CN115293448A - Method for calculating manufacturing energy consumption of single product in discrete manufacturing industry - Google Patents
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Abstract
The invention discloses a method for calculating the manufacturing energy consumption of a single product in the discrete manufacturing industry, which comprises the steps of S1, data acquisition; s2, establishing an operation unit energy consumption model, and determining an optimal operation unit energy consumption model by utilizing an optimization algorithm iterative optimization; determining an energy consumption predicted value of the operation unit by using standard energy consumption data of the operation unit based on the optimal operation unit energy consumption model; s3, establishing a relation between the production process of the single product and each operation unit; and S4, calculating the energy consumption of the single product. The advantages are that: the method combines the production process information, comprehensively considers the production process data and has higher precision. The energy consumption model in the invention is a dynamic algorithm, and the parameters are dynamically adjusted along with the change of data volume. According to the method and the system, the energy consumption of the single product in a certain period can be generated in a one-key mode, the energy consumption trend can be accurately monitored based on the trend analysis of the energy consumption of the product, and data support is provided for improving the accuracy of management decision.
Description
Technical Field
The invention relates to the technical field of discrete manufacturing industry, in particular to a method for calculating manufacturing energy consumption of a single product in the discrete manufacturing industry.
Background
The discrete manufacturing industry has the characteristics of multiple working procedures, complex flow and the like, and key parts are produced in batch in the production process and finally assembled. Under the condition, the energy consumption condition of each link in the production process of the product cannot be distinguished, and at present, the calculation is mainly carried out by adopting a mode of single product energy consumption = current total energy consumption/current yield. In the actual production process, parts produced in the same month are not necessarily assembled in the same month, so that the calculation accuracy of the method is insufficient, and the requirement of lean management cannot be met.
Disclosure of Invention
The invention aims to provide a method for calculating the manufacturing energy consumption of a single product in the discrete manufacturing industry, so as to solve the problems in the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a method for calculating the energy consumption for manufacturing single product in discrete manufacturing industry includes such steps as,
s1, data acquisition
Selecting a certain period as a reference, collecting energy consumption data of production lines and equipment in a workshop, and summarizing and calculating to obtain actual energy consumption data of each operation unit; acquiring actual work starting related information by taking actual energy consumption data of each operation unit in the production process as a reference;
s2, constructing an energy consumption model of the operation unit
Establishing an operation unit energy consumption model, and determining an optimal operation unit energy consumption model by utilizing an optimization algorithm iterative optimization; determining an energy consumption predicted value of the operation unit by using standard energy consumption data of the operation unit based on the optimal operation unit energy consumption model;
s3, establishing a relation between the process and the operation unit
Determining the relation between the production process of a certain single product and each operation unit based on the process of production circulation in the product manufacturing process; further determining all operation units related to the production process of the single product;
s4, calculating energy consumption of single product
Based on the determined relation between the production process of a certain single product and each operation unit, performing accumulation calculation on the energy consumption predicted values of all operation units related to the production process of the single product to obtain the single product manufacturing energy consumption predicted value; the calculation formula is as follows,
the method comprises the following steps that (1) a single-product manufacturing energy consumption predicted value = the energy consumption predicted value of an operation unit 1 + the energy consumption predicted value of an operation unit 2 + \8230, + the energy consumption predicted value of an operation unit m;
where m is the total number of work units involved in the single product manufacturing process.
Preferably, in step S2, specifically,
establishing an operation unit energy consumption model based on the actual energy consumption data of the operation unit and the standard energy consumption data of the operation unit; iteratively optimizing the model by using an optimization algorithm, determining the optimal value of the parameter in the model, and substituting the optimal value of the parameter into the model to obtain an optimal operation unit energy consumption model; and inputting the standard energy consumption data of the operation unit into the optimal operation unit energy consumption model, so as to obtain the energy consumption predicted value of the operation unit.
Preferably, the energy consumption model of the operation unit established in step S2 is as follows,
wherein, a and b are energy consumption influencing factors; f (x) i ) The energy consumption predicted value of the ith work unit; x is the number of i The energy consumption actual value of the ith operation unit; y is i The standard energy consumption value of the ith operation unit; i =1,2,3, \ 8230;, n; n is the total number of job units.
Preferably, in step S2, since the energy consumption model of the job unit is a quadratic function, and there is a minimum value, when J (a, b) takes the minimum value, the difference between the predicted energy consumption value and the standard energy consumption value of the job unit is minimum; based on actual energy consumption data of the multi-cycle operation unit, performing iterative optimization on the energy consumption model of the operation unit by using a gradient descent method, giving a learning rate alpha, gradually modifying a until J (a) obtains a minimum value, and finally determining an optimal value of a; the calculation formula is as follows,
the beneficial effects of the invention are: 1. the method combines the production process information, comprehensively considers the production process data and has higher precision. 2. The energy consumption model in the invention is a dynamic algorithm, and the parameters are dynamically adjusted along with the change of the data volume. 3. According to the invention, the energy consumption of a single product in a certain period can be generated in a one-key mode, the energy consumption trend can be accurately monitored based on the trend analysis of the energy consumption of the product, and data support is provided for improving the accuracy of management decision.
Drawings
Fig. 1 is a schematic flow chart of a method for calculating energy consumption in an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
Example one
In this embodiment, a method for calculating energy consumption for manufacturing a single product in discrete manufacturing industry is provided, which includes the following steps,
s1, data acquisition;
selecting a certain period (month) as a reference, acquiring energy consumption data of production lines and equipment in a workshop by using the Internet of things and big data technology, and summarizing, calculating and acquiring actual energy consumption data of each operation unit; acquiring actual work starting related information by taking actual energy consumption data of each operation unit in the production process as a reference;
s2, constructing an operation unit energy consumption model
Establishing an operation unit energy consumption model, and determining an optimal operation unit energy consumption model by utilizing an optimization algorithm iterative optimization; determining an energy consumption predicted value of the operation unit by using standard energy consumption data of the operation unit based on the optimal operation unit energy consumption model;
the specific process is as follows:
establishing an operation unit energy consumption model based on the actual energy consumption data of the operation unit and the standard energy consumption data of the operation unit; iteratively optimizing the model by using an optimization algorithm, determining the optimal value of the parameter in the model, and substituting the optimal value of the parameter into the model to obtain an optimal operation unit energy consumption model; inputting the standard energy consumption data of the operation unit into the optimal operation unit energy consumption model, and acquiring the energy consumption predicted value of the operation unit;
the operating unit energy consumption model is as follows,
wherein, a and b are energy consumption influencing factors; f (x) i ) The energy consumption predicted value of the ith work unit; x is the number of i The energy consumption actual value of the ith operation unit; y is i The standard energy consumption value of the ith operation unit; i =1,2,3, \ 8230;, n; n is the total number of job units.
It can be assumed that the energy consumption (dependent variable) of each production line and other characteristics (independent variables) satisfy linear correlation, so that the energy consumption prediction problem can be converted into a multiple linear regression problem, the independent variable is daily work reporting data, the dependent variable is the energy consumption of the production line of the corresponding process, and the model parameter is single process energy consumption. Solving a multiple linear regression problem with the goal of minimizing the difference between the dependent variables predicted by the constructed model and the actual dependent variables.
Because the energy consumption model of the operation unit is a quadratic function and has a minimum value, when J (a, b) takes the minimum value, the difference between the predicted energy consumption value and the standard energy consumption value of the operation unit is minimum; based on actual energy consumption data of the multi-cycle operation unit, performing iterative optimization on the energy consumption model of the operation unit by using a gradient descent method, giving a learning rate alpha, gradually modifying a until J (a) obtains a minimum value, and finally determining an optimal value of a; the calculation formula is as follows,
where α is a learning rate and is set in advance.
S3, establishing a relation between the working procedures and the operation units;
determining the relation between the production process of a certain single product and each operation unit based on the process of production circulation in the product manufacturing process; further determining all operation units related to the production process of the single product;
s4, calculating the energy consumption of the single product;
based on the determined relation between the production process of a certain single product and each operation unit, performing accumulation calculation on the energy consumption predicted values of all operation units related to the production process of the single product to obtain the single product manufacturing energy consumption predicted value; the calculation formula is as follows,
the method comprises the following steps that (1) a single-product manufacturing energy consumption predicted value = the energy consumption predicted value of an operation unit 1 + the energy consumption predicted value of an operation unit 2 + \8230, + the energy consumption predicted value of an operation unit m;
where m is the total number of work units involved in the single product manufacturing process.
Example two
In the embodiment, 56 operation units in a certain workshop are selected for verification, one month is selected as a period, data of 15 intelligent electric meters in the workshop are collected in real time, energy consumption of the 56 operation units is automatically calculated through the model and is effectively associated with the operation units based on 82 processes, most part-level energy consumption conditions are finally formed, three months of continuous data are trained and verified, single-product energy consumption (most part-level) is finally obtained, the calculation result is compared with historical energy consumption data, and the accuracy is remarkably improved.
By adopting the technical scheme disclosed by the invention, the following beneficial effects are obtained:
the invention provides a method for calculating the manufacturing energy consumption of a single product in the discrete manufacturing industry. The energy consumption model in the invention is a dynamic algorithm, and the parameters are dynamically adjusted along with the change of the data volume. According to the invention, the energy consumption of a single product in a certain period can be generated in a one-key mode, the energy consumption trend can be accurately monitored based on the trend analysis of the energy consumption of the product, and data support is provided for improving the accuracy of management decision.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and improvements can be made without departing from the principle of the present invention, and such modifications and improvements should also be considered within the scope of the present invention.
Claims (4)
1. A method for calculating the manufacturing energy consumption of a single product in discrete manufacturing industry is characterized in that: comprises the following steps of (a) carrying out,
s1, data acquisition
Selecting a certain period as a reference, collecting energy consumption data of production lines and equipment in a workshop, and summarizing and calculating to obtain actual energy consumption data of each operation unit; acquiring actual work starting related information by taking actual energy consumption data of each operation unit in the production process as a reference;
s2, constructing an energy consumption model of the operation unit
Establishing an operation unit energy consumption model, and determining an optimal operation unit energy consumption model by utilizing an optimization algorithm iterative optimization; determining an energy consumption predicted value of the operation unit by using standard energy consumption data of the operation unit based on the optimal operation unit energy consumption model;
s3, establishing a relation between the process and the operation unit
Determining the relation between the production process of a certain single product and each operation unit based on the process of production circulation in the product manufacturing process; further determining all operation units related to the production process of the single product;
s4, calculating energy consumption of single product
Based on the determined relation between the production process of a certain single product and each operation unit, performing accumulation calculation on the energy consumption predicted values of all operation units related to the production process of the single product to obtain the single product manufacturing energy consumption predicted value; the calculation formula is as follows,
the method comprises the following steps that (1) a single-product manufacturing energy consumption predicted value = the energy consumption predicted value of an operation unit 1 + the energy consumption predicted value of an operation unit 2 + \8230, + the energy consumption predicted value of an operation unit m;
where m is the total number of work units involved in the single product manufacturing process.
2. The discrete manufacturing industry single product manufacturing energy consumption calculation method of claim 1, wherein: in the step S2, specifically, the step S,
establishing an operation unit energy consumption model based on the actual energy consumption data of the operation unit and the standard energy consumption data of the operation unit; iteratively optimizing the model by using an optimization algorithm, determining the optimal value of the parameter in the model, and substituting the optimal value of the parameter into the model to obtain an optimal operation unit energy consumption model; and inputting the standard energy consumption data of the operation unit into the optimal operation unit energy consumption model, so as to obtain the energy consumption predicted value of the operation unit.
3. The method of claim 1, wherein the method comprises: the job unit energy consumption model established in step S2 is as follows,
wherein a and b are energy consumption influence factors; f (x) i ) The energy consumption predicted value of the ith work unit; x is the number of i The energy consumption actual value of the ith operation unit; y is i The standard energy consumption value of the ith operation unit; i =1,2,3, \ 8230;, n; n is a job ticketThe total number of elements.
4. The discrete manufacturing industry single product manufacturing energy consumption calculation method of claim 3, wherein: in step S2, since the energy consumption model of the operation unit is a quadratic function and has a minimum value, when J (a, b) takes the minimum value, the difference between the predicted energy consumption value and the standard energy consumption value of the operation unit is the minimum; based on actual energy consumption data of the multi-period operation unit, performing iterative optimization on the energy consumption model of the operation unit by using a gradient descent method, giving a learning rate alpha, gradually modifying a until J (a) obtains a minimum value, and finally determining an optimal value of a; the calculation formula is as follows,
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