CN113848831A - Automatic statistics and control method and system for utilization rate of old equipment - Google Patents
Automatic statistics and control method and system for utilization rate of old equipment Download PDFInfo
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- CN113848831A CN113848831A CN202111089056.5A CN202111089056A CN113848831A CN 113848831 A CN113848831 A CN 113848831A CN 202111089056 A CN202111089056 A CN 202111089056A CN 113848831 A CN113848831 A CN 113848831A
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- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000010977 unit operation Methods 0.000 claims abstract description 49
- 238000004364 calculation method Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 description 15
- 238000001755 magnetron sputter deposition Methods 0.000 description 6
- 239000000047 product Substances 0.000 description 5
- 238000003754 machining Methods 0.000 description 3
- 238000007726 management method Methods 0.000 description 3
- 238000007619 statistical method Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000013178 mathematical model Methods 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32339—Object oriented modeling, design, analysis, implementation, simulation language
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses an automatic statistics and control method for utilization rate of old equipment, wherein the old equipment comprises at least one functional unit, and the method comprises the following steps: the method comprises the following steps: setting a state model relationship, wherein the state model relationship is used for judging the equipment running state of the old equipment; step two: acquiring a unit operation state of at least one functional unit of the old equipment; step three: judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation; step four: counting the running state parameters of the old equipment, wherein the running state parameters correspond to the judged running state of the old equipment; step five: and calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment. The utilization rate automatic counting control method and the utilization rate automatic counting control system can provide more accurate equipment utilization rate counting.
Description
Technical Field
The invention relates to a utilization rate control technology, in particular to a utilization rate automatic statistical control method and system for old equipment.
Background
The utilization rate refers to the proportion of the time occupied by the equipment in the available time for creating value, and also refers to the ratio of the actual production quantity of a machine equipment to the possible production quantity. The utilization rate is an important reference index for production planning and reasonable work order arrangement of a factory planning department.
A utilization rate statistical method based on the operation state of machining equipment is disclosed in a Chinese patent document with the publication number of CN104808587A, the utilization rate statistical method is based on the identification of a power characteristic model to the operation state of the machining equipment, and the utilization rate indexes such as time utilization rate, performance utilization rate and the like are obtained through statistics of time parameters of the operation states such as load time, starting time, standby time and the like of the machining equipment, so that the utilization rate statistical method has the advantages of high accuracy, strong reliability and the like.
However, some factories purchase old equipment for production due to insufficient funds and other problems, and find that the equipment state reported by the old equipment and the unit states of each level of the equipment are not in accordance with the current actual state during actual production, and the original manufacturer of the old equipment cannot correspondingly modify the equipment program, so that the following problems are present:
1. the failure to correctly acquire the utilization rate of the equipment and the failure of the planning department to reasonably arrange the work order of the product according to the utilization rate can lead to the early completion of the work order of the product or the failure of the work order of the product to be completed within the specified time, thereby wasting the capacity or compensating the loss of the client.
2. The automatic dispatching of the equipment cannot be started, manpower is added to manually carry intermediate products, automatic production cannot be realized, and the target is not in accordance with the 4.0 target of the industry for creating a digital workshop and building an intelligent factory.
Disclosure of Invention
In order to solve the defects of the prior art, the invention provides an automatic statistics and control method and system for the utilization rate of old equipment, which can provide more accurate statistics for the utilization rate of the equipment.
The technical problem to be solved by the invention is realized by the following technical scheme:
an automatic statistics and control method for utilization rate of old equipment, wherein the old equipment comprises at least one functional unit, and the method comprises the following steps:
the method comprises the following steps: setting a state model relationship, wherein the state model relationship is used for judging the equipment running state of the old equipment;
step two: acquiring a unit operation state of at least one functional unit of the old equipment;
step three: judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation;
step four: counting the running state parameters of the old equipment, wherein the running state parameters correspond to the judged running state of the old equipment;
step five: and calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
Further, in step three, the unit operation states of all the functional units of the old device are all involved in the determination of the device operation states, and in step two, the unit operation states of all the functional units of the old device need to be acquired.
Further, in step three, only the unit operating state of the core function unit of the old device participates in the determination of the device operating state, and in step two, only the unit operating state of the core function unit of the old device needs to be acquired.
Further, in step three, only the unit operation state of the functional unit preset by the old device is involved in the determination of the device operation state, and in step two, only the unit operation state of the functional unit preset by the old device needs to be acquired.
Further, the first step further comprises: and setting the functional unit needing to acquire the running state of the unit.
An automatic statistics management and control system for utilization rate of old equipment, wherein the old equipment comprises at least one functional unit, and the automatic statistics management and control system comprises:
the first setting module is used for setting a state model relationship, and the state model relationship is used for judging the equipment running state of the old equipment;
an obtaining module, configured to obtain a unit operation state of at least one functional unit of the old device;
the judging module is used for judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation;
the statistical module is used for counting the running state parameters of the old equipment, and the running state parameters correspond to the judged running state of the old equipment;
and the calculation module is used for calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
Further, the judging module judges the device operating status according to the unit operating statuses of all the functional units of the old device, and the acquiring module acquires the unit operating statuses of all the functional units of the old device.
Further, the judging module judges the device operating state according to the unit operating state of the core function unit of the old device, and the acquiring module acquires only the unit operating state of the core function unit of the old device.
Further, the judging module judges the device operation state according to the unit operation state of the functional unit preset by the old device, and the acquiring module acquires only the unit operation state of the functional unit preset by the old device.
Further, still include:
and the second setting module is used for setting the functional unit needing to acquire the running state of the unit.
The invention has the following beneficial effects: according to the automatic utilization rate counting control method and system, the operation state of the equipment is judged again through the unit operation states of all the functional units in the old equipment and the preset state model relationship, more accurate equipment utilization rate counting can be provided, a planning department is helped to reasonably arrange a product work order better according to the utilization rate, the production efficiency is improved, meanwhile, automatic dispatching and goods making of the equipment are realized, the labor input is saved, the working labor intensity is reduced, and the utilization rate of equipment scheduling is improved.
Drawings
Fig. 1 is a block diagram illustrating steps of an automatic utilization rate statistics and control method according to the present invention;
fig. 2 is a schematic block diagram of the utilization rate automatic statistics management and control system provided by the present invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
As shown in fig. 1, a method for automatically counting and controlling utilization rate of an old device, where the old device includes at least one functional unit, includes the following steps:
the method comprises the following steps: and setting a state model relationship, wherein the state model relationship is used for judging the equipment running state of the old equipment.
In this step, there are a plurality of device operating states of the old device, and each device operating state is set with a corresponding state model relationship for determination, for example, the device operating state of the old device mainly includes two types, namely "on" and "standby", and in this step, it is necessary to set a corresponding state model relationship for the device operating state of "on" of the old device and a corresponding state model relationship for the device operating state of "standby" of the old device.
Of course, the device operating status of the old device is not limited to "working" and "standby", and technicians may add other types of device operating statuses according to actual production requirements, such as "down", "idle", "energy saving", and the like.
In this embodiment, in order to determine the device operating state of "working" of the old device, a plurality of state model relationships are provided, such as a first state model relationship, a second state model relationship, and a third state model relationship, where the first state model relationship is to determine that the device operating state of the old device is "working" when the unit operating states of all the obtained functional units are "working"; the second state model relationship is that when the number of the 'working' is larger than the number of the 'standby' in the unit operation states of all the obtained functional units, the equipment operation state of the old equipment is judged to be 'working'; and the third state model relationship is that when the number of the 'working' in the unit operation states of all the obtained functional units is larger than the preset number, the equipment operation state of the old equipment is judged to be 'working'.
Of course, the state model relationship for determining the operation state of the old equipment in "working" is not limited to the above three types, and technicians may add other state model relationships according to actual production requirements.
Similarly, in this embodiment, in order to determine the device operating state of "standby" of the old device, a plurality of state model relationships are provided, such as a fourth state model relationship, a fifth state model relationship and a sixth state model relationship, where the fourth state model relationship is to determine that the device operating state of the old device is "standby" when the acquired unit operating states of all the functional units are "standby"; the fifth state model relationship is that when the number of the standby units is larger than the number of the working units in the unit operation states of all the obtained functional units, the equipment operation state of the old equipment is judged to be the standby state; the sixth state model relationship is that when the number of the standby units in the unit operation states of all the obtained functional units is greater than the preset number, the equipment operation state of the old equipment is judged to be the standby state.
Step two: the unit operating state of at least one functional unit of the old device is obtained.
In the second step, the functional units refer to the units required for the old equipment to complete its production, such as an electric control unit, a conveying unit, a material taking and feeding unit, and the like, and the functional units of different old equipment are not consistent.
The unit operation states of the functional units are various, for example, the unit operation states of the functional units mainly include two types, i.e., "on" and "off". The corresponding sensors can be additionally arranged in each functional unit of the old equipment, the unit operation state of the corresponding functional unit can be judged through sensing signals of various sensors, for example, whether the corresponding functional unit operates can be sensed through a photoelectric sensor, and then the unit operation state of the corresponding functional unit can be judged, and for example, whether the voltage value or the current value of the corresponding functional unit is at rated voltage/current or standby voltage/current can be sensed through a voltage sensor or a current sensor, and then the unit operation state of the corresponding functional unit can be judged.
Of course, the unit operation states of the functional units are not limited to "working" and "standby", and technicians may add other types of unit operation states, such as "down", "idle", and the like, according to actual production requirements.
In an embodiment, the unit operation states of all the functional units of the old device are all involved in the determination of the device operation state, and at this time, the unit operation states of all the functional units of the old device need to be acquired.
In another embodiment, only the unit operation states of the core function units of the old device participate in the determination of the device operation states, and at this time, only the unit operation states of the core function units of the old device need to be obtained, taking a magnetron sputtering device as an example, the magnetron sputtering device has a production function of sputtering a target on the surface of a substrate, and the core function units performing the production function are magnetron sputtering chambers formed by plasma filaments, magnetron assemblies, and the like, so that only corresponding sensors need to be arranged in each magnetron sputtering chamber to obtain the unit operation states of each magnetron sputtering chamber of the magnetron sputtering device, and no unit operation states need to be obtained for other non-core function units (such as an electronic control unit, a conveying unit, and the like).
In another embodiment, only the unit operation status of the functional unit preset by the old device participates in the determination of the device operation status, and at this time, only the unit operation status of the functional unit preset by the old device needs to be acquired, so the first step further includes: and setting the functional unit needing to acquire the running state of the unit.
Step three: and judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation.
In this embodiment, for the device operating state of "working", when the set state model relationship is the first state model relationship, if the unit operating states of all the obtained functional units are "working", it is determined that the device operating state of the old device is "working"; when the set state model relationship is the second state model relationship, if the number of the 'working' in the unit operation states of all the obtained functional units is larger than the number of the 'standby', judging that the equipment operation state of the old equipment is 'working'; and when the set state model relationship is the third state model relationship, if the number of the 'works' in the unit operation states of all the obtained functional units is larger than the preset number, judging that the equipment operation state of the old equipment is 'works'.
For the equipment running state of 'standby', when the set state model relationship is the fourth state model relationship, if the unit running states of all the obtained functional units are 'standby', judging that the equipment running state of the old equipment is 'standby'; when the set state model relationship is the fifth state model relationship, if the number of the standby units in the unit operation states of all the obtained functional units is larger than the number of the working units, the equipment operation state of the old equipment is judged to be the standby state; and when the set state model relationship is the sixth state model relationship, if the number of the standby units in the unit operation states of all the acquired functional units is greater than the preset number, judging that the equipment operation state of the old equipment is the standby state.
It should be noted here that the first state model relationship, the second state model relationship, and the third state model relationship are only used for determining whether the device operation state of the old device is "working", and are not used for determining whether the device operation state of the old device is "standby"; similarly, the fourth state model relationship, the fifth state model relationship and the sixth state model relationship are only used for judging whether the device operation state of the old device is in a standby state, but not for judging whether the device operation state of the old device is in a working state; namely, different equipment running states are judged by adopting different state model relations.
Step four: and counting the running state parameters of the old equipment, wherein the running state parameters correspond to the judged running state of the old equipment.
In the fourth step, if the device operating status of the old device is determined as "working", the corresponding operating status parameters such as device operating time, device operating power, and the like are counted, and if the device operating status of the old device is determined as "standby", the corresponding operating status parameters such as device standby time, device standby power, and the like are counted.
Step five: and calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
In the fifth step, different indexes and different mathematical models are used for calculating the equipment utilization rate of the old equipment according to the actual production demand, which is the prior art and is not described much, for example, the method disclosed in the chinese patent document with publication number CN104808587A mentioned in the background art can be used for calculating the corresponding index of the equipment utilization rate.
As shown in fig. 2, an automatic utilization rate statistics and control system for old equipment is used to implement the automatic utilization rate statistics and control method, and includes:
the first setting module is used for setting a state model relationship, and the state model relationship is used for judging the equipment running state of the old equipment;
the second setting module is used for setting the functional unit needing to acquire the running state of the unit;
an obtaining module, configured to obtain a unit operation state of at least one functional unit of the old device;
the judging module is used for judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation;
the statistical module is used for counting the running state parameters of the old equipment, and the running state parameters correspond to the judged running state of the old equipment;
and the calculation module is used for calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
In an embodiment, the determining module determines the device operating status according to unit operating statuses of all functional units of the old device, and the obtaining module obtains the unit operating statuses of all functional units of the old device.
In another embodiment, the determining module determines the device operating status according to a unit operating status of the core function unit of the old device, and the obtaining module obtains only the unit operating status of the core function unit of the old device.
In another embodiment, the determining module determines the device operating status according to a unit operating status of a functional unit preset by the old device, and the obtaining module obtains only the unit operating status of the functional unit preset by the old device.
According to the automatic utilization rate counting control method and system, the operation state of the equipment is judged again through the unit operation states of all the functional units in the old equipment and the preset state model relationship, more accurate equipment utilization rate counting can be provided, a planning department is helped to reasonably arrange a product work order better according to the utilization rate, the production efficiency is improved, meanwhile, automatic dispatching and goods making of the equipment are realized, the labor input is saved, the working labor intensity is reduced, and the utilization rate of equipment scheduling is improved.
The above-mentioned embodiments only express the embodiments of the present invention, and the description is more specific and detailed, but not understood as the limitation of the patent scope of the present invention, but all the technical solutions obtained by using the equivalent substitution or the equivalent transformation should fall within the protection scope of the present invention.
Claims (10)
1. An automatic statistics and control method for utilization rate of old equipment, wherein the old equipment comprises at least one functional unit, and is characterized by comprising the following steps:
the method comprises the following steps: setting a state model relationship, wherein the state model relationship is used for judging the equipment running state of the old equipment;
step two: acquiring a unit operation state of at least one functional unit of the old equipment;
step three: judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation;
step four: counting the running state parameters of the old equipment, wherein the running state parameters correspond to the judged running state of the old equipment;
step five: and calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
2. The method according to claim 1, wherein in step three, the unit operation states of all functional units of the old device are all involved in the determination of the device operation state, and in step two, the unit operation states of all functional units of the old device need to be acquired.
3. The method according to claim 1, wherein in step three, only the unit operation status of the core function unit of the old device participates in the determination of the device operation status, and in step two, only the unit operation status of the core function unit of the old device needs to be acquired.
4. The method according to claim 1, wherein in step three, only the unit operation status of the functional unit preset by the old device is involved in the determination of the device operation status, and in step two, only the unit operation status of the functional unit preset by the old device needs to be obtained.
5. The automatic statistical management and control method for utilization rate of old equipment according to claim 4, wherein the first step further comprises: and setting the functional unit needing to acquire the running state of the unit.
6. An automatic statistics management and control system for utilization rate of old equipment, wherein the old equipment comprises at least one functional unit, and the automatic statistics management and control system is characterized by comprising:
the first setting module is used for setting a state model relationship, and the state model relationship is used for judging the equipment running state of the old equipment;
an obtaining module, configured to obtain a unit operation state of at least one functional unit of the old device;
the judging module is used for judging the equipment running state of the old equipment according to the acquired unit running state and the set state model relation;
the statistical module is used for counting the running state parameters of the old equipment, and the running state parameters correspond to the judged running state of the old equipment;
and the calculation module is used for calculating the equipment utilization rate of the old equipment according to the counted running state parameters of the old equipment.
7. The automatic statistics and control system for utilization rate of old equipment according to claim 6, wherein the judging module judges the equipment operation status through the unit operation statuses of all functional units of the old equipment, and the acquiring module acquires the unit operation statuses of all functional units of the old equipment.
8. The automatic statistics and control system for utilization rate of old equipment according to claim 6, wherein the judging module judges the equipment operation state according to the unit operation state of the core function unit of the old equipment, and the acquiring module acquires only the unit operation state of the core function unit of the old equipment.
9. The automatic utilization rate statistics and control system for the old equipment as claimed in claim 6, wherein the judging module judges the equipment operation state according to the unit operation state of the preset functional unit of the old equipment, and the acquiring module acquires only the unit operation state of the preset functional unit of the old equipment.
10. The automatic statistics management and control system for utilization rate of old equipment according to claim 9, further comprising:
and the second setting module is used for setting the functional unit needing to acquire the running state of the unit.
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