Energy-saving and consumption-reducing transformation method and system for non-intelligent production equipment

Abstract

The invention discloses an energy-saving and consumption-reducing transformation method and system for non-intelligent production equipment, and belongs to the technical field of energy conservation and consumption reduction. According to the method, the working state of the production equipment is detected through a sensing technology, and sensor data are collected through an energy consumption collection control terminal and reported to an energy consumption server; and the energy consumption server communicates with the production equipment through the energy consumption acquisition control terminal or simulates manual operation through software to execute a dormancy or shutdown action according to a line body switch line instruction of the production management system and the state of the production equipment, and closes or adjusts an energy channel of the production equipment through the valve, so that energy-saving and consumption-reducing transformation of the equipment is realized. By adopting the technical scheme of the invention, the production equipment is timely and remotely dormant or shut down according to the execution of the production management system, so that the energy consumption is reduced, a worker does not need to go to the field to perform dormancy or shutdown operation on the equipment, the manual labor amount is reduced, the equipment operation is simplified, and the remote control capability on the equipment is enhanced.

Description

Technical Field

[0001] The present invention relates to the technical field of energy saving and consumption reduction, and in particular to a method and system for energy saving and consumption reduction transformation of non-intelligent production equipment. Background Art

[0002] The development of the ESG system and the realization of the dual carbon goals drive the manufacturing industry to adopt corresponding energy-saving technologies and energy-saving products to improve energy utilization efficiency and reduce energy loss and waste. There are many high-energy-consuming non-intelligent devices in traditional manufacturing enterprises. These devices do not support automatic autonomous working state switching, such as reflow ovens used in electronic product manufacturing, annealing furnaces, cutting machines, grinders, and spin dryers used in the production of aluminum substrates for hard disks. When not in production, personnel are required to go to the site to perform sleep or shutdown operations on the equipment. Automatic remote sleep or shutdown control cannot be achieved. Therefore, the delay in manual sleep or shutdown operations often leads to energy loss and waste. Summary of the invention

[0003] The technical problem to be solved by the present invention is: to provide a method and system for energy-saving and consumption-reducing transformation of non-intelligent production equipment in order to solve the problem of energy waste caused by the inability of non-intelligent equipment to automatically sleep or shut down remotely.

[0004] To achieve the above object, the present invention provides a method for energy-saving and consumption-reducing transformation of non-intelligent production equipment, comprising the following steps:

[0005] S1, installing an energy consumption collection control terminal and a current sensor on the non-intelligent production equipment that is the energy-saving object, and installing remote control software on the industrial computer of the non-intelligent production equipment that does not have a control command communication interface, wherein the energy consumption collection control terminal is connected to the current sensor and the non-intelligent production equipment by wire, the energy consumption collection control terminal is used to collect the working current of the non-intelligent production equipment detected by the current sensor, and the energy consumption server is used to judge the working state of the non-intelligent production equipment according to the working current detected by the current sensor;

[0006] S2, on the background page of the energy consumption server, bind the energy consumption collection and control terminal with the corresponding sensor and non-intelligent production equipment, then create a line body, and bind the line body name with all the energy consumption collection and control terminals in the line body;

[0007] S3, the production management system schedules production according to the PPC plan and sends the line switch line status information to the energy consumption server;

[0008] S4, the energy consumption server analyzes the line switch status information issued by the production management system, locates the line that needs to be shut down, and executes steps S5-S9 for the line that needs to be shut down;

[0009] S5, the energy consumption server determines whether the non-intelligent production equipment in the line can be put into sleep or shut down according to the equipment information collected by the sensor. If so, it sends a sleep or shutdown instruction to the energy consumption collection control terminal bound to the non-intelligent production equipment;

[0010] S6, for non-intelligent production equipment with a control command communication interface, the energy consumption collection and control terminal sends a sleep or shutdown command to the non-intelligent production equipment through the communication interface with the non-intelligent production equipment, and then returns the command execution status to the energy consumption server;

[0011] S7, for non-intelligent production equipment without a control command communication interface, the energy consumption collection control terminal sends a sleep or shutdown command to the remote control software installed on the non-intelligent production equipment, and the remote control software executes the sleep or shutdown command by simulating the manual operation of the employee, and the energy consumption collection control terminal returns the execution status to the energy consumption server according to the execution result of the remote control software;

[0012] S8, the energy consumption collection and control terminal closes or adjusts the energy channel valve corresponding to the non-intelligent production equipment;

[0013] S9, the energy consumption server reads the working current data reported by the current sensor of the non-intelligent production equipment through the energy consumption collection control terminal, compares it with the set sleep threshold, and determines whether the non-intelligent production equipment has successfully sleep.

[0014] The present invention also provides a non-intelligent production equipment energy-saving and consumption-reducing transformation system, including: non-intelligent production equipment, sensors, control actuators, energy consumption servers, energy consumption collection and control terminals, and production management systems, wherein:

[0015] Non-intelligent production equipment is the object of energy-saving control;

[0016] Sensors are used to collect information from non-intelligent production equipment, including photoelectric sensors, current sensors, flow meters, and meters. Flow meters and meters are used to collect energy consumption and evaluate energy-saving and consumption-reduction effects.

[0017] Control actuators are used to realize energy channel control and power on / off control of non-intelligent production equipment, including solenoid valves, electric / pneumatic valves and remote control software installed on the industrial computer of production equipment;

[0018] The energy consumption server is used to receive the equipment information reported by the energy consumption collection and control terminal and the instructions issued by the production management system, and issue control instructions to the non-intelligent production equipment according to the instructions of the production management system and the status of the non-intelligent production equipment;

[0019] The energy consumption collection control terminal is connected to the sensor in a wired manner, and is used to collect information of the non-intelligent production equipment detected by the sensor. One energy consumption collection control terminal can be connected to multiple sensors; the energy consumption collection control terminal is connected to the energy consumption server in a wireless manner, and is used to receive control instructions sent by the energy consumption server; the energy consumption collection control terminal is connected to the non-intelligent production equipment in a wired manner, and is used to execute the control instructions sent by the energy consumption server;

[0020] The production management system is used to perform production management control and send switch line instructions to the energy consumption server;

[0021] The production management system schedules production according to output and sends line switch status information to the energy consumption server. The energy consumption server parses the line switch status information sent by the production management system and locates the line that needs to be shut down. The energy consumption server determines whether the line can be shut down based on the sensor information of the non-intelligent production equipment. If the line can be shut down, a control instruction is sent to the energy consumption collection control terminal bound to the non-intelligent production equipment. The energy consumption collection control terminal sends the control instruction to the non-intelligent production equipment through the communication interface or the remote control software on the industrial computer of the non-intelligent production equipment.

[0022] The technical solution of the present invention detects the working status of production equipment through sensing technology, collects sensor data through energy consumption collection and control terminal and reports it to energy consumption server. The energy consumption server establishes a customized sleep or shutdown strategy based on the line switch line instruction of the production management system and the status of the production equipment, communicates with the production equipment through the energy consumption collection and control terminal or performs sleep or shutdown actions through software simulation of manual operation, closes or adjusts the energy channel of the production equipment through valves, achieves multi-level and multi-mode comprehensive control of valves, equipment communication, and line management, and realizes energy-saving and consumption-reducing transformation of equipment. The technical solution of the present invention is adopted, and non-intelligent production equipment is put into sleep or shutdown remotely in time according to the execution of the production management system, which reduces energy consumption, does not require personnel to go to the site to perform sleep or shutdown operations on the equipment, reduces manual labor, simplifies equipment operation, and enhances the remote control capability of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0024] Figure 1 A flowchart of a method for energy-saving and consumption-reducing transformation of non-intelligent production equipment provided in one embodiment of the present invention.

[0025] Figure 2-3This is a page diagram for binding sensors on the energy consumption collection and control terminal.

[0026] Figure 4 This is a page diagram for binding non-intelligent production equipment to the energy consumption collection and control terminal.

[0027] Figure 5 This is the non-intelligent production equipment information page for line L7.

[0028] Figure 6 The software control flow chart of the energy consumption server reflow oven.

[0029] Figure 7 This is a block diagram of a non-intelligent production equipment energy-saving and consumption-reducing transformation system.

[0030] Figure 8 This is a system architecture diagram for energy-saving and consumption-reducing transformation of non-intelligent production equipment.

[0031] Fig. 9 This is the circuit diagram of the energy consumption collection and control terminal. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] The general idea of ​​the present invention is: install sensors on the equipment side, the sensors collect equipment information, and send it to the energy consumption server through the energy consumption collection control terminal. The energy consumption server determines what kind of control action to take on the equipment based on the production plan, collected equipment data, etc., and sends the action instructions to be executed to the energy consumption collection control terminal wirelessly. The energy consumption collection control terminal "shakes hands" with the equipment to communicate and realize the control of the working status of the equipment.

[0034] The embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings of the specification. It should be understood that the embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0035] The present invention is applicable to non-intelligent production equipment in traditional manufacturing enterprises that cannot be remotely hibernated or shut down.

[0036] like Figure 1The figure is a flow chart of a non-intelligent production equipment energy-saving and consumption-reducing transformation method provided by an embodiment of the present invention. The embodiment of the present invention provides a non-intelligent production equipment energy-saving and consumption-reducing transformation method, which includes the following steps:

[0037] S1, install an energy consumption collection control terminal 5 and a current sensor 2 on the non-intelligent production equipment 1 that is the energy-saving object, and install remote control software on the industrial computer of the non-intelligent production equipment 1 that does not have a control command communication interface, wherein the energy consumption collection control terminal 5 is connected to the current sensor 2 and the non-intelligent production equipment 1 by wire, the energy consumption collection control terminal 5 is used to collect the working current of the non-intelligent production equipment 1 detected by the current sensor 2, and the energy consumption server 4 is used to judge the working status of the non-intelligent production equipment 1 according to the working current detected by the current sensor 2.

[0038] The energy consumption collection control terminal is wired to the sensor through the communication interface supported by the sensor, and the driver code corresponding to the communication protocol supported by the sensor is implanted to collect data from the sensor. The energy consumption collection control terminal 5 is also wired to the non-intelligent production equipment 1.

[0039] The remote control software is a newly developed independent software that runs on the industrial computer of non-intelligent production equipment. It is used to receive control instructions issued by the energy consumption server or the energy consumption collection and control terminal, and execute control instructions by simulating the manual operation of employees. Different non-intelligent production equipment 1 needs to be adapted to different remote control software according to the equipment conditions.

[0040] S2, on the background page of the energy consumption server 4, bind the energy consumption collection and control terminal 5 with the corresponding sensor 2 and non-intelligent production equipment 1, and then create a line body, and bind the line body name with all the energy consumption collection and control terminals 5 in the line body.

[0041] A line refers to a complex of various equipment, tools, and working environments in a production workshop, including production lines, machines, equipment, workbenches, etc. Creating a line means binding the line name with the machines and equipment in the line, thereby turning all the equipment in the entire line into a device collection to facilitate the on / off line control of all the equipment on the entire line.

[0042] like Figure 2-3 The figure shows a page diagram for binding sensors on an energy consumption collection and control terminal. In the embodiment of the present invention, one energy consumption collection and control terminal can be connected to three sensors, among which: Figure 2 To bind the three-phase current sensor to Channel 2 of the energy consumption collection and control terminal, Figure 3To bind the photoelectric sensor to Channel 1 of the energy consumption collection and control terminal, the 05600000001161 in the upper left corner of the figure is the serial number of the energy consumption collection and control terminal and the identification code of the energy consumption collection and control terminal. Figure 4 The following is a page diagram for binding a non-intelligent production device to an energy consumption collection and control terminal. Different devices are distinguished by device serial numbers. Multiple energy consumption collection and control terminals may be installed on the same non-intelligent production device to collect data from multiple sensors on the non-intelligent production device. Figure 5 The figure shows the non-intelligent production equipment information page of line body L7. When creating a line body, according to the binding relationship between the energy consumption collection control terminal and the non-intelligent production equipment, all energy consumption collection control terminals corresponding to the line body are bound to the line body name, thereby realizing the binding of the line body name with the non-intelligent production equipment in the line body.

[0043] S3, the production management system 6 schedules production according to the output according to the PPC (Production Planning and Control) plan, and sends the line switch line status information to the energy consumption server 4.

[0044] Line production management refers to whether the line has a production plan today as set in the production management system. If the line is open, it means that the line has production today; if the line is closed, it means that there is no production plan for the line today. To save energy, all equipment on the line needs to be shut down or dormant. PPC schedules whether a line is in production or not according to the production plan. If the line is in production, it is open, and if the line is not in production, it is closed. In the production management system, there is only the concept of the line, and the energy consumption server controls the corresponding non-intelligent production equipment in the line.

[0045] In the embodiment of the present invention, the production management system is an MES system independent of the energy consumption server. The MES system sends the switch line status information of each line to the energy consumption server in the form of JSON. The example is as follows:

[0046] {

[0047] "data":{

[0048] "lineStatusList":[

[0049] {

[0050] "linename":"test-001",

[0051] "status":"1" / / 0 off 1 on

[0052] },{

[0053] "linename":"test-002",

[0054] "status":"1" / / 0 off 1 on

[0055] },

[0056] {

[0057] "linename":"test-003",

[0058] "status":"1" / / 0 off 1 on

[0059] },

[0060] {

[0061] "linename":"test-004",

[0062] "status":"1" / / 0 off 1 on

[0063] },

[0064] {

[0065] "linename":"test-005",

[0066] "status":"1" / / 0 off 1 on

[0067] } ]

[0069] }

[0070] }

[0071] The linename field indicates the name of the line, and status indicates the status of the line, 0 indicates off, and 1 indicates on.

[0072] S4, the energy consumption server 4 analyzes the line switch status information issued by the production management system 6, locates the line that needs to be shut down, and executes steps S5-S9 for the line that needs to be shut down.

[0073] S5, the energy consumption server 4 determines whether the non-intelligent production equipment 1 in the line can sleep or shut down according to the equipment information collected by the sensor 2. If so, it sends a sleep or shutdown instruction to the energy consumption collection control terminal 5 bound to the non-intelligent production equipment 1.

[0074] The energy consumption server 4 sets the conditions for allowing sleep or shutdown according to the situation of the device, and can add sensors as needed to collect information about the device so that the energy consumption server can make a decision on whether to allow sleep or shutdown.

[0075] In the embodiment of the present invention, a private protocol is used for data exchange between the energy consumption server and the energy consumption collection and control terminal. The protocol format is shown in the following table:

[0076] Table 1 Communication protocol format between energy consumption server and energy consumption collection and control terminal

[0077] <header> < / header> <len> < / len> <sn> < / sn> <swiftnum> < / swiftnum> <time> < / time> <flag> < / flag> <cmd> < / cmd> [Data] <checksum> < / checksum>

[0078] Among them, the SN field represents the serial number of the energy consumption collection and control terminal, which is written by the R&D and production departments to ensure that each machine has one number, and the Cmd field represents the command word.

[0079] S6, for the non-intelligent production equipment 1 with a control command communication interface, the energy consumption collection and control terminal 5 sends a sleep or shutdown command to the non-intelligent production equipment 1 through the communication interface with the non-intelligent production equipment 1, and then returns the command execution status to the energy consumption server 4.

[0080] The energy consumption collection control terminal 5 communicates with the non-intelligent production equipment 1 through the communication interface supported by the non-intelligent production equipment 1. The communication interface includes RS485, RS232, and switch quantity. Different production equipment may have different communication interfaces, and the energy consumption collection control terminal 5 adapts to various communication interfaces. The energy consumption collection control terminal 5 establishes communication with the non-intelligent production equipment 1 through the communication interface and sends control instructions according to the communication protocol of the non-intelligent production equipment 1.

[0081] S7, for non-intelligent production equipment 1 that does not have a control command communication interface, the energy consumption collection and control terminal 5 sends a sleep or shutdown command to the remote control software installed on the non-intelligent production equipment 1, and the remote control software executes the sleep or shutdown command by simulating the manual operation of the employee. The energy consumption collection and control terminal 5 returns the execution status to the energy consumption server 4 according to the execution result of the remote control software.

[0082] In the step S7, the energy consumption server 4 may also directly send a sleep or shutdown instruction to the non-intelligent production equipment 1 that does not have a control command communication interface.

[0083] S8, the energy consumption collection and control terminal 5 closes or adjusts the energy channel valve corresponding to the non-intelligent production equipment 1.

[0084] Some non-intelligent production equipment 1 is connected with valves to provide the energy or environmental support such as water, electricity, gas, etc. required by the non-intelligent production equipment. For example, the reflow furnace is connected to the nitrogen channel through the solenoid valve. After the energy consumption acquisition control terminal puts the reflow furnace into sleep mode, it controls the solenoid valve through the relay to close the nitrogen channel of the reflow furnace. When not in production, the reflow furnace will not be filled with nitrogen. During production, the nitrogen solenoid valve will be opened in time to fill the reflow furnace with nitrogen. When some non-intelligent production equipment is in sleep mode, the valve needs to be adjusted to the appropriate angle through the energy consumption acquisition control terminal to enter the low-flow energy supply state.

[0085] S9, the energy consumption server 4 reads the working current data reported by the current sensor 2 of the non-intelligent production equipment 1 through the energy consumption collection control terminal 5, compares it with the set sleep threshold, and determines whether the non-intelligent production equipment 1 has successfully sleep.

[0086] After receiving the information that the control command is successfully executed from the remote control software on the energy consumption collection control terminal 5 or the industrial computer of the non-intelligent production equipment 1, the energy consumption server 4 detects the working current of the non-intelligent production equipment through the current sensor installed on the power line of the non-intelligent production equipment after a configurable time interval. When the read current value is less than or equal to the preset sleep threshold, the non-intelligent production equipment is prompted to "sleep successfully"; when the read current value is greater than the preset sleep threshold, it is prompted to "sleep abnormality".

[0087] For the reflow oven equipment, after step S1, it also includes:

[0088] S1A, install photoelectric sensors on the board entry and exit tracks of the reflow oven, and connect the photoelectric sensors to the energy consumption collection and control terminal installed on the reflow oven by wire. The energy consumption collection and control terminal uses the photoelectric sensors to continuously detect in real time whether there are PCB boards on the front and rear docking station tracks of the reflow oven equipment, and send the detection results to the energy consumption server.

[0089] The photoelectric sensors are arranged on the board inlet track and the board outlet track of the reflow furnace, and one photoelectric sensor is arranged on each of the board inlet track and the board outlet track, or two are arranged on the board inlet track and one is arranged on the board outlet track. When three photoelectric sensors are arranged, the detection accuracy is higher, and the energy consumption server automatically identifies which photoelectric sensor is abnormal according to the rules.

[0090] In the embodiment of the present invention, the energy consumption server determines whether the photoelectric sensor is abnormal in the following manner:

[0091] (1) The photoelectric sensor uploads data every minute. If no data is uploaded, it is considered abnormal.

[0092] (2) Within the same period of time, the detection results of the three photoelectric sensors are basically consistent. If the detection result of one photoelectric sensor is significantly different from that of the other two, it indicates that the photoelectric sensor is abnormal.

[0093] For the reflow furnace equipment, after step S4, it also includes:

[0094] S4A, after receiving the reflow oven equipment shutdown command issued by the production management system, the energy consumption server determines whether the photoelectric sensor is abnormal. If there is no abnormality, within time T1, it continuously reads the output data of the photoelectric sensor of the current reflow oven equipment to identify whether there is a PCB board in the reflow oven. If there is a PCB board, the system platform prompts that the PPC plan is incorrect and does not perform sleep or shutdown operations. Among them, the value of T1 is the preset value.

[0095] When there is a PCB board in the reflow oven, the components of the PCB board are cured according to the normal process.

[0096] For the reflow oven, a photoelectric sensor is needed to detect whether there is a PCB board on the docking station track. This is because if there is a PCB board, the reflow oven will enter a dormant state and the PCB board will be scrapped.

[0097] When the production management system issues a line shutdown instruction, but there are PCB boards in the reflow oven, it means that the production schedule does not match the actual production status, and the production management system needs to be pushed to modify the production schedule.

[0098] The control instructions of the energy consumption server to non-intelligent production equipment are not limited to sleep and shutdown. The specific control instructions depend on the support of the non-intelligent production equipment for the control instructions. For non-intelligent production equipment that does not require manual intervention in the startup process, the startup control is performed through the energy consumption server.

[0099] The following takes the control process of the reflow furnace by the energy consumption server as an example to further elaborate on the technical solution of the present invention.

[0100] like Figure 6 The figure shows a software control flow chart of an energy consumption server reflow furnace provided by an embodiment of the present invention, and the control flow is as follows:

[0101] (1) Three photoelectric sensors are set on the board inlet and outlet tracks of the reflow furnace to detect whether there are PCB boards in the reflow furnace. A current sensor is set on the power line of the reflow furnace to detect the working current of the reflow furnace. The detection results of the PCB board and the working current are reported to the energy consumption server through the energy consumption collection and control terminal.

[0102] (2) A resident process A is set on the energy consumption server to continuously detect whether a board enters the reflow oven when it is turned off. If a board is found, a "board abnormality" notification is sent to the non-intelligent production equipment manager. The resident process A determines whether the reflow oven is turned off based on the current value reported by the reflow oven current sensor. If the current is lower than the set startup current, the reflow oven is considered to be turned off. If the current is lower than the set sleep current, the reflow oven is considered to be in sleep mode.

[0103] (3) A resident process B is set up on the energy consumption server to continuously detect whether there are any abnormalities in the three photoelectric sensors. If there are any abnormalities, a "photoelectric sensor equipment abnormality" notification is sent to the non-intelligent production equipment manager.

[0104] (4) The energy consumption server receives the line opening instruction from the production management system and determines whether the status of the three photoelectric sensors is normal. If normal, it sends an "open line" notification to the non-intelligent production equipment management personnel. Because the reflow furnace equipment needs to be manually checked when starting up to ensure that the temperature is correct before starting up, only the line opening notification is sent here, and no remote start-up control is performed.

[0105] (5) The energy consumption server receives the shutdown command from the production management system and determines whether the three photoelectric sensors are normal. If so, it determines whether there is a PCB board in the nearest reflow oven. If there is a PCB board, it sends a "production does not match the plan" notification to the non-intelligent production equipment manager. If there is no PCB board, it waits for T1 time and continuously checks whether there is a PCB board during this time. If there is no board, it sends a "cooling down" notification to the non-intelligent production equipment manager and sends a sleep command to the energy consumption collection and control terminal. The energy consumption collection and control terminal communicates with the reflow oven equipment, sends a sleep control command to the reflow oven equipment, and returns the command execution result to the energy consumption server.

[0106] For reflow ovens, sleep usually refers to cooling. The oven temperature is 80 degrees during sleep, 245 degrees during normal working state, 14kw / h of normal working energy consumption, and 1kw / h after cooling. When shutting down the line, whether to put non-intelligent production equipment into sleep or shut down depends on the characteristics of different non-intelligent production equipment.

[0107] (6) After receiving the command execution result information returned by the energy consumption collection and control terminal, the energy consumption server waits for T2 time to detect whether the current value of the three-phase current sensor drops to the specified range. If the current value drops to the specified range, a "cooling success" notification is sent to the non-intelligent production equipment manager; otherwise, a "cooling failure" notification is sent to the non-intelligent production equipment manager.

[0108] The notification to the production manager may be sent by WeChat, email, SMS, etc. The values ​​of T1 and T2 are set in the WEB interface of the energy consumption server. In the embodiment of the present invention, T1 is set to 20 minutes and T2 is set to 10 minutes by default.

[0109] like Figure 7 FIG. 1 is a block diagram of a non-intelligent non-intelligent production equipment energy-saving and consumption-reducing transformation system provided by an embodiment of the present invention. Figure 8 The figure shows an architecture diagram of a non-intelligent non-intelligent production equipment energy-saving and consumption-reducing transformation system provided by an embodiment of the present invention. The embodiment of the present invention also provides a non-intelligent non-intelligent production equipment energy-saving and consumption-reducing transformation system, the system comprising: non-intelligent production equipment 1, sensor 2, control actuator 3, energy consumption server 4, energy consumption collection control terminal 5, production management system 6, wherein:

[0110] The non-intelligent production equipment 1 is the energy-saving control object;

[0111] Sensor 2 is used to collect information of non-intelligent production equipment 1, including photoelectric sensor, current sensor, flow meter, meter, among which flow meter and meter are used to collect energy consumption and evaluate energy saving and consumption reduction effect;

[0112] The photoelectric sensor is used in the reflow oven to detect whether there is a PCB board in the reflow oven, so as to prevent the PCB board from being damaged due to the forced sleep of the reflow oven when the line is shut down while there is still a PCB board in the reflow oven.

[0113] The current sensor is used to detect the working current of the non-intelligent production equipment 1, and judge whether the non-intelligent production equipment 1 is successfully in sleep mode, or whether it is in sleep mode, power-on mode, or power-off mode by comparing with the threshold value.

[0114] In order to evaluate the energy-saving effect of the technical solution of the present invention, it is necessary to collect energy consumption before implementing this solution, and to continuously collect energy consumption after implementing this solution to compare energy consumption for evaluating the energy-saving and consumption-reducing effect of this solution.

[0115] The control actuator 3 is used to realize the energy channel control and the on / off control of the non-intelligent production equipment 1, including a solenoid valve, an electric / pneumatic valve and a remote control software installed on the industrial computer of the non-intelligent production equipment;

[0116] Solenoid valves and electric / pneumatic valves are used to control the water, electricity, gas and other energy channels of non-intelligent production equipment. The remote control software installed on the industrial computer of the non-intelligent production equipment 1 executes control instructions by simulating the manual operation of employees. It is used when the non-intelligent production equipment 1 does not have a control instruction communication interface.

[0117] The energy consumption server 4 is used to receive the equipment information reported by the energy consumption collection control terminal 5 and the instructions issued by the production management system 6, and issue control instructions to the non-intelligent production equipment 1 according to the instructions of the production management system 6 and the status of the non-intelligent production equipment 1;

[0118] The energy consumption collection and control terminal 5 is connected to the sensor 2 in a wired manner, and is used to collect information of the non-intelligent production equipment 1 detected by the sensor 2. One energy consumption collection and control terminal 5 can access three sensors 2; the energy consumption collection and control terminal 5 is connected to the energy consumption server 4 in a wireless manner, and is used to receive control instructions sent by the energy consumption server 4; the energy consumption collection and control terminal 5 is connected to the non-intelligent production equipment 1 in a wired manner, and is used to execute the control instructions sent by the energy consumption server 4;

[0119] The production management system 6 is used to perform production management and control, and send a switch line instruction to the energy consumption server 4 .

[0120] The production management system 6 schedules production according to output and sends line switch status information to the energy consumption server 4. The energy consumption server 4 parses the line switch status information sent by the production management system 6 and locates the line that needs to be shut down. The energy consumption server 4 determines whether the line can be shut down based on the sensor information of the non-intelligent production equipment 1. If the line can be shut down, a control instruction is sent to the energy consumption collection control terminal 5 bound to the non-intelligent production equipment 1. The energy consumption collection control terminal 5 sends the control instruction to the non-intelligent production equipment 1 through the communication interface or the remote control software on the industrial computer of the non-intelligent production equipment 1.

[0121] For the non-intelligent production equipment 1 that does not require manual intervention in the startup process, the energy consumption server 4 sends a startup instruction to the non-intelligent production equipment 1 through the energy consumption collection and control terminal 5. For the non-intelligent production equipment 1 that requires manual intervention in the startup process, the energy consumption server 4 sends a startup notification to the manager of the non-intelligent production equipment 1.

[0122] The communication methods between the energy consumption collection and control terminal 5 and the sensor 2 include RS485, Modbus RTU, DL / T 645, DL / T 698.45, CJ / T, and PLC.

[0123] The communication method between the energy consumption collection and control terminal 5 and the non-intelligent production equipment 1 depends on the protocol supported by the non-intelligent production equipment 1 .

[0124] The energy consumption collection and control terminal 5 is connected to the energy consumption server 4 via wireless methods such as WIFI, LoRa, and LAN.

[0125] The energy consumption server 4 is connected to the production management system 6 via HTTP API, HTTP, MQTT, TCP / IP, CoAP, etc.

[0126] like Fig. 9 The circuit diagram of the energy consumption collection and control terminal 5 is shown. The MCU of the energy consumption collection and control terminal 5 adopts the GD32 series MCU. In the circuit diagram, A+ and A- are analog input or output channels, and RS485 is a digital communication interface.

[0127] The non-intelligent production equipment energy-saving and consumption-reducing transformation system also includes a WEB server 7, which is used to provide a page for binding the energy consumption collection and control terminal 5 with the sensor 2 and the non-intelligent production equipment 1, and for line creation and management operations.

[0128] The binding relationship between the energy consumption collection and control terminal 5 and the sensor 2, the non-intelligent production equipment 1, and the corresponding relationship between the line body and the energy consumption collection and control terminal 5 are stored in the background database. The energy consumption server 4 sends control instructions to the energy consumption collection and control terminal 5 corresponding to the line body based on the above binding relationship and corresponding relationship.

[0129] The technical solution of the present invention detects the working status of non-intelligent production equipment through sensing technology, collects sensor data through energy consumption collection and control terminal and reports it to energy consumption server. The energy consumption server establishes a customized sleep or shutdown strategy based on the line switch line instruction of the production management system and the status of non-intelligent production equipment, communicates with non-intelligent production equipment through energy consumption collection and control terminal or performs sleep or shutdown actions through software simulation manual operation, closes or adjusts the energy channel of non-intelligent production equipment through valves, achieves multi-level and multi-mode comprehensive control of valves, equipment communication, and line management, and realizes energy-saving and consumption-reducing transformation of equipment. The technical solution of the present invention is adopted, and non-intelligent production equipment is put into sleep or shutdown remotely in time according to the execution of the production management system, which reduces energy consumption, does not require personnel to go to the site to perform sleep or shutdown operations on the equipment, reduces manual labor, simplifies equipment operation, and enhances the remote control capability of the equipment.

[0130] The above are only specific implementations of the present invention, which cannot be used to limit the scope of the present invention. Equivalent changes made by ordinary technicians in this technical field based on this creation, as well as changes known to technicians in this field, should still fall within the scope of the present invention.

Claims

1. A method for energy-saving and consumption-reducing transformation of non-intelligent production equipment, characterized in that: The following steps are involved: S1, installing an energy consumption collection control terminal (5) and a current sensor (2) on a non-intelligent production device (1) that is an energy-saving object, and installing remote control software on an industrial computer of the non-intelligent production device (1) that does not have a control command communication interface, wherein the energy consumption collection control terminal (5) is connected to the current sensor (2) and the non-intelligent production device (1) by wired means, the energy consumption collection control terminal (5) is used to collect the working current of the non-intelligent production device (1) detected by the current sensor (2), and the energy consumption server (4) is used to judge the working state of the non-intelligent production device (1) according to the working current detected by the current sensor (2); S2, on the background page of the energy consumption server (4), the energy consumption collection control terminal (5) is bound to the corresponding sensor (2) and the non-intelligent production equipment (1), and then a line body is created, and the line body name is bound to all the energy consumption collection control terminals (5) in the line body; S3, the production management system (6) arranges production according to the output according to the PPC plan, and sends the line switch line status information to the energy consumption server (4); S4, the energy consumption server (4) analyzes the line switch status information sent by the production management system (6), locates the line that needs to be shut down, and executes steps S5-S9 for the line that needs to be shut down; S5, the energy consumption server (4) determines whether the non-intelligent production equipment (1) in the line can be put into sleep or shut down according to the equipment information collected by the sensor, and if so, sends a sleep or shut down instruction to the energy consumption collection control terminal (5) bound to the non-intelligent production equipment (1); S6, for a non-intelligent production device (1) having a control command communication interface, the energy consumption collection control terminal (5) sends a sleep or shutdown command to the non-intelligent production device (1) through the communication interface with the non-intelligent production device (1), and then returns the command execution status to the energy consumption server (4); S7, for a non-intelligent production device (1) without a control command communication interface, the energy consumption collection control terminal (5) sends a sleep or shutdown command to the remote control software installed on the non-intelligent production device (1), and the remote control software executes the sleep or shutdown command by simulating the manual operation of the employee, and the energy consumption collection control terminal (5) returns the execution status to the energy consumption server (4) according to the execution result of the remote control software; S8, the energy consumption collection and control terminal (5) closes or adjusts the energy channel valve corresponding to the non-intelligent production equipment (1); S9, the energy consumption server (4) reads the working current data reported by the current sensor (2) of the non-intelligent production equipment (1) through the energy consumption collection control terminal (5), compares it with the set sleep threshold, and determines whether the non-intelligent production equipment (1) has successfully sleep.

2. The energy-saving and consumption-reducing transformation method for non-intelligent production equipment according to claim 1 is characterized in that: For the reflow oven equipment, the following steps are included after step S1: S1A, photoelectric sensors are installed on the board entry track and board exit track of the reflow furnace, and the energy consumption collection and control terminal (5) continuously detects whether there are PCB boards on the front and rear docking station tracks of the reflow furnace equipment through the photoelectric sensors in real time, and sends the detection results to the energy consumption server (4); After step S4, the method further includes: S4A, after receiving the reflow oven equipment shutdown command issued by the production management system (6), the energy consumption server (4) determines whether the photoelectric sensor is abnormal. If there is no abnormality, within the time T1, the output data of the photoelectric sensor of the current reflow oven equipment is continuously read to identify whether there is a PCB board in the reflow oven. If there is a PCB board, the system platform prompts that the PPC plan is incorrect and does not perform the sleep or shutdown operation, wherein the value of T1 is a preset value.

3. The energy-saving and consumption-reducing transformation method for non-intelligent production equipment according to claim 2 is characterized in that: In step 1A, the photoelectric sensors are arranged on the board inlet track and the board outlet track of the reflow furnace, one photoelectric sensor is arranged on each of the board inlet track and the board outlet track, or two are arranged on the board inlet track and one is arranged on the board outlet track.

4. The energy-saving and consumption-reducing transformation method for non-intelligent production equipment according to claim 1 is characterized in that: In step S4, the energy consumption collection control terminal (5) communicates with the non-intelligent production equipment (1) through a communication interface supported by the non-intelligent production equipment (1), wherein the communication interface includes RS485, RS232, and switch quantity. The energy consumption collection control terminal (5) establishes communication with the non-intelligent production equipment (1) through the communication interface and sends control instructions in accordance with the communication protocol of the non-intelligent production equipment (1).

5. The energy-saving and consumption-reducing transformation method for non-intelligent production equipment according to claim 1 is characterized in that: In the step S7, the energy consumption server (4) may directly send a sleep or shutdown instruction to the non-intelligent production equipment (1) that does not have a control command communication interface.

6. The energy-saving and consumption-reducing transformation method for non-intelligent production equipment according to claim 1 is characterized in that: The control instructions of the energy consumption server (4) to the non-intelligent production equipment (1) are not limited to sleep and shutdown, and the specific control instructions depend on the support of the non-intelligent production equipment (1) for the control instructions.

7. A non-intelligent production equipment energy-saving and consumption-reducing transformation system, characterized in that: include: Non-intelligent production equipment (1), sensor (2), control actuator (3), energy consumption server (4), energy consumption collection and control terminal (5), production management system (6), wherein: Non-intelligent production equipment (1) is the object of energy-saving control; The sensor (2) is used to collect information from the non-intelligent production equipment (1), including a photoelectric sensor, a current sensor, a flow meter, and a meter, wherein the flow meter and the meter are used to collect energy consumption and evaluate energy saving and consumption reduction effects; The control actuator (3) is used to realize energy channel control and on / off control of the non-intelligent production equipment (1), including a solenoid valve, an electric / pneumatic valve and remote control software installed on an industrial computer of the production equipment; The energy consumption server (4) is used to receive the equipment information reported by the energy consumption collection control terminal (5) and the instructions issued by the production management system (6), and issue control instructions to the non-intelligent production equipment (1) according to the instructions of the production management system (6) and the status of the non-intelligent production equipment (1); The energy consumption collection control terminal (5) is connected to the sensor (2) via a wired manner, and is used to collect information of the non-intelligent production equipment (1) detected by the sensor (2). One energy consumption collection control terminal (5) can be connected to a plurality of sensors (2); the energy consumption collection control terminal (5) is connected to the energy consumption server (4) via a wireless manner, and is used to receive control instructions sent by the energy consumption server (4); the energy consumption collection control terminal (5) is connected to the non-intelligent production equipment (1) via a wired manner, and is used to execute the control instructions sent by the energy consumption server (4); The production management system (6) is used to perform production management control and send a switch line instruction to the energy consumption server (4); The production management system (6) arranges production according to the output and sends the line switch line status information to the energy consumption server (4). The energy consumption server (4) parses the line switch line status information sent by the production management system (6) and locates the line that needs to be shut down. The energy consumption server (4) determines whether the line can be shut down based on the sensor information of the non-intelligent production equipment (1). If the line can be shut down, a control instruction is sent to the energy consumption collection control terminal (5) bound to the non-intelligent production equipment (1). The energy consumption collection control terminal (5) sends the control instruction to the non-intelligent production equipment (1) through the communication interface or the remote control software on the industrial computer of the non-intelligent production equipment (1).

8. The non-intelligent production equipment energy-saving and consumption-reducing transformation system according to claim 9 is characterized in that: The system also includes a WEB server (7) for providing a page for binding the energy consumption collection and control terminal (5) with the sensor (2) and the non-intelligent production equipment (1), as well as line creation and management operations.

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