CN114026511A - Industrial installation, in particular a metal production or aluminium or steel industry installation, and method for operating an industrial installation, in particular a metal production or aluminium or steel industry installation - Google Patents
Industrial installation, in particular a metal production or aluminium or steel industry installation, and method for operating an industrial installation, in particular a metal production or aluminium or steel industry installation Download PDFInfo
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- CN114026511A CN114026511A CN202080047431.7A CN202080047431A CN114026511A CN 114026511 A CN114026511 A CN 114026511A CN 202080047431 A CN202080047431 A CN 202080047431A CN 114026511 A CN114026511 A CN 114026511A
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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], computer integrated manufacturing [CIM]
- G05B19/41875—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], computer integrated manufacturing [CIM] characterised by quality surveillance of production
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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
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
- G05B23/0283—Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL]
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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
- G05B2219/32061—Central controls modules grouped according to function
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/80—Management or planning
Abstract
The invention relates to an industrial installation (1) and a method for operating an industrial installation (1), in particular of the metal production industry or of the aluminium or steel industry, comprising: a production planning system (2) for creating a production sequence, an automation system (3) for controlling the industrial installation (1) and for executing the created production sequence, a condition monitoring system (4) for monitoring one or more regions of the industrial installation (1), a quality management system (5) for detecting quality characteristics of manufactured products, a maintenance planning system (5) for planning maintenance work to be performed in the industrial installation (1), characterized in that the industrial installation (1) also comprises a central data collection and analysis unit (7), for collecting data of a production planning system (2), an automation system (3), a condition monitoring system (4), a quality management system (5) and a maintenance planning system (6) and for analyzing the collected data to optimize the production and maintenance process of the industrial facility (1).
Description
Technical Field
The present invention relates to an industrial plant, in particular a plant for the metal production industry or for the aluminium or steel industry. The invention also relates to a method for operating an industrial installation, in particular an installation of the metal production industry or of the aluminium or steel industry.
Background
The present invention relates to industrial plants, in particular plants for the metal production industry or the aluminium or steel industry. Examples of such industrial facilities are blast furnaces, direct reduction facilities, electric arc furnaces, converter or ladle process facilities, facilities for the primary forming or reshaping of metals, such as continuous or billet casting facilities and hot and/or cold rolling facilities, or facilities upstream or downstream of said facilities, such as furnaces, for example reheating or holding furnaces, alignment devices, cladding lines, cooling sections, pickling or annealing and also facility components which are indirectly required for the process, such as also raw material warehouses (for example ore warehouses), intermediate products (for example slab or coil warehouses) or end products, storage (for example for gases) or other auxiliary facilities, such as transport devices or mechanisms, for example cranes, material tankers or trains. In particular, the industrial installation according to the invention also relates to a combination of a plurality of the above-mentioned installations for manufacturing a plurality of products in a production sequence.
Such industrial facilities typically include the following systems:
a production planning system for creating a production sequence for an industrial facility,
an automated system for controlling an industrial facility and for executing a production sequence created by a production planning system,
a condition monitoring system for monitoring one or more areas of an industrial facility,
a quality management system for detecting quality characteristics of products produced in an industrial facility,
a maintenance planning system for planning maintenance work to be performed in an industrial facility.
The disadvantages of the industrial installations known from the prior art are: the individual systems are closed and no data exchange usually takes place. Since the system also uses its own data structure, data exchange can be difficult to implement. Furthermore, there are useful tasks in industrial facility operations that cannot be unambiguously associated with a single system and therefore cannot be considered.
The following disadvantages also arise by the division into the proposed systems: the user must be familiar with each system, in particular its operation, and must adapt to multiple systems if necessary in the event of changes and/or expansions of the industrial installation.
WO 2018/145947 a1 proposes exchanging data between various systems of an industrial facility to improve the operation of the industrial facility. However, due to the system differences, different data structures and mutually incompatible interfaces of the individual systems can only be realized with a high initial outlay.
Disclosure of Invention
The object on which the invention is based is: the operation of an industrial installation is optimized, in particular in order to improve the installation load rate, the service life of the components, the average quality of the products and the deadline backups.
According to the invention, this object is achieved by an industrial installation, in particular of the metal production industry or of the aluminium or steel industry, comprising:
a production planning system for creating a production sequence for an industrial facility,
an automated system for controlling an industrial facility and for executing a production sequence created by a production planning system,
a condition monitoring system for monitoring one or more areas of an industrial facility,
a quality management system for detecting quality characteristics of products manufactured in an industrial facility,
a maintenance planning system for planning maintenance work to be performed in an industrial facility,
the plant is characterized in that it is provided with,
the industrial facility also includes a central data collection and analysis unit for collecting data of the production planning system, the automation system, the condition monitoring system, the quality management system and/or the maintenance planning system and for analyzing the collected data to optimize the production and maintenance processes of the industrial facility.
Therefore, data of the production planning system, the automation system, the condition monitoring system, the quality management system, and the maintenance planning system are collected collectively, for example, by: the system transmits the data to a central data collection and analysis unit. Since all data for an industrial facility is at a central point, all collected data can be evaluated for process improvement in the industrial facility. From the analysis, the operation of the industrial installation can be optimized with respect to different criteria.
According to the optimization objective, there is no mandatory need: data is collected from all systems of an industrial facility in a central data collection and analysis unit and analyzed. If data for one or more of the systems is not important for a particular optimization objective, the corresponding system and its data may be ignored.
Since the individual systems of the industrial installation each transmit data to a central data collection and evaluation unit, the effort for data exchange is significantly reduced, since the individual systems do not have to transmit their data to a plurality of different systems. This can be a complex task, especially in terms of different data structures, interfaces and transmission protocols, and requires extensive adaptation of all systems of an industrial installation.
In addition, the advantage of performing centralized analysis on the collected data is that: the overall performance of the industrial installation can be optimized, while in the case of decentralized analysis of the data only important parameters in the system are taken into account during the optimization. Even if the systems exchange data with each other, optimization is performed only within one system, and optimization from the other system is ignored in some cases.
According to an advantageous variant of the invention, the data collection and evaluation unit is designed to control a production planning system, an automation system, a condition monitoring system, a quality management system and/or a maintenance planning system. The data collection and analysis unit can thus carry out the discovered optimizations directly in the production planning system, automation system, condition monitoring system, quality management system and/or maintenance planning system after analyzing the collected data. For this purpose, information suitable for controlling the respective system is transmitted and implemented locally. Thus, there is no longer a need to perform control actions in the respective systems to implement the discovered optimization.
According to a particularly advantageous variant of the invention, the data collection and evaluation unit has a graphical operating interface, in particular a unified operating interface for a production planning system, an automation system, a condition monitoring system, a quality management system and/or a maintenance planning system. The data collection and analysis unit can be operated visually through a graphical operating interface. Particularly suitable are: the graphical operation interface of the data collection and analysis unit provides a unified graphical operation interface for the production planning system, the automation system, the state monitoring system, the quality management system and/or the maintenance planning system. The operator therefore only needs to be familiar with the graphical user interface and the operation of the entire industrial installation is simplified for the operator.
In one variant of the invention, the data of the production planning system, automation system, state monitoring system, quality management system and/or maintenance planning system are divided into a quality list, a planning list, a process list, a maintenance list, a state monitor, a maintenance monitor, a process monitor and/or a quality monitor. The quality catalogue includes a collection of all producible products and their corresponding quality requirements. The planning list comprises a set of all products to be produced together with their quality requirements, in particular a reference quality catalogue. The process criteria required to achieve a particular quality requirement in the quality list are listed in the process list. All maintenance measures that are suitable or desirable to eliminate current or predictable limitations are listed in the maintenance catalog. The current and predicted status of the facility with respect to current or predictable limiting aspects, in particular entries in the process directory, is included in the status monitor. Information about all planned maintenance measures is included in the maintenance monitor. Process data from in production is included in the process monitor. The achieved quality of the individual products is included in the quality monitor.
The object is also achieved by a method for operating an industrial installation, in particular an installation of the metal production industry or of the aluminium or steel industry, preferably an industrial installation according to the invention, comprising the steps of:
collecting data of a production planning system, an automation system, a condition monitoring system, a quality management system and/or a maintenance planning system in a central data collection and analysis unit,
analyzing the collected data by a data collection and analysis unit to optimize the manufacturing and maintenance process of the industrial facility, an
The optimized manufacturing and maintenance process is performed by a production planning system and a maintenance planning system.
The collection of data of the production planning system, automation system, condition monitoring system, quality management system and/or maintenance planning system in the central data collection and evaluation unit can be carried out in the following manner: the individual systems transmit their data to a central data collection and analysis unit or the data collection and analysis unit calls the data from the individual systems. Likewise, the central data collection and analysis unit may transmit data to the individual systems or the individual systems may call data from the central data collection and analysis unit. In particular, the data collection and analysis unit may provide a database for storing data of the various systems, which database is accessible by all systems of the industrial facility. The costs associated with the exchange of data between the individual systems can be significantly reduced by the central data collection and evaluation unit, in particular because not all systems have to be adapted for each exchange of data with one another.
By means of the data of all relevant systems of the industrial installation being present in the central data collection and analysis unit, an overall analysis and optimization can be provided, while according to the prior art only partial optimization is always performed in the subsystems.
According to an advantageous variant of the invention, the method comprises accessing, processing and/or modifying the collected data in the data collection and analysis unit by means of a production planning system, an automation system, a condition monitoring system, a quality management system and/or a maintenance planning system. Thus, all systems of an industrial installation have complete access to the data in the central data collection and analysis unit.
In a particularly advantageous variant of the invention, the analysis of the collected data is based on a machine learning method and/or statistical method, wherein the machine learning method and/or statistical method particularly describes the entire process running in the industrial installation. The machine learning process and/or statistical method is for example selected from: classification, regression through, for example, linear models, neural networks, decision trees, integration methods, support vector machines, hidden markov models, and the like. However, methods in the unsupervised learning domain, such as clustering algorithms (e.g., k-means, k-models, k-protocols, DBSCAN, Gaussian mixture models, etc.), may also be used. Algorithms, i.e., gradient descent, back propagation, reinforcement learning, evaluation-decision methods, evolutionary development, for example, can be used for the training method. In particular, the advantages of the machine learning method are: over time, the accuracy of the prediction of processes in an industrial facility improves continuously, thereby improving the optimization as well.
According to a variant of the invention, the collection of data comprises:
monitoring the status of the component, the facility component or the entire industrial facility,
monitoring the frequency/frequency of component failures, down time and maintenance expenditures,
the quality of the product is monitored and controlled,
the stock of raw materials is monitored and controlled,
the stock of the spare parts is monitored and controlled,
personnel deployment plans with respect to operation of an industrial facility, and/or
Technical target presets for manufacturing individual products in an industrial facility are determined.
According to a particularly advantageous variant of the invention, the optimization of the manufacturing and maintenance processes in the industrial installation is based on a prediction of the future state of the industrial installation. Based on data collected from various systems of the industrial facility, a prediction of a future state of the industrial facility is created. For example, the predictions are created by machine learning methods, in particular by continuously improved artificial intelligence. Based on the predictions, optimization of manufacturing and maintenance processes is performed in the industrial facility, and then performed.
According to a variant of the invention, the prediction of the future state of the industrial installation comprises:
each product is predicted to achieve the target quality,
the possible date of delivery is predicted and,
predicting the consumption of resources used, and/or
The consumption of the spare parts/consumables used is predicted.
According to another variant of the invention, the optimization of the manufacturing and maintenance processes in an industrial installation aims at:
the maximization of the availability of the installation and,
the maximization of the productivity of the production line,
maximization of output (throughput and product quality)
The minimization of the resources used is achieved by,
the maintenance costs are minimized and the maintenance costs are minimized,
the cost of the spare parts is minimized and,
the consumption of the personnel is minimized and,
the minimization of the cost of the resources is achieved,
the maximization of profits, particularly in terms of product mix control,
the maximization of the reliability of the time frame gatekeeper,
the maximization of the reliability of the availability of the installation,
the minimization of the warehousing cost is achieved by,
minimization of binding capital, and/or
The overall economy of operation of the industrial facility is maximized.
According to a variant of the invention, the optimization of the manufacturing and maintenance processes in an industrial installation is achieved by:
planning the production sequence in the entire industrial facility and/or in the individual sub-areas/production units,
the production order is distributed to the various production units,
the process of transportation and warehousing is planned,
ordering raw materials and/or
And ordering the spare parts.
In a particularly advantageous variant of the invention, the method comprises a step of evaluating an optimization of the manufacturing and maintenance processes in the industrial installation, wherein the evaluation of the optimization comprises, for example:
the reliability of the production plan is evaluated,
the economic benefit of the measure/process is evaluated,
the achievement of the optimization objective is evaluated, in particular by comparison with a hypothetical non-optimized run of the industrial facility.
According to this variant of the invention, the check is carried out: whether the optimization performed actually achieves the predicted advantages/benefits.
According to another variant of the invention, a unified graphical operating interface is provided for executing the method according to the invention on a computing device. Suitably, the production planning system, the automation system, the condition monitoring system, the quality management system and/or the maintenance planning system are likewise controlled via a unified graphical operating interface. Thus, a unified graphical operator interface is provided to control all systems of an industrial facility. The operator must therefore only be familiar with the graphical operator interface in order to control the entire industrial installation and to carry out the method according to the invention in order to optimize the manufacturing and maintenance process.
According to an advantageous variant of the invention, an interface for transmitting, querying and/or modifying data in a central data collection and evaluation unit is provided. By means of the provided interface, the data collection and analysis unit can be integrated into an existing industrial installation, since the interface undertakes communication with existing systems within the industrial installation.
In a particularly preferred variant of the invention, the data in the central data collection and analysis unit comprises:
a quality catalog in which is included a set of all producible products and their corresponding quality requirements,
a planning list in which all products that are in the face of production are included, together with a set of their quality requirements, for example by referring to a quality catalogue,
a process directory in which process criteria required to achieve a particular quality requirement in the quality directory are listed,
a maintenance directory in which all maintenance measures that are suitable and/or necessary for eliminating current or predictable restrictions are listed,
a status monitor in which current and/or predicted status and/or current or predictable limitations of the industrial facility, particularly limitations regarding process catalogs,
a maintenance monitor in which information of all planned maintenance measures is included,
a process monitor in which process data in production is included, and/or
A quality monitor in which the achieved quality of the respective product is included.
In a variant, the maintenance measures can be planned automatically, for example, according to the quality requirements of the production to be met. For this purpose, the following data are linked and analyzed with one another in a central data collection and analysis unit: plan list- > quality directory- > status monitor- > maintain directory- > plan.
In another variation, production planning may be limited to or prioritize production of such products that are compatible with current and up to production anticipated limits, thereby reducing downtime and increasing production and component life. For this purpose, the following data are linked and analyzed with one another in a central data collection and analysis unit: status monitor- > maintain directory- > schedule list- > schedule.
In another variant, the yield can be increased by: a systematic balancing between the process state and the achievable quality is performed. For this purpose, the following data are linked and analyzed with one another in a central data collection and analysis unit: state monitor- > process monitor- > quality monitor- > process directory- > plan list- > plan.
In another variant, the yield can be increased and the reduced product quality can be reduced by: i.e. the information from the status monitor and the plan list are linked together in the production plan and re-planning is avoided.
In another variant, data from the process monitor and data from the quality monitor are linked to each other to thereby create new entries or modify existing entries in the process catalog. Thereby, the system continuously learns: which conditions are really important for a certain quality requirement.
In another variant, data from the status monitor and data from the quality monitor are linked to each other to create new entries or modify existing entries in the maintenance directory. Thereby, the system continuously learns: there is what correlation between facility status and product quality and which measures positively affect which facility status and product characteristics.
In a further variant, the deadline guard is increased by better predictability of downtime, by more frequently reaching the required product quality and by more specifically planning the product.
In another variation, the maintenance cost is reduced by increasing the service life of the assembly and continuously optimizing the maintenance schedule.
Drawings
In the following, the invention is explained in more detail on the basis of embodiments shown in the drawings. The figures show:
fig. 1 shows a schematic view of an industrial installation according to the invention.
Detailed Description
Fig. 1 shows a schematic view of an industrial installation 1 according to the invention, in particular of the metal production industry or of the aluminium or steel industry. The industrial facility 1 includes a production planning system 2 for creating a production sequence for the industrial facility 1, an automation system 3 for controlling the industrial facility 1 and for executing the production sequence created by the production planning system 2, a condition monitoring system 4 for monitoring one or more areas of the industrial facility 1, a quality management system 5 for detecting quality characteristics of products manufactured in the industrial facility 1, and a maintenance planning system 6 for planning maintenance work to be performed in the industrial facility 1.
According to the invention, the industrial installation 1 also comprises a central data collection and analysis unit 7 for collecting data of the production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and/or the maintenance planning system 6 and for analyzing the collected data in order to optimize the production and maintenance process of the industrial installation 1. The data exchange between the individual systems 2, 3, 4, 5, 6 and the central data collection and analysis device 7 preferably takes place bidirectionally, which is indicated by the double arrows.
Suitably, the data collection and analysis device 7 is configured for controlling the production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and/or the maintenance planning system 6.
The data collection and evaluation unit 7 also has a graphical operator interface 8, in particular a unified operator interface 8 for the production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and/or the maintenance planning system 6.
Preferably, data of the production planning system 2, the automation system 3, the status monitoring system 4, the quality management system 5 and/or the maintenance planning system 6 is divided into a quality catalog, a planning list, a process catalog, a maintenance catalog, a status monitor, a maintenance monitor, a process monitor and/or a quality monitor.
The invention relates in particular to a method for an industrial installation 1, in particular for a metal production industry or for an aluminium or steel industry, for example an industrial installation 1 according to fig. 1. The method according to the invention comprises the following steps:
data of the production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and/or the maintenance planning system 6 are collected in a central data collection and analysis unit 7,
analyzing the collected data by the data collection and analysis unit 7 to optimize the manufacturing and maintenance process in the industrial installation 1, and
the optimized manufacturing and maintenance process is performed by production planning system 2 and maintenance planning system 6.
The production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and the maintenance planning system 6 can access, process and/or modify the data collected in the central data collection and analysis unit 7.
The analysis of the collected data is preferably based on machine learning methods and/or statistical methods, wherein the machine learning methods and/or statistical methods in particular describe the entire process running in the industrial installation 1.
According to the method of the invention, the collection of data comprises, for example:
monitoring the status of the component, the plant part or the entire industrial plant 1,
monitoring the frequency/frequency of component failures, down time and maintenance expenditures,
the quality of the product is monitored and controlled,
the stock of raw materials is monitored and controlled,
the stock of the spare parts is monitored and controlled,
personnel deployment plan with respect to the operation of the industrial installation 1, and/or
Technical target presets for manufacturing the respective products in the industrial installation 1 are determined.
Optimization of manufacturing and maintenance processes in the industrial facility 1 is advantageously based on a prediction of the future state of the industrial facility 1. The prediction of the future state of the industrial installation 1 includes, for example:
with respect to the prediction of each product to achieve a target quality,
a prediction of the possible delivery date of the goods,
predictions about consumption of resources used, and/or
Prediction of consumption of spare parts/consumables used.
For example, the optimization of the manufacturing and maintenance processes in the industrial installation 1 aims at:
the maximization of the availability of the installation and,
the maximization of the productivity of the production line,
maximization of output (productivity and product quality)
The minimization of the resources used is achieved by minimizing the amount of resources used,
the maintenance costs are minimized and the maintenance costs are minimized,
the cost of the spare parts is minimized and,
the cost of the personnel is minimized and,
the minimization of the cost of the resources is achieved,
the benefits, particularly in terms of product mix control,
the maximization of the reliability of the time frame gatekeeper,
the maximization of the reliability of the availability of the installation,
the minimization of the warehousing cost is achieved by,
minimization of binding capital, and/or
The overall economy of operation of the industrial installation 1 is maximized.
Here, the optimization of the manufacturing and maintenance processes in the industrial installation 1 is achieved, for example, by:
planning the production sequence in the entire industrial installation 1 and/or in the individual sub-areas/production units,
the production order is distributed to the various production units,
planning the transportation and storage process and the storage process,
ordering raw materials and/or
And ordering the spare parts.
Suitably, the optimization of the manufacturing and maintenance processes in the industrial installation 1 is evaluated. Therefore, the following checks are carried out: whether the optimized manufacturing and maintenance procedures achieve the desired advantages. The evaluation of the optimization includes, for example:
the reliability of the production plan is evaluated,
the economic benefit of the measure/process is evaluated,
the achievement of the optimization objective is evaluated, in particular by comparison with a hypothetical non-optimized run of the industrial facility.
The method according to the invention provides a unified graphical user interface 8 for carrying out the method according to the invention on a computing device, wherein the computing device can be designed as a central data collection and evaluation unit 7. As described above, in particular the production planning system 2, the automation system 3, the condition monitoring system 4, the quality control system 5 and/or the maintenance planning system 6 can be controlled via a unified graphical operating interface 8.
The central data collection and evaluation unit 7 provides, in particular, an interface for transmitting, querying and/or modifying data, via which the data in the central data collection and evaluation unit can be accessed and, if necessary, processed and/or modified, in particular the production planning system 2, the automation system 3, the condition monitoring system 4, the quality management system 5 and/or the maintenance planning system 6.
The data in the central data collection and analysis unit 7 include, for example:
a quality catalog in which is included a set of all producible products and their corresponding quality requirements,
a planning list in which all products that are in the face of production are included, together with a set of their quality requirements, for example by referring to a quality catalogue,
a process directory in which process criteria required to achieve a particular quality requirement in the quality directory are listed,
a maintenance catalog in which all maintenance measures are listed that are suitable and/or necessary to remove current or predictable limitations,
a status monitor, in which the current and/or predicted status of the industrial installation 1 and/or the current or required to be expected restrictions, in particular restrictions with regard to the process catalog,
a maintenance monitor in which information of all planned maintenance measures is included,
a process monitor in which process data in production is included, and/or
A quality monitor in which the achieved quality of the respective product is included.
List of reference numerals
1 Industrial installation
2 production planning system
3 automatic system
4 status monitoring system
5 quality management system
6 maintenance planning system
7 central data collection and analysis unit
8 unified operation interface
Claims (18)
1. An industrial installation (1), in particular of the metal production industry or of the aluminium or steel industry, comprising:
a production planning system (2) for creating a production sequence of the industrial facility (1);
an automation system (3) for controlling the industrial installation (1) and for executing the production sequence created by the production planning system (2);
a condition monitoring system (4) for monitoring one or more zones of the industrial installation (1);
a quality management system (5) for detecting quality characteristics of products manufactured in the industrial installation (1);
a maintenance planning system (5) for planning maintenance work to be performed in the industrial installation (1),
it is characterized in that the preparation method is characterized in that,
the industrial installation (1) further comprises a central data collection and analysis unit (7) for collecting data of the production planning system (2), the automation system (3), the status monitoring system (4), the quality management system (5) and/or the maintenance planning system (6) and for analyzing the collected data to optimize the production and maintenance progress of the industrial installation (1).
2. The industrial installation (1) according to claim 1,
wherein the data collection and analysis unit (7) is used for controlling the production planning system (2), the automation system (3), the status monitoring system (4), the quality management system (5) and/or the maintenance planning system (6).
3. The industrial installation (1) according to claim 1 or claim 2,
wherein the data collection and analysis unit (7) has a graphical operating interface (8), in particular a unified operating interface (8) for the production planning system (2), the automation system (3), the status monitoring system (4), the quality management system (5) and/or the maintenance planning system (6).
4. The industrial installation (1) according to one of claims 1 to 3,
wherein data of the production planning system (2), the automation system (3), the status monitoring system (4), the quality management system (5) and/or the maintenance planning system (6) are divided into a quality directory, a plan list, a process directory, a maintenance directory, a status monitor, a maintenance monitor, a process monitor and/or a quality monitor.
5. A method for operating an industrial installation (1), in particular an installation of the metal production industry or of the aluminium or steel industry, preferably an industrial installation (1) according to any one of claims 1 to 4, comprising the steps of:
collecting data of the production planning system (2), the automation system (3), the condition monitoring system (4), the quality management system (5) and/or the maintenance planning system (6) in a central data collection and analysis unit (7);
analyzing the collected data by the data collection and analysis unit (7) to optimize manufacturing and maintenance processes in the industrial facility (1); and
performing an optimized manufacturing and maintenance procedure by the production planning system (2) and the maintenance planning system (6).
6. The method of claim 5, comprising:
accessing, processing and/or modifying the data collected in the data collection and analysis unit (7) by the production planning system (2), the automation system (3), the status monitoring system (4), the quality management system (5) and/or the maintenance planning system (6).
7. The method of claim 5 or claim 6,
wherein the analysis of the collected data is based on a machine learning method and/or a statistical method, wherein the machine learning method and/or the statistical method particularly describes the entire process running in the industrial installation (1).
8. The method according to any one of claims 5 to 7,
wherein the collecting of data comprises:
monitoring the status of components, plant parts or the entire industrial plant (1);
monitoring component failures, down time and frequency of maintenance expenditures;
monitoring the product quality;
monitoring raw material inventory;
monitoring spare part inventory;
-a personnel deployment plan regarding the operation of the industrial installation (1); and/or
Determining a technical target preset (1) for manufacturing the respective product in the industrial installation (1).
9. The method according to any one of claims 5 to 8,
wherein optimization of manufacturing and maintenance processes in the industrial facility (1) is based on prediction of future states of the industrial facility (1).
10. The method of claim 9, wherein the first and second light sources are selected from the group consisting of,
wherein the prediction of the future state of the industrial installation (1) comprises:
predicting that each product reaches the target quality;
predicting a likely delivery date;
predicting the consumption of the used resources; and/or
The consumption of the spare parts/consumables used is predicted.
11. The method according to any one of claims 5 to 10,
wherein optimizing the manufacturing and maintenance processes in the industrial installation (1) aims at:
maximizing facility availability;
maximizing productivity;
maximizing output (throughput and product quality);
minimizing the resources used;
the maintenance cost is minimized;
the spare part cost is minimized;
the personnel consumption is minimized;
minimizing resource costs;
maximizing revenue, particularly in terms of product mix control;
maximizing reliability of deadline gatekeeper;
maximizing reliability of facility availability;
the warehousing cost is minimized;
minimizing binding capital; and/or
The overall economy of operation of the industrial installation (1) is maximized.
12. The method according to any one of claims 5 to 11,
wherein optimization of manufacturing and maintenance processes in the industrial facility (1) is achieved by:
planning a production sequence in the entire industrial facility (1) and/or in individual sub-areas/production units;
distributing the production order to each production unit;
planning transportation and storage processes;
ordering raw materials; and/or
And ordering the spare parts.
13. The method according to any one of claims 5 to 12, comprising the steps of:
evaluating an optimization of a manufacturing and maintenance process in the industrial facility (1).
14. The method of claim 13, wherein the first and second light sources are selected from the group consisting of,
wherein the evaluation of the optimization comprises:
evaluating the reliability of the production plan;
assessing the economic benefit of the measure/process;
the achievement of an optimization objective is evaluated, in particular by comparison with a hypothetical non-optimized run of the industrial installation (1).
15. The method of any of claims 5 to 14, comprising:
a unified graphical operation interface (8) is provided to perform the method according to the invention on a computing device.
16. The method of claim 15, wherein the first and second light sources are selected from the group consisting of,
wherein the production planning system (2), the automation system (3), the condition monitoring system (4), the quality management system (5) and/or the maintenance planning system (6) are controlled via a unified graphical operating interface (8).
17. The method of any of claims 5 to 16, comprising:
an interface is provided for transmitting, querying and/or modifying data in the central data collection and analysis unit (7).
18. The method of any one of claims 5 to 17,
wherein the data in the central data collection and analysis unit (7) comprises:
a quality catalog including a set of all producible products and their corresponding quality requirements in the quality catalog;
a plan list in which is included a set of all products in production along with their quality requirements, for example by reference to a quality catalog;
a process directory in which process criteria required to meet a particular quality requirement in the quality directory are listed;
a maintenance directory in which all maintenance measures that are suitable and/or necessary for eliminating current or predictable restrictions are listed;
a status monitor in which current and/or predicted status and/or current or predictable restrictions, in particular restrictions regarding the process catalog, of the industrial installation (1) are included;
a maintenance monitor including information of all planned maintenance measures in the maintenance monitor;
a process monitor including in-production process data in the process monitor; and/or
A quality monitor in which the achieved quality of the respective product is included.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102019209110.5A DE102019209110A1 (en) | 2019-06-24 | 2019-06-24 | Industrial plant, in particular plant in the metal-producing industry or the aluminum or steel industry, and method for operating an industrial plant, in particular a plant in the metal-producing industry or the aluminum or steel industry |
| DE102019209110.5 | 2019-06-24 | ||
| PCT/EP2020/067642 WO2020260361A1 (en) | 2019-06-24 | 2020-06-24 | Industrial installation, in particular installation for the metal-producing industry or the aluminium or steel industry, and method for operating an industrial installation, in particular an installation for the metal-producing industry or the aluminium or steel industry |
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| CN114026511A true CN114026511A (en) | 2022-02-08 |
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| EP (1) | EP3987371A1 (en) |
| CN (1) | CN114026511A (en) |
| DE (1) | DE102019209110A1 (en) |
| TW (1) | TWI768386B (en) |
| WO (1) | WO2020260361A1 (en) |
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Also Published As
| Publication number | Publication date |
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| TWI768386B (en) | 2022-06-21 |
| DE102019209110A1 (en) | 2020-12-24 |
| TW202109222A (en) | 2021-03-01 |
| EP3987371A1 (en) | 2022-04-27 |
| WO2020260361A1 (en) | 2020-12-30 |
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