CN111985709A - Coating energy consumption analysis method - Google Patents
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- CN111985709A CN111985709A CN202010832335.5A CN202010832335A CN111985709A CN 111985709 A CN111985709 A CN 111985709A CN 202010832335 A CN202010832335 A CN 202010832335A CN 111985709 A CN111985709 A CN 111985709A
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- 238000005265 energy consumption Methods 0.000 title claims abstract description 246
- 239000011248 coating agent Substances 0.000 title claims abstract description 51
- 238000000576 coating method Methods 0.000 title claims abstract description 51
- 238000004458 analytical method Methods 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 claims abstract description 27
- 238000000034 method Methods 0.000 claims abstract description 19
- 239000003973 paint Substances 0.000 claims description 14
- 238000004378 air conditioning Methods 0.000 claims description 13
- 239000003292 glue Substances 0.000 claims description 13
- 238000010422 painting Methods 0.000 claims description 13
- 230000001932 seasonal effect Effects 0.000 claims description 13
- 238000004364 calculation method Methods 0.000 claims description 7
- 238000001035 drying Methods 0.000 claims description 6
- 238000005238 degreasing Methods 0.000 claims description 3
- 238000001962 electrophoresis Methods 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 230000003247 decreasing effect Effects 0.000 abstract description 2
- 239000002987 primer (paints) Substances 0.000 description 15
- 238000005057 refrigeration Methods 0.000 description 4
- 230000019771 cognition Effects 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000003892 spreading Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 238000013139 quantization Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/04—Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem"
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
-
- 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
- Y02P90/80—Management or planning
- Y02P90/82—Energy audits or management systems therefor
Abstract
The coating energy consumption analysis method comprises the steps of dividing a coating workshop into a plurality of groups according to energy consumption influence factors, determining energy consumption types in each group according to process production characteristics of the coating workshop, obtaining energy consumption standards of different energy consumption types in each group through statistics, calculating influence values of different energy consumption types in each group according to the energy consumption standards of different energy consumption types in each group, wherein the influence values are the difference between the unit energy consumption of a reference period and the unit energy consumption of a compared period, if the influence values are positive values, the energy consumption of the reference period is increased compared with that of the compared period, and if the influence values are negative values, the energy consumption of the reference period is decreased compared with that of the compared period. The method is convenient for workers to efficiently correct or make a coating management strategy aiming at reducing energy consumption.
Description
Technical Field
The invention belongs to the technical field of energy consumption monitoring, and particularly relates to a coating energy consumption analysis method.
Background
In order to comply with the national energy saving and emission reduction requirements, reduce the production cost and improve the product competitiveness, the energy consumption of a single car body in a factory is required to be reduced by 11% -15%, however, the coating energy consumption generally accounts for 60% -75% in the automobile manufacturing industry chain, and in order to complete the energy consumption reduction index of the single car body in the factory, the energy consumption of a system in a coating workshop needs to be analyzed, and a corresponding adjustment strategy for meeting the energy consumption reduction is worked out. The existing energy consumption analysis method has the following problems:
1. the reason for the excessive energy consumption is not clear. Often, the reason of the excessive energy consumption is classified into natural factors or perceptual cognition, and the reason of the excessive energy consumption cannot be controlled, so that corresponding countermeasures cannot be implemented.
2. And the difference degree of the reasons of the over-standard energy consumption cannot be quantized without quantization indexes. The specific excessive energy consumption is judged by staff experience, and staff with insufficient energy consumption management experience cannot perform energy consumption analysis work because the staff does not have system cognition on coating energy consumption.
3. And the energy consumption prediction tool is lacked, and the energy consumption prediction of the next period cannot be realized.
Disclosure of Invention
The invention aims to overcome the problems in the prior art and provide a coating energy consumption analysis method capable of determining energy consumption influence factors and quantifying the difference degree of the energy consumption influence factors.
In order to achieve the above purpose, the invention provides the following technical scheme:
a coating energy consumption analysis method sequentially comprises the following steps:
firstly, dividing a coating workshop into a plurality of groups according to energy consumption influence factors, determining energy consumption types in each group according to the process production characteristics of the coating workshop, and then obtaining energy consumption standards of different energy consumption types in each group through statistics, wherein the energy consumption types comprise fixed energy consumption and hourly energy consumption;
and secondly, calculating influence values of different energy consumption types in each team according to energy consumption standards of different energy consumption types in each team, wherein the influence values are the difference degrees between the unit energy consumption of the reference period and the unit energy consumption of the compared period, if the influence values are positive values, the energy consumption of the reference period is increased compared with that of the compared period, and if the influence values are negative values, the energy consumption of the reference period is reduced compared with that of the compared period.
In the second step, the influence values comprise a fixed energy consumption influence value and an hour energy consumption influence value,
the fixed energy consumption influence value is obtained by calculation according to a first formula, wherein the first formula is as follows:
the fixed energy consumption influence value is the actual fixed energy consumption/the yield in the reference period-the actual fixed energy consumption/the yield in the compared period;
the hour energy consumption influence value is obtained by calculation according to a formula II, wherein the formula II is as follows:
hourly energy consumption impact value-actual hourly energy consumption/hourly production in the baseline period-actual hourly energy consumption/hourly production in the compared period.
In the formula one, the actual fixed energy consumption is a fixed energy consumption standard, i.e., a power factor, wherein the power factor is 0 to 100%.
In the formula two, the actual hourly energy consumption is an hourly energy consumption standard seasonal factor, wherein the seasonal factor is 0-100%.
In the first step, the fixed energy consumption is energy consumption irrelevant to production after the painting workshop is put into operation or energy consumption irrelevant to yield and hourly yield in a production preparation procedure of the painting workshop, and the hourly energy consumption is energy consumption relevant to yield and hourly yield during the production of the painting workshop.
In the first step, the energy consumption influencing factors comprise a primer, a glue coating, a finishing, a finish and key energy consumption equipment.
The key energy consumption equipment is high-power energy consumption equipment or process parameter control type equipment and comprises an air-conditioning refrigerating unit, a finish paint drying furnace, a centrifugal refrigerating unit, air supply and exhaust equipment, a screw unit and a primer line process groove.
The fixed energy consumption comprises energy consumption generated by electrophoresis, a paint conveying and mixing system, a drying furnace, degreasing and a paint spraying chamber.
Compared with the prior art, the invention has the beneficial effects that:
the invention relates to a coating energy consumption analysis method, which comprises the steps of dividing a coating workshop into a plurality of groups according to energy consumption influence factors, determining the energy consumption type in each group according to the process production characteristics of the coating workshop, obtaining the energy consumption standard of different energy consumption types in each group through statistics, calculating the influence value of different energy consumption types in each group according to the energy consumption standard of different energy consumption types in each group, wherein the influence value is the difference between the unit energy consumption of a reference period and the unit energy consumption of a compared period, if the influence value is a positive value, the energy consumption of the reference period is increased compared with that of the compared period, and if the influence value is a negative value, the energy consumption of the reference period is decreased compared with that of the compared period, the method quantifies the difference between the unit energy consumption of the reference period and the unit energy consumption of the compared period according to the positive and negative values of the energy consumption influence factors by determining the energy consumption, therefore, the reason of the exceeding of the energy consumption is determined, and the painting personnel can conveniently amend or make a painting management strategy aiming at reducing the energy consumption. Therefore, the invention is convenient for workers to efficiently modify or make a coating management strategy aiming at reducing energy consumption.
Detailed Description
The present invention will be further described with reference to the following embodiments.
A coating energy consumption analysis method sequentially comprises the following steps:
firstly, dividing a coating workshop into a plurality of groups according to energy consumption influence factors, determining energy consumption types in each group according to the process production characteristics of the coating workshop, and then obtaining energy consumption standards of different energy consumption types in each group through statistics, wherein the energy consumption types comprise fixed energy consumption and hourly energy consumption;
and secondly, calculating influence values of different energy consumption types in each team according to energy consumption standards of different energy consumption types in each team, wherein the influence values are the difference degrees between the unit energy consumption of the reference period and the unit energy consumption of the compared period, if the influence values are positive values, the energy consumption of the reference period is increased compared with that of the compared period, and if the influence values are negative values, the energy consumption of the reference period is reduced compared with that of the compared period.
In the second step, the influence values comprise a fixed energy consumption influence value and an hour energy consumption influence value,
the fixed energy consumption influence value is obtained by calculation according to a first formula, wherein the first formula is as follows:
the fixed energy consumption influence value is the actual fixed energy consumption/the yield in the reference period-the actual fixed energy consumption/the yield in the compared period;
the hour energy consumption influence value is obtained by calculation according to a formula II, wherein the formula II is as follows:
hourly energy consumption impact value-actual hourly energy consumption/hourly production in the baseline period-actual hourly energy consumption/hourly production in the compared period.
In the formula one, the actual fixed energy consumption is a fixed energy consumption standard, i.e., a power factor, wherein the power factor is 0 to 100%.
In the formula two, the actual hourly energy consumption is an hourly energy consumption standard seasonal factor, wherein the seasonal factor is 0-100%.
In the first step, the fixed energy consumption is energy consumption irrelevant to production after the painting workshop is put into operation or energy consumption irrelevant to yield and hourly yield in a production preparation procedure of the painting workshop, and the hourly energy consumption is energy consumption relevant to yield and hourly yield during the production of the painting workshop.
In the first step, the energy consumption influencing factors comprise a primer, a glue coating, a finishing, a finish and key energy consumption equipment.
The key energy consumption equipment is high-power energy consumption equipment or process parameter control type equipment and comprises an air-conditioning refrigerating unit, a finish paint drying furnace, a centrifugal refrigerating unit, air supply and exhaust equipment, a screw unit and a primer line process groove.
The fixed energy consumption comprises energy consumption generated by electrophoresis, a paint conveying and mixing system, a drying furnace, degreasing and a paint spraying chamber.
The principle of the invention is illustrated as follows:
the coating energy consumption analysis method can not only analyze the energy consumption of the previous data, but also predict the energy consumption of the future data, and is used for guiding the working personnel to implement the coating management strategy, if the influence value is a negative value, the energy consumption of the reference period is reduced compared with that of the compared period, the coating management strategy for reducing the energy consumption does not need to be implemented on the team with the negative influence value, if the influence value is a positive value, the energy consumption of the reference period is improved compared with that of the compared period, the coating management strategy for reducing the energy consumption can be implemented on the team with the positive influence value, and the larger the absolute value of the influence value is, the larger the difference degree between the unit energy consumption of the reference period and the unit energy consumption of the compared period is.
The key energy consumption equipment is used for finely analyzing energy consumption influence factors, and energy consumption change is easily caused when the key energy consumption equipment is newly added, started, stopped and loaded, such as an air conditioning refrigerating unit is independently finished or coated with glue for cooling.
The seasonal factors are used for distinguishing actual hourly energy consumption of each team according to seasons, the hourly energy consumption of each team also changes along with the seasons due to the fact that equipment power in each team changes along with the seasonal changes, the hourly energy consumption standards of each team are obtained through statistics in order to facilitate calculation, the hourly energy consumption of each team in different seasons is distinguished through the seasonal factors, for example, the values of the seasonal factors of 5-10 months per year of the air conditioning and refrigerating unit are 40%, 60%, 80%, 50% and 30%, and the power factors are determined according to the actual power of each coating workshop.
Example 1:
a coating energy consumption analysis method is provided, which takes an automobile coating workshop of a certain company as an object, and the method is specifically carried out according to the following steps:
firstly, dividing a coating workshop into a primer, a glue coating, a fine decoration, a finish paint and a key energy consumption team according to energy consumption influence factors, wherein the key energy consumption team is an air-conditioning refrigerating unit team which is independently fine decoration or glue coating refrigeration, determining fixed energy consumption and hourly energy consumption types in each team according to the process production characteristics of the coating workshop, and then obtaining energy consumption standards of the fixed energy consumption and the hourly energy consumption in each team through statistics, wherein the energy consumption standards of the fixed energy consumption in each team are shown in table 1;
TABLE 1 fixed energy consumption Standard for each team and group of the painting shop (Yuan/Yue)
The energy consumption standards for hourly energy consumption within each team are shown in table 2:
TABLE 2 hourly energy consumption standards (Yuan/hr) for each team of the paint shop
| Factor of energy consumption | Electric power | Water (W) | Steam generating device | Natural gas | Total up to |
| Primer coating | 382 | 5 | 248 | 248 | 884 |
| Glue spreading | 142 | 0 | 16 | 143 | 301 |
| Finish paint | 2829 | 19 | 248 | 726 | 3822 |
| Finishing ornament | 125 | 0 | 16 | 0 | 141 |
| Air-conditioning refrigerating unit | 625 | 8 | 0 | 0 | 632 |
Step two, taking the month 5 of this year as a reference period, taking the month 5 of the last year as a compared period, and calculating influence values of the fixed energy consumption and the hourly energy consumption in each team according to energy consumption standards of the fixed energy consumption and the hourly energy consumption in each team, wherein the influence values are the difference between the unit energy consumption of the reference period and the unit energy consumption of the compared period, and the influence values of the fixed energy consumption in each team are calculated by the following formula:
the fixed energy consumption impact value is the actual fixed energy consumption/the yield in the reference period-the actual fixed energy consumption/the yield in the compared period,
actual fixed energy consumption is a fixed energy consumption criterion power factor;
wherein, the power factors of the primer, the glue coating, the finishing, the finish paint and the air-conditioning refrigerating unit are respectively 60%, 60% and 50%;
the hour energy consumption influence value in each team is calculated by the following formula:
hourly energy consumption impact value-actual hourly energy consumption/hourly production in the baseline period-actual hourly energy consumption/hourly production in the compared period,
actual hourly energy consumption is an hourly energy consumption criterion seasonal factor;
wherein, the seasonal factor of the air-conditioning refrigerating unit is 65%, and the seasonal factors of other teams and groups are all 100%;
the fixed energy consumption impact values for each team are shown in table 3:
TABLE 3 fixed energy consumption impact values for each team (Yuan/Tai)
As can be seen from table 3, the fixed energy consumption impact values of the primer and the topcoat teams are positive values, which indicates that the fixed energy consumption of the primer and the topcoat teams in this year 5 is improved compared with that of the primer and the topcoat teams in last year 5, and a coating management strategy capable of reducing the fixed energy consumption can be adopted for the primer, the glue coating and the topcoat teams respectively.
The hourly energy consumption impact values for the various groups are given in table 4:
TABLE 4 hourly energy consumption impact values (Yuan/Tai) for each team
| Factor of energy consumption | Production of 5 months per year | Hourly production in last 5 months | Varying the influence of energy consumption |
| Primer coating | 6.66 | 6.68 | 1.7 |
| Glue spreading | 2.8 | 6.4 | 44.4 |
| Finish paint | 6.8 | 8.2 | 22.2 |
| Finishing ornament | 2.8 | 6.4 | 44.4 |
| Air-conditioning refrigerating unit | 2.8 | 6.68 | 13.0 |
As can be seen from table 4, the influence values of the varied energy consumption of the primer, the glue coating, the finish and the air-conditioning refrigeration unit are all positive values, which indicates that the hourly energy consumption of the primer, the glue coating, the finish and the air-conditioning refrigeration unit in the month 5 is improved compared with that in the month 5, and a coating management strategy capable of reducing the hourly energy consumption can be adopted for the primer, the glue coating, the finish and the air-conditioning refrigeration unit team.
Claims (8)
1. A coating energy consumption analysis method is characterized in that:
the analysis method comprises the following steps in sequence:
firstly, dividing a coating workshop into a plurality of groups according to energy consumption influence factors, determining energy consumption types in each group according to the process production characteristics of the coating workshop, and then obtaining energy consumption standards of different energy consumption types in each group through statistics, wherein the energy consumption types comprise fixed energy consumption and hourly energy consumption;
and secondly, calculating influence values of different energy consumption types in each team according to energy consumption standards of different energy consumption types in each team, wherein the influence values are the difference degrees between the unit energy consumption of the reference period and the unit energy consumption of the compared period, if the influence values are positive values, the energy consumption of the reference period is increased compared with that of the compared period, and if the influence values are negative values, the energy consumption of the reference period is reduced compared with that of the compared period.
2. The coating energy consumption analysis method according to claim 1, characterized in that:
in the second step, the influence values comprise a fixed energy consumption influence value and an hour energy consumption influence value,
the fixed energy consumption influence value is obtained by calculation according to a first formula, wherein the first formula is as follows:
fixed energy consumption impact = actual fixed energy consumption/yield in baseline period-actual fixed energy consumption/yield in compared period;
the hour energy consumption influence value is obtained by calculation according to a formula II, wherein the formula II is as follows:
hourly energy consumption impact = actual hourly energy consumption/hourly production in baseline period-actual hourly energy consumption/hourly production in compared period.
3. The coating energy consumption analysis method according to claim 2, characterized in that:
in equation one, the actual fixed energy consumption = fixed energy consumption standard power factor, wherein the power factor is 0-100%.
4. The coating energy consumption analysis method according to claim 2 or 3, characterized in that:
in equation two, the actual hourly energy consumption = hourly energy consumption standard seasonal factor, wherein the seasonal factor is 0-100%.
5. A painting energy consumption analyzing and predicting method according to any one of claims 1 to 3, characterized in that:
in the first step, the fixed energy consumption is energy consumption irrelevant to production after the painting workshop is put into operation or energy consumption irrelevant to yield and hourly yield in a production preparation procedure of the painting workshop, and the hourly energy consumption is energy consumption relevant to yield and hourly yield during the production of the painting workshop.
6. A coating energy consumption analysis method according to any one of claims 1 to 3, characterized in that:
in the first step, the energy consumption influencing factors comprise a primer, a glue coating, a finishing, a finish and key energy consumption equipment.
7. The coating energy consumption analysis method according to claim 6, characterized in that:
the key energy consumption equipment is high-power energy consumption equipment or process parameter control type equipment and comprises an air-conditioning refrigerating unit, a finish paint drying furnace, a centrifugal refrigerating unit, air supply and exhaust equipment, a screw unit and a primer line process groove.
8. The coating energy consumption analysis method according to claim 5, characterized in that:
the fixed energy consumption comprises energy consumption generated by electrophoresis, a paint conveying and mixing system, a drying furnace, degreasing and a paint spraying chamber.
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| CN202010832335.5A CN111985709A (en) | 2020-08-18 | 2020-08-18 | Coating energy consumption analysis method |
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| CN105654240A (en) * | 2015-12-30 | 2016-06-08 | 江南大学 | Machine tool manufacturing system energy efficiency analysis method |
| CN111160598A (en) * | 2019-11-13 | 2020-05-15 | 浙江中控技术股份有限公司 | Energy prediction and energy consumption control method and system based on dynamic energy consumption benchmark |
-
2020
- 2020-08-18 CN CN202010832335.5A patent/CN111985709A/en active Pending
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|---|---|---|---|---|
| CN103455718A (en) * | 2013-08-26 | 2013-12-18 | 中国能源建设集团广东省电力设计研究院 | Energy utilization efficiency evaluation method and system |
| CN105160476A (en) * | 2015-09-07 | 2015-12-16 | 东华大学 | Level-3 energy consumption and production management method suitable for small and medium-sized production enterprises |
| CN105654240A (en) * | 2015-12-30 | 2016-06-08 | 江南大学 | Machine tool manufacturing system energy efficiency analysis method |
| CN111160598A (en) * | 2019-11-13 | 2020-05-15 | 浙江中控技术股份有限公司 | Energy prediction and energy consumption control method and system based on dynamic energy consumption benchmark |
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