CN116028887A - Analysis method of continuous industrial production data - Google Patents
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Abstract
The invention discloses an analysis method of continuous industrial production data, which analyzes production efficiency by utilizing the operation state and manual operation flow of the working environment of industrial equipment to be maintained, so as to obtain the standard value of each yield information of the industrial equipment to be maintained under the current production efficiency, further realize reliable identification of problem raw material supply information according to the standard value comparison result of the actual yield information and the corresponding yield information, greatly improve the fitting degree of the identification result and the actual production efficiency, furthest improve the evaluation efficiency of the abnormal reasons of the production data, fully consider that the abnormal production state and the abnormal production energy consumption of the production data are possibly caused when the abnormal production analysis of the problem raw material supply information is carried out, comprehensively analyze the two aspects, and enable the analysis dimension of the abnormal production of the problem raw material supply information to be more comprehensive.
Description
Technical Field
The invention belongs to the field of industrial production data analysis, and particularly relates to a method for analyzing continuous industrial production data.
Background
In the abnormal analysis of industrial production data, a testing station is used for carrying out abnormal analysis on the production data, and two analysis modes are generally adopted, namely, whether the abnormal condition of the data is judged in a most direct mode or not, namely, whether the upper limit and the lower limit are exceeded or not, defective products can be rapidly intercepted, and secondly, a quality manager is used for carrying out spot check, and meanwhile, an SPC management chart is drawn to judge the current production state, so that the quality of the produced products is ensured. The first abnormal analysis mode focuses on a single product, analysis of the whole batch of products is not covered, the quality lacks consistency, low-quality products are easy to flow out, and the second manual sampling inspection cannot ensure that the whole batch of products are in accordance with the specification, so that the real-time performance is poor, and defective products and low-quality products can flow out. Because the threshold of industrialization and informatization depth fusion is quite high, new generation information technologies such as artificial intelligence, cloud computing, internet of things and the like cannot be quickly and closely introduced into actual production of factories, so that the management and control of the product quality by the factories still stays in the conventional method at present, and high-quality and diversified demands of customers cannot be responded quickly.
Disclosure of Invention
Therefore, an objective of the embodiments of the present application is to provide a method and a system for analyzing continuous industrial production data, which can effectively solve the problems mentioned in the background art.
The aim of the invention can be achieved by the following technical scheme: in a first aspect, the present invention provides a method for analyzing continuous industrial production data, comprising the steps of: step A1: and marking the industrial equipment to be subjected to abnormal analysis of the production data as industrial equipment to be maintained, counting the yield information of the industrial equipment to be maintained in unit time, and simultaneously calling the associated raw material supply information corresponding to each yield information from the cloud equipment management platform.
Step A2: and arranging an equipment operation monitoring unit and a manual operation monitoring unit inside and outside the industrial equipment to be maintained respectively, and arranging different types of equipment monitoring sensors and worker control interfaces inside the industrial equipment to be maintained.
Step A3: in the production process of the industrial equipment to be maintained, monitoring measured values of the industrial equipment to be maintained corresponding to all yield information according to a set operation period by an equipment operation monitoring unit and a manual operation monitoring unit, comparing the measured values with standard values of the industrial equipment to be maintained corresponding to all yield information according to the operation period, determining whether production data abnormality exists in the industrial equipment to be maintained, and if the production data abnormality exists, identifying data abnormal production time and yield information when the data abnormality exists.
Step A6: and acquiring associated raw material supply information corresponding to the yield information when the data is abnormal according to the yield information when the data is abnormal, marking the associated raw material supply information as problem raw material supply information, and acquiring the production energy consumption and the equipment production state flow of the problem raw material supply information.
Step A7: analyzing the production energy consumption and the equipment production state flow corresponding to the problem raw material supply information, evaluating the data abnormality reasons of the yield information when the data is abnormal, and generating an evaluation report.
In one implementation of the first aspect of the present invention, the operating state includes a device load rate and an operating environment control, and the manual operation flow includes a worker operation proficiency, a compliance of the operation flow, and a worker health state.
In one implementation manner of the first aspect of the present invention, the analyzing the production efficiency of the working environment of the industrial equipment to be maintained in the operation period specifically includes the following steps:
step B1: and carrying out noise grabbing on abnormal sounds of the industrial equipment to be maintained corresponding to the start-stop state, and further tracking the abnormal sound position of the start-stop state from the noise.
Step B2: acquiring the relevance between the operation environment control of the operation period and the abnormal sound position of the start-stop state according to the operation environment control of the operation period and the abnormal sound position of the start-stop state of the working environment of the industrial equipment to be maintained, and marking the relevance as a relevance factor;
step B3: substituting the equipment load rate and the relevance factor of the working environment where the industrial equipment to be maintained is located in the operation period into a formula
Calculating the product qualification rate of the working environment of the industrial equipment to be maintained in the operation period, wherein +.>
Representing the product yield, x representing the equipment operation cycle number, ε representing the relevance factor, ++>
Indicating the number of operating cycles to be performed,h represents the rated equipment load rate corresponding to the industrial equipment to be maintained;
step B4: comparing the manual operation flow of the working environment of the industrial equipment to be maintained in the operation period with the manual operation flow of the industrial equipment to be maintained in the cloud equipment management platform in the normal production state, calculating the interference degree of the working environment of the industrial equipment to be maintained in the external environment of the operation period, wherein the calculation formula is as follows,
, wherein ,W l the interference degree of the external environment is represented, Y represents an environment change factor, B represents an environment stability constant, F represents the correctness of a manual operation flow, j 1 Representing a worker's proficiency in handling matrix, j 2 Compliance matrix, j, representing operational flow 3 Representing a worker health status matrix.
Step B5: substituting the sum into the formula
And calculating the production efficiency of the working environment where the industrial equipment to be maintained is located in the running period.
In one implementation manner of the first aspect of the present invention, the specific determining method for calculating the standard value of each yield information corresponding to the to-be-maintained industrial equipment in the operation period is as follows: step C1: and the required production efficiency of the industrial equipment to be maintained in the rated yield state is extracted from the cloud equipment management platform, and compared with the production efficiency of the industrial equipment to be maintained in the operation period, and the production efficiency error amount of the industrial equipment to be maintained in the operation period is calculated.
Step C2: and obtaining the production efficiency error level of the industrial equipment to be maintained in the operation period according to the production efficiency error amount of the industrial equipment to be maintained in the operation period.
Step C3: and matching the production efficiency error level of the industrial equipment to be maintained in the operation period with the standard value of each production efficiency error level of each production information in the cloud equipment management platform, and matching the production efficiency error level with the standard value of each production information corresponding to the industrial equipment to be maintained in the operation period.
In one implementation manner of the first aspect of the present invention, the determining whether the industrial equipment to be repaired has abnormal production data, if determining that the industrial equipment to be repaired has abnormal production data, identifying the abnormal production time of the data and executing steps corresponding to the output information when the data is abnormal are as follows: step D1: and extracting rated values of the industrial equipment to be maintained corresponding to the yield information from the cloud equipment management platform, and comparing the measured values of the industrial equipment to be maintained corresponding to the yield information in the operation period with the standard values of the industrial equipment to be maintained corresponding to the yield information in the operation period.
Step D2: comparing the variance of the corresponding yield information of the industrial equipment to be maintained in the operation period with the set allowable variance of the yield information, if the variance of the corresponding yield information of the industrial equipment to be maintained in a certain operation period is expected to be larger than the allowable variance of the yield information, determining that the industrial equipment to be maintained has abnormal production data, marking the operation period as abnormal production time of the data, and marking the yield information as the yield information when the data is abnormal.
In one implementation manner of the first aspect of the present invention, the specific method for acquiring the production energy consumption and the equipment production status flow of the problem raw material supply information is as follows: step E1: and acquiring the equipment production state flow of the industrial equipment to be maintained at the abnormal production moment by utilizing a worker control interface arranged in the industrial equipment to be maintained, and extracting automatic production steps and manual operation steps corresponding to the problem raw material supply information from the equipment production state flow of the industrial equipment to be maintained, thereby evaluating the equipment production state flow of the industrial equipment to be maintained according to the manual operation steps corresponding to the problem raw material supply information and obtaining the equipment production state flow corresponding to the problem raw material supply information.
Step E2: and acquiring the operation flow of the cabin of the industrial equipment to be maintained at the abnormal production moment of data by utilizing different equipment monitoring sensors arranged in the industrial equipment to be maintained, and positioning the operation flow at the time of the problem raw material supply information based on the automatic production step corresponding to the problem raw material supply information, so that the consumption of the time of the problem raw material supply information is extracted from the operation flow.
Step E3: and matching the consumption of the time of the problem raw material supply information with the steps corresponding to various consumption in the database, and further taking the step successfully matched as the production energy consumption corresponding to the problem raw material supply information.
In one implementation manner of the first aspect of the present invention, the data anomaly cause of the yield information when evaluating the data anomaly specifically refers to the following steps: step F1: comparing the equipment production state flow corresponding to the problem raw material supply information with the normal equipment production state flow corresponding to the problem raw material supply information in the cloud equipment management platform, identifying whether abnormality exists, and if the abnormality exists, evaluating that the data abnormality reason of the yield information when the data abnormality exists is that the production state of the problem raw material supply information exists abnormality.
Step F2: comparing the production energy consumption corresponding to the problem raw material supply information with a suitable production energy consumption interval corresponding to the problem raw material supply information in the cloud equipment management platform, and if the production energy consumption corresponding to the problem raw material supply information is not in the suitable production energy consumption interval, evaluating that the data abnormality cause of the output information when the data is abnormal is that the production energy consumption of the problem raw material supply information is abnormal.
In one implementation manner of the first aspect of the present invention, the step A6: and the method also comprises the steps of intelligently distributing the analysis steps of the raw material supply information of each problem when the number of the raw material supply information of the problem is more than one, wherein the specific distribution method comprises the following steps: step G1: and extracting the criticality of each problem raw material supply information in the yield process from the cloud device management platform based on the name of the problem raw material supply information.
Step G2: yield information to which the problem raw material supply information is associated is identified from the associated raw material supply information corresponding to each yield information based on the name of the problem raw material supply information.
Step G3: and calculating the corresponding production steps of the raw material supply information of each problem.
Step G4: and an analysis step of evaluating the raw material supply information of each problem according to the sequence of the production steps from first to second to obtain the raw material supply information of each problem.
The beneficial effects are that:
1. according to the invention, the production efficiency is analyzed by utilizing the running state and the manual operation flow of the working environment where the industrial equipment to be maintained is located, and the standard value of each yield information of the industrial equipment to be maintained under the current production efficiency is obtained, so that the accurate and reliable identification of the problem raw material supply information is realized according to the comparison result of the actual yield information and the standard value of the corresponding yield information, the fitting degree of the identification result and the actual production efficiency is greatly improved, the occurrence of invalid analysis of the problem raw material supply information is effectively avoided, and the evaluation efficiency of the abnormal reasons of the production data can be furthest improved.
2. According to the invention, when abnormal production analysis of the problem raw material supply information is carried out, production data abnormality is possibly caused by production state abnormality and production energy consumption abnormality, so that comprehensive analysis is carried out from the two aspects, the analysis dimension of abnormal production of the problem raw material supply information is more comprehensive, the expansion of an analysis range is realized, the occurrence rate of incapability of evaluating the cause of abnormal production data is reduced to a certain extent, and the purpose of abnormal production data analysis can be effectively realized.
3. According to the invention, when the number of the problem raw material supply information is more than one, the analysis steps of the problem raw material supply information are intelligently arranged, so that abnormal production analysis of the problem raw material supply information is carried out according to the arrangement sequence, the analysis time of the abnormal reasons of the production data is reduced to a certain extent, the evaluation efficiency of the abnormal reasons of the production data is further enhanced, and the method has a certain practical value.
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The invention will be further described with reference to the accompanying drawings, in which embodiments do not constitute any limitation of the invention, and other drawings can be obtained by one of ordinary skill in the art without inventive effort from the following drawings.
FIG. 1 is a flow chart of method steps of the present invention;
FIG. 2 is a block diagram of a method of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1, the present invention proposes a method for analyzing continuous industrial production data, comprising the steps of: step A1: and marking the industrial equipment to be subjected to abnormal analysis of the production data as industrial equipment to be maintained, counting the yield information of the industrial equipment to be maintained in unit time, and simultaneously calling the associated raw material supply information corresponding to each yield information from the cloud equipment management platform.
Step A2: and arranging an equipment operation monitoring unit and a manual operation monitoring unit inside and outside the industrial equipment to be maintained respectively, and arranging different types of equipment monitoring sensors and worker control interfaces inside the industrial equipment to be maintained.
Step A3: the method comprises the following steps of collecting the operation state of the working environment where the industrial equipment to be maintained is located and the manual operation flow in the production process of the industrial equipment to be maintained according to the set equipment operation period through an equipment operation monitoring unit and a manual operation monitoring unit, wherein the operation state comprises equipment load rate and operation environment control, and the manual operation flow comprises worker operation proficiency, compliance of the operation flow and worker health state, so that the production efficiency of the working environment where the industrial equipment to be maintained is located in the operation period is analyzed, and specifically comprises the following steps: step B1: and carrying out noise grabbing on abnormal sounds of the industrial equipment to be maintained corresponding to the start-stop state, and further tracking the abnormal sound position of the start-stop state from the noise.
Step B2: and acquiring the relevance between the operation environment control of the operation period and the abnormal sound position of the start-stop state according to the operation environment control of the operation environment of the industrial equipment to be maintained and the abnormal sound position of the start-stop state, and marking the relevance as a relevance factor.
Step B3: substituting the equipment load rate and the relevance factor of the working environment where the industrial equipment to be maintained is located in the operation period into a formula
Calculating the product qualification rate of the working environment of the industrial equipment to be maintained in the operation period, wherein +.>
Representing the product yield, x representing the equipment operation cycle number, ε representing the relevance factor, ++>
And h represents the rated equipment load rate corresponding to the industrial equipment to be maintained. />
It should be noted that, in the product percent of pass calculation formula, the closer the equipment load rate of the working environment where the industrial equipment to be maintained is located in a certain operation period is to the rated equipment load rate, the closer the relevance factor is to 90 degrees, and the larger the product percent of pass is.
Step B4: comparing the manual operation flow of the working environment of the industrial equipment to be maintained in the operation period with the manual operation flow of the industrial equipment to be maintained in the cloud equipment management platform in the normal production state, calculating the interference degree of the working environment of the industrial equipment to be maintained in the external environment of the operation period, wherein the calculation formula is as follows,
, wherein ,W l the interference degree of the external environment is represented, Y represents an environment change factor, B represents an environment stability constant, F represents the correctness of a manual operation flow, j 1 Representing a worker's proficiency in handling matrix, j 2 Compliance matrix, j, representing operational flow 3 Representing a worker health status matrix.
In the above external environment interference degree calculation formula, the larger the difference between the operating proficiency of the worker and the compliance of the operation flow in a certain operation period of the working environment of the industrial equipment to be maintained and the operating proficiency of the worker and the compliance of the operation flow in a normal production state of the industrial equipment to be maintained, the larger the external environment interference degree of the working environment of the industrial equipment to be maintained in the operation period.
Step B5: substituting the sum into the formula
And calculating the production efficiency of the working environment where the industrial equipment to be maintained is located in the running period.
Step A4: calculating a standard value of each output information corresponding to the industrial equipment to be maintained in the operation period by utilizing the production efficiency of the working environment of the industrial equipment to be maintained in the operation period, wherein the specific determination method comprises the following steps: step C1: and the required production efficiency of the industrial equipment to be maintained in the rated yield state is extracted from the cloud equipment management platform, and compared with the production efficiency of the industrial equipment to be maintained in the operation period, and the production efficiency error amount of the industrial equipment to be maintained in the operation period is calculated.
Step C2: and acquiring the production efficiency error level of the industrial equipment to be maintained in the operation period according to the production efficiency error amount of the industrial equipment to be maintained in the operation period, wherein the acquisition mode is to match the production efficiency error amount of the industrial equipment to be maintained in the operation period with the production efficiency error amount range corresponding to each set production efficiency error level, and the production efficiency error level of the industrial equipment to be maintained in the operation period is matched.
Step C3: and matching the production efficiency error level of the industrial equipment to be maintained in the operation period with the standard value of each production efficiency error level of each production information in the cloud equipment management platform, and matching the production efficiency error level with the standard value of each production information corresponding to the industrial equipment to be maintained in the operation period.
Step A5: monitoring measured values of the production information corresponding to the industrial equipment to be maintained in the operation period, comparing the measured values with standard values of the production information corresponding to the operation period, determining whether production data abnormality exists in the industrial equipment to be maintained, and if the production data abnormality exists, identifying production time of the data abnormality and the production information when the data abnormality exists, wherein the specific implementation steps are as follows:
step D1: and extracting rated values of the industrial equipment to be maintained corresponding to the yield information from the cloud equipment management platform, and comparing the measured values of the industrial equipment to be maintained corresponding to the yield information in the operation period with the standard values of the industrial equipment to be maintained corresponding to the yield information in the operation period.
Step D2: comparing the variance of the corresponding yield information of the industrial equipment to be maintained in the operation period with the set allowable variance of the yield information, if the variance of the corresponding yield information of the industrial equipment to be maintained in a certain operation period is expected to be larger than the allowable variance of the yield information, determining that the industrial equipment to be maintained has abnormal production data, marking the operation period as abnormal production time of the data, and marking the yield information as the yield information when the data is abnormal.
Step A6: and extracting the associated raw material supply information corresponding to the yield information when the data is abnormal from the associated raw material supply information corresponding to the yield information when the data is abnormal according to the yield information when the data is abnormal, marking the associated raw material supply information as problem raw material supply information, and simultaneously acquiring the production energy consumption of the problem raw material supply information and the equipment production state flow.
According to the invention, the production efficiency is analyzed by utilizing the running state and the manual operation flow of the working environment of the industrial equipment to be maintained, and the standard value of each yield information of the industrial equipment to be maintained under the current production efficiency is obtained, so that the accurate and reliable identification of the problem raw material supply information is realized according to the standard value comparison result of the actual yield information and the corresponding yield information, the fitting degree of the identification result and the actual production efficiency is greatly improved, the ineffective analysis of the problem raw material supply information is effectively avoided, and the evaluation efficiency of the abnormal reasons of the production data can be furthest improved.
As a preferred embodiment of the present invention, a specific acquisition method of the production energy consumption and equipment production state flow to acquire problem raw material supply information is as follows: step E1: and acquiring the equipment production state flow of the industrial equipment to be maintained at the abnormal production moment by utilizing a worker control interface arranged in the industrial equipment to be maintained, and extracting automatic production steps and manual operation steps corresponding to the problem raw material supply information from the equipment production state flow of the industrial equipment to be maintained, thereby evaluating the equipment production state flow of the industrial equipment to be maintained according to the manual operation steps corresponding to the problem raw material supply information and obtaining the equipment production state flow corresponding to the problem raw material supply information.
Step E2: and acquiring the operation flow of the industrial equipment cabin to be maintained at the abnormal production moment by utilizing different equipment monitoring sensors arranged in the industrial equipment cabin to be maintained, and positioning the operation flow at the time of the problem raw material supply information based on the automatic production step corresponding to the problem raw material supply information, so that the consumption of the time of the problem raw material supply information is extracted from the operation flow.
Step E3: and matching the consumption of the time of the problem raw material supply information with the steps corresponding to various consumption in the database, and further taking the step successfully matched as the production energy consumption corresponding to the problem raw material supply information.
As still another preferred embodiment of the present invention, the steps of analyzing the problem raw material supply information are intelligently arranged when the number of the problem raw material supply information is more than one, and the specific arrangement method thereof is as follows: step G1: and extracting the criticality of each problem raw material supply information in the yield process from the cloud device management platform based on the name of the problem raw material supply information.
Step G2: yield information to which the problem raw material supply information is associated is identified from the associated raw material supply information corresponding to each yield information based on the name of the problem raw material supply information, and is noted.
Step G3: and calculating the corresponding production steps of the raw material supply information of each problem.
Step G4: and an analysis step of evaluating the raw material supply information of each problem according to the sequence of the production steps from first to second to obtain the raw material supply information of each problem.
According to the invention, when the number of the problem raw material supply information is more than one, the analysis steps of the problem raw material supply information are intelligently arranged, so that abnormal production analysis of the problem raw material supply information is carried out according to the arrangement sequence, the analysis time of the abnormal reasons of the production data is reduced to a certain extent, the evaluation efficiency of the abnormal reasons of the production data is further enhanced, and the method has a certain practical value.
Step A7: analyzing the production energy consumption and the equipment production state flow corresponding to the problem raw material supply information, evaluating the data abnormality reasons of the yield information when the data is abnormal, and generating an evaluation report.
The data abnormality cause of the yield information in evaluating the data abnormality specifically refers to the following steps: step F1: comparing the equipment production state flow corresponding to the problem raw material supply information with the normal equipment production state flow corresponding to the problem raw material supply information in the cloud equipment management platform, identifying whether abnormality exists, and if the abnormality exists, evaluating that the data abnormality reason of the yield information when the data abnormality exists is that the production state of the problem raw material supply information exists abnormality.
Step F2: comparing the production energy consumption corresponding to the problem raw material supply information with a suitable production energy consumption interval corresponding to the problem raw material supply information in the cloud equipment management platform, and if the production energy consumption corresponding to the problem raw material supply information is not in the suitable production energy consumption interval, evaluating that the data abnormality cause of the output information when the data is abnormal is that the production energy consumption of the problem raw material supply information is abnormal.
According to the invention, when abnormal production analysis of the problem raw material supply information is carried out, production data abnormality is possibly caused by production state abnormality and production energy consumption abnormality, so that comprehensive analysis is carried out from the two aspects, the analysis dimension of abnormal production of the problem raw material supply information is more comprehensive, the expansion of an analysis range is realized, the occurrence rate of incapability of evaluating the cause of abnormal production data is reduced to a certain extent, and the purpose of abnormal production data analysis can be effectively realized.
As shown in fig. 2, the present invention provides a method for analyzing continuous industrial production data, which is implemented by the following units:
the production information associated raw material supply information statistics acquisition unit is connected with the cloud equipment management platform and is used for marking industrial equipment to be subjected to abnormal analysis of production data as industrial equipment to be maintained, counting the production information of the industrial equipment to be maintained in unit time and simultaneously calling associated raw material supply information corresponding to each production information from the cloud equipment management platform.
The industrial equipment to be maintained is provided with a monitoring equipment setting unit for setting equipment operation monitoring units and artificial operation monitoring units inside and outside the industrial equipment to be maintained respectively, and different types of equipment monitoring sensors and worker control interfaces are arranged inside the industrial equipment to be maintained.
The production efficiency monitoring and analyzing unit is respectively connected with the industrial equipment to be maintained monitoring equipment setting unit and the cloud equipment management platform and is used for collecting the running state and the manual operation flow of the working environment of the industrial equipment to be maintained according to the set equipment running period in the production process of the industrial equipment to be maintained through the equipment running monitoring unit and the manual operation monitoring unit, so that the production efficiency of the working environment of the industrial equipment to be maintained in the running period is analyzed.
The normal yield information calculation unit of the industrial equipment to be maintained is respectively connected with the production efficiency monitoring analysis unit and the cloud equipment management platform and is used for calculating the standard value of the industrial equipment to be maintained corresponding to each yield information in the operation period by utilizing the production efficiency of the working environment of the industrial equipment to be maintained in the operation period.
The cloud equipment management platform is used for storing the associated raw material supply information corresponding to each yield information, storing the manual operation flow of the industrial equipment to be maintained in the normal production state, storing the required production efficiency of the industrial equipment to be maintained in the rated yield state, storing the rated value of the industrial equipment to be maintained corresponding to each yield information and the standard value of each yield information in each production efficiency error level, and storing the normal equipment production state flow, the proper production energy consumption interval and the corresponding criticality of the normal equipment production state flow, the proper production energy consumption interval corresponding to each raw material supply information in the industrial equipment to be maintained.
And a database connected with the problem raw material supply information production information acquisition unit for storing steps corresponding to various consumption amounts.
The production data abnormality determining unit of the industrial equipment to be maintained is connected with the normal production information calculating unit of the industrial equipment to be maintained, is used for monitoring measured values of the production information corresponding to the industrial equipment to be maintained in an operation period, compares the measured values with standard values of the production information corresponding to the operation period, determines whether the production data abnormality exists in the industrial equipment to be maintained, and if the production data abnormality exists, identifies abnormal production time of the data and production information when the data abnormality exists.
The production information acquisition unit of the problem raw material supply information is respectively connected with the production information associated raw material supply information statistics acquisition unit, the industrial equipment to be maintained monitoring equipment setting unit and the industrial equipment to be maintained production data abnormality determination unit, and is used for acquiring associated raw material supply information corresponding to the production information when the data is abnormal according to the production information when the data is abnormal, and recording the associated raw material supply information as the problem raw material supply information, and simultaneously acquiring the production energy consumption of the problem raw material supply information and the equipment production state flow.
And the yield information missing reason evaluation display terminal is respectively connected with the problem raw material supply information production information acquisition unit and the cloud device management platform, and is used for analyzing the production energy consumption and the device production state flow corresponding to the problem raw material supply information, evaluating the data abnormality reason of the yield information when the data is abnormal, and generating an evaluation report on the data abnormality reason of the yield information when the data is abnormal.
The foregoing is merely illustrative of the structures of this invention and various modifications, additions and substitutions for those skilled in the art can be made to the described embodiments without departing from the scope of the invention or from the scope of the invention as defined in the accompanying claims.
Claims (8)
1. A method for analyzing continuous industrial production data, comprising the steps of:
step A1: the industrial equipment to be subjected to abnormal analysis of production data is marked as industrial equipment to be maintained, the yield information of the industrial equipment to be maintained in unit time is counted, and meanwhile, the associated raw material supply information corresponding to each yield information is called from a cloud equipment management platform;
step A2: the method comprises the steps that equipment operation monitoring units and artificial operation monitoring units are respectively arranged inside and outside industrial equipment to be maintained, and different types of equipment monitoring sensors and worker control interfaces are distributed inside the industrial equipment to be maintained;
step A3: in the production process of the industrial equipment to be maintained, acquiring the running state and the manual operation flow of the working environment of the industrial equipment to be maintained according to the set equipment running period by an equipment running monitoring unit and a manual operation monitoring unit, so as to analyze the production efficiency of the working environment of the industrial equipment to be maintained in the running period;
step A4: calculating a standard value of each output information corresponding to the industrial equipment to be maintained in the operation period by utilizing the production efficiency of the working environment of the industrial equipment to be maintained in the operation period;
step A5: monitoring measured values of the production information corresponding to the industrial equipment to be maintained in the operation period, comparing the measured values with standard values of the production information corresponding to the operation period, determining whether production data abnormality exists in the industrial equipment to be maintained, and if the production data abnormality exists, identifying production time of the data abnormality and the production information when the data abnormality exists;
step A6: acquiring associated raw material supply information corresponding to yield information when the data is abnormal according to the yield information when the data is abnormal, marking the associated raw material supply information as problem raw material supply information, and acquiring production energy consumption and equipment production state flow of the problem raw material supply information;
step A7: analyzing the production energy consumption and the equipment production state flow corresponding to the problem raw material supply information, evaluating the data abnormality reasons of the yield information when the data is abnormal, and generating an evaluation report.
2. The method for analyzing continuous industrial production data according to claim 1, wherein: the operating states include equipment load rate and operating environment control, and the manual operation flow includes worker operation proficiency, compliance of the operation flow, and worker health state.
3. A method of analyzing continuous industrial process data according to claim 2, wherein: the analysis of the production efficiency of the working environment of the industrial equipment to be maintained in the operation period specifically comprises the following steps:
step B1: carrying out noise grabbing on abnormal sounds of the industrial equipment to be maintained corresponding to the start-stop state, and further tracking abnormal sound positions of the start-stop state from noise;
step B2: acquiring the relevance between the operation environment control of the operation period and the abnormal sound position of the start-stop state according to the operation environment control of the operation period and the abnormal sound position of the start-stop state of the working environment of the industrial equipment to be maintained, and marking the relevance as a relevance factor;
step B3: substituting the equipment load rate and the relevance factor of the working environment where the industrial equipment to be maintained is located in the operation period into a formula
Calculating the product qualification rate of the working environment of the industrial equipment to be maintained in the operation period, wherein +.>
Representing the product yield, x representing the equipment operation cycle number, ε representing the relevance factor, ++>
The number of the operation periods is represented, and h represents the rated equipment load rate corresponding to the industrial equipment to be maintained;
step B4: comparing the manual operation flow of the working environment of the industrial equipment to be maintained in the operation period with the manual operation flow of the industrial equipment to be maintained in the cloud equipment management platform in the normal production state, and calculating the industrial equipment to be maintainedThe external environment interference degree of the working environment of the industrial equipment in the operation period is calculated according to the formula,
；/>
wherein ,W l the interference degree of the external environment is represented, Y represents an environment change factor, B represents an environment stability constant, F represents the correctness of a manual operation flow, j 1 Representing a worker's proficiency in handling matrix, j 2 Compliance matrix, j, representing operational flow 3 Representing a worker health status matrix;
step B5: substituting the sum into the formula
And calculating the production efficiency of the working environment where the industrial equipment to be maintained is located in the running period.
4. A method of analyzing continuous industrial process data according to claim 3, wherein: the specific determination method for calculating the standard value of each yield information corresponding to the industrial equipment to be maintained in the operation period is as follows:
step C1: the required production efficiency of the industrial equipment to be maintained in the rated yield state is extracted from the cloud equipment management platform, the required production efficiency is compared with the production efficiency of the industrial equipment to be maintained in the operation period, and the production efficiency error amount of the industrial equipment to be maintained in the operation period is calculated;
step C2: acquiring the production efficiency error level of the industrial equipment to be maintained in the operation period according to the production efficiency error amount of the industrial equipment to be maintained in the operation period;
step C3: and matching the production efficiency error level of the industrial equipment to be maintained in the operation period with the standard value of each production efficiency error level of each production information in the cloud equipment management platform, and matching the production efficiency error level with the standard value of each production information corresponding to the industrial equipment to be maintained in the operation period.
5. The method for analyzing continuous industrial production data according to claim 4, wherein: determining whether production data abnormality exists in the industrial equipment to be maintained, and if the production data abnormality exists, identifying the execution steps corresponding to the production time of the data abnormality and the production information when the data abnormality exists, wherein the execution steps are as follows:
step D1: extracting rated values of the industrial equipment to be maintained corresponding to the yield information from the cloud equipment management platform, comparing measured values of the industrial equipment to be maintained corresponding to the yield information in the operation period with standard values of the industrial equipment to be maintained corresponding to the yield information in the operation period, and calculating variances of the industrial equipment to be maintained corresponding to the yield information in the operation period;
step D2: comparing the variance of the corresponding yield information of the industrial equipment to be maintained in the operation period with the set allowable variance of the yield information, if the variance of the corresponding yield information of the industrial equipment to be maintained in a certain operation period is expected to be larger than the allowable variance of the yield information, determining that the industrial equipment to be maintained has abnormal production data, marking the operation period as abnormal production time of the data, and marking the yield information as the yield information when the data is abnormal.
6. The method for analyzing continuous industrial production data according to claim 1, wherein: the specific acquisition method for acquiring the production energy consumption of the problem raw material supply information and the equipment production state flow is as follows:
step E1: acquiring the equipment production state flow of the industrial equipment to be maintained at the abnormal production moment by utilizing a worker control interface arranged in the industrial equipment to be maintained, and extracting automatic production steps and manual operation steps corresponding to the problem raw material supply information from the equipment production state flow of the industrial equipment to be maintained, thereby evaluating the equipment production state flow of the industrial equipment to be maintained according to the manual operation steps corresponding to the problem raw material supply information and obtaining the equipment production state flow corresponding to the problem raw material supply information;
step E2: collecting the operation flow in the industrial equipment to be maintained at the abnormal production time by using different equipment monitoring sensors arranged in the industrial equipment to be maintained, and positioning the operation flow at the time of the problem raw material supply information based on the automatic production steps corresponding to the problem raw material supply information, so as to extract the consumption of the time of the problem raw material supply information from the operation flow;
step E3: and matching the consumption of the time of the problem raw material supply information with the steps corresponding to various consumption in the database, and further taking the step successfully matched as the production energy consumption corresponding to the problem raw material supply information.
7. The method for analyzing continuous industrial production data according to claim 6, wherein: the data abnormality cause of the yield information when the evaluation data is abnormal specifically refers to the following steps:
step F1: comparing the equipment production state flow corresponding to the problem raw material supply information with the normal equipment production state flow corresponding to the problem raw material supply information in the cloud equipment management platform, and identifying whether abnormality exists, if so, evaluating that the data abnormality reason of the yield information when the data abnormality exists is that the production state of the problem raw material supply information exists;
step F2: comparing the production energy consumption corresponding to the problem raw material supply information with a suitable production energy consumption interval corresponding to the problem raw material supply information in the cloud equipment management platform, and if the production energy consumption corresponding to the problem raw material supply information is not in the suitable production energy consumption interval, evaluating that the data abnormality cause of the output information when the data is abnormal is that the production energy consumption of the problem raw material supply information is abnormal.
8. The method for analyzing continuous industrial production data according to claim 1, wherein: the step A6: and the method also comprises the steps of intelligently distributing the analysis steps of the raw material supply information of each problem when the number of the raw material supply information of the problem is more than one, wherein the specific distribution method comprises the following steps:
step G1: extracting the criticality of each problem raw material supply information in the yield process from the cloud equipment management platform based on the name of the problem raw material supply information;
step G2: identifying yield information to which the problem raw material supply information is associated from the associated raw material supply information corresponding to each yield information based on the name of the problem raw material supply information;
step G3: calculating production steps corresponding to the raw material supply information of each problem;
step G4: and an analysis step of evaluating the raw material supply information of each problem according to the sequence of the production steps from first to second to obtain the raw material supply information of each problem.
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