Injection molding machine production energy consumption management method and system - Google Patents
Injection molding machine production energy consumption management method and system Download PDFInfo
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- CN111665812A CN111665812A CN202010616678.8A CN202010616678A CN111665812A CN 111665812 A CN111665812 A CN 111665812A CN 202010616678 A CN202010616678 A CN 202010616678A CN 111665812 A CN111665812 A CN 111665812A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 152
- 238000005265 energy consumption Methods 0.000 title claims abstract description 62
- 238000001746 injection moulding Methods 0.000 title claims abstract description 46
- 238000007726 management method Methods 0.000 title claims description 22
- 238000000034 method Methods 0.000 claims abstract description 26
- 230000002159 abnormal effect Effects 0.000 claims description 7
- 230000005540 biological transmission Effects 0.000 claims description 7
- 230000005611 electricity Effects 0.000 claims description 5
- 238000002360 preparation method Methods 0.000 claims description 5
- 238000007405 data analysis Methods 0.000 claims description 4
- 239000000463 material Substances 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000019771 cognition Effects 0.000 description 1
- 238000013480 data collection Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000010137 moulding (plastic) Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32252—Scheduling production, machining, job shop
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to the technical field of mold production, in particular to a method and a system for managing production energy consumption of an injection molding machine.
Description
Technical Field
The invention relates to the technical field of mold production, in particular to a method and a system for managing production energy consumption of an injection molding machine.
Background
An injection molding machine is a main molding device for making thermoplastic plastics or thermosetting plastics into plastic products with various shapes by using a plastic molding die. The injection molding machine can heat the plastic material and apply high pressure to the molten plastic material to inject the molten plastic material to fill the mold cavity. Therefore, the injection molding machine is an indispensable production equipment in the manufacturing industry at present.
At present, most manufacturers count production data through mold opening and closing times and manual records displayed by machine tables in production management of injection molding machines, and yield data cannot be synchronized with energy consumption data, so that energy consumption, production rate and the like in a production process of products do not have relatively accurate data analysis, production cognition of the products mostly stays on a theoretical level, and different products or different machine tables have difference between resource consumption and theoretical data in practical application production, so that most manufacturers cannot better utilize the injection molding machines to produce the products or cannot effectively perform better production planning on own product production, and certain resource waste is caused.
Disclosure of Invention
The invention provides a method for managing the production energy consumption of an injection molding machine, which aims at the problems in the prior art, and the method is characterized in that real-time production data of a plurality of products are collected and analyzed, and then the working data of the injection molding machine is combined to establish a working energy consumption management database of the injection molding machine, so that a worker can better know different products and working production of different machines according to the database, can better plan the matching problem of the production of the products and the machines and the time management problem, and can effectively control the energy consumption of the produced machines.
In order to solve the technical problems, the invention adopts the following technical scheme: a production energy consumption management method for an injection molding machine comprises the following steps:
A. establishing a basic database;
b, when the product starts to produce, acquiring and recording the time Ha0 when the machine starts to produce and the electricity consumption Ea0 when the machine starts to produce;
c.a when the product finishes production, acquiring and recording the time Ha1 when the machine finishes production, the power consumption Ea1 when the machine finishes production and the mold opening and closing times ma of the product a produced by the machine;
D. the system analyzes the production data of the product a according to a basic database and the acquired data, wherein the production data comprises the total production time Ha of the product a, the energy consumption Ea of the product a produced by a machine, the product yield Ma and the actual productivity Pa;
E. repeating the step A to the step C to obtain production data of the n products;
F. the system analyzes the working data of the machine according to the production data of the n products;
G. and comparing and analyzing the production data of the n products and the working data of the plurality of machines to form a working energy consumption management database.
In the step A, the basic database comprises a mold number No. of the injection molding machine, a mold model A, a theoretical production period T, a mold cavity number N, a cavity number N, a theoretical capacity P and a theoretical product unit weight G.
Wherein, the production data of the product a comprises:
the total production time of the product a is Ha1-Ha0, and the energy consumption Ea of a machine is Ea1-Ea 0;
the product yield was Ma ═ (Na ═ Na · Ma); na is the number of die cavities of the machine for producing a product a, Na is the number of models of the product a in each die cavity, and ma is the number of die opening and closing times of the machine in the process of producing the product a;
a, the unit consumption of the product is Ea/Ma;
a, the actual productivity Pa of the product is Ma/Ha;
the production data for the nth product includes:
the total production time of the nth product is Hn1-Hn0, and the energy consumption En of a machine station is En1-En 0;
the product yield is Mn ═ (Nn × Mn); the number of the mold cavities of the machine station for producing n products is Nn, the number of the models of the n products in each mold cavity is Nn, and the number of the mold opening and closing times of the machine station in the process of producing the n products is mn;
the unit consumption of n products is En/Mn;
the actual productivity Pn of n products is Mn/Hn.
Wherein, the working data of board includes:
the production utilization rate of the machine is (Ha + Hb +. + Hn)/H100%, wherein H is the total working time of the machine;
normal working time of a machine station is (Ha + Hb +.. + Hn), and abnormal working time of the machine station is H- (Ha + Hb +.. + Hn);
the energy consumption of the machine in the normal production time is (Ea + Eb +.. + En), and the energy consumption of the machine in the abnormal production time is E- (Ea + Eb +.. + En), wherein E is the total energy consumption of the machine.
Preferably, before each product is produced, an order of the two-dimensional code needs to be generated for a worker to track the production process.
Preferably, after the production preparation is completed, the staff scans the two-dimensional code through the mobile terminal equipment and starts the current order production; and when the order is finished, the staff scans the two-dimensional code through the mobile terminal equipment to finish the current order production.
Preferably, a threshold value X is set, and when the current production volume of the product compared to the target production volume is equal to the threshold value X, the staff member knows that the current order is about to end production.
Preferably, the data analysis result in the working energy consumption management database is presented in a form of a chart.
The production energy consumption management system of the injection molding machine comprises the injection molding machine, an electric energy acquisition device, a machine operating state acquisition device and a data transmission device, wherein the electric energy acquisition device and the machine operating state acquisition device are arranged on the injection molding machine; the electric energy acquisition device is used for acquiring power consumption data in the working process of the injection molding machine, the machine operating state acquisition device is used for acquiring and storing the operating working state of the injection molding machine and the mold opening and closing times in the production process of products, and the data transmission device is used for transmitting the acquired data of the electric energy acquisition device and the machine operating state acquisition device to the cloud server.
Preferably, the machine operation state acquisition device comprises an acquisition interface and a mobile terminal, the acquisition interface is used for recording the operation working state of the injection molding machine and the mold opening and closing times during product production, and the mobile terminal is used for recording the production starting time and the production ending time of the product.
The invention has the beneficial effects that:
according to the injection molding machine production energy consumption management method provided by the invention, real-time production data of a plurality of products are collected and analyzed to obtain data such as product production time, production energy consumption and actual capacity of the products, corresponding work data of a machine table are analyzed according to the real-time production data of the products, and the collected and analyzed product production data and the work data of the machine table are established as a work energy consumption management database for workers to analyze the work production conditions of different products and different machine tables, so that the energy consumption in the production process can be more clearly known, the matching problem between the production of the products and the machine table and the time management problem can be better planned, and the energy consumption of the produced machine table can be effectively controlled.
Drawings
FIG. 1 is a flow chart of the present invention.
Fig. 2 is a block diagram of the system of the present invention.
Detailed Description
In order to facilitate understanding of those skilled in the art, the present invention will be further described with reference to the following examples and drawings, which are not intended to limit the present invention. The present invention is described in detail below with reference to the attached drawings.
The method for managing the production energy consumption of the injection molding machine comprises the following steps:
A. establishing a basic database;
b, when the product starts to produce, acquiring and recording the time Ha0 when the machine starts to produce and the electricity consumption Ea0 when the machine starts to produce;
c.a when the product finishes production, acquiring and recording the time Ha1 when the machine finishes production, the power consumption Ea1 when the machine finishes production and the mold opening and closing times ma of the product a produced by the machine;
D. the system analyzes the production data of the product a according to a basic database and the acquired data, wherein the production data comprises the total production time Ha of the product a, the energy consumption Ea of the product a produced by a machine, the product yield Ma and the actual productivity Pa;
E. repeating the step A to the step C to obtain production data of the n products;
F. the system analyzes the working data of the machine according to the production data of the n products, wherein the working data comprises the production utilization rate and the relation between the working time of the machine and the energy consumption;
G. and comparing and analyzing the production data of the n products and the working data of the plurality of machines to form a working energy consumption management database.
Specifically, the basic database records basic data such as a mold number No. and a mold model A, a theoretical production period T, a mold cavity number N, a cavity number N, a theoretical capacity P, a theoretical product unit weight G and the like. The theoretical capacity is typically the number of theoretically producible products per hour, with the theoretical capacity P ═ 3600 × number of module wells N × number of wells N)/theoretical production cycle T.
In actual production, the production data of the product a comprises:
the total production time of the product a is Ha1-Ha0, and the energy consumption Ea of a machine is Ea1-Ea 0;
the product yield was Ma ═ (Na ═ Na · Ma); na is the number of die cavities of the machine for producing a product a, Na is the number of models of the product a in each die cavity, and ma is the number of die opening and closing times of the machine in the process of producing the product a;
a, the unit consumption of the product is Ea/Ma;
a, the actual productivity Pa of the product is Ma/Ha; comparing the theoretical capacity Pa0 of the product a with the actual capacity Pa;
the unit raw material electricity consumption for producing the product a can be calculated as Ea/Ga, and Ga is the theoretical single weight of the product a.
The production data collection and analysis of other products are the same as those of the product a, so that the production data of the product of the nth item comprises the following steps: the total production time of the nth product is Hn1-Hn0, and the energy consumption En of a machine station is En1-En 0;
the product yield is Mn ═ (Nn × Mn); the number of the mold cavities of the machine station for producing n products is Nn, the number of the models of the n products in each mold cavity is Nn, and the number of the mold opening and closing times of the machine station in the process of producing the n products is mn;
the unit consumption of n products is En/Mn;
n actual capacity Pn of the product is Mn/Hn, and similarly, each product can be compared and analyzed with theoretical capacity and actual capacity;
and the unit raw material electricity consumption of each product is En/Gn.
After the production data of each product is collected and analyzed, a practical analysis can be performed on the working data of the machine table of the injection molding machine, wherein the working data comprises the production utilization rate of the machine table (Ha + Hb +. + Hn)/H100%, and H is the total working time of the machine table; normal working time of a machine station is (Ha + Hb +.. + Hn), and abnormal working time of the machine station is H- (Ha + Hb +.. + Hn); the energy consumption of the machine in the normal production time is (Ea + Eb +.. + En), and the energy consumption of the machine in the abnormal production time is E- (Ea + Eb +.. + En), wherein E is the total energy consumption of the machine.
In fact, after the above-mentioned working data is obtained, the yield, the unit consumption, the actual capacity and the utilization rate of the same product produced by the same machine in different periods can be longitudinally compared, and the yield, the unit consumption, the actual capacity and the utilization rate of the same product produced by a plurality of machines can be transversely compared. Even the statistical comparison analysis can be carried out on the yield, unit consumption, actual capacity and utilization rate of different raw materials of different machines and machines of the same mould; by the method, the product unit consumption, the raw material unit consumption, the equipment utilization rate, the normal production time energy consumption and the abnormal production time energy consumption can be compared and analyzed in multiple dimensions and in the transverse and longitudinal directions of multiple platforms, and data support is provided for reducing energy consumption and promoting management.
In addition, in the method for managing production energy consumption of an injection molding machine provided in this embodiment, as shown in fig. 1, the production flow is as follows:
firstly, before each product is produced, an order with a two-dimensional code needs to be generated for a worker to track the production process;
then, after the order is generated, the order is provided to a worker, after the worker prepares production including preparation of a mold, preparation of a production material, machine adjustment and the like, the worker scans the two-dimensional code through mobile terminal equipment, starts the current order production and starts to collect and analyze working data; the production system is set with a threshold value X, when the production quantity of the current product is equal to the threshold value X compared with the target production quantity, the system can inform a worker of reaching the threshold value X or knowing that the order is about to be produced by the worker through inspection in a short message or other ways, and prepare to stop the machine; after the machine is stopped, the staff scans the two-dimensional code through the mobile terminal equipment to finish the current order production, namely, the current order is finished, in the whole process, the system synchronously records the time for the staff to scan the two-dimensional code to start the current order production and scan the two-dimensional code to finish the current order production and the data of the mold opening and closing times, energy consumption and the like in the working process of the machine, a database is formed, and the database is further analyzed.
The product production process provided by the embodiment is convenient for the staff to track the production process of each production order and is convenient for production management.
The system for managing the production energy consumption of the injection molding machine, as shown in fig. 2, includes an injection molding machine, an electric energy collection device, a machine operation state collection device, and a data transmission device, where the electric energy collection device and the machine operation state collection device are both installed on the injection molding machine; the electric energy acquisition device is used for acquiring power consumption data in the working process of the injection molding machine, the machine operating state acquisition device is used for acquiring and storing the operating working state of the injection molding machine and the mold opening and closing times in the production process of products, and the data transmission device is used for transmitting the acquired data of the electric energy acquisition device and the machine operating state acquisition device to the cloud server. The machine table running state acquisition device comprises an acquisition interface and a mobile terminal, wherein the acquisition interface is used for recording the running working state of the injection molding machine and the mold opening and closing times during product production, and the mobile terminal is used for recording the starting production time and the ending production time of the product. The operation status includes a status that the machine needs to be manually, semi-automatically, or fully automatically, for example, preparation before production is completed manually, the machine automatically performs production, or semi-automatically performs production with manual assistance when a fault occurs, but this embodiment is not limited to the above statuses.
Specifically, the electric energy collection device, the machine operation state collection device and the data transmission device are used for collecting, recording and analyzing working data in the working process of the machine, the time for product production is obtained, the production energy consumption of the product, the actual capacity and other data are obtained, corresponding working data of the machine are analyzed according to the real-time production data of multiple products, the collected and analyzed product production data and the working data of the machine are established as a working energy consumption management database, the working energy consumption management database is used for workers to analyze different products and working production conditions of different machines, the energy consumption in the production process can be more clearly known, the matching problem of production of the products and the matching problem of the machine and the time management problem can be better planned, and the energy consumption of the produced machine can be effectively controlled.
Although the present invention has been described with reference to the above preferred embodiments, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. The production energy consumption management method of the injection molding machine is characterized by comprising the following steps:
A. establishing a basic database;
b, when the product starts to produce, acquiring and recording the time Ha0 when the machine starts to produce and the electricity consumption Ea0 when the machine starts to produce;
c.a when the product finishes production, acquiring and recording the time Ha1 when the machine finishes production, the power consumption Ea1 when the machine finishes production and the mold opening and closing times ma of the product a produced by the machine;
D. the system analyzes the production data of the product a according to a basic database and the acquired data, wherein the production data comprises the total production time Ha of the product a, the energy consumption Ea of the product a produced by a machine, the product yield Ma and the actual productivity Pa;
E. repeating the step A to the step C to obtain production data of the n products;
F. the system analyzes the working data of the machine according to the production data of the n products;
G. and comparing and analyzing the production data of the n products and the working data of the plurality of machines to form a working energy consumption management database.
2. The method for managing the production energy consumption of the injection molding machine according to claim 1, characterized in that: in step A, the basic database comprises the mold number No. of the injection molding machine, the mold type A, the theoretical production period T, the mold cavity number N, the cavity number N, the theoretical productivity P and the theoretical product unit weight G.
3. The method for managing the production energy consumption of the injection molding machine as claimed in claim 2, wherein the production data of the product a comprises:
the total production time of the product a is Ha1-Ha0, and the energy consumption Ea of a machine is Ea1-Ea 0;
the product yield was Ma ═ (Na ═ Na · Ma); na is the number of die cavities of the machine for producing a product a, Na is the number of models of the product a in each die cavity, and ma is the number of die opening and closing times of the machine in the process of producing the product a;
a, the unit consumption of the product is Ea/Ma;
a, the actual productivity Pa of the product is Ma/Ha;
the production data for the nth product includes:
the total production time of the nth product is Hn1-Hn0, and the energy consumption En of a machine station is En1-En 0;
the product yield is Mn ═ (Nn × Mn); the number of the mold cavities of the machine station for producing n products is Nn, the number of the models of the n products in each mold cavity is Nn, and the number of the mold opening and closing times of the machine station in the process of producing the n products is mn;
the unit consumption of n products is En/Mn;
the actual productivity Pn of n products is Mn/Hn.
4. The method for managing production energy consumption of injection molding machines of claim 3, wherein the working data of the machine in step E comprises:
the production utilization rate of the machine is (Ha + Hb +. + Hn)/H100%, wherein H is the total working time of the machine;
normal working time of a machine station is (Ha + Hb +.. + Hn), and abnormal working time of the machine station is H- (Ha + Hb +.. + Hn);
the energy consumption of the machine in the normal production time is (Ea + Eb +.. + En), and the energy consumption of the machine in the abnormal production time is E- (Ea + Eb +.. + En), wherein E is the total energy consumption of the machine.
5. The method for managing the production energy consumption of the injection molding machine according to claim 1, characterized in that: before each product is produced, an order with a two-dimensional code needs to be generated for a worker to track the production process.
6. The method for managing the production energy consumption of the injection molding machine according to claim 5, wherein: after the production preparation is completed, the staff scans the two-dimensional code through the mobile terminal equipment and starts the current order production; and when the order is finished, the staff scans the two-dimensional code through the mobile terminal equipment to finish the current order production.
7. The method for managing the production energy consumption of the injection molding machine according to claim 1, characterized in that: a threshold X is set, and when the current production volume of the product compared to the target production volume is equal to the threshold X, the staff member can know that the current order is about to finish producing.
8. The method for managing the production energy consumption of the injection molding machine according to claim 1, characterized in that: and the data analysis result in the working energy consumption management database is presented in a form of a chart.
9. The utility model provides an injection molding machine production energy consumption management system which characterized in that: the device comprises an injection molding machine, an electric energy acquisition device, a machine operating state acquisition device and a data transmission device, wherein the electric energy acquisition device and the machine operating state acquisition device are arranged on the injection molding machine;
the electric energy acquisition device is used for acquiring power consumption data in the working process of the injection molding machine, the machine operating state acquisition device is used for acquiring and storing the operating working state of the injection molding machine and the mold opening and closing times in the production process of products, and the data transmission device is used for transmitting the acquired data of the electric energy acquisition device and the machine operating state acquisition device to the cloud server.
10. The system for managing production energy consumption of injection molding machines of claim 9, wherein: the machine table running state acquisition device comprises an acquisition interface and mobile terminal equipment, wherein the acquisition interface is used for recording the running working state of the injection molding machine and the mold opening and closing times during product production, and the mobile terminal equipment is used for recording the production starting time and the production ending time of the product.
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Cited By (1)
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| CN112848184A (en) * | 2021-02-01 | 2021-05-28 | 树根互联股份有限公司 | Yield determination method and device, injection molding machine production system and storage medium |
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