JP2018106425A - Method and apparatus for visualizing work loss - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and apparatus for visualizing a work loss in which a latent work loss is actualized by detecting an abnormality of energy consumption.SOLUTION: A method for visualizing a work loss comprises: determining an apparatus-period based energy consumption by totalizing, for each apparatus and for each unit period, energy consumption consumed by apparatuses 2 used in operation in each work process within an object facility consume; determining an apparatus-period based energy consumption rate by dividing the apparatus-period based energy consumption by a production volume of products produced in an object facility within each unit period; determining an average value and standard deviation of the apparatus-period based energy consumption rate in a sample including a plurality of unit periods; determining a deviation value of the apparatus-period based energy consumption rate in each unit period on the basis of the determined average value and standard deviation; comparing deviation values in the unit period for each apparatus; detecting a deviation value greater in deviation as compared with the other deviation value in a unit period out of the deviation values in a unit period of each apparatus; and estimating that there is a work loss in the work process performed using the relevant apparatus in the unit period in which the deviation value greater in deviation occurs.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a work loss visualization method and apparatus, and relates to a technique for finding out a work loss that exists in a facility.

  Conventionally, there is an energy management system for the purpose of energy saving. For example, what is described in Patent Document 1 relates to a demand calendar that displays one electricity billing period in a single sheet, and is displayed in units of days from the first day to the last day of one electricity billing period. It is a calendar that occupies a fixed section, the sections of each day of the same week are arranged horizontally from left to right, and the sections of each day of the same day of the week are arranged vertically from top to bottom.

  And as a horizontal axis of each day section, when viewed in the vertical direction, a time axis arranged with the passage of time from left to right so as to be the same time scale on the same day of the week on each day section, As the vertical axis of each day section, when viewed in the horizontal direction, the demand value axis arranged so that the same demand value is graduated in each day section of the same week, A demand value indication for indicating a demand value for each demand period according to the scale of the axis.

  What is described in Patent Document 2 is an energy usage visualization device, an energy usage acquisition unit that acquires the energy usage for each device arranged in a production line, the number of productions for each device, and each device A production facility information acquisition unit for acquiring production state information for each device such as a production / non-production state of the device, arrangement of each device in the manufacturing line, connection information / adjacent relationship between the devices, or a manufacturing process sequence Device-related information acquisition unit for acquiring device-related information such as, information on energy usage for each device obtained from the energy usage amount acquisition unit, and production status for each device obtained from the production facility information acquisition unit A graph creation unit that creates a graph of the energy usage associated with the production status information based on the information, and a scale of the graph created by the graph creation unit. A scale adjustment unit that adjusts, time information of the graph created by the graph creation unit, and device-related information obtained from the device-related information acquisition unit, a graph created by the graph creation unit, or the scale adjustment And a parallel display unit that displays the graph after scale adjustment by the unit along the time axis and the flow of production.

JP2015-213429 Patent No. 5832362

  As shown in Patent Document 1, when displaying energy usage on a daily basis in a graph, the amount of graphs displayed at one time for a month becomes large, and daily changes in energy consumption can be read from a large amount of graphs. It was difficult, and it was not possible to easily determine which equipment graph should be noted on which day, and work efficiency was poor in conducting energy saving analysis.

  In Patent Document 2, power consumption is finely classified and displayed in a graph, and the display target is energy consumption in time units. A plurality of graphs are displayed with the production flow on the vertical axis and the time flow on the horizontal axis. For this reason, it is impossible to determine whether or not energy consumption is wasted unless individual graphs are opened.

  In addition, Patent Documents 1 and 2 merely display changes in energy consumption. Therefore, when the production volume is small, the energy consumption is small and the evaluation is excellent in terms of energy saving. When the amount is large, the energy consumption increases and the evaluation becomes worse in terms of energy saving, and it is difficult to easily find a potential work loss in each production process.

  The present invention solves the above-described problems, and an object of the present invention is to provide a work loss visualization method and apparatus that make a potential work loss obvious by detecting an abnormality in energy consumption.

  In order to solve the above-mentioned problem, the work loss visualization method of the present invention adds up the amount of energy consumed by equipment used during operation in each work process in the target facility for each equipment and for each unit period. The energy consumption for each device period is obtained, and the energy consumption for each device period is obtained by dividing the energy consumption for each device period by the production amount of the product produced in the target facility within each unit period. Obtain the average value and standard deviation of the energy intensity for each device period in the sample including the period, and obtain the deviation value of the energy intensity for each device period based on the obtained average value and standard deviation for each device. A unit period in which deviation values of unit periods are compared, a deviation value that is larger than the deviation values of other unit periods is detected among the deviation values of the unit periods of each device, and a deviation value that produces a large deviation value is detected. And estimating the working loss in the work process was performed using Oite the device exists.

The work loss visualization apparatus according to the present invention includes an electric energy measuring device installed for each device in a target facility, a computer that receives a signal transmitted by each electric energy measuring device, and a display device that displays a processing result of the computer. And
Each power measurement device measures the power consumption of the power consumed by the measurement target device during operation in each work process, sends the measured power consumption to the computer, and the computer receives from each power measurement device The measured energy consumption is collected for each device and for each unit period to obtain energy consumption for each device period, and the production period of the product produced at the target facility within each unit period. Divide every energy consumption to find the energy intensity for each equipment period, find the average value and standard deviation of the energy intensity for each equipment period in a sample containing multiple unit periods, and based on the obtained average and standard deviation A deviation value of the energy intensity for each device period in each unit period is obtained, and the obtained deviation value is displayed on the display device in the order of the unit period.

  In the work loss visualization apparatus of the present invention, the computer compares the deviation values of the unit periods for each device, and the deviation among the deviation values of the unit periods of each device is larger than the deviation values of the other unit periods. A deviation value is detected, and the detected deviation value is displayed on a display device in a form different from other deviation values.

The work loss visualization device of the present invention is installed for each device in the target facility, displays a measurement device that measures a specific index, a computer that receives a signal transmitted by each measurement device, and a processing result of the computer. A display device,
Each measuring device sends a specific index measurement value of the measurement target device to the computer,
The computer collects the specific index measurement values received from each measurement device for each device and for each unit period to obtain the measurement value for each device period, and the measurement value for each device period in a sample including a plurality of unit periods. Obtain the average value and standard deviation, obtain the deviation value of the measured value for each device period in each unit period based on the obtained average value and standard deviation, and display the obtained deviation value on the display device in the order of the unit period, Compare the deviation value of the unit period for each device, detect the deviation value of the unit period of each device that is larger than the deviation value of the other unit period, and detect the deviation value It displays on a display apparatus with the form different from a deviation value, It is characterized by the above-mentioned.

  With the above configuration, by comparing the deviations in energy intensity for each device period, potential work loss can be accurately manifested without being confused by the increase or decrease in energy consumption accompanying the increase or decrease in production volume. .

The graph figure which shows the example of a table | surface in embodiment of this invention Partial enlarged view of FIG. The graph which shows the power consumption in the time unit of the apparatus with a certain day in FIG. The schematic diagram which shows the apparatus incidental to the cupola in the same embodiment

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention can be applied to various facilities such as industrial product manufacturing structures, water treatment facilities, and the like. In the present embodiment, a cupola will be described as an example.

  As shown in FIG. 4, the cupola 1 is provided with various devices 2, such as a filter cooling pump, a tuyere cooling pump, a building dust collector, a backwash dust collector, a blower blower, etc. Here, the devices are displayed as pumps # 1 to # 5 and as dust collectors # 1 to # 5.

  Each device 2 measures the power consumption (kWh) of the power consumed by the device 2 during operation in each work process as a specific index, and the measured power consumption is automatically transmitted through the communication line (wired, wireless) 3. An electric energy measuring device 5 for transmitting to a server 4 described later is connected. In this embodiment, the amount of power consumption is used as a specific index. However, as the specific index, it is possible to adopt an operation time or a stop time of the device, and any variation value generated with the operation of the device may be used.

  Here, a configuration in which the personal computer 6 is connected to the server 4 is illustrated, but the measured value of the power consumption (kWh) may be directly transmitted from the power amount measuring device 5 to the personal computer 6 without going through the server 4. Is possible.

  The server 4 accumulates the measured value of the power consumption (kWh) received from each power amount measuring device 5 as data for each device 2, for example, the pump # 1 and the dust collector # 5. This data can be taken out by designating an arbitrary unit period such as second, minute, hour, day, or month. Further, the production amount of the product produced at the target facility on each operation day (within the unit period), here, the output amount (t) is automatically registered in the server 4.

  The personal computer 6 collects the power consumption (kWh) for each device 2 as a unit and in a unit period designated by the operator, here, every operation day, and calculates the energy consumption for each device period (measured value for each device period). Ask.

  Next, the energy consumption per unit device period (kWh) is divided by the output amount (t) of the product produced at the target facility on each operation day (within the unit period), and the energy unit per unit device period Xij (i Is a date, and j is a device such as pump # 1).

  And the average value A for every apparatus of the energy basic unit Xij for every apparatus period is calculated | required in the period from the date of a measurement start to a process day here, including the some operation day (unit period). Further, the standard deviation B is obtained, and the deviation value C of the energy basic unit Xij for each equipment period on the operation day (unit period) is obtained based on the obtained average value A and standard deviation B. The specimen can be set for any particular period.

  A: Average value for each device

Ｂ：機器毎の標準偏差

B: Standard deviation for each device

Ｃ：機器毎・日毎の偏差値

C: Deviation value for each device / day

そして、求めた偏差値Ｃを操業日（単位期間）の経過順にディスプレイ（表示装置）７に表示する。

Then, the obtained deviation value C is displayed on the display (display device) 7 in the order of operation days (unit period).

  FIG. 1 shows an example of the display screen of the display 7. Here, the vertical axis is the day, and the horizontal axis is the device (equipment) 2 and is displayed as a list of energy consumption for each device on a horizontal line every day. If the date changes, the deviation value C is automatically calculated and stored as a graph with the previous day as the processing day.

  By displaying in this way, it is not necessary to search a large amount of daily graphs as in the conventional case, and the state of each device can be seen without opening the daily graph. Can be discriminated efficiently, visibility is improved, and wasteful consumption of energy, work loss, equipment abnormality, etc. can be efficiently discovered.

  In addition, by using the average value A, standard deviation B, and deviation value C of the energy intensity for each device period, the “unusual” state of power consumption can be clearly and accurately revealed, and waste of energy consumption. It is possible to efficiently detect work loss, equipment abnormality, and the like.

  The personal computer 6 compares the deviation value C for each device 2 and for each operation day, and compares the deviation value C for each operation day of each device 2 with the deviation value C for other operation days. A deviation value C having a large deviation is detected. And, as shown in FIG. 2, the detected deviation value C, for example, the deviation value 70.3 of 2016/2/2 of the dust collector # 5, the deviation value 63.5 of 2016/2/3, and 2016/2/4 The deviation value 65.8 is displayed on the display 7 in a different form from the other deviation values C, for example, by different colors or shades of colors (indicated by hatching in FIG. 2), and the larger the deviation value C, the darker the value. Further, it may be an expression that allows easy recognition and discrimination of symbols and the like.

  This makes it possible to determine at a glance whether the deviation value C is large or small, improve the visibility of the graph representing the abnormal state, and more efficiently discover wasteful energy consumption, work loss, equipment abnormality, etc. It can be carried out.

  For this reason, the operator who operates the personal computer 6 can easily recognize the deviation value C in the abnormal state, and the visibility of the graph is improved.

  Then, by selecting the operation value 2016/2/2 of the deviation value C in the abnormal state, for example, the deviation value 70.3 (click the value on the screen), as shown in FIG. 5 may be displayed by jumping to a graph showing the change in the power consumption amount.

  In this graph, the graph 11 of the operation day 2016/2/2 and the graph 12 showing the change in the standard power consumption amount are simultaneously compared and displayed, and the difference in the operation date 2016/2/2 is displayed. Display the excessive amount of power consumption and the time zone when the amount of power is excessive to clarify the existence of work loss.

  Then, by reviewing the work record of the day, it is possible to easily confirm the cause such as the maintenance of the device 2 or the occurrence of an accident, and measures can be taken.

  In the present embodiment, the deviation value C is obtained by calculating the energy consumption amount for each device period by totaling the power consumption amount within the operation day (unit period). The accuracy of finding work loss can be increased by summing up the amount of power consumption during the time when the emergency shut-off valve that is sometimes operated is OFF.

  In this embodiment, the power consumption is used as an index, but other general measurement data can be used as an index. Moreover, in this Embodiment, the energy basic unit for every apparatus period was calculated | required, and the average value A, the standard deviation B, and the deviation value C were used, However, The calculation value by another algorithm may be sufficient.

1 Cupola 2 Equipment 3 Communication line 4 Server 5 Energy meter 6 Personal computer 7 Display

Claims (4)

  The energy consumption consumed by the equipment used during operation in each work process in the target facility is calculated for each equipment and for each unit period to obtain the energy consumption for each equipment period. The energy consumption per device period is obtained by dividing the energy consumption per device period by the production volume of the product produced in step 2. The average value and standard deviation of the energy intensity per device period are obtained for samples containing multiple unit periods. Obtain the deviation value of energy intensity per unit period in each unit period based on the obtained average value and standard deviation, compare the deviation value of unit period for each unit, and calculate the deviation value of unit period of each unit Among them, a deviation value having a large deviation compared to the deviation values of other unit periods is detected, and there is a work loss in the work process performed using the equipment in the unit period in which the deviation value has a large deviation value. Work loss visualization method and estimating the that. A power measuring device installed for each device in the target facility, a computer that receives a signal transmitted by each power measuring device, and a display device that displays a processing result of the computer,
Each power measurement device measures the power consumption of the power consumed by the measurement target device during operation in each work process, sends the measured power consumption to the computer, and the computer receives from each power measurement device The measured energy consumption is collected for each device and for each unit period to obtain energy consumption for each device period, and the production period of the product produced at the target facility within each unit period. Divide every energy consumption to find the energy intensity for each equipment period, find the average value and standard deviation of the energy intensity for each equipment period in a sample containing multiple unit periods, and based on the obtained average and standard deviation A work loss visualization device, characterized in that a deviation value of energy intensity for each device period in each unit period is obtained and the obtained deviation value is displayed on a display device in the order of the unit period.   The computer compares the deviation value of the unit period for each device, detects the deviation value of the deviation of the unit period of each device that is larger than the deviation value of the other unit periods, and detects the detected deviation value The work loss visualization device according to claim 2, wherein the operation loss is displayed on the display device in a form different from other deviation values. It is installed for each device in the target facility, and includes a measuring device that measures a specific index, a computer that receives a signal transmitted by each measuring device, and a display device that displays a processing result of the computer,
Each measuring device sends a specific index measurement value of the measurement target device to the computer,
The computer collects the specific index measurement values received from each measurement device for each device and for each unit period to obtain the measurement value for each device period, and the measurement value for each device period in a sample including a plurality of unit periods. Obtain the average value and standard deviation, obtain the deviation value of the measured value for each device period in each unit period based on the obtained average value and standard deviation, and display the obtained deviation value on the display device in the order of the unit period, Compare the deviation value of the unit period for each device, detect the deviation value of the unit period of each device that is larger than the deviation value of the other unit period, and detect the deviation value A work loss visualization device, characterized in that it is displayed on a display device in a form different from a deviation value.

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