Production process dynamic scheduling method and system based on energy consumption optimization

Abstract

The invention relates to the technical field of industrial production process control, and provides a production process dynamic scheduling method and system based on energy consumption optimization. The method comprises the steps that the power waveform of an internal mixer and temperature control energy consumption data of a vulcanizing machine are collected in real time, and a process chain topological relation is constructed based on a material circulation path; generating an energy consumption coupling coefficient through a partial derivative of the power change of the internal mixer to the energy consumption of the vulcanizing machine according to the topological relation; generating a decoupling instruction when the coupling coefficient exceeds a threshold value, modifying the starting time of the operation plan of the internal mixer according to the decoupling instruction, and determining an energy consumption peak time period needing to be avoided by the vulcanizing machine; and after it is verified that the power peak value and the energy consumption peak value of the internal mixer are staggered, cooperative control is conducted on equipment. The system comprises a data acquisition module, a coupling coefficient generation module, a decoupling instruction generation module, a peak time period determination module and an equipment cooperative control module. According to the method, the process chain topological relation and the energy consumption coupling dynamic model are constructed, so that accurate energy consumption optimization of multi-device cooperation is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial production process control, and in particular to a production process dynamic scheduling method and system based on energy consumption optimization. Background Art

[0002] In process manufacturing industries such as rubber and chemicals, internal mixers and vulcanizers are core high-energy-consuming equipment, and their coordinated operating efficiency directly affects overall production energy consumption. Although traditional manufacturing execution systems (MES) can achieve basic task scheduling, they have significant drawbacks: Existing technologies often focus on energy conservation within individual pieces of equipment. While attempts to optimize individual equipment operations through energy consumption monitoring, such as optimizing vulcanizer insulation parameters or internal mixer soft-start curves, ignore the energy consumption transmission effect between upstream and downstream equipment in the process chain. In particular, after the vulcanizer enters the constant temperature phase, heating elements generate intermittent current spikes due to aging or ambient temperature fluctuations. If this coincides with batch feeding in the internal mixer, the combined effect of these two peaks can directly exceed the plant's power distribution capacity. Real-time prediction and dynamic avoidance of these cross-equipment energy consumption conflicts have become a technical blind spot hindering energy efficiency improvements in continuous manufacturing.

[0003] Furthermore, traditional operation plans are based on fixed time-series scheduling, and the industry generally adopts time-of-use electricity pricing strategies to passively stagger peak demand. However, this fails to address the real-time energy consumption conflicts between equipment within the same process chain caused by material flow delays and temperature control fluctuations. When the energy consumption of internal mixers and vulcanizers is strongly coupled, the system struggles to decouple them in a timely manner, making it impossible to dynamically adjust equipment start and stop sequences to avoid peak energy consumption periods. During production, equipment energy consumption peaks often overlap due to scheduling conflicts, resulting in sudden increases in grid load and low energy utilization. Summary of the Invention

[0004] The present invention provides a production process dynamic scheduling method and system based on energy consumption optimization, the main purpose of which is to solve the problem of how to dynamically resolve the energy consumption coupling conflict between the internal mixer and the vulcanizer in the continuous production process, and avoid the overall energy consumption surge caused by the superposition of energy consumption peaks of the two types of equipment.

[0005] To achieve the above objectives, the present invention provides a production process dynamic scheduling method based on energy consumption optimization, comprising: S1. Real-time collection of power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line, and construction of a process chain topology based on the power waveform data, the temperature control energy consumption data and the material flow path; S2. Based on the process chain topology, the process chain energy consumption coupling coefficient is generated by the partial derivative of the internal mixer power change on the curing press energy consumption; S3. When the process chain energy consumption coupling coefficient exceeds the preset decoupling threshold, a process chain decoupling instruction is generated; S4. Modify the operation plan of the internal mixer based on the adjustment start time in the process chain decoupling instruction, and determine the energy consumption peak period to be avoided according to the energy consumption characteristics of the current temperature control stage of the vulcanizer; S5. Verify whether the modified operation plan can completely stagger the power peak of the internal mixer and the energy consumption peak period. If the verification is successful, coordinately control the internal mixer and the vulcanizer based on the modified operation plan.

[0006] In order to solve the above problems, the present invention further provides a production process dynamic scheduling system based on energy consumption optimization, the system comprising: A data acquisition module is used to collect power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line in real time, and to build a process chain topology relationship based on the power waveform data, the temperature control energy consumption data and the material flow path; A process chain energy consumption coupling coefficient generation module is used to generate the process chain energy consumption coupling coefficient based on the process chain topology relationship by taking the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption; A process chain decoupling instruction generating module, configured to generate a process chain decoupling instruction when the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold; a peak period determination module for modifying the operation plan of the internal mixer based on the adjusted start time in the process chain decoupling instruction, and determining the energy consumption peak period to be avoided based on the energy consumption characteristics of the current temperature control stage of the vulcanizer; The equipment collaborative control module is used to verify whether the modified operation plan can achieve complete staggering of the power peak of the internal mixer and the energy consumption peak period. If the verification is successful, the internal mixer and the vulcanizer are collaboratively controlled based on the modified operation plan.

[0007] Compared with the prior art, the present invention has the following beneficial effects: 1. By collecting the power waveform of the internal mixer and the temperature control energy consumption data of the vulcanizer in real time, combined with the equipment connection relationship and material coding matching mechanism in the material flow path, the process chain topology relationship is dynamically constructed, and the energy consumption data of discrete equipment are integrated into a structured energy transmission network. On this basis, the partial derivative calculation of the internal mixer power change on the vulcanizer energy consumption is introduced to generate the process chain energy consumption coupling coefficient. The dynamic intensity of the energy consumption impact between equipment is quantified in mathematical form, improving the accuracy of identifying peak overlapping conditions, accurately capturing the energy interaction characteristics of the internal mixer and vulcanizer, and providing real-time data support for decoupling decision-making.

[0008] 2. When the energy consumption coupling coefficient exceeds the preset decoupling threshold, the decoupling instruction is automatically triggered. The temperature-energy consumption compensation factor is used to dynamically calculate the internal mixer startup offset, allowing its power peak to accurately avoid the energy consumption peak window marked by the vulcanizer current fluctuation. After adjusting the operation plan, it is mandatory to verify that the power peak and energy consumption peak periods do not overlap. The equipment operation is synchronized and controlled through the industrial real-time protocol, effectively avoiding secondary conflicts caused by operating condition drift. On the one hand, this invention avoids the grid load impact caused by the superposition of energy consumption peaks of multiple devices. On the other hand, it reduces energy loss by balancing energy consumption peaks and valleys, and overall optimizes the energy utilization efficiency of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 A schematic flow chart of a method for dynamic scheduling of a production process based on energy consumption optimization provided by one embodiment of the present invention; Figure 2 A functional module diagram of a production process dynamic scheduling system based on energy consumption optimization provided by one embodiment of the present invention; The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0010] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0011] The embodiment of the present application provides a method for dynamic scheduling of production processes based on energy consumption optimization. The execution subject of the method for dynamic scheduling of production processes based on energy consumption optimization includes but is not limited to at least one of the electronic devices such as a server and a terminal that can be configured to execute the method provided by the embodiment of the present application. In other words, the method for dynamic scheduling of production processes based on energy consumption optimization can be executed by software or hardware installed on a terminal device or a server device. The server includes but is not limited to: a single server, a server cluster, a cloud server or a cloud server cluster, etc. The server can be an independent server, or it can be a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communications, middleware services, domain name services, security services, content distribution networks, and big data and artificial intelligence platforms.

[0012] Reference Figure 1 FIG. 1 is a flow chart of a method for dynamic scheduling of production processes based on energy consumption optimization provided by an embodiment of the present invention.

[0013] The method described in this embodiment can be deployed in a manufacturing operations management system (MOM system). The MOM system integrates functional modules such as data collection, storage, calculation, scheduling, and instruction issuance.

[0014] In this embodiment, the production process dynamic scheduling method based on energy consumption optimization includes: S1. Real-time collection of power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line, and construction of a process chain topology based on the power waveform data, the temperature control energy consumption data, and the material flow path.

[0015] In an embodiment of the present invention, the real-time collection of power waveform data of an internal mixer and temperature control energy consumption data of a vulcanizer in a production line, and the establishment of a process chain topology relationship based on the power waveform data, the temperature control energy consumption data, and the material flow path include: Real-time acquisition of power waveform data of the internal mixer during operation and temperature control energy consumption data of the vulcanizer during temperature control through the industrial bus; Determine the equipment connection relationship between the internal mixer and the vulcanizer based on the material flow path; Identify the matching relationship between the material code of the mixer outlet and the material code of the vulcanizer inlet: When the material codes match, the energy transfer path from the internal mixer to the vulcanizer is established; When the material code does not match, the unmatched device node is removed from the device connection relationship; A minimum connectivity topology diagram is generated according to the energy transfer path and the elimination results as a process chain topology relationship.

[0016] In the rubber product production scenario, the MOM system suffers from fragmented equipment energy consumption data and fuzzy process chain relationships. For example, the energy transfer path between the internal mixer and the vulcanizer lacks a material coding matching mechanism, resulting in the failure of coordinated control of energy consumption peaks.

[0017] In the embodiment of the present application, the three-phase power waveform of the internal mixer is collected in real time from the Siemens S7-1500 PLC through the OPC UA protocol (sampling frequency 100 Hz), and the electric heating energy consumption data of the vulcanizer temperature control module is obtained synchronously.

[0018] Furthermore, if any instruments or software tools not produced by our company appear in the embodiments of the present invention, they are only used for illustration and do not represent actual use.

[0019] In this embodiment, the collected data is stored in a time series database, generating a time series table of internal mixer power waveforms (fields include timestamp, phase A power, phase B power, and phase C power) and a vulcanizer temperature control energy consumption log (fields include temperature control stage, heating power, and cumulative energy consumption). The bill of materials data is then used to analyze the physical connection between the internal mixer and the vulcanizer. For example, the process route configuration table determines that the discharge port of internal mixer M01 corresponds to the feed port R02 of vulcanizer S03.

[0020] In the embodiment of the present application, a directed graph is used to represent the equipment connection relationship G = (V, E), where the node V is the equipment entity (internal mixer / vulcanizer), the edge E is the material transmission pipeline (such as Φ100mm rubber material conveying pipe), and the edge attributes include pre-configured parameters such as transmission rate and transmission time.

[0021] In the embodiment of the present application, in accordance with the formulated "Rubber Products Material Coding Specification", the material coding format of the internal mixer outlet is "process code (ML) + equipment number (M01) + batch number (20250707) + serial number (001)", and the vulcanizer feed port coding must completely match the above fields; read the material code C_m of the internal mixer outlet RFID tag (such as ImpinjM730); query the target code C_s in the vulcanizer feed port PLC register in real time; when C_m=C_s, activate the "path establishment" instruction, otherwise trigger the "device node elimination" logic (such as marking S04 as inactive from the current process chain).

[0022] In this embodiment, a minimal connectivity graph is generated using the Neo4j graph database and the Dijkstra algorithm. The specific steps are as follows: The device connection relationship G and the energy transfer path set E_p (generated from the material code matching results) are determined; after removing unmatched device nodes, the shortest path between any two nodes in the graph is calculated; and a process chain topology diagram T = (V', E') is generated, where V' represents a valid device node and E' represents a directed edge with energy consumption parameters (for example, the attributes of the edge M01→S03 in E' include power transfer efficiency and heat loss coefficient).

[0023] In the embodiment of the present application, the material flow path refers to the material processing route, which includes the equipment connection sequence from the mixing process to the vulcanization process (such as M01→M02→S03→S04); the minimum connected topology graph is represented as a weighted directed graph, which is used to visualize the energy transfer relationship in the process chain.

[0024] In general, after the topology map is generated, the energy transfer efficiency from the internal mixer to the vulcanizer is monitored in real time, shortening the time spent on equipment energy consumption correlation analysis; at the same time, when the material coding mismatch causes the equipment node to be eliminated, an alarm is automatically triggered.

[0025] Specifically, the equipment connection relationships in the topology diagram serve as scheduling constraints (for example, vulcanizer S03 only accepts materials from internal mixers M01 / M02). The energy transfer paths in the topology diagram provide a data basis for energy consumption analysis and support the generation of energy consumption reports by process chain dimension (for example, a comparison table of unit product energy consumption in the internal mixing and vulcanization processes).

[0026] In the embodiment of the present application, the internal mixer M01 is model XK-550 with a rated power of 160kW; the vulcanizer S03 is model LL-B2000 with a temperature control range of 120-180°C. At x hour on x day of x month of x year, the peak value of the power waveform of M01 and the current cumulative value of the temperature control energy consumption of S03 are collected through the bus; when the material code of the M01 discharge port is consistent with the target code of the S03 feed port, the energy transfer path M01→S03 is established.

[0027] Based on the above data, a minimum connected topology graph containing 3 internal mixers and 5 vulcanizers is generated, where the edge weights of M01→S03 are transmission delay and heat loss.

[0028] In the embodiment of the present application, through industrial bus integration, material coding standardization and graph database technology, the dynamic construction of the process chain topology relationship is realized, providing a data basis for subsequent energy consumption coupling analysis and collaborative control.

[0029] S2. Based on the process chain topology, the process chain energy consumption coupling coefficient is generated by taking the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption.

[0030] In an embodiment of the present invention, the process chain energy consumption coupling coefficient is generated based on the process chain topology relationship by taking the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption, including: According to the process chain topology, determining a device pair between an internal mixer and a vulcanizer where an energy transfer path exists; Real-time acquisition of the power time series data of the internal mixer and the energy consumption time series data of the vulcanizer; Calculating the energy consumption change of the vulcanizing machine within a preset time window based on the energy consumption time series data as the energy consumption increment; Calculating the instantaneous power change of the internal mixer at the start of the corresponding time window based on the power time series data; The process chain energy consumption coupling coefficient is generated by calculating the ratio of the energy consumption increment to the instantaneous power change.

[0031] Specifically, in rubber product production, traditional energy consumption analysis cannot quantify the dynamic coupling between the internal mixer and the vulcanizer. For example, field measurements at a tire factory showed that a 10% fluctuation in mixer power resulted in a non-deterministic 20% to 40% fluctuation in vulcanizer energy consumption.

[0032] In an embodiment of the present application, the process chain topology diagram T = (V', E') is called, and the device pairs with energy transfer paths are filtered through Cypher query statements; the API interface is used to obtain a list of device pairs, such as the internal mixer M01 and the vulcanizer S03, M02 and S04, etc., and the results are stored in the real-time data cache; the power data of the internal mixer is collected from the Siemens S7-1500 PLC and stored in the time series database; the energy consumption data of the vulcanizer is obtained by reading the energy management table, including the accumulated energy consumption in the temperature control stage.

[0033] In detail, the calculation formula of the process chain energy consumption coupling coefficient is as follows: ; in, It is an internal mixer To the vulcanizing press The energy loss coupling coefficient, It is a vulcanizing press Energy consumption per unit time, It is an internal mixer The instantaneous power, is the data collection period, yes Energy consumption increment of internal vulcanizing machine, It is an internal mixer The instantaneous change in power.

[0034] In the embodiment of the present application, the data collection cycle Set by the MOM system process parameter configuration module, the typical value for rubber product vulcanization scenario is 10s (corresponding to the mixer discharge cycle); the window start time Take the characteristic point of the power fluctuation of the internal mixer (such as the moment when the power rising edge exceeds 80% of the rated power).

[0035] In the embodiment of the present application, the energy consumption increment of the vulcanizing machine is Through the real-time calculation function calcEnergyDelta() of the MOM system, read arrive Energy consumption log of the vulcanizer within a time period and calculate the difference; instantaneous change in power of the internal mixer By extracting the power waveform data at time t, the first-order derivative is calculated using the signal processing library (using the central difference method).

[0036] In the embodiment of the present application, the process chain topology relationship refers to the equipment energy transfer network, which includes nodes such as internal mixers and vulcanizers and energy transfer edges; the energy consumption time series data is collected from the real-time data sequence of equipment energy consumption, sorted by timestamp, and supports HMI interface query of historical curves; the instantaneous power change is defined as the rate of change of the internal mixer power in a very short time, which is extracted through signal processing algorithms and used to characterize the sudden change of equipment load.

[0037] In the embodiment of the present application, in a certain customer factory, an internal mixer M01 (rated power 160kW) and a vulcanizer S03 (heating power 80kW) form a device pair. The data collection period Δt = 10s, at x year x month x day x hour, is collected: the power of the internal mixer increases from 120kW to 135kW at t = 9:30:00. The energy consumption of the vulcanizing press increased from 450kW•h to 453kW•h from t to t+10s. ,but .

[0038] S3. When the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold, a process chain decoupling instruction is generated. The process chain decoupling instruction rearranges the start-up timing of the internal mixer to cut off the energy consumption peak conflict with the vulcanizer.

[0039] In an embodiment of the present invention, when the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold, generating a process chain decoupling instruction includes: Comparing the process chain energy consumption coupling coefficient with a preset decoupling threshold in real time, and obtaining the temperature change rate and remaining operation time of the current vulcanizer when the process chain energy consumption coupling coefficient exceeds the preset decoupling threshold; Multiplying the temperature change rate by the temperature-energy consumption compensation factor to obtain a time offset; Adding the time offset to the original start time of the internal mixer to obtain the adjusted start time of the internal mixer; A process chain decoupling instruction is constructed according to the adjusted start time, wherein the process chain decoupling instruction is used to cut off the energy consumption peak conflict between the internal mixer and the vulcanizer.

[0040] In detail, the calculation formula for adjusting the start time of the internal mixer is: ; in, is to adjust the start time, is the original startup moment, is the time offset, is the real-time temperature of the vulcanizing machine, is the temperature-energy compensation factor, It is the current vulcanization operation period.

[0041] In detail, it was found in the production of rubber products that when the energy consumption coupling between the internal mixer and the vulcanizer is too strong (such as the coupling coefficient κ ≥ 2.5h), the superposition of the equipment energy consumption peaks will cause the instantaneous power of the workshop to exceed the rated value by more than 15%.

[0042] Specifically, the preset decoupling threshold is set by the process parameter module, and the typical value for the rubber vulcanization scenario is 2.0h. When the energy consumption coupling coefficient of the process chain is greater than the preset decoupling threshold, the decoupling process is triggered, and the triggering time t_trigger and the equipment pair ID (such as M01-S03) are recorded. The real-time temperature data of the vulcanizer temperature control module is read. , when the sampling period is 1s, the first-order derivative is calculated by the signal processing library (forward difference method): .

[0043] In an embodiment of the present application, the set duration of the vulcanization process is extracted from the work order information, and the remaining duration is calculated in real time, which is equal to the set duration of the vulcanization process minus the current time, plus the vulcanization start time, and the result is stored in the real-time data cache.

[0044] In detail, the temperature-energy consumption compensation factor is provided by the energy model library, with a value range of [-0.5, 0.5], and a typical value of 0.3 in the rubber vulcanization scenario (unit: s / °C); the relationship between temperature fluctuation and energy consumption change is fitted based on the least squares method (e.g. =(1) indicates that for every 1°C change in temperature, the energy consumption change corresponds to a time offset of 0.3s. If the temperature change rate is 2°C / s, ,but .

[0045] In detail, the original start time comes from the work order plan; the adjusted start time The result is verified by the scheduling algorithm (such as not violating the process sequence constraints); the instruction is sent to the mixer PLC through the industrial communication protocol (such as OPC UA) to control the start relay action.

[0046] In the embodiment of the present application, the preset decoupling threshold refers to the critical value of the coupling coefficient that triggers the energy consumption decoupling strategy, which is pre-configured according to the equipment characteristics and grid capacity, and supports dynamic adjustment by production managers; the temperature-energy consumption compensation factor characterizes the degree of influence of the temperature change of the vulcanizer on the time distribution of energy consumption, which is obtained through training of historical energy consumption data and stored in the parameter database; the process chain decoupling instruction is a generated equipment control instruction used to adjust the startup timing of the internal mixer, follow the factory instruction protocol specifications, and ensure communication compatibility with the underlying equipment.

[0047] In an embodiment of the present application, after application in a rubber products factory, the peak power of the workshop was reduced through decoupling instructions, and the transformer overload alarm was eliminated; the internal mixer and vulcanizer were prevented from running at full load at the same time, the replacement cycle of the motor bearings of the internal mixer of a certain factory was extended, and the maintenance cost was reduced.

[0048] S4. Modify the operation plan of the internal mixer based on the adjustment start time in the process chain decoupling instruction, and determine the energy consumption peak period to be avoided according to the energy consumption characteristics of the current temperature control stage of the vulcanizer.

[0049] In an embodiment of the present invention, the step of modifying the operation plan of the internal mixer based on the adjusted start time in the process chain decoupling instruction includes: parsing the adjustment start time in the process chain decoupling instruction; Obtain equipment preheating parameters and material preparation status in the original operation plan of the internal mixer; Converting the difference between the adjusted start time and the original start time into a timing offset; The feed valve opening sequence and motor preheating curve of the internal mixer are rearranged according to the timing offset, and an internal mixer operation plan including an adjusted start-up time is generated.

[0050] In an embodiment of the present invention, determining the energy consumption peak period to be avoided based on the energy consumption characteristics of the current temperature control stage of the vulcanizer includes: During the temperature maintenance stage of the vulcanizer, the current fluctuation value of the heating element is monitored in real time; When the current fluctuation value continuously exceeds the set threshold, it is marked as a candidate period of energy consumption peak; The energy consumption intensity of the candidate time period is verified according to the historical energy consumption database, and the energy consumption peak time period including the start and end times is output.

[0051] Specifically, in a rubber production scenario, it was discovered that traditional work plan adjustments were unable to synchronously respond to the need for energy decoupling, resulting in a tire factory experiencing overlapping energy consumption peaks between internal mixers and vulcanizers. This step addresses the issue of ineffective coordination between production scheduling and energy management by dynamically modifying work plans and accurately identifying peak energy consumption periods.

[0052] In an embodiment of the present application, the adjusted start time in the decoupling instruction is extracted, such as parsing the specific time value from the instruction "adjustedStart":"T09:30:00.600Z"; t_start' is calibrated using the NTP clock server (accuracy ±1ms) to ensure consistency with the workshop equipment clock and avoid scheduling errors caused by clock deviation.

[0053] In the embodiment of the present application, the preheating curve corresponding to the internal mixer model is read from the equipment process library. For example, the motor preheating parameters of the XK-550 internal mixer are: Warm-up stage 1: 0-5 minutes, power increases from 0 to 30% of rated power (48kW); Warm-up stage 2: 5-10 minutes, power increased to 80% (128kW).

[0054] In this embodiment, the data is stored in a real-time database by querying the inventory location of the rubber material to be processed (e.g., intermediate silo B03) and the status of the valves in the delivery pipeline (e.g., whether feed valve V01 is open). For example, if the original time is 9:30:00 and the adjusted time is 9:30:00.6, the time difference is +0.6s. This time difference is proportionally distributed to each step of the preheating phase. For example, if the total preheating time is 10 minutes (600 seconds), the per-minute offset is 0.6s / 10 = 0.06s.

[0055] In the embodiment of the present application, the opening timing of the feed valve is modified. For example, the original plan to open V01 at 9:25:00 is now delayed by 0.6s to 9:25:00.6; the curve editing tool is called to shift the time axis of the motor preheating curve to keep the power change slope unchanged (such as the end time of preheating stage 1 is adjusted from 9:25:00 to 9:25:00.6).

[0056] In an embodiment of the present application, the new plan is sent to the internal mixer PLC via an industrial communication protocol (such as EtherNet / IP), and the PLC generates a pulse signal to control the actuator according to the offset.

[0057] In an embodiment of the present application, when the current fluctuation value continuously exceeds the threshold for a period of ≥100ms (i.e., 10 sampling points), it is marked as a candidate period; for example: during 9:30:00.1-9:30:00.2, the current is continuously 135A>133A, triggering the candidate period mark.

[0058] In an embodiment of the present application, energy consumption data under the same process conditions is queried, for example, the energy consumption curve at a vulcanization temperature of 160°C and a pressure of 10 MPa in the past 30 days is queried; the energy consumption intensity of the candidate time period is calculated: energy consumption intensity = cumulative energy consumption in the time period / time period duration. When the energy consumption intensity exceeds the historical mean plus 2 times the standard deviation, it is confirmed as an energy consumption peak period. For example, if the historical mean is 0.5kW•h / s and the standard deviation is 0.1, the threshold is 0.7kW•h / s; the peak period is visualized through the energy dashboard, such as marking "9:30:00.1-9:30:00.2 is the energy consumption peak period, energy consumption intensity 0.8kW•h / s", and synchronized to the peak avoidance strategy library.

[0059] In the embodiment of the present application, the equipment preheating parameters are defined as the heating program of the motor and cavity before the internal mixer is started, including the power-time curve; the current fluctuation threshold represents the critical value of the abnormal load of the vulcanizer heating element, which is set according to the equipment rated parameters and the grid capacity and stored in the parameter management module of the MOM system; the energy consumption intensity is used to quantify the energy consumption per unit time and is the core parameter for judging the peak period. The calculation formula is "energy consumption intensity = cumulative energy consumption / time length".

[0060] In an embodiment of the present application, the energy consumption peak period identification result is automatically associated with the maintenance record of the vulcanizer heating element.

[0061] In this example, the original start time t_start = 14:00:00, the adjusted t_start' = 14:00:00.8, and Δt = +0.8s. The total preheating time for the XK-550 internal mixer is 10 minutes (600 seconds), and the timing offsets are: preheating phase 1 (0-5 minutes) is offset by 0.4s, and phase 2 (5-10 minutes) is offset by 0.4s. The opening time of feed valve V01 is rearranged from 13:55:00 to 13:55:00.8, and the motor preheating curve is shifted back by 0.8s. During the temperature maintenance phase (160°C) of vulcanizer S03, the current was monitored to be 136A (threshold 133A) from 14:15:00.5 to 14:15:00.7, marking this as a candidate period.

[0062] In the embodiment of the present application, the historical database query shows that under the same process, the average energy consumption intensity of this period is 0.6kW•h / s, the standard deviation is 0.08, and the current energy consumption intensity is (0.2kW•h) / 0.2s=1.0kW•h / s>0.6+2×0.08=0.76, which is confirmed as the peak period; 14:15:00.5-14:15:00.7 is added to the peak avoidance list, and the subsequent internal mixer start-up plan automatically avoids this period.

[0063] S5. Verify whether the modified operation plan can completely stagger the power peak of the internal mixer and the energy consumption peak period. If the verification is successful, coordinately control the internal mixer and the vulcanizer based on the modified operation plan.

[0064] In an embodiment of the present invention, the step of verifying whether the modified operation plan achieves complete staggering of the power peak of the internal mixer and the energy consumption peak period, and if the verification is successful, collaboratively controlling the internal mixer and the vulcanizer based on the modified operation plan includes: Based on the modified operation plan, the power peak period of the internal mixer and the energy consumption peak period of the vulcanizer are obtained; Comparing the time sequence overlap intervals of the power peak period and the energy consumption peak period, and when there is no time sequence overlap, determining that the power peak period of the internal mixer and the energy consumption peak period of the vulcanizer are completely staggered; When the verification is passed, the start control signal of the internal mixer and the temperature control stage instruction of the vulcanizer are generated; The start control signal and the temperature control stage instruction are synchronously issued through the industrial real-time communication protocol to achieve coordinated control of the internal mixer and the vulcanizer.

[0065] In this embodiment, the motor preheating curve and operating power data are extracted from the modified operation plan to identify power peaks. For example, when starting an XK-550 internal mixer, the power peak occurs at the end of preheating phase 2 (e.g., t = 9:30:00, power 160kW). The peak period is defined as the 500ms before and after this time (9:29:59.5-9:30:00.5).

[0066] In an embodiment of the present application, the energy consumption peak period data output by step S4 is called and read from the energy log. The interval intersection judgment method is adopted to define the power peak period of the internal mixer as [P_start, P_end], and the energy consumption peak period of the vulcanizer as [E_start, E_end]; when P_end≤E_start or E_end≤P_start, it is determined that there is no overlap, otherwise there is overlap.

[0067] In an embodiment of the present application, when the power peak period is 9:30:00.1-9:30:00.3 and the energy consumption peak period is 9:30:00.4-9:30:00.6, there is no overlap between the two; when the power peak period is 9:30:00.1-9:30:00.3, if the energy consumption period is 9:30:00.2-9:30:00.5, the overlapping interval between the two is 9:30:00.2-9:30:00.3.

[0068] In the embodiment of the present application, the internal mixer start-up control signal includes parameters such as the start-up time and the preheating power curve, and the SCL code is generated through the PLC programming interface.

[0069] Specifically, the curing press temperature control stage instructions refer to temperature control parameter adjustment instructions generated according to the process recipe library, such as {stage: "hold", targetTemp: 160°C, holdTime: 30min}; the internal mixer instructions are sent to the Siemens PLC via the bus, and the curing press instructions are sent to the Omron temperature controller via ModbusTCP.

[0070] In the embodiment of the present application, the power peak period is defined as a continuous period when the power of the internal mixer exceeds 90% of the rated value during operation, which is automatically identified by analyzing the power curve in the operation plan; the timing overlap interval is used to determine the key parameters of the equipment peak conflict. When the time axes of the two periods intersect, it is determined to be an overlap, triggering the decoupling strategy; the industrial real-time communication protocol is used as the communication standard for the underlying equipment control.

[0071] In an embodiment of the present application, after the collaborative control instruction is issued, equipment operation data (such as mixer current and vulcanizer temperature) is collected in real time, and a dynamic monitoring curve is generated on the HMI interface to support process engineers in adjusting control parameters in real time; the peak staggered status is linked to product quality data, and product performance indicators during periods without peak overlap are automatically recorded to provide data support for process optimization; collaborative control effect reports are generated regularly, including indicators such as peak staggered rate, energy savings, and equipment efficiency.

[0072] In the embodiment of the present application, the modified internal mixer operation plan shows that the power peak of M01 occurs at 15:00:00.2, and the peak period is 15:00:00.1-15:00:00.3 (power 160kW); the energy consumption peak period of vulcanizer S03 is 15:00:00.4-15:00:00.6 (energy consumption intensity 0.9kW•h / s); the power period ends at 15:00:00.3, and the energy consumption period starts at 15:00:00.4, so there is no overlap between the two, and the verification is passed.

[0073] In the embodiment of the present application, a start signal is sent to M01, and the PLC executes the preheating program as planned; a temperature control instruction is sent to S03 to maintain the insulation state at 160°C; real-time monitoring shows that the peak periods of the two devices are completely staggered, and the total power curve of the workshop is smooth without sudden changes.

[0074] like Figure 2 , which is a functional module diagram of a production process dynamic scheduling system based on energy consumption optimization provided by an embodiment of the present invention.

[0075] The energy-optimized production process dynamic scheduling system 100 of the present invention can be installed in an electronic device. Depending on the functionality implemented, the energy-optimized production process dynamic scheduling system 100 can include a data acquisition module 101, a process chain energy consumption coupling coefficient generation module 102, a process chain decoupling instruction generation module 103, a peak period determination module 104, and an equipment collaborative control module 105. The modules of the present invention, also referred to as units, refer to a series of computer program segments that can be executed by an electronic device processor and perform fixed functions, and are stored in the memory of the electronic device.

[0076] In this embodiment, the functions of each module / unit are as follows: The data acquisition module 101 is used to collect the power waveform data of the internal mixer and the temperature control energy consumption data of the vulcanizer in the production line in real time, and to build a process chain topology relationship based on the power waveform data, the temperature control energy consumption data and the material flow path; A process chain energy consumption coupling coefficient generating module 102 is configured to generate a process chain energy consumption coupling coefficient based on the process chain topology by taking the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption; A process chain decoupling instruction generating module 103 is configured to generate a process chain decoupling instruction when the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold; a peak period determination module 104 for modifying the operation plan of the internal mixer based on the adjusted start time in the process chain decoupling instruction, and determining an energy consumption peak period to be avoided based on the energy consumption characteristics of the curing press during the current temperature control stage; The equipment collaborative control module 105 is used to verify whether the modified operation plan can achieve complete staggering of the power peak of the internal mixer and the energy consumption peak period. If the verification is successful, the internal mixer and the vulcanizer are collaboratively controlled based on the modified operation plan.

[0077] In the several embodiments provided by the present invention, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For example, the module division is merely a logical function division, and other division methods may be used in actual implementation.

[0078] The modules described as separate components may or may not be physically separate, and the components shown as modules may or may not be physical units, that is, they may be located in one place or distributed across multiple network elements. Some or all of the modules may be selected to achieve the purpose of the solution of this embodiment according to actual needs.

[0079] In addition, the functional modules in various embodiments of the present invention may be integrated into a single processing unit, each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or hardware plus software functional modules.

[0080] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0081] The embodiments of the present application can acquire and process relevant data based on artificial intelligence technology. Artificial intelligence refers to the theories, methods, technologies, and application systems that use digital computers or machines controlled by digital computers to simulate, extend, and expand human intelligence, perceive the environment, acquire knowledge, and use knowledge to achieve optimal results.

[0082] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A production process dynamic scheduling method based on energy consumption optimization, characterized in that: The method comprises: S1. Real-time collection of power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line, and construction of a process chain topology based on the power waveform data, the temperature control energy consumption data and the material flow path; S2. Based on the process chain topology, the process chain energy consumption coupling coefficient is generated by the partial derivative of the internal mixer power change on the curing press energy consumption; S3. When the process chain energy consumption coupling coefficient exceeds the preset decoupling threshold, a process chain decoupling instruction is generated; S4. Modify the operation plan of the internal mixer based on the adjustment start time in the process chain decoupling instruction, and determine the energy consumption peak period to be avoided according to the energy consumption characteristics of the current temperature control stage of the vulcanizer; S5. Verify whether the modified operation plan can completely stagger the power peak of the internal mixer and the energy consumption peak period. If the verification is successful, coordinately control the internal mixer and the vulcanizer based on the modified operation plan.

2. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The real-time collection of power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line, and the construction of a process chain topology relationship based on the power waveform data, the temperature control energy consumption data and the material flow path, include: Real-time acquisition of power waveform data of the internal mixer during operation and temperature control energy consumption data of the vulcanizer during temperature control through the industrial bus; Determine the equipment connection relationship between the internal mixer and the vulcanizer based on the material flow path; Identify the matching relationship between the material code of the mixer outlet and the material code of the vulcanizer inlet: When the material codes match, the energy transfer path from the internal mixer to the vulcanizer is established; When the material code does not match, the unmatched device node is removed from the device connection relationship; A minimum connectivity topology diagram is generated according to the energy transfer path and the elimination results as a process chain topology relationship.

3. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The process chain energy consumption coupling coefficient is generated based on the process chain topology relationship by the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption, including: According to the process chain topology, determining a device pair between an internal mixer and a vulcanizer where an energy transfer path exists; Real-time acquisition of the power time series data of the internal mixer and the energy consumption time series data of the vulcanizer; Calculating the energy consumption change of the vulcanizing machine within a preset time window based on the energy consumption time series data as the energy consumption increment; Calculating the instantaneous power change of the internal mixer at the start of the corresponding time window based on the power time series data; The process chain energy consumption coupling coefficient is generated by calculating the ratio of the energy consumption increment to the instantaneous power change.

4. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The calculation formula of the process chain energy consumption coupling coefficient is as follows: ； in, It is an internal mixer To the vulcanizing press The energy loss coupling coefficient, It is a vulcanizing machine Energy consumption per unit time, It is an internal mixer The instantaneous power, is the data collection period, yes Energy consumption increment of internal vulcanizing machine, It is an internal mixer The instantaneous change in power.

5. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: When the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold, generating a process chain decoupling instruction includes: Comparing the process chain energy consumption coupling coefficient with a preset decoupling threshold in real time, and obtaining the temperature change rate and remaining operation time of the current vulcanizer when the process chain energy consumption coupling coefficient exceeds the preset decoupling threshold; Multiplying the temperature change rate by the temperature-energy consumption compensation factor to obtain a time offset; Adding the time offset to the original start time of the internal mixer to obtain the adjusted start time of the internal mixer; A process chain decoupling instruction is constructed according to the adjusted start time, wherein the process chain decoupling instruction is used to cut off the energy consumption peak conflict between the internal mixer and the vulcanizer.

6. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The calculation formula for adjusting the start time of the internal mixer is: ； in, is to adjust the start time, is the original startup moment, is the time offset, is the real-time temperature of the vulcanizing machine, is the temperature-energy compensation factor, It is the current vulcanization operation period.

7. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The step of modifying the operation plan of the internal mixer based on the adjusted start time in the process chain decoupling instruction includes: parsing the adjustment start time in the process chain decoupling instruction; Obtain equipment preheating parameters and material preparation status in the original operation plan of the internal mixer; Converting the difference between the adjusted start time and the original start time into a timing offset; The feed valve opening sequence and motor preheating curve of the internal mixer are rearranged according to the timing offset, and an internal mixer operation plan including an adjusted start-up time is generated.

8. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: Determining the energy consumption peak period to be avoided based on the energy consumption characteristics of the current temperature control stage of the vulcanizer includes: During the temperature maintenance stage of the vulcanizer, the current fluctuation value of the heating element is monitored in real time; When the current fluctuation value continuously exceeds the set threshold, it is marked as a candidate period of energy consumption peak; The energy consumption intensity of the candidate time period is verified according to the historical energy consumption database, and the energy consumption peak time period including the start and end times is output.

9. The method for dynamic scheduling of production processes based on energy consumption optimization according to claim 1, characterized in that: The step of verifying whether the modified operation plan achieves complete staggering of the power peak of the internal mixer and the energy consumption peak period; if the verification is successful, collaboratively controlling the internal mixer and the vulcanizing press based on the modified operation plan includes: Based on the modified operation plan, the power peak period of the internal mixer and the energy consumption peak period of the vulcanizer are obtained; Comparing the time sequence overlap intervals of the power peak period and the energy consumption peak period, and when there is no time sequence overlap, determining that the power peak period of the internal mixer and the energy consumption peak period of the vulcanizer are completely staggered; When the verification is passed, the start control signal of the internal mixer and the temperature control stage instruction of the vulcanizer are generated; The start control signal and the temperature control stage instruction are synchronously issued through the industrial real-time communication protocol to achieve coordinated control of the internal mixer and the vulcanizer.

10. A production process dynamic scheduling system based on energy consumption optimization, characterized in that: The system comprises: A data acquisition module is used to collect power waveform data of the internal mixer and temperature control energy consumption data of the vulcanizer in the production line in real time, and to build a process chain topology relationship based on the power waveform data, the temperature control energy consumption data and the material flow path; A process chain energy consumption coupling coefficient generation module is used to generate the process chain energy consumption coupling coefficient based on the process chain topology relationship by taking the partial derivative of the internal mixer power change with respect to the vulcanizer energy consumption; A process chain decoupling instruction generating module, configured to generate a process chain decoupling instruction when the process chain energy consumption coupling coefficient exceeds a preset decoupling threshold; a peak period determination module for modifying the operation plan of the internal mixer based on the adjusted start time in the process chain decoupling instruction, and determining the energy consumption peak period to be avoided based on the energy consumption characteristics of the current temperature control stage of the vulcanizer; The equipment collaborative control module is used to verify whether the modified operation plan can achieve complete staggering of the power peak of the internal mixer and the energy consumption peak period. If the verification is passed, the internal mixer and the vulcanizer are collaboratively controlled based on the modified operation plan.

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