JP2003227853A - Measuring method for energy use amount and diagnosis method for energy saving - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a measuring method for energy use amount and a diagnosis method for energy saving which is capable of surely grasping use of energy amount by everybody for any equipment and easily judging energy saving method. <P>SOLUTION: By continuously measuring energy use amount for every equipment element having fabrication process and comparing the production amount in the fabrication process, an ideal energy use amount is confirmed for every equipment element. By comparing energy use amount of the measured equipment element, an energy capable of being saved is found. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for measuring the amount of energy used in the process of production of industrial products and the like, and for the purpose of energy saving based on the results obtained from the amount of energy used. It relates to a method of diagnosing.

[0002]

2. Description of the Related Art Industrial products are processed by various processes such as cutting, plastic working, casting, injection molding, extrusion molding, painting, washing, heat treatment, and drying by a single process or a plurality of continuous processes. Be seen. And the proper equipment is used according to the product. More specifically, the equipment used for production includes general-purpose equipment that is commercially available, remodeled equipment that is obtained by modifying commercially available equipment according to the processing content,
Design equipment manufactured by designing from scratch is used, and it is selected and used according to the content of the product, the production amount, the type of the product to be produced, and the like.

The equipment also has equipment elements. Here, the equipment element is a functional element that operates by using energy, such as one that converts energy into force or heat in order to realize processing, and specifically, electric There is a motor for converting electric power into rotational torque, a hydraulic (pneumatic) cylinder for converting hydraulic pressure (pneumatic pressure) into force, an electric heater for converting electricity into heat, and the like. And one facility may have one or a plurality of facility elements.

The energy used in the facility element includes electric power, hydraulic pressure, pneumatic pressure, etc., and the facility element operates using these energy sources alone or in plural. The equipment elements that use a plurality of energy sources include those that use different types of energy sources and those that use the same type of energy sources.

[0005]

[Problems to be Solved by the Invention] Due to the problems of global warming due to carbon dioxide emission resulting from the use of energy and the circumstances in Japan where most of fuel resources have to depend on imports, A law concerning the rationalization of energy use (hereinafter referred to as the Energy Conservation Law) has been enforced, and it has been an important issue to reduce the amount of energy used in order to further reduce the cost of industrial production.

The current state of equipment for producing industrial products is
In many cases, it is not in the optimal energy use state according to the production situation. For example, when general-purpose equipment is used, there are cases where equipment having a significantly higher capacity than the processing conditions is used because of the introduction of equipment that can be used for the processing conditions. In addition, in remodeling equipment and design equipment,
Due to factors such as too high a safety factor and insufficient verification at the design stage of equipment design, there were cases where it was not in the ideal energy usage state according to the production situation. In addition, if the contents of processing change after the period from the introduction of the equipment due to changes in the products produced, etc.,
In some cases, it was not in the ideal energy use state according to the production situation.

However, it has been difficult to confirm whether or not the state of ideal energy use is in accordance with the above-mentioned production situation and further improve. In addition, there are often no specialists for individual equipment at the production site, and everyone has been required to find a way to improve by confirming whether or not the energy usage state is ideal according to the production situation.

[0008] In addition, in general, in the process of processing industrial products, since it has a wide variety of equipment, it is a method that can be used with any kind of equipment. Since it requires a lot of time and cost, there has been a demand for a method that can reliably produce results.

The implementation of energy saving must not affect the current quality and productivity.

[0010] Therefore, anyone, regardless of equipment, can surely grasp the amount of energy used and can confirm the ideal energy use state according to the production situation, and save energy without affecting the current quality and productivity. It is an object of the present invention to provide an energy consumption measuring method and an energy saving diagnosis method that can be easily determined by the above method.

[0011]

According to the invention described in claim 1 of the present invention, in a processing step comprising one equipment or a series of two or more continuous equipment, the equipment has equipment elements for using energy. Then, the entire processing step has a plurality of equipment elements, and it is possible to continuously measure the energy consumption of the equipment elements to confirm the change over time in the energy consumption of each equipment element. This is a characteristic energy usage measuring method, and since it can be surely measured by a simple method, it is possible to easily confirm the energy usage status by anyone and any equipment. When one equipment element has a plurality of energy supply sources, it is also possible to measure the amount of energy used for each energy source and confirm changes over time in the amount of energy used. In such a case, more detailed confirmation can be made. Further, even if there is only one equipment element, it suffices if the entire processing step has a plurality of equipment elements.

According to the second aspect of the present invention, the production amount in the processing step is continuously measured, and the energy use amount of each equipment element and the change in the production amount in the processing step with time are compared. The energy usage measuring method according to claim 1, wherein the energy usage and the production quantity can be compared.

The invention described in claim 3 is the invention according to claim 1 or 2.
An ideal energy derivation means for deriving an ideal energy consumption amount according to the production situation for each equipment element, as a state in which the measurement results obtained by the energy consumption amount measurement method described in (3) can be compared in time series. An energy-saving diagnostic method characterized by having an energy-saving finding means for finding energy that can be saved by comparing the ideal energy usage derived by the means with the measured energy usage for each equipment element. The ideal energy consumption of each equipment element can be easily confirmed, and it is possible to confirm whether or not energy saving is possible by comparing the ideal energy consumption with the measured energy consumption.

Here, "comparable" means, for example, that the obtained data is made into a table, a graph, or the like, and it also includes processing of numerical values for comparison. The ideal energy consumption of equipment elements is the energy consumption that is considered to be the minimum required energy consumption for each equipment element in the processing. In addition, the derivation of the ideal energy consumption of a facility element is derived from the change in the time-series energy consumption of that facility element and the relationship with the energy consumption and production volume of other facility elements. By referring to other data related to the equipment element such as temperature, pressure, position, angle, etc., the ideal energy usage amount of the equipment element can be derived more accurately. Further, the energy saving finding means is performed by confirming the difference between the ideal energy usage amount according to the production status of the equipment element and the measured energy usage amount of the equipment element.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below. FIG. 1 is a schematic diagram showing processing steps used in the energy consumption measuring method and the energy saving diagnosis method according to the first embodiment of the present invention. Figure 2
FIG. 6 is a diagram showing a line graph showing the measurement results obtained by the energy consumption measuring method according to the first embodiment of the present invention. FIG. 3 is a diagram showing a line graph obtained by adding the ideal energy use amount of each facility element to the graph of FIG. FIG. 4 is a schematic diagram showing processing steps used in the energy consumption measuring method and the energy saving diagnosis method according to the embodiment of the present invention, the processing steps having a plurality of facilities. FIG. 5 is a schematic diagram showing processing steps used in the energy consumption measuring method and the energy saving diagnosis method according to the embodiment of the present invention, the processing steps having one equipment element in one equipment.

The processing step 1 used in the energy consumption measuring method and the energy saving diagnosis method in the first embodiment of the present invention is shown in FIG. The processing step 1 is a hydraulic press step and has equipment 5 which is a hydraulic press machine. Furthermore, the equipment 5 is provided with equipment elements 7. The facility element 7 is a facility element that uses electricity as an energy source, and is specifically a motor. Further, the equipment element 8 is a hydraulic cylinder, which converts hydraulic pressure into force, and further, the equipment element 8 has a motor which is a power source 8a of a hydraulic pump used only for the equipment element 8. There is. Since it is configured as described above, the processing step 1 as a whole has a plurality of equipment elements.

The equipment element 7 and the power source 8a are
It is connected to the power source via the electric energy measuring device 15. The electric energy measuring device 15 is not attached during normal use, but is attached when implementing the present invention.
Measure the amount of electricity per hour. Further, the processing step 1 is provided with a counter 20 capable of continuously checking the processing quantity. Electric energy measuring device 15 and counter 20
A known material can be used, and an appropriate material is used depending on the object of measurement.

Next, a concrete method of carrying out the energy consumption measuring method and the energy saving diagnosis method of the present invention will be explained. First, the processing step 1 is used to continuously perform processing in the same manner as in a commonly used method. Further, the electric energy measuring device 15 and the counter 20 are operated to continuously measure the electric energy and the processing quantity. Then, the measured values of the energy consumption of the equipment elements 7 and 8 and the processing quantity, which is the production quantity, are obtained. In the present embodiment, the value accumulated every hour is used to measure for 23 hours from 9:00 to 8:00 the next morning,
The hour from 10:00 to 1 hour was compared with the value at 9 o'clock, and the hour from 10:00 to 11:00 was compared with the value at 10 hours. In the embodiment of the present invention, the energy consumption of the equipment element 8 is the power source 8 of the hydraulic pump used only for the equipment element 8.
It is calculated based on the electric power consumption of the motor which is a, and thus the energy consumption may be indirectly measured.

Next, using the energy consumption of the equipment elements 7 and 8 and the production amount obtained by the counter 20, the horizontal axis is the time, the vertical axis is the measured value of the used electric energy and the number of machining, and the line graph is shown. create. The graph 1 showing this is shown in FIG. 2, whereby the energy usage and production of the facility elements 7 and 8 are in a time-sequential comparable state.

From this graph, the ideal energy usage amount deriving means is used to derive the ideal energy usage amount of the equipment elements 7 and 8 according to the production situation. Specifically, the production amount at the same time and the measured energy values of other equipment elements, and in some cases, the characteristic values of the equipment elements, processing conditions, etc. will also be determined. In the method according to the embodiment of the present invention, the energy usage amount per production quantity of each equipment element 7, 8 when the production quantity is maximum is calculated, and the actual production quantity is multiplied by the energy usage amount per production quantity. Calculated by subtracting the energy consumed regardless of the production amount.
Then, a line graph is added to the graph of FIG. 2 showing the ideal energy usage of the equipment elements 7 and 8 obtained by this. Graph 2 showing this is shown in FIG.

Further, by means of energy saving discovery,
Find energy that can save energy. Specifically, using Graph 2, the difference is confirmed by comparing the ideal energy usage according to the production status of each equipment element with the measured energy usage for each equipment element. In this embodiment, the difference between the ideal energy usage amount and the measured energy usage amount of the equipment element is around 14:00 to 16:00 in the equipment element 7 and around 22:00 to 2:00 in the equipment element 8. Since it is large, it can be seen that the energy has a high possibility of energy saving. Then, in order to reduce the energy that can be saved, the control is changed, or the facility element is changed to save energy.

The processing step targeted in the embodiment of the present invention has one facility, but it may have a plurality of facilities. For example, it is the processing step 2 of the manufacturing process of the parts shown in FIG. Then, in the processing step 2, the press machine 19 as the first equipment has the hydraulic cylinder 20 to punch the plate material, and the press machine 21 as the second equipment has the hydraulic cylinder 22 and the parts. In addition, in the heater 23 which is the third equipment, the heater 24
Is a step of performing heat treatment of parts,
It is a series of processing steps up to equipment.

Further, the machining process may be composed of one facility having one facility element, as long as the machining process as a whole has a plurality of facility elements. For example, the equipment has one equipment element, and further, a plurality of energy sources of the equipment elements are connected, each energy source operates independently, and a plurality of equipment elements are provided as a whole processing step. Specifically, it is the same as a processing step 3 for performing press processing as shown in FIG. The processing step 3 has only one press machine 30, and the press machine 30 has one hydraulic cylinder 31. Further, a plurality of pumps 33, 34, 35 that generate three hydraulic pressures are connected to the hydraulic cylinder, and each pump is separately controlled by the controller 37. Therefore, although the number of facility elements in the processing step is apparently one, in reality, since the pump is independently controlled, the number of facility elements in the processing step 3 is plural.

Further, although all the equipment elements of the equipment of the present embodiment were measured, it is possible to measure only the necessary equipment elements, and it is not necessary to measure all the equipment elements.

[0025]

As described above, according to the first aspect of the present invention, the energy consumption of the equipment element is continuously measured to confirm the temporal change of the energy consumption of each equipment element. Therefore, since the measurement can be surely performed by a simple method, it is possible to easily confirm the energy use status by anyone and any equipment. The invention according to claim 2 continuously measures the production amount in the processing step,
Since the changes in the energy consumption of each equipment element and the production in the machining process are compared, it is possible to compare the energy consumption and the production. According to the invention described in claim 3, the results obtained by the energy consumption measuring method according to claim 1 or 2 are set as a state in which the results can be compared in time series, and the ideal energy corresponding to the production situation for each equipment element is set. By comparing the ideal energy confirmation means for confirming the amount of use, the ideal amount of energy used according to the production status of the above-mentioned equipment element, and the measured amount of energy used for each equipment element, energy that can be saved Since it has an energy saving discovery means to find out, the ideal energy usage of each equipment element can be easily confirmed, and whether energy saving is possible by comparing the ideal energy usage with the measured energy usage You can check.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing a processing step used in an energy consumption measuring method and an energy saving diagnosis method according to a first embodiment of the present invention.

FIG. 2 is a diagram showing a line graph showing the measurement results obtained by the energy consumption measuring method according to the first embodiment of the present invention.

FIG. 3 is a diagram showing a line graph in which the ideal energy consumption of each facility element is added to the graph of FIG.

FIG. 4 is a schematic diagram showing processing steps used in the energy consumption measuring method and the energy saving diagnosis method according to the embodiment of the present invention, the processing steps having a plurality of facilities.

FIG. 5 is a schematic diagram showing a processing step used in the energy consumption measuring method and the energy saving diagnosis method in the embodiment of the present invention, the processing step having one equipment element in one equipment;

[Explanation of symbols] 1, 2, 3 processing steps 5 facilities 7,8 equipment elements

Claims (3)

[Claims] 1. A processing step comprising one equipment or a series of two or more continuous equipment, wherein the equipment has equipment elements that use energy, and the entire processing step has a plurality of equipment elements. And measuring the energy consumption of the equipment element continuously to confirm the change over time in the energy consumption of each equipment element. 2. The method according to claim 1, wherein the production amount in the processing step is continuously measured, and the energy usage amount of each equipment element and the change in the production amount in the processing step with time are compared. Energy consumption measurement method. 3. An ideal energy consumption amount according to the production status of each equipment element, with the measurement results obtained by the energy consumption measuring method according to claim 1 or 2 being set as a state in which they can be compared in time series. An ideal energy derivation means for deriving energy, and an ideal energy use amount derived by the means, and an energy saving discovering means for finding energy that can save energy by comparing the measured energy use amount for each equipment element. An energy-saving diagnosis method characterized by the above.