CN112686501A - Production line analysis method and device, production line, storage medium and processor - Google Patents
Production line analysis method and device, production line, storage medium and processor Download PDFInfo
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Abstract
The invention discloses an analysis method, an analysis device, a production line, a storage medium and a processor of a production line, wherein the method comprises the following steps: determining the energy consumption condition of the production line, determining the operation condition of equipment in the production line, and determining the production condition of products on the production line; the energy consumption condition comprises the following steps: an actual energy consumption value; the operation condition of the equipment comprises the following steps: equipment point stop time; the production situation of the product comprises: the actual production volume of the product; and analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of equipment in the production line and the production condition of the production line. According to the scheme, early warning and resource allocation are timely and effectively carried out on the production process, so that the running risk and energy consumption of equipment in the production line are reduced.
Description
Technical Field
The invention belongs to the technical field of computers, and particularly relates to an analysis method, an analysis device, a production line, a storage medium and a processor of a production line, and particularly relates to an analysis method, an analysis device, a production line, a storage medium and a processor of energy consumption of a production line.
Background
In the related scheme, the energy consumption of the production line can be analyzed based on time-varying data, namely, the energy consumption situation of the energy source changing along with the time is analyzed by counting the change trend of the effective running time of each device in the process, the positive active power unit consumption, the station production and other data changing along with the time. However, the method for analyzing the energy consumption of the production line based on the time-varying data only compares the difference between the planned energy consumption and the actual energy consumption of the single equipment and the production line to control the stop and start of the equipment, and has the advantages of complex analysis logic, low calculation speed, incapability of timely and effectively performing early warning and resource allocation, and increased operation risk and energy consumption of the equipment.
The above is only for the purpose of assisting understanding of the technical aspects of the present invention, and does not represent an admission that the above is prior art.
Disclosure of Invention
The invention aims to provide an analysis method, an analysis device, a production line, a storage medium and a processor of the production line, which are used for solving the problems that the early warning and resource allocation cannot be timely and effectively carried out on the production process and the running risk and energy consumption of equipment in the production line are increased in a mode of analyzing the energy consumption of the production line based on time-varying data, and the effects of reducing the running risk and energy consumption of the equipment in the production line by timely and effectively carrying out the early warning and resource allocation on the production process are achieved.
The invention provides an analysis method of a production line, which comprises the following steps: determining the energy consumption condition of the production line, determining the operation condition of equipment in the production line, and determining the production condition of products on the production line; the energy consumption condition comprises the following steps: an actual energy consumption value; the operation condition of the equipment comprises the following steps: equipment point stop time; the production situation of the product comprises: the actual production volume of the product; and analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of equipment in the production line and the production condition of the production line.
In some embodiments, determining the energy consumption profile of the production line comprises: monitoring the water consumption condition, the power consumption condition and the gas consumption condition of the production line, recording the respective actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line, and recording the starting time and the ending time of the generation of the actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line respectively.
In some embodiments, determining the operational condition of the equipment in the production line comprises: monitoring the abnormal production condition and the fault condition of the equipment in the production line, and controlling an on-off system of the production line to perform on-off control on the equipment in the production line under the condition that at least one of the abnormal production condition and the fault condition of the equipment in the production line is monitored; in the process of performing point stop control on the equipment in the production line by the point stop system of the production line, recording the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition, and taking the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition as the point stop time of the equipment.
In some embodiments, determining production of the product on the production line comprises: the actual production of the product on the production line is monitored and recorded.
In some embodiments, the operating conditions of the production line comprise: the utilization rate of the production line; analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, wherein the analysis comprises the following steps: determining the actual production time of the production line according to the equipment running time of the production line; determining the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line; and under the condition that the utilization rate of the production line is less than the set utilization rate, determining that the utilization rate of the production line does not reach the standard, and adjusting the running condition of the production line.
In some embodiments, the operation of the production line further comprises: a performance utilization rate of the production line; analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, wherein the analysis comprises the following steps: determining a performance utilization rate of the production line based on the actual production volume of the production line and the rated production volume of the production line; and under the condition that the performance utilization rate of the production line is less than the set performance utilization rate, if the actual energy consumption value of the production line is greater than the planned energy, determining that the equipment in the production line has a fault or is idle, and performing point stop control and fault check on the equipment in the production line.
In accordance with the above method, another aspect of the present invention provides an analysis apparatus for a production line, comprising: a determining unit configured to determine an energy consumption situation of the production line, determine an operation situation of equipment in the production line, and determine a production situation of a product on the production line; the energy consumption condition comprises the following steps: an actual energy consumption value; the operation condition of the equipment comprises the following steps: equipment point stop time; the production situation of the product comprises: the actual production volume of the product; an analysis unit configured to analyze the operation condition of the production line according to at least one of an energy consumption condition of the production line, an operation condition of a device in the production line, and a production condition of the production line.
In some embodiments, the determining unit, determining the energy consumption condition of the production line, includes: monitoring the water consumption condition, the power consumption condition and the gas consumption condition of the production line, recording the respective actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line, and recording the starting time and the ending time of the generation of the actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line respectively.
In some embodiments, the determining unit, determining the operation condition of the equipment in the production line, includes: monitoring the abnormal production condition and the fault condition of the equipment in the production line, and controlling an on-off system of the production line to perform on-off control on the equipment in the production line under the condition that at least one of the abnormal production condition and the fault condition of the equipment in the production line is monitored; in the process of performing point stop control on the equipment in the production line by the point stop system of the production line, recording the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition, and taking the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition as the point stop time of the equipment.
In some embodiments, the determining unit determines the production condition of the product on the production line, including: the actual production of the product on the production line is monitored and recorded.
In some embodiments, the operating conditions of the production line comprise: the utilization rate of the production line; the analysis unit analyzes the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, and comprises: determining the actual production time of the production line according to the equipment running time of the production line; determining the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line; and under the condition that the utilization rate of the production line is less than the set utilization rate, determining that the utilization rate of the production line does not reach the standard, and adjusting the running condition of the production line.
In some embodiments, the operation of the production line further comprises: a performance utilization rate of the production line; the analysis unit analyzes the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, and comprises: determining a performance utilization rate of the production line based on the actual production volume of the production line and the rated production volume of the production line; and under the condition that the performance utilization rate of the production line is less than the set performance utilization rate, if the actual energy consumption value of the production line is greater than the planned energy, determining that the equipment in the production line has a fault or is idle, and performing point stop control and fault check on the equipment in the production line.
In accordance with the above apparatus, a further aspect of the present invention provides a production line, comprising: the above-described analysis device for a production line.
In accordance with the above method, a further aspect of the present invention provides a storage medium, which includes a stored program, wherein when the program runs, a device on which the storage medium is located is controlled to execute the above analysis method of the production line.
In accordance with the above method, a further aspect of the present invention provides a processor for executing a program, wherein the program executes the method for analyzing a production line.
Therefore, according to the scheme provided by the invention, the optimal decision of energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that early warning and resource allocation can be timely and effectively carried out on the production process, and the running risk and the energy consumption of equipment in the production line can be reduced.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic flow chart diagram illustrating an embodiment of a method for analyzing a manufacturing line according to the present invention;
FIG. 2 is a schematic flow chart illustrating one embodiment of determining the operation of the equipment in the production line in the method of the present invention;
FIG. 3 is a schematic flow chart illustrating an embodiment of a process line utilization analysis performed in the method of the present invention;
FIG. 4 is a schematic flow chart illustrating one embodiment of the process of the present invention for analyzing the performance utilization of the production line;
FIG. 5 is a schematic structural diagram of an embodiment of an analysis apparatus of a production line according to the present invention;
FIG. 6 is a schematic structural diagram of an analysis model according to an embodiment of the method for analyzing energy consumption of a production line of the present invention;
fig. 7 is a schematic analysis flow diagram of an embodiment of the method for analyzing energy consumption of production line according to the present invention.
The reference numbers in the embodiments of the present invention are as follows, in combination with the accompanying drawings:
102-a determination unit; 104-analysis unit.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
According to an embodiment of the present invention, a method for analyzing a production line is provided, as shown in fig. 1, which is a schematic flow chart of an embodiment of the method of the present invention. The analysis method of the production line can comprise the following steps: step S110 and step S120.
At step S110, the energy consumption situation of the production line is determined, the operation situation of the devices in the production line is determined, and the production situation of the products on the production line is determined. The energy consumption condition comprises the following steps: actual energy consumption value. The operation condition of the equipment comprises the following steps: the equipment stops for a time. The production situation of the product comprises: actual production volume of product.
In some embodiments, the determining the energy consumption condition of the production line in step S110 includes: monitoring the water consumption condition, the power consumption condition and the gas consumption condition of the production line, recording the respective actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line, and recording the starting time and the ending time of the generation of the actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line respectively.
Specifically, the water consumption, electricity consumption and gas consumption conditions of the production line are monitored through the monitoring device, and the energy consumption values and the starting time and the ending time of energy consumption generation of the water consumption, the electricity consumption and the gas consumption conditions are recorded in the energy consumption monitoring system.
In some embodiments, a specific process of determining the operation condition of the equipment in the production line in step S110 is further described with reference to a flowchart of an embodiment of determining the operation condition of the equipment in the production line in the method of the present invention shown in fig. 2, including: step S210 and step S220.
Step S210, monitoring the abnormal production condition and the fault condition of the equipment in the production line, and controlling the point stop system of the production line to perform point stop control on the equipment in the production line under the condition that at least one of the abnormal production condition and the fault condition of the equipment in the production line is monitored.
Step S220, in the process that the point stop system of the production line performs point stop control on the equipment in the production line, the time when the equipment in the production line has abnormal production conditions and the total time when the equipment in the production line has abnormal production conditions are recorded, the time when the equipment in the production line has fault conditions and the total time when the equipment in the production line has fault conditions are recorded, and the time when the equipment in the production line has abnormal production conditions and the total time when the equipment in the production line has fault conditions are taken as the equipment point stop time.
Specifically, when the production abnormity monitoring device detects the production abnormity of the equipment and the fault monitoring device monitors the equipment fault, the point stop system performs point stop control on the equipment, records the time when the production abnormity is monitored and the total time of the abnormity, and records the time when the equipment fault occurs and the total time.
In some embodiments, the determining the production condition of the product on the production line in step S110 includes: the actual production of the product on the production line is monitored and recorded.
Specifically, the production volume and the production duration of the product are monitored by the production monitoring device and recorded in the monitoring system.
At step S120, analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, so as to manage and control the production line according to the operation condition of the production line.
Specifically, through the intelligent point of production line stops monitoring system, production line energy consumption monitoring center, production monitoring system gathers the fault information of stopping the line of whole production line, the monitoring of production information and energy consumption information three major part data is detailed to carry out the integrated analysis with the three, formulate the energy utilization of the production line body, the optimum decision of equipment management, thereby, solve the problem that production line body equipment trouble and unusual stop the line information feedback untimely, can in time carry out early warning and resource allocation to the production process effectively, can reduce the running risk and the energy consumption of equipment in the production line.
In some embodiments, the operating conditions of the production line comprise: the utilization ratio of the production line.
In step S120, analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, including: and analyzing the utilization rate of the production line.
The following further describes a specific process for analyzing the utilization rate of the production line with reference to a schematic flow chart of an embodiment of analyzing the utilization rate of the production line in the method of the present invention shown in fig. 3, including: step S310 to step S330.
Step S310, determining the actual production time of the production line according to the equipment running time of the production line.
Specifically, the utilization rate of the production line is determined according to the actual production time and the planned production time of the production line. For example: the production abnormity and fault time and duration of the production line equipment are obtained through the point stop control system, the operation duration of the production line equipment is calculated through the operation and stop time, namely the actual production time, and the utilization rate of the production line is the actual production time/planned production time.
Step S320, determining the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line.
Step S330, determining that the utilization rate of the production line does not reach the standard under the condition that the utilization rate of the production line is less than the set utilization rate, and adjusting the operation condition of the production line.
Specifically, when the utilization rate of the production line is less than 1, it is stated that a worker performs the passing-point stop control on the production line during the operation of the production line, and the reason for the passing-point stop may be insufficient. When the utilization rate of the production line is not less than 1, the production line is controlled to be stopped without points, and the production line runs normally.
In some embodiments, the operation of the production line further comprises: a performance utilization rate of the production line.
In step S120, analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, including: a process of analyzing the performance utilization rate of the production line.
The following further describes, with reference to a schematic flow chart of an embodiment of analyzing the performance utilization rate of the production line in the method of the present invention shown in fig. 4, a specific process of analyzing the performance utilization rate of the production line, including: step S410 to step S420.
Step S410, determining the performance utilization rate of the production line according to the actual production capacity of the production line and the rated yield of the production line.
Step S420, if the performance utilization rate of the production line is less than the set performance utilization rate, and if the actual energy consumption value of the production line is greater than the planned energy, determining that the equipment in the production line has a fault or is idle, and performing point stop control and fault check on the equipment in the production line, for example, controlling a point stop system of the production line to perform point stop control on the equipment in the production line, and performing fault check and maintenance.
Specifically, the time for generating energy consumption and the actual energy consumption including the electricity consumption, the water consumption and the gas consumption are obtained through an energy consumption monitoring system, and the planned energy consumption is calculated according to the actual production time.
The performance utilization rate of the production line is determined based on the actual production volume and the rated production volume of the production line. For example: and obtaining the actual production time and the actual production capacity of the production line through a production monitoring system, and calculating the rated production according to the actual production time, wherein the performance utilization rate is actual production/rated production. The energy consumption analysis system is produced to all data input that record three major systems down, through whole analysis, the influence to actual output and energy consumption of energy utilization ratio and stopping when analysis production line production realizes effectual management and control to equipment to reach the effect that reduces the energy consumption, realize the maximize of energy utilization, thereby reduce the energy consumption, improve output.
When the performance utilization rate is greater than or equal to 1, the actual yield is achieved, and the operating condition of the production line is good. When the performance utilization ratio is less than 1, it means that the productivity of the facility during production does not reach the maximum and the time throughput does not reach the rated production. If the actual energy consumption is less than or equal to the planned energy consumption, the operation condition is good. If the actual energy consumption is larger than the planned energy consumption, the situation that the equipment has idling phenomenon or fault is shown, and a manager needs to stop in time to check the equipment condition so as to avoid damaging the equipment.
Therefore, the utilization rate of the production line is calculated, the performance utilization rate is calculated, the running condition of the equipment is comprehensively judged through the energy consumption condition, the idling problem of the equipment of the production line is avoided, the equipment can be effectively regulated and controlled, and the condition of low utilization efficiency is reduced.
Through a large number of tests, the technical scheme of the embodiment is adopted, and the optimal decision of energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that early warning and resource allocation can be timely and effectively carried out on the production process, and the running risk and the energy consumption of equipment in the production line can be reduced.
According to an embodiment of the present invention, there is also provided an analysis apparatus of a production line corresponding to the analysis method of the production line. Referring to fig. 5, a schematic diagram of an embodiment of the apparatus of the present invention is shown. The analysis device of the production line may include: a determination unit 102 and an analysis unit 104.
Wherein the determining unit 102 is configured to determine an energy consumption situation of the production line, determine an operation situation of devices in the production line, and determine a production situation of products on the production line. The energy consumption condition comprises the following steps: actual energy consumption value. The operation condition of the equipment comprises the following steps: the equipment stops for a time. The production situation of the product comprises: actual production volume of product. The specific function and processing of the determination unit 102 are referred to in step S110.
In some embodiments, the determining unit 102, determining the energy consumption condition of the production line, includes: the determining unit 102 is specifically further configured to monitor a water usage condition, an electricity usage condition, and an gas usage condition of the production line, record respective actual energy consumption values of the water usage condition, the electricity usage condition, and the gas usage condition of the production line, and record start time and end time of the generation of the actual energy consumption values of the water usage condition, the electricity usage condition, and the gas usage condition of the production line.
Specifically, the water consumption, electricity consumption and gas consumption conditions of the production line are monitored through the monitoring device, and the energy consumption values and the starting time and the ending time of energy consumption generation of the water consumption, the electricity consumption and the gas consumption conditions are recorded in the energy consumption monitoring system.
In some embodiments, the determining unit 102, determining the operation condition of the equipment in the production line, includes:
the determining unit 102 is specifically further configured to monitor a production abnormal condition and a failure condition of the equipment in the production line, and control an on-off system of the production line to perform on-off control on the equipment in the production line when at least one of the production abnormal condition and the failure condition of the equipment in the production line is monitored. The specific function and processing of the determination unit 102 are also referred to in step S210.
The determining unit 102 is specifically further configured to, during the point-stop control of the point-stop system of the production line on the devices in the production line, record a time when the abnormal production condition occurs and a total time length when the abnormal condition occurs on the devices in the production line, and take the time when the abnormal production condition occurs and the total time length when the abnormal condition occurs on the devices in the production line, and the time when the abnormal production condition occurs and the total time length when the fault condition occurs on the devices in the production line as the device point-stop time. The specific function and processing of the determination unit 102 are also referred to in step S220.
Specifically, when the production abnormity monitoring device detects the production abnormity of the equipment and the fault monitoring device monitors the equipment fault, the point stop system performs point stop control on the equipment, records the time when the production abnormity is monitored and the total time of the abnormity, and records the time when the equipment fault occurs and the total time.
In some embodiments, the determining unit 102, determining the production condition of the product on the production line, includes: the determining unit 102 is further configured to monitor an actual production amount of the product on the production line and record the actual production amount of the product on the production line.
Specifically, the production volume and the production duration of the product are monitored by the production monitoring device and recorded in the monitoring system.
An analyzing unit 104 configured to analyze the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, so as to manage and control the production line according to the operation condition of the production line. The specific functions and processes of the analysis unit 104 are shown in step S120.
Specifically, through the intelligent point of production line stops monitoring system, production line energy consumption monitoring center, production monitoring system gathers the fault information of stopping the line of whole production line, the monitoring of production information and energy consumption information three major part data is detailed to carry out the integrated analysis with the three, formulate the energy utilization of the production line body, the optimum decision of equipment management, thereby, solve the problem that production line body equipment trouble and unusual stop the line information feedback untimely, can in time carry out early warning and resource allocation to the production process effectively, can reduce the running risk and the energy consumption of equipment in the production line.
In some embodiments, the operating conditions of the production line comprise: the utilization ratio of the production line.
The analysis unit 104, for analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, includes: the process of analyzing the utilization rate of the production line specifically comprises the following steps:
the analyzing unit 104 is in particular further configured to determine an actual production time of the production line based on the device runtime of the production line. The specific functions and processes of the analysis unit 104 are also referred to in step S310.
Specifically, the utilization rate of the production line is determined according to the actual production time and the planned production time of the production line. For example: the production abnormity and fault time and duration of the production line equipment are obtained through the point stop control system, the operation duration of the production line equipment is calculated through the operation and stop time, namely the actual production time, and the utilization rate of the production line is the actual production time/planned production time.
The analyzing unit 104 is specifically further configured to determine the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line. The specific functions and processes of the analysis unit 104 are also referred to in step S320.
The analysis unit 104 is further specifically configured to determine that the utilization rate of the production line does not reach the standard and the operation condition of the production line needs to be adjusted when the utilization rate of the production line is less than a set utilization rate. The specific function and processing of the analysis unit 104 are also referred to in step S330.
Specifically, when the utilization rate of the production line is less than 1, it is stated that a worker performs the passing-point stop control on the production line during the operation of the production line, and the reason for the passing-point stop may be insufficient. When the utilization rate of the production line is not less than 1, the production line is controlled to be stopped without points, and the production line runs normally.
In some embodiments, the operation of the production line further comprises: a performance utilization rate of the production line.
The analysis unit 104, for analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line, and the production condition of the production line, includes: the process of analyzing the performance utilization rate of the production line specifically comprises the following steps:
the analysis unit 104 is in particular further configured to determine a performance utilization rate of the production line based on the actual production volume of the production line and the rated production volume of the production line. The specific functions and processes of the analysis unit 104 are also referred to in step S410.
The analysis unit 104 is specifically further configured to, when the performance utilization rate of the production line is less than the set performance utilization rate, determine that there is a failure or idling of the equipment in the production line if the actual energy consumption value of the production line is greater than the planned energy, and need to perform stop-and-go control and fault check on the equipment in the production line, for example, control a stop-and-go system of the production line to perform stop-and-go control on the equipment in the production line, and perform fault check and maintenance. The specific function and processing of the analysis unit 104 are also referred to in step S420.
Specifically, the time for generating energy consumption and the actual energy consumption including the electricity consumption, the water consumption and the gas consumption are obtained through an energy consumption monitoring system, and the planned energy consumption is calculated according to the actual production time.
The performance utilization rate of the production line is determined based on the actual production volume and the rated production volume of the production line. For example: and obtaining the actual production time and the actual production capacity of the production line through a production monitoring system, and calculating the rated production according to the actual production time, wherein the performance utilization rate is actual production/rated production. The energy consumption analysis system is produced to all data input that record three major systems down, through whole analysis, the influence to actual output and energy consumption of energy utilization ratio and stopping when analysis production line production realizes effectual management and control to equipment to reach the effect that reduces the energy consumption, realize the maximize of energy utilization, thereby reduce the energy consumption, improve output.
When the performance utilization rate is greater than or equal to 1, the actual yield is achieved, and the operating condition of the production line is good. When the performance utilization ratio is less than 1, it means that the productivity of the facility during production does not reach the maximum and the time throughput does not reach the rated production. If the actual energy consumption is less than or equal to the planned energy consumption, the operation condition is good. If the actual energy consumption is larger than the planned energy consumption, the situation that the equipment has idling phenomenon or fault is shown, and a manager needs to stop in time to check the equipment condition so as to avoid damaging the equipment.
Therefore, the utilization rate of the production line is calculated, the performance utilization rate is calculated, the running condition of the equipment is comprehensively judged through the energy consumption condition, the idling problem of the equipment of the production line is avoided, the equipment can be effectively regulated and controlled, and the condition of low utilization efficiency is reduced.
Since the processes and functions implemented by the apparatus of this embodiment substantially correspond to the embodiments, principles and examples of the method shown in fig. 1 to 4, the description of this embodiment is not detailed, and reference may be made to the related descriptions in the foregoing embodiments, which are not repeated herein.
Through a large number of tests, the technical scheme of the invention is adopted, and the optimal decision of the energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that the effect of reducing the energy consumption is achieved, and the maximization of the energy utilization is realized.
According to an embodiment of the present invention, there is also provided a production line corresponding to an analysis apparatus of the production line. The production line may include: the above-described analysis device for a production line.
In some embodiments, according to the scheme of the invention, the influence of the energy utilization rate and the point stop on the actual yield and the energy consumption during production of the production line is analyzed by a production line energy consumption analysis method in combination with the point stop times and duration, so that the effect of reducing the energy consumption is achieved, and the maximization of the energy utilization is realized.
According to the scheme, the production line energy consumption analysis method is characterized in that an intelligent point stop monitoring system, a production line energy consumption monitoring center and an output monitoring system of a production line are used for monitoring and summarizing line stop fault information, output information and energy consumption information of the whole production line in detail, comprehensively analyzing the three parts, and making an optimal decision of energy utilization and equipment management of a production line body.
Specifically, according to the scheme of the invention, various data such as energy consumption conditions, equipment operation conditions, product production conditions and the like are monitored and recorded in detail in real time through three systems of an energy consumption monitoring center, a point stop system and a yield detection center and a production line analysis system, so that problems and feedback problems can be found in time, and the problems that equipment faults and abnormal line stop information of a production line body cannot be fed back in time are solved.
According to the scheme, the utilization rate of the production line is calculated firstly, the performance utilization rate is calculated secondly, and finally the operation condition of the equipment is comprehensively judged according to the energy consumption condition, so that the problem of idling of the equipment of the production line is avoided, the equipment can be effectively regulated and controlled, and the condition of low utilization efficiency is reduced.
In some embodiments, the scheme of the invention provides a production line energy consumption scheme based on-off control, yield and energy consumption, so that an energy consumption manager can control equipment in time, find equipment problems in time and reasonably distribute energy. The influence of the energy utilization rate and the stopping on the actual yield and the energy consumption during production of the production line is analyzed, so that the effect of reducing energy loss is achieved, and the maximization of energy utilization is realized.
Fig. 6 is a schematic structural diagram of an analysis model according to an embodiment of the method for analyzing energy consumption of a production line of the present invention. In the analysis model of the production line energy consumption analysis method shown in fig. 6, the energy consumption monitoring center is respectively connected to a plurality of monitoring devices, such as an electricity consumption monitoring device, a water consumption monitoring device and a gas consumption monitoring device. And the point stop system is respectively connected with the production abnormity monitoring devices and the fault monitoring devices of n devices (such as the devices 1 to n), wherein n is a positive integer. And the yield monitoring system is connected with a yield monitoring device of the product production line. The production line energy consumption analysis system is respectively connected with the energy consumption monitoring center, the point stop system and the yield monitoring system so as to control the equipment, and the production line energy consumption analysis system is also favorable for reducing energy consumption and improving yield.
In the example shown in fig. 6, the water consumption, electricity consumption and gas consumption of the production line are monitored by the monitoring device, and the energy consumption values and the start time and end time of the energy consumption generation are recorded in the energy consumption monitoring system.
Wherein, the starting time and the ending time for generating the energy consumption are the whole processing production time of the production line, namely the actual production time of the production line.
When the production abnormity monitoring device detects the production abnormity of the equipment and the fault monitoring device monitors the fault of the equipment, the point-stop system performs point-stop control on the equipment, records the time when the production abnormity is monitored and the total time of the abnormity, and records the time when the equipment is in fault and the total time.
The production abnormity monitoring device monitors abnormal line stop of a production line, abnormal production and processing products and the like, the fault monitoring device is specially used for monitoring whether each device operates normally, and if the device operates normally, the working voltage, the current, the operation parameters and the like are detected. Abnormal line stop of the production abnormal production line, abnormal production and processing products and the like, wherein the fault is whether each device normally operates or not, and if the working voltage, the current, the operation parameters and the like of the device exist.
The production quantity and the production duration of the product are monitored by the production monitoring device and recorded in the monitoring system.
All data recorded by the three systems are input into a production line energy consumption analysis system, and effective management and control are realized on the equipment through integral analysis, so that energy consumption is reduced, and yield is improved.
The production line energy consumption analysis system provides information monitored by the intelligent on-off monitoring system, the production line energy consumption monitoring center and the yield monitoring system for the production line energy consumption analysis system, and evaluates the production efficiency and the production cost by calculating and analyzing the energy consumption condition of the whole production through the monitored water, electricity and gas consumption data of each production line, the monitored whole production model and quantity data and the abnormal line stop condition of the production lines.
Fig. 7 is a schematic analysis flow diagram of an embodiment of the method for analyzing energy consumption of production line according to the present invention. As shown in fig. 7, the process of the production line energy consumption analysis method includes:
step 1, determining the utilization rate of the production line according to the actual production time and the planned production time of the production line.
Specifically, the time and duration of production abnormity and fault of the production line equipment are obtained through the point stop control system, the operation duration of the production line equipment, namely the actual production time, is calculated through the operation and stop time, and the utilization rate of the production line is the actual production time/planned production time. The energy monitoring module monitors the on-off time of the equipment by monitoring the current value of the equipment during working.
And 2, determining the performance utilization rate of the production line according to the actual production capacity and the rated yield of the production line.
Specifically, by the production monitoring system, the actual production time and the actual production capacity of the production line are obtained, and the rated production is calculated from the actual production time, so that the performance utilization rate is equal to the actual production/the rated production.
And 3, obtaining the time for generating energy consumption and the actual energy consumption including the electricity consumption, the water consumption and the gas consumption through an energy consumption monitoring system, and calculating the planned energy consumption according to the actual production time.
Step 4, analyzing the on-line stop, the actual output and the actual energy consumption of the production line, wherein the analysis method comprises the following steps:
(1) when the utilization rate of the production line is less than 1, the fact that workers perform over-point stop control on the production line during the operation of the production line is explained, and the reason of the over-point stop is probably insufficient. When the utilization rate of the production line is not less than 1, the production line is controlled to be stopped without points, and the production line runs normally.
(2) When the performance utilization rate is greater than or equal to 1, the actual yield is achieved, and the operating condition of the production line is good.
When the performance utilization ratio is less than 1, it means that the productivity of the facility during production does not reach the maximum and the time throughput does not reach the rated production. If the actual energy consumption is less than or equal to the planned energy consumption, the running condition is good; if the actual energy consumption is larger than the planned energy consumption, the situation that the equipment has idling phenomenon or fault is shown, and a manager needs to stop in time to check the equipment condition so as to avoid damaging the equipment.
Since the processes and functions implemented by the production line of this embodiment substantially correspond to the embodiments, principles and examples of the apparatus shown in fig. 5, the description of this embodiment is not given in detail, and reference may be made to the related descriptions in the embodiments, which are not described herein again.
Through a large number of tests, the technical scheme of the invention is adopted, and the optimal decision of energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that the problem that the equipment fault and abnormal line stop information of the production line are not fed back timely can be solved, and early warning and resource allocation are timely and effectively carried out on the production process.
According to an embodiment of the present invention, there is also provided a storage medium corresponding to an analysis method of a production line, the storage medium including a stored program, wherein when the program is executed, a device on which the storage medium is located is controlled to execute the analysis method of the production line.
Since the processing and functions implemented by the storage medium of this embodiment substantially correspond to the embodiments, principles, and examples of the methods shown in fig. 1 to fig. 4, details are not described in the description of this embodiment, and reference may be made to the related descriptions in the foregoing embodiments, which are not described herein again.
Through a large number of tests, the technical scheme of the invention is adopted, and the optimal decision of energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that the problem of idling of production line equipment can be avoided, and the condition of low utilization efficiency is reduced.
According to an embodiment of the present invention, there is also provided a processor corresponding to an analysis method of a production line, the processor being configured to run a program, wherein the program is run to perform the analysis method of the production line.
Since the processing and functions implemented by the processor of this embodiment substantially correspond to the embodiments, principles, and examples of the methods shown in fig. 1 to fig. 4, details are not described in the description of this embodiment, and reference may be made to the related descriptions in the foregoing embodiments, which are not described herein again.
Through a large number of tests, the technical scheme of the invention is adopted, and the optimal decision of the energy utilization and equipment management of the production line is made by comprehensively analyzing the line stop fault information, the yield information and the energy consumption information of the whole production line, so that the influence of the energy utilization rate and the point stop on the actual yield and the energy consumption during the production of the production line can be analyzed in combination with the point stop times and the time length, the effect of reducing the energy consumption is achieved, and the maximization of the energy utilization is realized.
In summary, it is readily understood by those skilled in the art that the advantageous modes described above can be freely combined and superimposed without conflict.
The above description is only an example of the present invention, and is not intended to limit the present invention, and it is obvious to those skilled in the art that various modifications and variations can be made in the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.
Claims (15)
1. A method of analyzing a production line, comprising:
determining the energy consumption condition of the production line, determining the operation condition of equipment in the production line, and determining the production condition of products on the production line; the energy consumption condition comprises the following steps: an actual energy consumption value; the operation condition of the equipment comprises the following steps: equipment point stop time; the production situation of the product comprises: the actual production volume of the product;
and analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of equipment in the production line and the production condition of the production line.
2. The method of claim 1, wherein determining the energy consumption profile of the production line comprises:
monitoring the water consumption condition, the power consumption condition and the gas consumption condition of the production line, recording the respective actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line, and recording the starting time and the ending time of the generation of the actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line respectively.
3. The method for analyzing a production line of claim 1, wherein determining the operation of the equipment in the production line comprises:
monitoring the abnormal production condition and the fault condition of the equipment in the production line, and controlling an on-off system of the production line to perform on-off control on the equipment in the production line under the condition that at least one of the abnormal production condition and the fault condition of the equipment in the production line is monitored;
in the process of performing point stop control on the equipment in the production line by the point stop system of the production line, recording the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition, and taking the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition as the point stop time of the equipment.
4. The method for analyzing a manufacturing line as recited in claim 1, wherein determining the production status of the product on the manufacturing line comprises:
the actual production of the product on the production line is monitored and recorded.
5. The method for analyzing a production line according to any one of claims 1 to 4, wherein the operation condition of the production line includes: the utilization rate of the production line;
analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, wherein the analysis comprises the following steps:
determining the actual production time of the production line according to the equipment running time of the production line;
determining the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line;
and under the condition that the utilization rate of the production line is less than the set utilization rate, determining that the utilization rate of the production line does not reach the standard, and adjusting the running condition of the production line.
6. The method for analyzing a production line according to any one of claims 1 to 4, wherein the operation condition of the production line further includes: a performance utilization rate of the production line;
analyzing the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, wherein the analysis comprises the following steps:
determining a performance utilization rate of the production line based on the actual production volume of the production line and the rated production volume of the production line;
and under the condition that the performance utilization rate of the production line is less than the set performance utilization rate, if the actual energy consumption value of the production line is greater than the planned energy, determining that the equipment in the production line has a fault or is idle, and performing point stop control and fault check on the equipment in the production line.
7. An analysis device for a production line, comprising:
a determining unit configured to determine an energy consumption situation of the production line, determine an operation situation of equipment in the production line, and determine a production situation of a product on the production line; the energy consumption condition comprises the following steps: an actual energy consumption value; the operation condition of the equipment comprises the following steps: equipment point stop time; the production situation of the product comprises: the actual production volume of the product;
an analysis unit configured to analyze the operation condition of the production line according to at least one of an energy consumption condition of the production line, an operation condition of a device in the production line, and a production condition of the production line.
8. The apparatus for analyzing a production line according to claim 7, wherein the determining unit determines the energy consumption situation of the production line, and includes:
monitoring the water consumption condition, the power consumption condition and the gas consumption condition of the production line, recording the respective actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line, and recording the starting time and the ending time of the generation of the actual energy consumption values of the water consumption condition, the power consumption condition and the gas consumption condition of the production line respectively.
9. The analysis apparatus for a production line according to claim 7, wherein the determination unit determines the operation condition of the equipment in the production line, and includes:
monitoring the abnormal production condition and the fault condition of the equipment in the production line, and controlling an on-off system of the production line to perform on-off control on the equipment in the production line under the condition that at least one of the abnormal production condition and the fault condition of the equipment in the production line is monitored;
in the process of performing point stop control on the equipment in the production line by the point stop system of the production line, recording the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition, and taking the time of the equipment in the production line with abnormal production condition and the total time of the equipment in the production line with abnormal production condition as the point stop time of the equipment.
10. The analysis device for a production line according to claim 7, wherein the determination unit determines the production condition of the product on the production line, and includes:
the actual production of the product on the production line is monitored and recorded.
11. The analyzing apparatus for a manufacturing line according to any one of claims 7 to 10, wherein the operating condition of the manufacturing line includes: the utilization rate of the production line;
the analysis unit analyzes the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, and comprises:
determining the actual production time of the production line according to the equipment running time of the production line;
determining the utilization rate of the production line according to the actual production time of the production line and the planned production time of the production line;
and under the condition that the utilization rate of the production line is less than the set utilization rate, determining that the utilization rate of the production line does not reach the standard, and adjusting the running condition of the production line.
12. The analyzing apparatus for a manufacturing line according to any one of claims 7 to 10, wherein the operating condition of the manufacturing line further includes: a performance utilization rate of the production line;
the analysis unit analyzes the operation condition of the production line according to at least one of the energy consumption condition of the production line, the operation condition of the equipment in the production line and the production condition of the production line, and comprises:
determining a performance utilization rate of the production line based on the actual production volume of the production line and the rated production volume of the production line;
and under the condition that the performance utilization rate of the production line is less than the set performance utilization rate, if the actual energy consumption value of the production line is greater than the planned energy, determining that the equipment in the production line has a fault or is idle, and performing point stop control and fault check on the equipment in the production line.
13. A production line, comprising: the analysis device of the production line according to any one of claims 7 to 12.
14. A storage medium characterized by comprising a stored program, wherein a device on which the storage medium is located is controlled to execute the analysis method of the production line according to any one of claims 1 to 6 when the program is executed.
15. A processor, characterized in that the processor is configured to run a program, wherein the program when running performs the method of analysis of a production line of any one of claims 1 to 6.
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