WO2020149198A1 - 解析システム及び解析方法 - Google Patents
解析システム及び解析方法 Download PDFInfo
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- WO2020149198A1 WO2020149198A1 PCT/JP2020/000345 JP2020000345W WO2020149198A1 WO 2020149198 A1 WO2020149198 A1 WO 2020149198A1 JP 2020000345 W JP2020000345 W JP 2020000345W WO 2020149198 A1 WO2020149198 A1 WO 2020149198A1
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Definitions
- the present invention relates to an analysis system and an analysis method for performing a numerical analysis on the basis of operation data relating to an operating state of a manufacturing facility, and further performing a statistical analysis based on a result of the numerical analysis and a state of a product manufactured by the manufacturing facility. It is a thing.
- operation data of the manufacturing equipment in the manufacturing process of products is generally collected and recorded.
- the operation data is data relating to the operating state of the manufacturing equipment, and includes, for example, information such as various physical quantities indicating the state of the manufacturing equipment, and information on various operating conditions set in the manufacturing equipment.
- Operation data is used for quality control by identifying abnormalities in manufacturing conditions when a defect occurs in a manufactured product, or statistical analysis is performed to determine the operating conditions set in the manufacturing equipment. It is used to improve the operation after investigating the effect on the characteristics.
- the operation data is also used to investigate the cause of troubles that occur during manufacturing and to maintain equipment.
- numerical analysis is also widely used to improve operations.
- Numerical analysis is to perform a calculation using a physical model to reproduce a phenomenon or calculate a physical quantity.
- Numerical analysis does not require experimental equipment, and the analysis results can be obtained relatively quickly at low cost.
- the degree of freedom is high because the operating conditions and the like of the operating equipment to be numerically analyzed can be easily changed to perform the analysis.
- Patent Document 1 describes a technique for visualizing a steel material rolling process by executing a numerical analysis using operation data in the steel material rolling process.
- the temperature distribution, stress, etc. of the steel material during rolling are calculated by numerical analysis.
- Patent Document 2 describes an optimum load estimation method in rolling.
- a numerical analysis result database is constructed by performing numerical calculations in advance using a numerical analysis method such as a finite element method, and an appropriate numerical analysis result is created from the database for each operating condition. To determine the optimum load.
- Patent Document 3 describes a method of using a database of numerical analysis results for controlling the operation of the heating furnace.
- the numerical analysis using the operation results is performed in advance, and when the heating furnace is operated, the numerical calculation result calculated under the condition closest to the operating condition is extracted from the database. Proximity is used as an index in the selection of operating conditions to be extracted.
- weighting is performed according to the proximity.
- Patent Document 4 describes that the operation of blowing the diluted gas fuel into the sintering machine is performed in advance, and the operation result is statistically processed in advance.
- basic data the data (hereinafter also referred to as "basic data") that is the basis for analyzing the correlation is required, and the more accurate and accurate the statistical analysis result is, the greater the amount and type of basic data.
- Basic data the data (hereinafter also referred to as "basic data") that is the basis for analyzing the correlation is required, and the more accurate and accurate the statistical analysis result is, the greater the amount and type of basic data.
- necessary basic data may not be obtained in some cases.
- the number of installable measuring devices may be limited depending on the conditions such as manufacturing facilities and devices. When the number of measurement devices that can be installed is limited, it may not be possible to acquire a sufficient amount of basic data and the spatial distribution information about the physical quantity to be measured may not be known.
- the physical quantity it may be difficult to measure with a measuring device. For example, it may be difficult to obtain a physical quantity such as density, stress, or concentration by measurement. Furthermore, for example, in the case of making a prediction regarding an operating condition that greatly differs from the actual operating condition, it is difficult to make a prediction by statistical analysis unless there is data similar to the changed operating condition.
- Patent Documents 1 to 4 described above use a result predicted based on a numerical analysis executed in advance.
- the actual phenomenon includes various factors that can fluctuate, it cannot always be said that highly accurate prediction can be performed by numerical analysis.
- the present invention has been made in view of such a conventional problem, by performing a more accurate analysis, operation data and defects that occurred in the manufactured product, or the cause of the defect that occurred during the manufacturing It is an object of the present invention to provide an analysis system and an analysis method capable of analyzing the correlation with.
- An analysis system is an operation data acquisition unit that acquires operation data including an operation state of a manufacturing facility, and a product that acquires the state of a product manufactured by the manufacturing facility and outputs it as product information. Based on the operation data acquired by the information acquisition unit and the operation data acquisition unit, a predetermined physical quantity of the product is obtained, and a manufacturing state analysis unit that outputs it as information regarding the physical quantity, information regarding the physical quantity, and the product A correlation analysis unit that analyzes a correlation with information.
- the manufacturing state analysis unit based on the operation data acquired by the operation data acquisition unit, performs a numerical analysis for the predetermined physical quantity using a physical model, The result of the executed numerical analysis is output as information on the physical quantity.
- an analysis result database for storing a result of numerical analysis of the predetermined physical quantity, which is executed in advance using a physical model based on operation data of the manufacturing facility.
- the manufacturing state analysis unit based on the operation data acquired by the operation data acquisition unit, using the result of the numerical analysis stored in the analysis result database, determines the information about the physical quantity, the determined Outputs information about physical quantity.
- the manufacturing state analysis unit based on the operation data acquired by the operation data acquisition unit, of the results of the plurality of numerical analysis stored in the analysis result database Information regarding the physical quantity is determined by performing a weighted calculation for each.
- the analysis system further includes an analysis result storage unit that stores the analysis result of the correlation by the correlation analysis unit.
- the product information includes information on product quality.
- the manufacturing state analysis unit and the correlation analysis unit are installed in different independent devices.
- the manufacturing state analysis unit and the correlation analysis unit are installed in one device.
- an analysis method is an analysis method executed by an analysis system, which includes a step of acquiring operation data including an operation state of manufacturing equipment, and a product manufactured by the manufacturing equipment. Information about the physical quantity, a step of obtaining a status, a step of outputting the status of the product as product information, a step of obtaining a predetermined physical quantity of the product based on the acquired operation data, and a step of obtaining the predetermined physical quantity. And a step of analyzing the correlation between the physical quantity information and the product information, including.
- FIG. 1 is a functional block diagram showing a schematic configuration of an analysis system 10 according to the first embodiment of the present invention.
- the analysis system 10 includes an operation data acquisition unit 11, a manufacturing state analysis unit 12, a product information acquisition unit 13, a correlation analysis unit 14, an analysis result storage unit 15, and an analysis result output unit. 16 and.
- the analysis system 10 is composed of an information processing device such as a computer.
- the analysis system 10 may be configured by one information processing device or may be configured by two or more information processing devices.
- the analysis result output unit 16 is included in the one information processing device.
- the analysis system 10 is composed of two or more information processing devices, the operation data acquisition unit 11, the manufacturing state analysis unit 12, the product information acquisition unit 13, the correlation analysis unit 14, the analysis result storage unit 15, and the analysis result output.
- the unit 16 is provided in at least one of the two or more information processing devices.
- the first information processing device includes the operation data acquisition unit 11 and the manufacturing state analysis unit 12
- the second information processing device includes the product information acquisition unit. 13 and the correlation analysis unit 14, and the third information processing apparatus may include the analysis result storage unit 15 and the analysis result output unit 16.
- the content described here is only an example.
- Each functional unit of the analysis system 10 may be provided in an appropriate information processing device according to the processing executed by each information processing device.
- the operation data acquisition unit 11 acquires operation data in the manufacturing equipment 20.
- the manufacturing facility 20 is a facility that executes a predetermined operation.
- the manufacturing facility 20 may be, for example, a manufacturing facility installed in a factory.
- the product is manufactured by operating the manufacturing facility 20.
- the manufacturing facility 20 is configured to include a plurality of manufacturing devices.
- the manufacturing facility 20 will be described as a manufacturing facility for manufacturing a product.
- the product is not limited to a finished product, but includes a product in a manufacturing process (hereinafter, also referred to as a “semi-finished product”).
- a measuring device 21 is attached to the manufacturing facility 20.
- the measuring device 21 is a device that measures a predetermined physical quantity.
- the measuring device 21 may include, for example, a thermometer for measuring temperature, a pressure gauge for measuring pressure, a flow meter for measuring flow rate, a load meter for measuring load, an acceleration sensor for detecting acceleration, and the like. I can't.
- the measuring device 21 is attached to an appropriate position of the manufacturing facility 20.
- the operation data acquired by the operation data acquisition unit 11 includes data on the operation state of the manufacturing equipment 20.
- the operation data includes, for example, data measured by the measuring device 21 when the manufacturing facility 20 is operating.
- the operation data acquisition unit 11 acquires directly or indirectly the data measured by the measuring device 21 (that is, operation data).
- the operation data acquisition unit 11 is, for example, communicably connected to the measuring device 21, and directly receives the operating data measured by the measuring device 21 from the measuring device 21. Get by.
- the measuring device 21 is communicably connected to a server or the like that collects the operation data, and transmits the operation data to the server or the like.
- the operation data acquisition unit 11 is communicably connected to the server or the like, and can acquire the operation data indirectly by acquiring the operation data from the server or the like. Therefore, the operation data acquisition unit 11 is configured to include a communication interface or the like used to communicate with the measuring device 21 or the server.
- the operation data may include data related to the target of manufacturing processing by the manufacturing facility 20 (for example, raw material or semi-finished product).
- the data regarding the target of the manufacturing process by the manufacturing facility 20 may include, for example, the type of raw material, the chemical composition, the size and weight of the semi-finished product, which are the target of the manufacturing process.
- the operation data may include the operation conditions set in the manufacturing equipment 20.
- the operation data acquisition unit 11 outputs the acquired operation data to the manufacturing state analysis unit 12.
- the manufacturing state analysis unit 12 obtains a predetermined physical quantity of the product based on the operation data acquired by the operation data acquisition unit 11, and outputs information regarding the obtained physical quantity to the correlation analysis unit 14.
- the predetermined physical quantity indicates a numerical value obtained by numerical calculation using a physical model based on the operation data, and its distribution.
- the manufacturing state analysis unit 12 performs numerical analysis using a physical model based on the operation data acquired by the operation data acquisition unit 11 to obtain information regarding a predetermined physical quantity.
- the manufacturing state analysis unit 12 outputs the result of the executed numerical analysis as information on a predetermined physical quantity. That is, the manufacturing state analysis unit 12 outputs a value as a result of the numerical analysis.
- the value as a result of numerical analysis may include the distribution.
- the manufacturing state analysis unit 12 is composed of, for example, a processor capable of executing numerical analysis.
- the manufacturing state analysis unit 12 is configured by a processor such as a CPU (Central Processing Unit) that executes a program that defines an execution procedure of numerical analysis.
- a program is stored in, for example, a storage unit included in the analysis system 10 or an external storage medium.
- the physical model is constructed in advance according to a predetermined physical quantity that is the target of the numerical analysis to be estimated, and is stored in, for example, a storage unit included in the analysis system 10 or an external storage medium.
- various models such as an elasto-plastic analysis model for structure analysis, a Navier-Stokes equation for thermofluid analysis, a Maxwell equation for electromagnetic field analysis, etc. can be appropriately used according to a predetermined physical quantity.
- the manufacturing state analysis unit 12 calculates, by numerical analysis, a physical quantity that is difficult to measure with the measuring device 21 as a predetermined physical quantity that is the target of the numerical analysis to be estimated.
- the physical quantity that is difficult to measure by the measuring device 21 may include a physical quantity that cannot be directly measured by the measuring device 21 or a physical quantity that cannot be seen by the measurement.
- the physical quantity that cannot be directly measured by the measuring device 21 is, for example, the temperature inside the semi-finished product in the manufacturing process of the product.
- the physical quantity that is difficult to measure with the measuring device 21 may include a physical quantity at a location where the measuring device 21 cannot be attached due to the nature of the manufacturing facility 20.
- the physical quantity that is difficult to measure with the measuring device 21 may include a distribution of a predetermined physical quantity.
- the distribution of the physical quantity may be included in the physical quantity that is difficult to measure by the measuring device 21, as described above.
- the manufacturing state analysis unit 12 outputs the result of numerical analysis to the correlation analysis unit 14.
- the product information acquisition unit 13 acquires the state of the product manufactured by the manufacturing facility 20 when the operation data is measured by the measuring device 21, and the correlation analysis unit 14 acquires the information regarding the acquired product state as the product information. Output to.
- the product information includes any information regarding the state of the product.
- the product information may include, for example, information about product quality.
- the information regarding the quality of the product may include, for example, information regarding the size, weight and strength of the product, information regarding the chemical composition of the product, information regarding defects (for example, cracks and cracks) found in the product, and the like.
- the product information may be, for example, an inspection result by a device such as a specific inspection device, or may be an inspection result including visual inspection by an operator or the like.
- product information is not limited to information on the state of finished products, but may be information on the state of semi-finished products during manufacturing.
- the product information only needs to include information on the state after the processing when some processing (processing) is executed by at least one specific device of the manufacturing facility 20.
- the product information acquisition unit 13 is communicably connected to the inspection device and acquires the product information as the inspection result from the inspection device.
- the product information acquisition unit 13 may acquire the product information as the inspection result by accepting the input of the inspection result information.
- the product information as the inspection result is input by an operator or the like using an input device such as a keyboard or a touch panel.
- the input device may be included in the analysis system 10 or may be included in an external device capable of communicating with the analysis system 10.
- the product information acquisition unit 13 outputs the acquired product information to the correlation analysis unit 14.
- the correlation analysis unit 14 analyzes the correlation between the information on the predetermined physical quantity acquired from the manufacturing state analysis unit 12 and the product information acquired from the product information acquisition unit 13.
- the correlation analysis unit 14 analyzes the correlation between the result of the numerical analysis acquired from the manufacturing state analysis unit 12 and the product information acquired from the product information acquisition unit 13. That is, the correlation analysis unit 14 performs statistical analysis on the result of the numerical analysis and the product information.
- the correlation analysis unit 14 further acquires the data measured by the measurement device 21 from the operation data acquisition unit 11 or the measurement device 21 installed in the manufacturing facility 20, as necessary, and executes statistical analysis. May be.
- the correlation analysis unit 14 is composed of, for example, a processor capable of executing statistical analysis.
- the correlation analysis unit 14 may be configured by a processor such as a CPU that executes a program that defines the execution procedure of the statistical analysis. Such a program is stored in, for example, a storage unit included in the analysis system 10 or an external storage medium.
- a known statistical analysis method can be used. For example, by using multiple regression analysis, regression analysis, neural network model, or other statistical analysis, analyze the correlation between the operating state of the manufacturing facility 20 when the manufacturing facility 20 is in operation and the products manufactured by the facility. You can
- the numerical analysis results acquired from the manufacturing state analysis unit 12 include various calculation results of products or semi-finished products.
- the correlation analysis unit 14 it is possible to perform statistical analysis between these various calculation results and the product information to check whether there is a correlation, and to know the result of the numerical analysis showing the highest correlation with the product information. it can. That is, as compared with the case where the numerical analysis is not executed, it becomes easier to specify the operating factor and operating condition (hereinafter collectively referred to as “operating factor”) that may affect the state of the product.
- the correlation analysis unit 14 outputs the result of statistical analysis.
- the correlation analysis unit 14 may output the statistical analysis result by transmitting the statistical analysis result to an external device that can communicate with the analysis system 10, for example.
- the correlation analysis unit 14 may output the result of the statistical analysis to the analysis result storage unit 15.
- the analysis result storage unit 15 stores the result of the statistical analysis output from the correlation analysis unit 14.
- the analysis result storage unit 15 can be configured by a semiconductor memory, a magnetic memory, or the like.
- the correlation analysis unit 14 outputs the result of the statistical analysis to the analysis result storage unit 15 every time the statistical analysis is executed.
- the analysis result storage unit 15 stores the statistical analysis result output from the correlation analysis unit 14.
- the correlation analysis unit 14 may use the past analysis results accumulated in the analysis result storage unit 15 when executing the statistical analysis.
- the accuracy of the statistical analysis improves as the number of data used for the analysis increases. Therefore, when performing statistical analysis, it is possible to obtain a more accurate statistical analysis result by adding the results of past statistical analysis of the same product, and to identify operating factors that may affect the state of the product. , Get easier.
- the analysis result output unit 16 outputs and displays the result of the statistical analysis.
- the analysis result output unit 16 is, for example, a display device such as a liquid crystal display (LCD: Liquid Crystal Display), an organic EL display (OELD: Organic Electro-Luminescence Display), or an inorganic EL display (IELD: Inorganic Electro-Luminescence Display).
- LCD Liquid Crystal Display
- OELD Organic Electro-Luminescence Display
- IELD Inorganic Electro-Luminescence Display
- a printing machine such as a printer.
- the analysis result output unit 16 may obtain the information of the analysis result from the correlation analysis unit 14 and display the information of the analysis result, and display the information of the analysis result stored in the analysis result storage unit 15. You may acquire and display the information of the said analysis result.
- the analysis result output unit 16 does not necessarily have to be included in the analysis system 10 and may be included in an external device that can communicate with the analysis system 10.
- the analysis system 10 may output and display the result of the statistical analysis by transmitting the result of the statistical analysis to an external device that can communicate with the analysis system 10, for example. Further, it goes without saying that there is no problem even if the analysis result output unit 16 is provided in the same device as the correlation analysis unit 14 and the analysis result storage unit 15.
- the operating conditions in the manufacturing equipment 20 can be set or changed based on the result of the analysis executed by the analysis system 10 as described above.
- the setting or changing of the operating condition is executed by the operating condition control unit 30, for example.
- the operating condition control unit 30 sets or changes the operating conditions in the manufacturing facility 20.
- the operating condition control unit 30 may be composed of, for example, a computer device.
- the user or manager of the manufacturing equipment 20 refers to the information of the analysis result displayed on the analysis result output unit 16 to cause the operation condition control unit 30 to set or change the operation condition. Input operation.
- the operating condition control unit 30 transmits a signal for setting or changing the operating condition to the manufacturing equipment 20 based on the operation input.
- the operating condition control unit 30 is composed of, for example, a processor capable of executing setting or changing control of operating conditions.
- the operating condition control unit 30 is configured to include a processor such as a CPU that executes a program that defines an execution procedure of control for setting or changing operating conditions.
- a program is stored in, for example, a storage unit included in the computer device forming the operating condition control unit 30 or an external storage medium.
- the operating condition control unit 30 transmits to the manufacturing facility 20 a signal that is set in the manufacturing facility 20 to set or change the operating condition.
- the operating conditions are set based on the signal, and the manufacturing equipment 20 operates under the set operating conditions.
- the correlation analysis unit 14 obtains the result of the statistical analysis and the result of the numerical analysis showing the highest correlation with the product information. Since the result of this numerical analysis is obtained based on the operation data, the operating conditions to be changed can be known by referring to the result of the numerical analysis.
- the operating condition control unit 30 controls the operating conditions of the manufacturing facility 20 such that the user or the manager of the manufacturing facility 20 can improve the quality of the product based on the result of the statistical analysis by the correlation analyzing unit 14. A signal for setting or changing is transmitted. In addition, for example, the operating condition control unit 30 may automatically set the operating condition based on the result of the statistical analysis. When the operating conditions are set or changed so that the quality of the product is improved, the product manufactured by the manufacturing facility 20 has a higher possibility that, for example, a defective product is less likely to be manufactured. As a result, the quality of the product is improved. In this way, according to the analysis system 10, it is possible to improve the product quality and the operation of the manufacturing facility 20.
- the operating condition control unit 30 may automatically set the operating condition based on the result of the statistical analysis.
- the operating condition control unit 30 may be configured as one of the constituent elements of the analysis system 10. That is, the analysis system 10 may include the operating condition control unit 30 that automatically sets the operating condition as one functional unit.
- the analysis system 10 of the present invention when used for investigating the cause of a trouble that occurs during manufacturing, it can be dealt with by acquiring the details of the trouble in the product information acquisition unit 13, so that the product information acquisition unit 13 is not in trouble. It may be read as an information acquisition unit or the like.
- the operation data acquisition unit 11 acquires operation data in the manufacturing equipment 20 (step S1).
- the manufacturing state analysis unit 12 executes numerical analysis using a physical model based on the operation data acquired by the operation data acquisition unit 11 in step S1 (step S2).
- the product information acquisition unit 13 acquires product information (step S3).
- the correlation analysis unit 14 executes the statistical analysis based on the result of the numerical analysis in step S2 and the product information acquired in step S3 (step S4). Specifically, the correlation analysis unit 14 analyzes the correlation between the result of the numerical analysis in step S2 and the product information acquired in step S3.
- the analysis result storage unit 15 stores the result of the statistical analysis in step S4 (step S5). By repeating Step S1 to Step S5, the statistical analysis result is accumulated in the analysis result storage unit 15.
- analysis result output unit 16 outputs the result of the statistical analysis (step S6).
- the user, the administrator, or the like of the manufacturing facility 20 refers to the information of the analysis result displayed on the analysis result output unit 16 and inputs an operation to the operation condition control unit 30 to set or change the operation condition. I do.
- the operation condition control unit 30 determines the operation condition of the manufacturing equipment 20 based on the result of the statistical analysis stored in the analysis result storage unit 15 (step S7). Specifically, the operating condition control unit 30 determines the value of the operating condition in the manufacturing facility 20.
- the operating condition control unit 30 outputs a signal for setting or changing the operating condition determined in step S6 to the manufacturing equipment 20 (step S8).
- the manufacturing facility 20 sets or changes the operating condition designated by the signal and manufactures the product according to the condition.
- the analysis system 10 according to this embodiment can be used in various industrial fields. Hereinafter, some examples will be described in detail.
- the analysis system 10 can be applied to an annealing furnace for annealing a steel material.
- the manufacturing facility 20 is an annealing furnace.
- the operation data acquisition unit 11 uses, as operation data, the size and composition of the steel material that is the target of the manufacturing process, the furnace temperature of the annealing furnace, the annealing time, and Information such as heating/cooling speed is acquired from the manufacturing facility 20.
- the information on the size and composition of the steel material is, for example, information input to the manufacturing facility 20 in advance by an operation by a worker or the like before the manufacturing facility 20 starts operating.
- the in-furnace temperature of the annealing furnace is, for example, temperature information acquired by a thermometer as a measuring instrument installed in the annealing furnace.
- the annealing time and the heating/cooling rate are operating conditions set for the manufacturing facility 20, for example.
- the manufacturing state analysis unit 12 executes a numerical analysis using a physical model based on the operation data acquired by the operation data acquisition unit 11.
- the manufacturing state analysis unit 12 calculates, for example, a temperature distribution inside the annealing furnace, a temperature distribution inside the steel material, and an estimated value of a physical quantity such as thermal stress applied to the steel material, by numerical analysis.
- the product information acquisition unit 13 acquires product information regarding the steel material after annealing.
- the product information regarding the annealed steel material is, for example, the strength, composition and shape of the annealed steel material.
- the correlation analysis unit 14 performs statistical analysis based on the estimated physical quantity calculated by the manufacturing state analysis unit 12 and the product information acquired by the product information acquisition unit 13.
- the correlation analysis unit 14 may perform the statistical analysis using the operation data acquired by the operation data acquisition unit 11 in addition to the estimated value of the physical quantity calculated by the manufacturing state analysis unit 12.
- the correlation analysis unit 14 analyzes the correlation between various parameters (physical quantities) and the characteristics of the annealed steel material to identify the operating factor that has a large effect on the quality of the annealed steel material.
- the analysis result storage unit 15 stores the result of the statistical analysis by the correlation analysis unit 14. Each time the statistical analysis is performed by the correlation analysis unit 14, the analysis result storage unit 15 stores the result of the statistical analysis, so that the result of the statistical analysis is accumulated in the analysis result storage unit 15.
- the shape of a steel material is defective and the annealing process is suspected as the cause, it is common to check the temperature in the annealing furnace.
- the correlation between the shape of the steel material and the temperature in the annealing furnace is examined, if the measured temperature in the annealing furnace is within the predetermined range, it is determined that there is no correlation.
- the temperature rising rate of the steel material is obtained by numerical analysis in consideration of the thickness and width of the steel material.
- the presence or absence of correlation can be checked by performing a statistical analysis between the shape of the steel material and the temperature rising rate of the steel material. This is something that cannot be obtained without numerical analysis.
- the maximum temperature reached by the steel material and the temperature distribution within the steel material can be obtained by numerical analysis.
- Numerical analysis can supplement the data required for statistical analysis, so it is easy to identify operating factors that have a large impact on product quality. Then, if the correlation between the temperature rising rate and the shape defect is the highest, the temperature rising rate during annealing can be specified as the cause of the shape defect. At this time, since it is possible to know the influence of the plate thickness and the plate width of the steel material by the numerical calculation, it is possible to set the operating condition in which the shape defect does not occur in the manufacturing equipment 20 for each steel material.
- the analysis system 10 it is possible to improve the quality of the steel material during annealing.
- the estimated value is also calculated for the inside of the steel material by the numerical analysis of the manufacturing state analysis unit 12. It is possible to calculate and use this estimated value for statistical analysis. Therefore, it is possible to realize more accurate analysis and control as compared with the related art.
- the analysis system 10 can be applied to a converter for refining hot metal in a similar manner. Since the inside of the converter is a high temperature and harsh environment, it is difficult to directly measure the physical quantity using the measuring device 21.
- the physical quantity measured by the measuring device 21 for the molten steel discharged, the exhaust gas discharged from the converter, etc. is acquired as the operation data.
- the manufacturing state analysis unit 12 uses the physical model based on the operation data, and uses the molten steel surface velocity of the top-blown jet, the reaction area in the converter (that is, the interface area of the molten steel), and the amount of adhered metal in the converter. , Calculate estimated values of secondary combustion efficiency of converter.
- the state of molten steel after the refining is completed can be obtained by the product information acquisition unit 13.
- the correlation analysis unit 14 performs statistical analysis by using these estimated values, which are the results of numerical analysis, and product information regarding the molten steel after refining, such as refining efficiency (decarburization rate).
- the operation condition control unit 30 controls the operation condition in the converter in accordance with the operation input of the user or the administrator based on the result of the statistical analysis by the correlation analysis unit 14. In this way, according to the analysis system 10, even in a converter in which it is difficult to measure a physical quantity due to a harsh environment, an estimated value can be calculated by numerical analysis, and statistical analysis can be performed using the estimated value.
- the results after refining may vary due to variations in the composition and temperature of the charged molten steel.Therefore, operating conditions should be adjusted based on the accumulated results of multiple statistical analyzes. By determining, control can be performed with higher accuracy.
- the analysis system 10 can be applied to a heating furnace that heats an object such as a metal in a similar manner.
- the object is heated using, for example, a burner or a radiant tube, and the temperature distribution of the object being heated at this time (hereinafter also referred to as “target object”) is directly measured using the measuring device 21. It's difficult.
- the temperature distribution of the target object can be estimated by applying the analysis system 10 and executing the numerical analysis.
- the manufacturing state analysis unit 12 includes, as the operation data, the temperature of the target object when the target object is loaded into the furnace and the temperature inside the furnace, the size of the target object, the material of the target object, and the outside temperature.
- Numerical analysis is performed to estimate the temperature distribution during heating of the target object.
- the correlation analysis unit 14 performs statistical analysis based on the estimated value as a result of the numerical analysis and the quality of the product after heating.
- the operating condition control unit 30 controls the operating condition in the heating furnace according to the operation input of the user or the administrator based on the result of the statistical analysis.
- the texture formation state of the product after heating may be poor depending on the heating state, but the numerical analysis and the statistical analysis by the analysis system 10 have a great influence on the texture formation state. It becomes easier to identify the operating factor.
- the analysis system 10 can be applied to a device that performs molding by machining in a similar manner.
- a device that performs molding by machining in a similar manner.
- the stress distribution of the workpiece can be estimated by applying the analysis system 10 and executing the numerical analysis.
- statistical analysis based on the estimated stress distribution and the quality of the processed workpiece, it is possible to correlate the stress applied to the workpiece during processing with the processing accuracy of the processed product. it can.
- it becomes easy to identify the operating factor that influences the quality of the processing among the operating factors including, for example, the processing load, the speed, the size of the tool used in the processing, and the like.
- the above example is only a part of the example to which the analysis system 10 can be applied.
- the analysis system 10 can also be applied to operating equipment other than the above examples.
- the manufacturing state analysis unit 12 executes the numerical analysis using the physical model, and the correlation analysis unit 14 analyzes the correlation between the result of the numerical analysis and the product information.
- the processing executed by the manufacturing state analysis unit 12 and the correlation analysis unit 14 is not limited to this.
- the second embodiment an example in which the manufacturing state analysis unit 12 and the correlation analysis unit 14 execute other processing different from that of the first embodiment will be described.
- the analysis system according to the second embodiment will be described while omitting the points similar to those in the first embodiment as appropriate.
- FIG. 3 is a functional block diagram showing a schematic configuration of the analysis system 40 according to the second embodiment of the present invention.
- the analysis system 40 according to the second embodiment includes an operation data acquisition unit 11, a manufacturing state analysis unit 12, a product information acquisition unit 13, a correlation analysis unit 14, and an analysis result storage unit 15. And an analysis result output unit 16 and an analysis result database 17.
- the configurations and functions of the operation data acquisition unit 11, the product information acquisition unit 13, the analysis result storage unit 15, and the analysis result output unit 16 are the same as those in the first embodiment, and therefore detailed description will be given here. The description is omitted.
- the analysis result database 17 may be provided in the same information processing device as other functional units, or may be provided in an information processing device different from other functional units.
- the analysis result is calculated in advance.
- the results of numerical analysis are stored in the database 17.
- the result of the numerical analysis stored in the analysis result database 17 is the result of the numerical analysis for a predetermined physical quantity executed by using a physical model based on the operation data of the manufacturing facility 20. That is, the manufacturing equipment 20 is operated in advance, and the numerical analysis process for a predetermined physical quantity is executed using the physical model using the analysis system 40 or another computer device based on the operation data at this time.
- a difference method for the numerical analysis, for example, a difference method, a finite element method, a finite volume method, a particle method, a lattice Boltzmann method, or other known numerical analysis methods may be used.
- the analysis result database 17 stores the results of multiple numerical analyses.
- the results of the plurality of numerical analyzes are the results of the numerical analysis performed based on the operation data acquired when the manufacturing facility 20 is operated under different operating conditions.
- the result of the numerical analysis is preferably performed based on the operation data acquired under the operation under various operation conditions.
- the analysis result database 17 stores the results of numerical analysis under various conditions. In this way, the analysis result database 17 stores in advance the results of the numerical analysis for a predetermined physical quantity, which is executed using the physical model based on the operation data of the manufacturing facility 20.
- the manufacturing state analysis unit 12 uses the result of the numerical analysis stored in the analysis result database 17 based on the operation data acquired by the operation data acquisition unit 11 to determine information regarding a predetermined physical quantity. ..
- the manufacturing state analysis unit 12 stores in the analysis result database 17 by an arbitrary method such that the information about the predetermined physical quantity falls within a range estimated to indicate the operating state of the operation data acquired by the operation data acquisition unit 11.
- the stored numerical analysis results may be used to determine information about running values.
- the range estimated to indicate the operation state of the operation data acquired by the operation data acquisition unit 11 is not limited to the physical quantity (numerical value) of the operation data acquired by the operation data acquisition unit 11 when the operation is performed, but a predetermined range from the physical quantity. Including physical quantity (numerical value) within the range.
- the information regarding the value at the time of operation may be indicated by a numerical value.
- the information about the value at the time of operation may be shown as a numerical range.
- the manufacturing state analysis unit 12 refers to the result of the numerical analysis stored in the analysis result database 17 based on the operation data acquired by the operation data acquisition unit 11, and refers to the numerical analysis stored in the analysis result database 17.
- the result of the numerical analysis under the condition closest to the condition of the operation data acquired by the operation data acquisition unit 11 may be determined as the information regarding the value at the time of operation.
- the manufacturing state analysis unit 12 refers to the result of the numerical analysis stored in the analysis result database 17 on the basis of the operation data acquired by the operation data acquisition unit 11, and refers to the numerical analysis stored in the analysis result database 17.
- a weighted calculation may be performed on each of the results, and the value obtained as a result of the calculation may be determined as the information regarding the value at the time of operation.
- the weighting is performed by giving greater weight to the result of the numerical analysis stored in the analysis result database 17 with respect to the result of the numerical analysis under the condition closer to the condition of the operation data acquired by the operation data acquisition unit 11. It can be carried out.
- the magnitude of the weight by weighting is represented by a coefficient. Therefore, the weighting is performed by multiplying the numerical value as the result of the numerical analysis stored in the analysis result database 17 by a predetermined coefficient.
- the method of determining the information regarding the value at the time of operation is not limited to the method shown here.
- the manufacturing state analysis unit 12 outputs information on the determined predetermined physical quantity to the correlation analysis unit 14.
- the correlation analysis unit 14 analyzes the correlation between the information about the value at the time of operation acquired from the manufacturing state analysis unit 12 and the product information acquired from the product information acquisition unit 13. At this time, as in the first embodiment, the correlation analysis unit 14 further adds the data measured by the measurement device 21 from the operation data acquisition unit 11 or the measurement device 21 installed in the manufacturing facility 20 as necessary. You may acquire and perform a statistical analysis.
- the details of the correlation analysis process executed by the correlation analysis unit 14 may be the same as in the first embodiment, and therefore detailed description thereof is omitted here.
- the analysis result database 17 stores a plurality of numerical analysis results in advance.
- step S2 is replaced with step S12, and is common in other points.
- the manufacturing state analysis unit 12 refers to the result of the numerical analysis stored in the analysis result database 17 based on the operation data acquired by the operation data acquisition unit 11 in step S1, Information regarding the values at the time of operation is determined (step S12).
- the manufacturing state analysis unit 12 outputs information regarding the determined predetermined physical quantity to the correlation analysis unit 14.
- the correlation analysis unit 14 executes statistical analysis in step S4.
- the correlation analysis unit 14 analyzes the correlation between the information about the operating value acquired from the manufacturing state analysis unit 12 and the product information acquired from the product information acquisition unit 13.
- the results of a plurality of numerical analyzes are stored in the analysis result database 17 in advance, and when executing the analysis processing of the correlation, it has been described in the first embodiment.
- the numerical analysis is not executed, and instead, the information on the predetermined physical quantity is determined by referring to the result of the numerical analysis stored in the analysis result database 17.
- the numerical analysis requires calculation time, but as in the present embodiment, the numerical analysis result is stored in the analysis result database 17 in advance, and the analysis result database 17 is referred to when executing the correlation analysis process. By executing the processing in this manner, a more real-time correlation analysis processing can be realized.
- the analysis system 40 according to the second embodiment can also be applied to the above-mentioned annealing furnace, converter, heating furnace, and apparatus for performing forming by machining.
- the analysis system 10 can be applied to maintenance of the manufacturing facility 20.
- the analysis system 10 acquires information on the state of the manufacturing equipment 20 after the operation (for example, the rotation speed of the rotating component, the load received by the component, the load current, the operating time, etc.), and the result of the numerical analysis and the operation.
- Statistical analysis is performed based on the information on the state of the manufacturing facility 20 later.
- the manufacturing facility 20 can be operated under the condition that the manufacturing facility 20 is less likely to deteriorate.
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Abstract
Description
また、製造途中で発生したトラブルの原因の調査や設備の保全にも、操業データが活用されている。
を含む。
図1は、本発明の第1実施形態に係る解析システム10の概略構成を示す機能ブロック図である。図1に示すように、解析システム10は、操業データ取得部11と、製造状態解析部12と、製品情報取得部13と、相関解析部14と、解析結果記憶部15と、解析結果出力部16とを備える。
ここで、製品とは、完成品のみに限られず、製造途中の状態のもの(以下、「半製品」とも称する)も含まれる。
前述のとおり、操業データは製品情報との関係を直接示しているとは限らない。そこで、操業データに基づき、物理モデルを用いて数値解析を行うことにより、直接計測できない、又は計測では見えない所定の物理量を推測することができる。数値解析は、例えば、差分法、有限要素法(FEM)、有限体積法(FVM)、粒子法(SPH、MPS)、格子ボルツマン法(LBM)、その他公知の数値解析手法を用いることができる。製造状態解析部12は、例えば、数値解析を実行可能なプロセッサにより構成されている。製造状態解析部12は、数値解析の実行手順を規定したプログラムを実行するCPU(Central Processing Unit)等のプロセッサにより構成されている。このようなプログラムは、例えば、解析システム10が備える記憶部又は外部の記憶媒体等に記憶されている。
また、解析結果出力部16が、相関解析部14や解析結果記憶部15と同一の装置に備えられていても問題は無いことは言うまでもない。
上記第1実施形態では、製造状態解析部12が、物理モデルを用いて数値解析を実行し、相関解析部14が、数値解析の結果と製品情報との相関関係を解析すると説明した。しかしながら、製造状態解析部12及び相関解析部14が実行する処理は、これに限られない。第2実施形態では、製造状態解析部12及び相関解析部14が、第1実施形態とは異なる他の処理を実行する場合の例について説明する。以下、第2実施形態に係る解析システムについて、第1実施形態と同様の点については適宜省略しながら、説明する。
11 操業データ取得部
12 製造状態解析部
13 製品情報取得部
14 相関解析部
15 解析結果記憶部
16 解析結果出力部
17 解析結果データベース
20 製造設備
21 計測機器
30 操業条件制御部
Claims (9)
- 製造設備の操業状態を含む操業データを取得する操業データ取得部と、
前記製造設備によって製造された製品の状態を取得し、製品情報として出力する製品情報取得部と、
前記操業データ取得部が取得した前記操業データに基づいて、前記製品の所定の物理量を求め、前記物理量に関する情報として出力する製造状態解析部と、
前記物理量に関する情報と、前記製品情報との相関関係を解析する相関解析部と、
を備える、解析システム。 - 前記製造状態解析部は、前記操業データ取得部が取得した操業データに基づき、物理モデルを用いて前記所定の物理量について数値解析を実行し、実行した数値解析の結果を、前記物理量に関する情報として出力する、請求項1に記載の解析システム。
- 前記製造設備の操業データに基づいて物理モデルを用いてあらかじめ実行した、前記所定の物理量の数値解析の結果を格納する解析結果データベースをさらに備え、
前記製造状態解析部は、前記操業データ取得部が取得した操業データに基づき、前記解析結果データベースに格納された前記数値解析の結果を使用して、前記物理量に関する情報を決定し、決定した前記物理量に関する情報を出力する、
請求項1に記載の解析システム。 - 前記製造状態解析部は、前記操業データ取得部が取得した操業データに基づき、前記解析結果データベースに格納された複数の前記数値解析の結果のそれぞれに対して重み付けした演算を行うことによって、前記物理量に関する情報を決定する、請求項3に記載の解析システム。
- 前記相関解析部による相関関係の解析結果を記憶する解析結果記憶部をさらに備える、請求項1から4のいずれか一項に記載の解析システム。
- 前記製品情報は、製品の品質に関する情報を含む、請求項1から5のいずれか一項に記載の解析システム。
- 前記製造状態解析部と前記相関解析部とが、それぞれ異なる独立した装置に搭載される、請求項1から6のいずれか一項に記載の解析システム。
- 前記製造状態解析部と前記相関解析部とが、1つの装置に搭載される、請求項1から6のいずれか一項に記載の解析システム。
- 解析システムにより実行される解析方法であって、
製造設備の操業状態を含む操業データを取得するステップと、
前記製造設備によって製造された製品の状態を取得するステップと、
前記製品の状態を、製品情報として出力するステップと、
前記取得した操業データに基づいて、前記製品の所定の物理量を求めるステップと、
前記所定の物理量を前記物理量に関する情報として出力するステップと、
前記物理量に関する情報と、前記製品情報との相関関係を解析するステップと、
を含む、解析方法。
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JP7028375B1 (ja) * | 2020-07-29 | 2022-03-02 | Jfeスチール株式会社 | ドロス欠陥予測方法、ドロス欠陥低減方法、溶融亜鉛めっき鋼板の製造方法、合金化溶融亜鉛めっき鋼板の製造方法、ドロス欠陥予測モデルの生成方法、ドロス欠陥予測装置、およびドロス欠陥予測端末システム |
WO2022049859A1 (ja) | 2020-09-03 | 2022-03-10 | Jfeスチール株式会社 | 鋼帯の鋼中水素量予測方法、鋼中水素量制御方法、製造方法、鋼中水素量予測モデルの生成方法及び鋼中水素量予測装置 |
WO2022270092A1 (ja) * | 2021-06-25 | 2022-12-29 | Jfeスチール株式会社 | 鋼板の不めっき欠陥予測方法、鋼板の欠陥低減方法、溶融亜鉛めっき鋼板の製造方法、及び鋼板の不めっき欠陥予測モデルの生成方法 |
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JP2023065177A (ja) * | 2021-10-27 | 2023-05-12 | 本田技研工業株式会社 | 加工支援システム |
Also Published As
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KR20210110661A (ko) | 2021-09-08 |
CN113272748A (zh) | 2021-08-17 |
JPWO2020149198A1 (ja) | 2021-02-18 |
US20220091597A1 (en) | 2022-03-24 |
JP7027536B2 (ja) | 2022-03-01 |
EP3913449A4 (en) | 2022-06-01 |
BR112021013249A2 (pt) | 2021-09-14 |
EP3913449A1 (en) | 2021-11-24 |
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