JP2010015207A - Energy management system - Google Patents

Abstract

To provide an energy management system capable of greatly improving the accuracy of prediction of energy consumption and determining an optimum manufacturing parameter from the viewpoint of energy saving. When the parameter monitoring device 12, the energy consumption monitoring device 13, the energy consumption calculation formula having the energy consumption calculation formula, and the difference between the predicted energy consumption and the actual energy consumption exceeds a predetermined value Includes a consumption energy calculation formula update unit 15 that adds a correction for eliminating the difference to the consumption energy calculation formula. Further, the target consumption energy setting means 21 is a predetermined manufacturing parameter calculated backward from the consumption energy calculation formula based on the set target consumption energy, and the rate of change based on the set or monitored predetermined actual manufacturing parameter is minimized. Manufacturing parameter optimization means 22 for calculating new manufacturing parameters.
[Selection] Figure 4

Description

  The present invention relates to an energy management system, and more particularly to an energy management system incorporated in a manufacturing system that performs a process including a plurality of manufacturing parameters.

  In various plants and factories, the importance of energy management is increasing in order to realize appropriate energy consumption (energy saving) from the viewpoint of reducing process costs and environmental loads. Therefore, it is required to use energy efficiently by predicting energy consumption in units of factories, plants, or manufacturing processes (manufacturing equipment). However, many manufacturing systems are composed of a plurality of manufacturing facilities and include a plurality of manufacturing conditions (manufacturing parameters), and there are many factors that affect energy consumption. It is not easy to predict the energy consumption by accurately specifying the relationship with the energy consumption. In view of this situation, several systems have been developed.

  For example, Patent Document 1 discloses energy information analysis means for obtaining information according to energy intensity for each process, process information storage means for storing process information, and energy information analysis according to processing and schedule conditions. Energy demand forecast information as an index from information obtained by the means and information stored in the process information storage means, for example, process basic unit, process setup information, production conditions, and other constraints (delivery date, factory model, etc.) A scheduling system is disclosed that includes a scheduler that generates a plurality of production schedules. In addition to Patent Document 1, several systems having means for predicting energy consumption based on actual energy consumption values and the like have been developed (for example, Patent Documents 2 and 3).

  Further, Patent Document 4 discloses that energy consumption can be obtained by accurately grasping energy consumption, alarm output, control output, etc. by obtaining predicted energy consumption that reflects changes in energy load due to climate change within the energy management unit period. A system capable of exhibiting a suppression effect is disclosed. Specifically, actual energy consumption collecting means for collecting actual energy consumption (actual energy consumption), and actual energy amount storage means for dividing the energy management unit period into a plurality of times and storing the actual energy consumption at each division point. Target energy amount setting means for setting an individual target energy amount for each division time, target energy amount storage means for storing the target energy amount, and actual energy consumption for each division time stored in the actual energy amount storage means It is a system comprising energy amount predicting means for predicting energy consumption at each future dividing time from the target energy for each dividing time stored in the target energy amount storing means.

In addition, the system disclosed in Patent Document 5 includes means for executing real-time simulation in parallel with monitoring of actual energy consumption using actual process data. It is possible to quickly grasp the effect prediction. Further, in Patent Document 5, the energy monitoring system reflects a means for calculating a difference between simulation data and actual process data, and an operation condition arbitrarily set based on the difference result, that is, a manufacturing parameter, in the manufacturing system. And means for performing the control.
JP 2005-92827 A JP 2007-148726 A JP 2004-280172 A JP 2005-234746 A JP 2002-259508 A

  According to the systems disclosed in Patent Documents 1 to 3, although the energy consumption can be predicted based on the accumulated energy consumption actual measurement value or the like, a specific means for determining the difference between the predicted energy consumption and the actual energy consumption is provided. However, when the manufacturing parameters vary due to deterioration of manufacturing equipment parts or climate change due to seasonal changes, there is a problem that it is difficult to predict energy consumption with high accuracy suitable for an actual manufacturing system.

  The systems disclosed in Patent Documents 4 and 5 can set a target energy consumption (energy saving target), but the system of Patent Document 4 cannot obtain manufacturing parameters for achieving the target energy consumption. In the system of Patent Document 5, since the parameters that are the simulation conditions are arbitrarily set, the production parameters are greatly changed to achieve the target energy consumption. There is a problem that defective products can be produced.

  An object of the present invention is to provide an energy management system capable of greatly improving the accuracy of predicting energy consumption and determining optimum manufacturing parameters from the viewpoint of energy saving.

  An energy management system according to the present invention is incorporated in a manufacturing system that executes a process including a plurality of manufacturing parameters, monitors manufacturing parameters during process execution, and stores manufacturing parameters, and monitors and stores energy consumption. Energy consumption storage means for calculating energy consumption from the manufacturing parameters, and energy consumption calculating means for calculating the energy consumption by inputting the manufacturing parameters to the energy consumption calculation formula. When the difference between the predicted energy consumption and the monitored actual energy consumption exceeds a predetermined value, the consumption energy calculation formula is corrected to eliminate the difference based on the manufacturing parameter and energy consumption data. It has an energy calculation formula update means.

  In addition, the energy management system according to the present invention is incorporated in a manufacturing system that executes a process including a plurality of manufacturing parameters, sets manufacturing parameter storage means for monitoring and storing manufacturing parameters during process execution, and sets target energy consumption Target manufacturing energy setting means, and a predetermined manufacturing parameter calculated based on the set target energy consumption, and a new manufacturing that minimizes the rate of change based on the set or monitored actual manufacturing parameter It has a manufacturing parameter optimization means for calculating a parameter.

  Further, the apparatus has energy consumption storage means for monitoring and storing energy consumption, and a consumption energy calculation formula for calculating consumption energy from manufacturing parameters. The consumption energy for calculating consumption energy by inputting manufacturing parameters into the consumption energy calculation formula When the difference between the calculation means, the calculated predicted consumption energy and the monitored actual consumption energy exceeds a predetermined value, the difference is eliminated in the consumption energy calculation formula based on the manufacturing parameter and consumption energy data. And a manufacturing parameter optimizing unit is a predetermined manufacturing parameter that is calculated backward from the consumption energy calculation formula based on the set target consumption energy, and is set or monitored. New manufacturing parameter that minimizes the rate of change based on specified actual manufacturing parameters Calculation it is preferable to.

  The energy management system according to the present invention includes manufacturing parameter storage means for monitoring and storing manufacturing parameters during process execution, and energy consumption storage means for monitoring and storing energy consumption. A high energy management system can be constructed.

  In addition, a consumption energy calculation formula for calculating the consumption energy from the manufacturing parameter, a consumption energy calculation means for calculating the consumption energy by inputting the manufacturing parameter into the consumption energy calculation formula, the calculated predicted consumption energy and the monitored When the actual energy consumption difference exceeds a predetermined value, the energy consumption calculation formula updating means for correcting the energy consumption calculation formula for eliminating the difference based on the manufacturing parameter and the energy consumption data is provided. Therefore, it is possible to determine the deviation between the predicted consumption energy and the actual consumption energy, and when a predetermined deviation occurs, the deviation can be eliminated. For example, even when manufacturing parameter fluctuations occur due to deterioration of manufacturing equipment parts, climate change due to seasonal changes, etc., it is possible to perform highly accurate energy consumption prediction that reflects the fluctuations.

  The manufacturing parameter storage means for monitoring and storing the manufacturing parameters during the process execution, the target consumption energy setting means for setting the target consumption energy, and the predetermined manufacturing parameters calculated based on the set target consumption energy New manufacturing parameters for achieving the energy saving target if the configuration includes a manufacturing parameter optimization means for calculating a new manufacturing parameter that minimizes the rate of change based on a predetermined actual manufacturing parameter set or monitored. Can be easily obtained. Furthermore, it is possible to prevent the new manufacturing parameter from greatly fluctuating from the currently set manufacturing parameter, and it is possible to ensure product standards and suppress lot blurring.

  In addition, a consumption energy calculation formula for calculating the consumption energy from the manufacturing parameter, a consumption energy calculation means for calculating the consumption energy by inputting the manufacturing parameter into the consumption energy calculation formula, the calculated predicted consumption energy and the monitored When the actual energy consumption difference exceeds a predetermined value, the energy consumption calculation formula updating means for adding a correction for eliminating the difference to the energy consumption calculation formula based on manufacturing parameter and energy consumption data is provided. The manufacturing parameter optimizing means is a predetermined manufacturing parameter calculated backward from the energy consumption calculation formula based on the set target energy consumption, and the rate of change based on the predetermined actual manufacturing parameter set or monitored is minimized. For example, the new manufacturing parameters can be calculated using, for example, deterioration of manufacturing equipment parts or changes in seasons. Even if manufacturing parameters fluctuate due to climate change, etc., a highly accurate energy consumption calculation formula that reflects the fluctuations can be prepared, and the calculation accuracy of new manufacturing parameters to achieve the energy saving target can be improved. Further improve.

  Embodiments according to the present invention will be described below in detail with reference to the drawings. FIG. 1 is a block diagram showing a configuration of an energy management system having an energy consumption calculation formula update unit. FIG. 2 is a block diagram showing a configuration when an energy management system having an energy consumption calculation formula update unit is applied to a manufacturing system including a plurality of steps.

  The energy management system 10 is a system that manages energy used (consumed) by being incorporated in a manufacturing system that executes a process including a plurality of manufacturing parameters. The manufacturing system to which the energy management system 10 is applied (incorporated) includes various large machines (vehicles, etc.), precision machines, mechanical parts, electrical appliances, electronic parts, pharmaceuticals, chemicals, and other factories. A plant, a production line, and manufacturing equipment can be mentioned, and the energy management system 10 is preferably applied in units of plants or production lines. FIG. 1 shows a configuration of an energy management system 10 that is applied to a manufacturing system 11 (production line 11) that has three manufacturing facilities and includes three manufacturing steps by each manufacturing apparatus.

  As shown in FIG. 2, the basic configuration of the energy management system 10 includes a manufacturing parameter monitoring device 12, a consumption energy monitoring device 13, and a consumption energy calculation formula that is a theoretical calculation formula for calculating a predicted consumption energy. Based on this, energy consumption calculating means 14 for calculating predicted energy consumption is provided. Furthermore, the energy management system 10 includes a consumption energy calculation formula update unit 15 that corrects the consumption energy calculation formula so as to match the actual manufacturing process. The energy management system 10 is a component important for performing energy management of the manufacturing system 11, for example, a manufacturing parameter setting means (manufacturing parameter setting means 16) which is a condition for operating the manufacturing system 11, a keyboard. And an external input device 17 for inputting manufacturing parameters and the like, and an output device 18 for displaying monitoring data and predicted energy consumption. In the present specification, the manufacturing parameters (control parameters) are described as widely including parameters for operating and controlling the manufacturing system 11.

  As described above, the manufacturing system 11 includes the three manufacturing facilities ABC, and includes the manufacturing system control panel (plant control panel) 19 for uniformly controlling these facilities. The manufacturing system control panel 19 includes a CPU, an external input device 17 such as a keyboard used for inputting manufacturing parameters, a recording device that stores manufacturing parameters and manufacturing programs, an output device 18 such as a monitor, and an input / output A device including a port or the like, which can be configured by a dedicated control device or a computer. The functions of each device and each means of the energy management system 10 and the manufacturing system 11 can be realized by executing software, for example, specifically, the energy management program and the manufacturing system 11 stored in the storage device. This can be realized by executing a manufacturing program that defines the manufacturing procedure.

  A plant including the manufacturing system 11 is generally provided with a monitoring room (also referred to as an instrument room or a control room), and an instrument or a computer for monitoring a plurality of manufacturing facilities including the manufacturing system 11 is installed. ing. The calculation means such as the above-described consumption energy calculation means 14 and consumption energy calculation formula update means 15 are preferably configured as part of the manufacturing system control panel 19 or the monitoring room computer 20 as shown in FIG.

  As shown in FIG. 1, the manufacturing system control panel 19 is provided with manufacturing parameter setting means 16 for setting manufacturing parameters, which are conditions for operating the manufacturing system 11, for example, by an external input device 17 such as a keyboard or a numeric keypad. Manufacturing parameters input by the operator are set by the function of the manufacturing parameter setting means 16, and the manufacturing system 11 executes a predetermined process. The operation information of the manufacturing system 11 including the manufacturing parameters described later is displayed on the monitor of the output device 18 of the manufacturing system control panel 19 and the monitoring room computer 20.

  As described above, the external input device 17 and the output device 18 are important elements in executing energy management. When the external input device 17 and the output device 18 are not installed in the manufacturing system 11, it is preferable to newly provide them. In general, since the external input device 17 and the output device 18 are installed in the manufacturing system 11, existing devices can be shared. As shown in FIG. 1, the energy management system 10 is connected to the manufacturing system 11 by electrical means, mechanical means, or both, and the energy management system 10 can be easily retrofitted to the existing manufacturing system 11. Is possible.

  As manufacturing parameters set by the manufacturing parameter setting means 16, there are items common to each manufacturing system or each manufacturing process, and items that differ depending on each manufacturing system or each manufacturing process. 5A and 5B show common manufacturing parameter items and manufacturing parameter items for each process. As shown in FIGS. 5A and 5B, common manufacturing parameter items include date, temperature, humidity, production line, production type, tact time, operating rate, and the like. As an item of manufacturing parameters peculiar to the process, for example, in the hot forging process, material, material diameter, material length, heating voltage, heating current, heating feed rate, press load, etc. can be mentioned, and in the arc welding process, The plate thickness, joint shape, welding posture, shield gas type, pulse frequency, welding current, welding voltage and the like can be mentioned.

  As described above, the manufacturing parameter monitoring device 12 which is a main component of the energy management system 10 is a manufacturing parameter input by the external input device 17 and set by the manufacturing parameter setting means 16, or general parameters such as temperature and humidity. Has a function of monitoring manufacturing parameters that cannot be set, and storing the monitored manufacturing parameters as electronic data in a storage device. That is, the manufacturing parameter monitoring device 12 is a manufacturing parameter storage unit that monitors and stores manufacturing parameters during process execution, and the manufacturing parameter monitoring device 12 acquires information from various measuring devices and sensors of the manufacturing system 11. It has a function. In addition, the storage device has a function of storing the manufacturing parameters monitored in the storage device as electronic data. Here, as a storage device provided in the manufacturing parameter monitoring device 12, a known storage device (nonvolatile storage device) can be used, and an existing storage device of the manufacturing system 11 can be shared.

  Examples of the manufacturing parameters monitored and stored by the manufacturing parameter monitoring device 12 include the parameters as described above (see FIGS. 5A and 5B), and are particularly parameters that have a great influence on energy consumption. Is preferred. For example, in the hot forging process, heating voltage, heating current, press load, mold temperature, and the like can be mentioned. By storing the manufacturing parameters during process execution, the correction accuracy of the energy consumption calculation formula described later is improved, and the energy consumption prediction accuracy can be improved.

  The energy consumption monitoring device 13 has a function of monitoring various energy consumptions and storing the monitored energy consumption as electronic data. That is, the energy consumption monitoring device 13 is energy consumption storage means for monitoring and storing energy consumption, and has the function of acquiring information from various measuring devices, sensors, etc. of the manufacturing system 11 as with the manufacturing parameter monitoring device 12. Prepare. In addition, the storage device has a function of storing the manufacturing parameters monitored in the storage device as electronic data.

  The items of energy consumption to be monitored and stored include items as shown in FIGS. 5A and 5B, and it is particularly preferable that the energy consumption amount of the entire manufacturing system 11 is large. The types of energy consumed are mainly electric power, gas, steam, heavy oil, kerosene, etc., and include wind power, sunlight, wave power, geothermal heat, biomass, waste heat utilization, and the like. Specifically, for example, in the hot forging process, material supply device power, heating device power, press power, lubrication air consumption, lubrication recovery device power, control cooling power and the like can be mentioned. Examples include material supply device power, carburizing furnace gas consumption, transfer robot power, and pallet changer power. By storing the actual energy consumption, the correction accuracy of a later-described energy consumption calculation formula is improved, and the energy consumption prediction accuracy can be improved.

  The monitoring interval and storage interval by each of the monitoring devices 12 and 13 can be arbitrarily set in consideration of the load of the storage device or the like, the calculation accuracy of predicted energy consumption, and the like. The monitoring of each data is preferably executed for each manufacturing apparatus or manufacturing process, and the energy consumption is preferably stored in association with manufacturing parameters.

  The consumption energy calculation means 14 has a consumption energy calculation formula for calculating the predicted consumption energy, and has a function of calculating the predicted consumption energy by inputting manufacturing parameters into the calculation formula. Formulas for calculating energy consumption include analytical formulas obtained by performing multiple regression analysis based on manufacturing parameters and actual values of energy consumption, empirical formulas obtained empirically based on experiments, etc., physical laws From the viewpoints of improving prediction accuracy and shortening prediction time, it is preferable that the theoretical formula is theoretically obtained from a physical law.

  When a theoretical formula is applied as the energy consumption calculation formula, for example, when correction is performed by the power consumption calculation formula update means 15 described later, as a parameter to be corrected (parameter related to the correction coefficient), a physical phenomenon such as frictional resistance or motor efficiency is obtained. Since the parameter directly related to the change in the value can be corrected, the prediction accuracy after correction is high. In the case of analytical formulas and empirical formulas, it is necessary to redo analysis and experiments when the specifications of equipment and production lines change. However, when theoretical formulas are applied, such troubles are not generated. There are advantages such as easy application to processes in different fields.

  The theoretical formula derived from the physical law is preferably provided for each manufacturing apparatus or each manufacturing process, and the small processes constituting the manufacturing process (for example, the process in the manufacturing process A shown in FIG. 1, the hot forging process) For each heating process and molding process). Specifically, it is preferable to provide about 5 to 10 theoretical formulas in the hot forging process of a crankshaft or the like. As an example of the theoretical formula, theoretical formulas (formula 1) and (formula 2) applied to the heating process and the forming process in the hot forging process of the crankshaft are shown.

  Where, W: energy consumption, m: material weight, c: specific heat of iron, T: heating temperature, T0: room temperature, F: feed roller driving force, L: material length, e1: coil loss, e2: inverter loss, etc. E3: loss due to refrigeration, t: cycle time.

  Where, W: energy consumption, I: flywheel moment of inertia, ω1: flywheel angular velocity immediately before molding, ω2: flywheel angular velocity immediately after molding, t: cycle time, ε: mobility, z: average stop per hour Number of times, Ts: Rotational torque of mold / slider / connector, etc. F: Frictional force of mold / slider, L: Descent distance of mold / slider, η: Motor efficiency.

  When the difference between the calculated predicted consumption energy and the monitored actual consumption energy exceeds a predetermined value, the consumption energy calculation formula update unit 15 stores the manufacturing parameter and the consumption energy stored by each of the monitoring devices 12 and 13. Based on the data, a function for adding a correction to eliminate the difference in the energy consumption calculation formula is provided. More specifically, the energy consumption calculation formula update unit 15 has a function of analyzing which of the plurality of manufacturing parameters causes a difference exceeding a predetermined value due to which parameter, for example, and stored manufacturing. An analysis is performed based on the parameter and energy consumption data. The analysis method is not particularly limited in terms of the configuration of the present invention, and is an experimental design method, neural network method, fuzzy control method, multivariate analysis (principal component analysis, multiple regression analysis, factor analysis, discriminant analysis, etc.) A known analysis method (algorithm) can be applied.

  When the difference analysis result is obtained, the energy consumption calculation formula updating unit 15 has a function of adding correction for eliminating the difference to the energy consumption calculation formula based on the analysis result. For example, the correction is executed by adding a predetermined correction coefficient to the manufacturing parameter which is a main factor of the difference occurrence. When the energy consumption calculation formula is corrected in this way, even when manufacturing parameter fluctuations occur due to deterioration of manufacturing equipment parts or climate change due to seasonal changes, etc., accurate energy consumption prediction that reflects the fluctuations is made. Can be executed.

  As shown in FIG. 3, the energy management system 10 can have a function of setting a target energy consumption, a so-called energy saving target, and determining manufacturing parameters for achieving the energy saving target. The energy management system 10 shown in FIG. 3 includes target consumption energy setting means 21 and manufacturing parameter optimization means 22 for calculating new manufacturing parameters for realizing the set target energy consumption as main components.

  The target consumption energy setting means 21 has a function of setting target consumption energy as one manufacturing parameter of the manufacturing system 11. When the target energy consumption input by the operator by the external input device 17 of the monitoring room computer 20 is set by the function of the target energy setting means 21, a predetermined manufacturing parameter is calculated by the manufacturing parameter optimization means 22 described later. . The target energy consumption setting means 21 can also have a function of automatically setting, for example, when any interval or production item is changed.

  Also in the energy management system 10 shown in FIG. 3, the external input device 17 and the output device 18 are important elements for executing energy management. When the energy management system 10 is not installed in the manufacturing system 11, it is newly provided. Is preferred.

  Examples of the target energy consumption set by the target energy setting means 21 include numerical values input by the operator from the external input device 17, or numerical values automatically set when an arbitrary interval or production item is changed. be able to. The target energy consumption is a target value (energy saving target) set to suppress energy consumption from the viewpoint of reducing process costs and environmental loads as described above.

  The manufacturing parameter optimizing unit 22 has a function of calculating a predetermined manufacturing parameter calculated based on the set target energy consumption. Furthermore, it is preferable to have a function of accessing the manufacturing parameter setting means 16 of the manufacturing system 11 or the energy management system 10 and updating the currently set manufacturing parameter to a new manufacturing parameter for achieving the target energy consumption.

  The manufacturing parameter calculated by the manufacturing parameter optimizing unit 22 is preferably a parameter that has a small influence on the product standard and a large influence on the energy consumption due to the fluctuation of the parameter. Therefore, the manufacturing parameter calculated by the manufacturing parameter optimizing means 22 is a predetermined parameter that can be set by the operator or automatically. The number of new production parameters to be calculated is preferably 1 to 10, more preferably 2 to 7, and particularly preferably 3 to 5. When there are a plurality of new manufacturing parameters to be calculated, a large number of solutions exist. Therefore, the manufacturing parameter optimizing unit 22 needs to have a parameter change limiting function in order to select a specific solution from the calculated values, and further to ensure product standards and suppress product lot blurring. For example, from the viewpoint of specifying a solution, a new manufacturing parameter has a minimum rate of change based on a predetermined actual manufacturing parameter set or monitored, and the sum of deviations from the standard median value (average value) of each parameter is A first restriction such as being minimal can be provided. Further, the rate of change based on a predetermined actual manufacturing parameter that has been set or monitored can be arbitrarily set within a predetermined value range (for example, ± 5 to 20%), and can be set individually for each parameter. ), And the second restriction such that the sum of deviations from the standard median value (average value) of each parameter is within a predetermined value range. The range of these second restrictions can be determined based on, for example, the specifications of equipment or the like, or past empirical rules (or experimental results).

  As a method for calculating the new manufacturing parameter by the manufacturing parameter optimizing means 22, a method for performing multivariate analysis or the like based on the stored control parameter and energy consumption, and a method for back-calculating the above energy consumption calculation formula may be mentioned. As will be described in detail later, it is preferable that the manufacturing parameter optimizing unit 22 apply a method of calculating back the energy consumption calculation formula from the viewpoint of improving calculation accuracy and shortening the calculation time.

  As shown in FIG. 4, the energy management system 10 can include an energy consumption calculation unit 14 and a manufacturing parameter optimization unit 22. The manufacturing parameter optimizing unit 22 is linked to the energy consumption calculating unit 14 and can calculate a new manufacturing parameter by using the energy consumption calculation formula used when calculating the predicted energy consumption. As described above, the consumption energy calculation formula is updated by the consumption energy calculation formula update unit 15, and it is possible to calculate a new manufacturing parameter with high accuracy in accordance with the actual manufacturing process.

  Specifically, the target energy consumption is input to the energy consumption calculation formula, and a specific new manufacturing parameter is calculated by calculating back the formula. As described above, the new manufacturing parameter is calculated by limiting the parameter change. For example, a new manufacturing parameter that minimizes the rate of change based on a predetermined actual manufacturing parameter that is set or monitored is calculated. Further, there is a restriction that the rate of change is within a predetermined value range. Therefore, when these change restrictions are not cleared, the optimization calculation of the manufacturing parameter is repeated, and when the calculation cannot be performed, an error display indicating that the target energy consumption cannot be achieved is displayed on the output device 18. Can do. By providing such a change restriction, it is possible to prevent a new manufacturing parameter from greatly fluctuating from the currently set manufacturing parameter, and it is possible to ensure product standards and suppress lot blurring.

  The energy management system 10 shown in FIGS. 1, 3, and 4 is incorporated in a manufacturing system 11 including three manufacturing processes, but is powder metallurgy, casting, and sheet metal as shown in FIG. The present invention can also be applied to manufacturing processes (manufacturing systems) such as press, arc welding, carburizing and quenching, and induction hardening as shown in FIG. As shown in FIGS. 5 (a) and 5 (b), when the manufacturing process to be applied is different, manufacturing parameters and energy consumption measurement items that are monitored and stored are greatly different.

  The manufacturing parameters and energy consumption monitoring status output and displayed on the output device 18, the predicted energy consumption results, and the new production parameter calculation results are shown in FIGS. 6, 7, and 8, respectively. The operator can check the monitoring data, the predicted energy consumption, and the new manufacturing parameters by looking at the monitor of the output device 18, and can give a predetermined command by the external input device 17 or the like as necessary.

  As shown in FIG. 8, the target consumption energy input and set by the operator is shown with an underline, and new manufacturing parameters for realizing the target prize energy are calculated, and the currently set manufacturing parameters are changed. The part is also underlined. When displayed in this way, the operator can confirm that the parameter change restriction function by the manufacturing parameter optimization means 22 is functioning normally.

  The energy management process by the energy management system 10 having the above configuration will be described below in detail with reference to FIGS. FIG. 9 is a flowchart showing a procedure of energy consumption prediction and energy consumption calculation formula update. For example, the procedure can be executed by the energy management system 10 shown in FIG. 1 or FIG. FIG. 10 is a flowchart showing a procedure for optimizing manufacturing parameters. For example, the procedure can be executed by the energy management system 10 shown in FIG. 3 or FIG.

  As shown in FIG. 9, first, when the process of the manufacturing system 11 is being executed, the manufacturing parameters and the energy consumption are monitored by the monitoring devices 12 and 13 and output and displayed on the monitor of the output device 18 (FIG. 9). 6). The monitored manufacturing parameters and energy consumption are stored as electronic data in the storage devices of the monitoring devices 12 and 13 (S10).

  When calculating the predicted energy consumption when changing an arbitrary interval or manufacturing parameter, it is determined whether or not the energy consumption calculation formula needs to be updated prior to the calculation operation (S11). . Specifically, the currently set or monitored manufacturing parameter is input to calculate the predicted energy consumption.

  The calculated predicted energy consumption is compared with the actual energy consumption that is currently set or monitored to determine whether the difference between the two values exceeds a predetermined value (S12). The predetermined value can be arbitrarily set, for example, ± 5%.

  In S12, when the difference between the predicted energy consumption and the actual energy consumption exceeds a predetermined value, the energy consumption calculation formula does not conform to the actual manufacturing process due to deterioration of the manufacturing equipment parts or climate change due to seasonal changes, That is, the deviation can be confirmed, and the energy consumption calculation formula is corrected to eliminate the difference (S13). The correction of the consumption energy calculation formula is executed by the function of the consumption energy calculation formula update unit 15 and, for example, analyzes which of the plurality of manufacturing parameters causes a difference exceeding a predetermined value. Specifically, based on the stored manufacturing parameters and energy consumption data, analysis such as an experimental design method, a neural network method, a fuzzy control method, and a multivariate analysis are executed, and the difference is calculated based on the analysis result. The correction is executed by eliminating the correction, for example, by adding a predetermined correction coefficient to the manufacturing parameter which is the main cause of the difference.

  In S13, when the energy consumption calculation formula is updated, a new manufacturing parameter which is a condition for calculating the predicted energy consumption is input (S14), and the predicted energy consumption is calculated using the updated energy consumption calculation formula. Is executed (S15).

  On the other hand, according to the energy management system 10 shown in FIG. 3 or FIG. 4, new manufacturing parameters for realizing the target energy consumption can be automatically determined according to the procedure shown in FIG.

  As shown in FIG. 10, first, target energy consumption is set (S16). Examples of the target energy consumption include a numerical value input by the operator from the external input device 17, or a numerical value automatically set when an arbitrary interval or a production item is changed.

  A predetermined new manufacturing parameter is calculated based on the set target energy consumption (S17). The calculation of the new manufacturing parameter is executed by the function of the manufacturing parameter optimizing unit 22, and the predetermined manufacturing parameter calculated is, for example, a new manufacturing with a minimum change rate based on the predetermined actual manufacturing parameter set or monitored. It is a parameter. Note that the calculated new manufacturing parameter is a predetermined parameter that can be set manually by an operator or automatically.

  The predetermined manufacturing parameter calculated in S17 is a new manufacturing parameter that minimizes the rate of change based on the set or monitored predetermined actual manufacturing parameter, and determines whether the rate of change does not exceed a predetermined value ( S18). That is, it is necessary to have a parameter change restriction from the viewpoint of ensuring product standards, suppressing product lot blurring, and the like, and the manufacturing parameter optimization means 22 has a parameter change restriction function (first restriction, second restriction). Restrictions).

  If it is determined in S18 that the change rate based on the set or monitored predetermined actual manufacturing parameter does not exceed the predetermined value, the calculated new manufacturing parameter is set by the function of the manufacturing parameter setting means 16. (S19).

  As described above, according to the energy management system 10, the manufacturing parameter monitoring device 12 that is a manufacturing parameter storage unit, the consumed energy monitoring device 13 that is a consumed energy storage unit, the consumed energy calculation unit 14, and the consumed energy calculation formula. Since the updating means 15 is provided, it is possible to determine the deviation between the predicted energy consumption and the actual energy consumption, and to eliminate the deviation when a predetermined deviation occurs.

  In addition, the energy management system 10 can further include target consumption energy setting means 21 and manufacturing parameter optimization means 22, so that new manufacturing parameters for achieving the energy saving target can be easily obtained. Furthermore, it is possible to prevent the new manufacturing parameter from greatly fluctuating from the currently set manufacturing parameter, and it is possible to ensure product standards and suppress lot blurring.

It is a block diagram which shows the structure of the energy management system which has a consumption energy calculation formula update means. It is a block diagram which shows the structure at the time of applying the energy management system which has a consumption energy calculation formula update means to the manufacturing system containing several processes. It is a block diagram which shows the structure at the time of applying the energy management system which has a manufacturing parameter optimization means to the manufacturing system containing several processes. It is a block diagram which shows a structure at the time of applying the energy management system which has a consumption energy calculation formula update means and a manufacturing parameter optimization means to the manufacturing system containing several processes. It is a figure which shows the manufacturing parameter and energy consumption measurement item in each process (hot forging, powder metallurgy, casting, sheet metal press). It is a figure which shows the manufacturing parameter and energy consumption measurement item in each process (arc welding, carburizing quenching, induction hardening). It is a figure which shows the monitoring screen of a manufacturing parameter and energy consumption. It is a figure which shows the output screen of energy consumption prediction. It is a figure which shows the output screen of manufacturing parameter optimization. It is a flowchart which shows the procedure of consumption energy prediction and consumption energy calculation formula update. It is a flowchart which shows the optimization procedure of a manufacturing parameter.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Energy management system, 11 Manufacturing system, 12 Manufacturing parameter monitoring apparatus, 13 Consumption energy monitoring apparatus, 14 Consumption energy calculation means, 15 Consumption energy calculation formula update means, 16 Manufacturing parameter setting means, 17 External input device, 18 Output device, 19 Manufacturing system control panel (plant control panel; PLC), 20 Monitoring room computer, 21 Target energy setting means, 22 Control parameter optimization means.

Claims (3)

Embedded in a manufacturing system that performs a process involving multiple manufacturing parameters,
Manufacturing parameter storage means for monitoring and storing manufacturing parameters during process execution;
Energy consumption storage means for monitoring and storing energy consumption;
An energy consumption calculating formula for calculating energy consumption from manufacturing parameters, energy consumption calculating means for calculating energy consumption by inputting manufacturing parameters to the energy consumption calculating formula;
With
When the difference between the calculated predicted energy consumption and the monitored actual energy consumption exceeds a predetermined value, a correction for eliminating the difference is made in the energy consumption calculation formula based on the manufacturing parameter and energy consumption data. An energy management system comprising: an energy consumption calculation formula update means for adding. Embedded in a manufacturing system that performs a process involving multiple manufacturing parameters,
Manufacturing parameter storage means for monitoring and storing manufacturing parameters during process execution;
Target energy consumption setting means for setting target energy consumption;
With
Manufacturing parameter optimization means for calculating a new manufacturing parameter which is a predetermined manufacturing parameter calculated based on the set target energy consumption and has a minimum change rate based on the set or monitored predetermined actual manufacturing parameter An energy management system characterized by that. The energy management system according to claim 2,
Energy consumption storage means for monitoring and storing energy consumption;
An energy consumption calculating formula for calculating energy consumption from manufacturing parameters, energy consumption calculating means for calculating energy consumption by inputting manufacturing parameters to the energy consumption calculating formula;
When the difference between the calculated predicted energy consumption and the monitored actual energy consumption exceeds a predetermined value, a correction for eliminating the difference is made in the energy consumption calculation formula based on the manufacturing parameter and energy consumption data. Energy consumption calculation formula update means to be added;
With
The manufacturing parameter optimizing means is a predetermined manufacturing parameter that is calculated backward from the energy consumption calculation formula based on the set target energy consumption. An energy management system characterized by calculating manufacturing parameters.

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