A method and system for energy saving and consumption reduction of non-intelligent production equipment

Abstract

The application discloses a kind of non-intelligent production equipment energy saving and consumption reducing reforming method and system, belong to energy saving and consumption reducing technical field, this method with sensing technology detects production equipment working condition, through energy consumption acquisition control terminal collection sensor data and report to energy consumption server, energy consumption server according to the line body switch line instruction of production management system and the state of production equipment, through energy consumption acquisition control terminal and production equipment communication or through software simulation manual operation executes hibernation or shutdown action, through valve closing or adjusting the energy channel of production equipment, realize equipment energy saving and consumption reducing reforming.The technical scheme of the application, according to the execution of production management system, hibernation or shutdown of production equipment is remotely controlled in time, reduces energy consumption, without personnel to site to execute hibernation or shutdown operation on equipment, reduces manual labor, simplifies equipment operation, enhances the remote control ability to equipment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of energy saving and consumption reduction, and particularly relates to a non-intelligent production equipment energy saving and consumption reduction reconstruction method and system. BACKGROUND

[0002] The development of the ESG system and the realization of the double carbon target 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-consumption non-intelligent devices in traditional production and manufacturing enterprises. These devices do not support automatic and autonomous working state switching. For example, a reflow oven used for electronic product manufacturing, an annealing furnace, a cutting machine, a grinding machine, a spin dryer, etc. used for hard disk aluminum substrate production, when not producing, personnel need to go to the site to perform hibernation or shutdown operation on the device, and automatic remote hibernation or shutdown control cannot be realized. Therefore, energy loss and waste often occur due to the lag of manual hibernation or shutdown operation. SUMMARY

[0003] The technical problem to be solved by the present application is the problem of energy waste caused by the fact that non-intelligent devices cannot automatically and remotely hibernate or shut down. The present application provides a non-intelligent production equipment energy saving and consumption reduction reconstruction method and system.

[0004] To achieve the above-mentioned purpose, the present application provides a non-intelligent production equipment energy saving and consumption reduction reconstruction method, comprising the following steps:

[0005] S1, installing an energy consumption collection control terminal and a current sensor on a non-intelligent production equipment as an energy saving object, and installing a remote control software on an industrial computer of the non-intelligent production equipment without a control command communication interface, wherein the energy consumption collection control terminal is connected with the current sensor and the non-intelligent production equipment in a wired manner, 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 an 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, in the background page of the energy consumption server, binding the energy consumption collection control terminal with the corresponding sensor and non-intelligent production equipment, and then creating a line body, binding the line body name with all energy consumption collection control terminals in the line body;

[0007] S3, the production management system schedules production according to the yield according to the PPC plan, and sends line body on-off state information to the energy consumption server;

[0008] S4, the energy consumption server parses the line body on-off state information issued by the production management system, locates the line body that needs to be turned off, and executes steps S5-S9 for the line body that needs to be turned off;

[0009] S5, the energy consumption server determines whether the non-intelligent production equipment in the line body can hibernate or shut down according to the equipment information collected by the sensor, and if so, issues a hibernation or shutdown instruction to the energy consumption collection control terminal bound to the non-intelligent production equipment;

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

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

[0012] S8, the energy consumption collection 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 hibernation threshold, and judges whether the non-intelligent production equipment hibernates successfully.

[0014] The application also provides a non-intelligent production equipment energy-saving and consumption-reducing reconstruction system, comprising: non-intelligent production equipment, sensors, control actuators, an energy consumption server, an energy consumption collection control terminal, and a production management system, wherein:

[0015] The non-intelligent production equipment is an energy-saving control object;

[0016] The sensors are used to collect information of the non-intelligent production equipment, including photoelectric sensors, current sensors, flow meters, and meters, wherein the flow meters and meters are used to collect energy consumption and evaluate energy-saving and consumption-reducing effects;

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

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

[0019] The energy consumption collection control terminal is connected with the sensor through a wired mode, and is used for collecting information of the non-intelligent production equipment detected by the sensor; one energy consumption collection control terminal can access multiple sensors; the energy consumption collection control terminal is connected with the energy consumption server through a wireless mode, and is used for receiving the control instruction sent by the energy consumption server; the energy consumption collection control terminal is connected with the non-intelligent production equipment through a wired mode, and is used for executing the control instruction sent by the energy consumption server.

[0020] The production management system is used for production management control, and sends a switch line instruction to the energy consumption server.

[0021] The production management system schedules production according to production capacity, and sends line body switch line state information to the energy consumption server; the energy consumption server analyzes the line body switch line state information sent by the production management system, locates the line body that needs to be switched off, judges whether the non-intelligent production equipment can be switched off according to the sensor information of the non-intelligent production equipment, and if so, sends a control instruction to the energy consumption collection control terminal bound to the non-intelligent production equipment, so that the energy consumption collection control terminal sends a control instruction to the non-intelligent production equipment through a communication interface or remote control software on an industrial personal computer of the non-intelligent production equipment.

[0022] The technical scheme of the present application detects the working state of the production equipment through a sensing technology, collects sensor data through the energy consumption collection control terminal and reports to the energy consumption server, the energy consumption server establishes a custom sleep or shutdown strategy based on the line body switch line instruction of the production management system and the state of the production equipment, executes the sleep or shutdown action through the energy consumption collection control terminal and the production equipment communication or through software simulation of manual operation, closes or adjusts the energy channel of the production equipment through the valve, and achieves comprehensive control of valve, equipment communication and line body management in multiple levels and multiple modes, and realizes equipment energy saving and consumption reduction transformation. According to the technical scheme of the present application, the non-intelligent production equipment is remotely put into sleep or shutdown according to the execution of the production management system, energy consumption is reduced, personnel are not required to perform sleep or shutdown operation on the equipment on site, manual labor is reduced, equipment operation is simplified, and remote control ability of the equipment is enhanced. BRIEF DESCRIPTION OF DRAWINGS

[0023] The drawings described herein are used to provide further understanding of the present application, and form a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application, and do not constitute improper limitations on the present application. In the drawings:

[0024] Figure 1 A flowchart of a non-intelligent production equipment energy saving and consumption reduction transformation method provided for an embodiment of the present application.

[0025] Figures 2-3The page diagram for binding the sensor on the energy consumption collection control terminal.

[0026] Figure 4 The page diagram for binding the non-intelligent production equipment on the energy consumption collection control terminal.

[0027] Figure 5 The non-intelligent production equipment information page diagram of the line body L7.

[0028] Figure 6 The software control flowchart of the energy consumption server backflow furnace.

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

[0030] Figure 8 The architecture diagram of a non-intelligent production equipment energy-saving and consumption-reducing reconstruction system.

[0031] Figure 9 The circuit diagram of the energy consumption collection control terminal. DETAILED DESCRIPTION

[0032] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0033] The general idea of the present application is as follows: a sensor is installed on the equipment side, the sensor collects equipment information, and sends the information to an energy consumption server through an energy consumption collection control terminal; the energy consumption server judges what control action is to be taken on the equipment according to a production plan and collected equipment data, and sends the action instruction to be executed to the energy consumption collection control terminal through a wireless mode; the energy consumption collection control terminal communicates with the equipment to realize the control of the working state of the equipment.

[0034] The embodiments of the present application will be described in further detail below with reference to the drawings in the description. It should be understood that the embodiments described herein are only used for illustrating and explaining the present application, and are not used for limiting the present application.

[0035] The present application is applicable to non-intelligent production equipment in traditional production and manufacturing enterprises, which cannot be remotely put into hibernation or shut down.

[0036] As Figure 1As shown is a flow chart of a non-intelligent production equipment energy saving and consumption reducing reform method provided by an embodiment of the application, the embodiment of the application provides a non-intelligent production equipment energy saving and consumption reducing reform method, the method comprises 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 as an energy saving object, and install remote control software on the industrial computer of the non-intelligent production equipment 1 without a control command communication interface, wherein the energy consumption collection control terminal 5 is connected with the current sensor 2 and the non-intelligent production equipment 1 in a wired mode, 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 state 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 connected with the sensor in a wired mode through a communication interface supported by the sensor, and a driving code corresponding to a communication protocol supported by the sensor is implanted to collect data from the sensor. The energy consumption collection control terminal 5 and the non-intelligent production equipment 1 are also connected in a wired mode.

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

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

[0041] The line body refers to a comprehensive body of various equipment, tools and working environment in a production workshop, including production lines, machine equipment and workbenches. Creating a line body refers to binding the line body name and the machine equipment in the line body, so as to change all the equipment in the entire line body into a device set, so as to facilitate on-off line control of all the equipment in the entire line body.

[0042] As Figures 2-3 As shown is a page diagram of binding sensors on the energy consumption collection control terminal, in the embodiment of the application, one energy consumption collection control terminal can access three sensors, wherein, Figure 2 The three-phase current sensor is bound to the Channel 2 channel of the energy consumption collection control terminal, Figure 3To bind the photoelectric sensor to Channel 1 of the energy consumption acquisition and control terminal, the number 05600000001161 in the upper left corner of the diagram is the serial number of the energy consumption acquisition and control terminal, which is also its identification code. For example... Figure 4 The image shows a page diagram of a non-intelligent production device being bound to an energy consumption data acquisition and control terminal. Different devices are distinguished by their serial numbers. Multiple energy consumption data acquisition and control terminals may be installed on the same non-intelligent production device to collect data from multiple sensors on that device. Figure 5 The image shows the information page for non-intelligent production equipment in line L7. When creating a production line, based on the binding relationship between the energy consumption acquisition and control terminals and the non-intelligent production equipment, all energy consumption acquisition and control terminals corresponding to that production line are bound to the production line name, thus achieving the binding between the production line name and the non-intelligent production equipment within that production line.

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

[0044] Production line management refers to whether a production line has a production plan for the current day, as defined in the production management system. A line being "on" indicates that the line is in production for the day; a line being "off" indicates that there is no production plan for the day, and to save energy, all equipment on the line must be in a shutdown or dormant state. The Production Planning and Control System (PPC) schedules production based on the production plan to determine whether a line is in production or not; a line in production is marked as "on," and a line not in production is marked as "off." In the production management system, only the concept of a production line exists; the energy consumption server controls the corresponding non-intelligent production equipment within that line.

[0045] In this embodiment of the invention, the production management system is a MES system independent of the energy consumption server. The MES system sends the on / off status information of each production line to the energy consumption server in JSON format, as shown in the following example:

[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 represents the name of the line, and the status field represents the status of the line, with 0 indicating off and 1 indicating on.

[0072] S4, the energy consumption server 4 parses 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 production line can go into hibernation or be shut down based on the equipment information collected by the sensor 2. If so, it sends a hibernation or shutdown command to the energy consumption collection and control terminal 5 bound to the non-intelligent production equipment 1.

[0074] The energy server 4 sets conditions for allowing hibernation or shutdown based on the device's status. Sensors can be added as needed to collect device information so that the energy server can make a decision on whether to allow hibernation or shutdown.

[0075] In the embodiment of the present application, the energy consumption server and the energy consumption collection control terminal adopt a private protocol to interact with each other, and the protocol format is shown in the following table.

[0076] Table 1: Communication protocol format of the energy consumption server and the energy consumption collection control terminal

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

[0078] The SN field represents the serial number of the energy consumption collection control terminal, which is written by the research and development and production department to ensure that each terminal has a unique serial number. 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 control terminal 5 sends a sleep or shutdown instruction to the non-intelligent production equipment 1 through the communication interface of the non-intelligent production equipment 1, and then returns the instruction 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, which includes RS485, RS232, and switching value. Different production equipment may have different communication interfaces, which can be adapted by the energy consumption collection control terminal 5. The energy consumption collection control terminal 5 communicates 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 the non-intelligent production equipment 1 without a control command communication interface, the energy consumption collection control terminal 5 sends a sleep or shutdown instruction to the remote control software installed on the non-intelligent production equipment 1. The remote control software executes the sleep or shutdown command by simulating the manual operation of an employee. 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.

[0082] In the step S7, the energy consumption server 4 can also directly send a sleep or shutdown instruction to the non-intelligent production equipment 1 without a control command communication interface.

[0083] S8, the energy consumption collection 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 a valve for providing water, electricity, gas and other energy or environmental support required by non-intelligent production equipment, for example, a backflow furnace is connected with a nitrogen channel through a solenoid valve, and the energy consumption collection control terminal closes the nitrogen channel of the backflow furnace through a relay control solenoid valve after the backflow furnace is dormant, so that nitrogen is not continuously supplied to the backflow furnace when it is not in production; when it is in production, the solenoid valve of the nitrogen is opened in time to supply nitrogen to the backflow furnace. Some non-intelligent production equipment needs to be adjusted to a suitable angle by the energy consumption collection control terminal when it is dormant, and enters a 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 dormancy threshold, and judges whether the non-intelligent production equipment 1 is successfully dormant.

[0086] After the energy consumption server 4 receives the information returned by the remote control software on the energy consumption collection control terminal 5 or the industrial computer of the non-intelligent production equipment 1 that the control command is executed successfully, it 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 settable time interval. When the read current value is less than or equal to the pre-set dormancy threshold, the non-intelligent production equipment is prompted to "dormant success"; when the read current value is greater than the pre-set dormancy threshold, it is prompted to "dormant abnormally".

[0087] For the backflow furnace equipment, after step S1, it further includes:

[0088] S1A, photoelectric sensors are installed on the backflow furnace plate entry track and plate exit track, the photoelectric sensors are wired connected with the energy consumption collection control terminal installed on the backflow furnace, and the energy consumption collection control terminal continuously detects whether there is a PCB board on the front and rear docking table tracks of the backflow furnace equipment through the photoelectric sensors, and sends the detection results to the energy consumption server.

[0089] The photoelectric sensors are arranged on the backflow furnace plate entry track and plate exit track, one photoelectric sensor is arranged on each of the plate entry track and the plate exit track, or two photoelectric sensors are arranged on the plate entry track and one photoelectric sensor is arranged on the plate exit 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 rules.

[0090] In the embodiment of the application, the energy consumption server judges whether the photoelectric sensor is abnormal by the following way:

[0091] (1) The photoelectric sensor uploads data every minute, and if there is no data uploaded, it is considered abnormal;

[0092] (2) In the same period of time, the detection results of the three photoelectric sensors are basically consistent, if the detection result of a certain photoelectric sensor is different from the other two, it means that the photoelectric sensor is abnormal.

[0093] For the reflow oven equipment, after step S4, further comprising:

[0094] S4A, after the energy consumption server receives the reflow oven equipment shutdown instruction issued by the production management system, it is judged whether the photoelectric sensor is abnormal, if there is no abnormality, the output data of the photoelectric sensor of the current reflow oven equipment is read within time T1, it is identified 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 wrong, and the sleep or shutdown operation is not executed, wherein the value of T1 is a preset value.

[0095] When there is a PCB board in the reflow oven, the PCB board is processed according to the normal process.

[0096] For the reflow oven, the photoelectric sensor is needed to detect whether there is a PCB board on the docking table track, because if there is a PCB board, the reflow oven will be scrapped when it enters the sleep state.

[0097] When the production management system issues a shutdown instruction, but there is a PCB board in the reflow oven, it means that the production planning and the actual production state do not match, and the production management system needs to modify the production planning.

[0098] The control instruction of the energy consumption server for the non-intelligent production equipment is not limited to sleep and shutdown, and the specific control instruction depends on the support of the non-intelligent production equipment for the control instruction. For the non-intelligent production equipment which does not need manual intervention in the boot process, the energy consumption server is used to control the boot.

[0099] The technical scheme of the present application will be further described in detail below taking the control process of the energy consumption server for the reflow oven as an example.

[0100] As Figure 6 The software control flow chart of the energy consumption server for the reflow oven provided by an embodiment of the present application is shown in the figure, and the control process is as follows:

[0101] (1) Three photoelectric sensors are arranged on the PCB board inlet track and the PCB board outlet track of the reflow oven, which are used to detect whether there is a PCB board in the reflow oven, and a current sensor is arranged on the power line of the reflow oven, which is used to detect the working current of the reflow oven, and the detection results of the PCB board and the working current are reported to the energy consumption server through the energy consumption collection control terminal.

[0102] (2) In the energy consumption server side, set a resident process A to continuously detect whether there is a plate entering the reflow oven in the shutdown state. If there is a plate, send a "plate abnormality" notification to the non-intelligent production equipment manager. Resident process A determines whether the reflow oven is in the shutdown state according to the current value reported by the reflow oven current sensor. If the current is lower than the set startup current, it is considered that the reflow oven is in the shutdown state. If the current is lower than the set hibernation current, it is considered that the reflow oven is in the hibernation state.

[0103] (3) In the energy consumption server side, set a resident process B to continuously detect whether there is an abnormality in the three photoelectric sensors. If there is an abnormality, send a "photoelectric sensor device abnormality" notification to the non-intelligent production equipment manager.

[0104] (4) The energy consumption server receives the start line instruction from the production management system, determines whether the states of the three photoelectric sensors are normal, and if so, sends a "start line" notification to the non-intelligent production equipment manager. Because the reflow oven device needs to be manually inspected for temperature when starting up, and the temperature must be checked before starting up, only the start line notification is sent, and remote start control is not performed.

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

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

[0107] (6) After the energy consumption server receives the command execution result information returned by the energy consumption collection control terminal, it waits for T2 time, detects whether the three-phase current sensor current value is within the specified range, and if so, sends a "cooling down success" notification to the non-intelligent production equipment manager. Otherwise, send a "cooling down failure" notification to the non-intelligent production equipment manager.

[0108] The notification sent to the production manager can be in the form of WeChat, email, short message, etc. The values of T1 and T2 are set in the WEB interface of the energy consumption server, and in the embodiment of the application, T1 is 20 minutes and T2 is 10 minutes by default.

[0109] As shown in Figure 7 Fig. 1 is a block diagram of a non-intelligent non-intelligent production equipment energy-saving and consumption-reducing reconstruction system according to an embodiment of the application, and Fig. 2 is an architecture diagram of the non-intelligent non-intelligent production equipment energy-saving and consumption-reducing reconstruction system according to an embodiment of the application. Figure 8 Fig. 1 is a block diagram of a non-intelligent non-intelligent production equipment energy-saving and consumption-reducing reconstruction system according to an embodiment of the application, and Fig. 2 is an architecture diagram of the non-intelligent non-intelligent production equipment energy-saving and consumption-reducing reconstruction system according to an embodiment of the application.

[0110] The non-intelligent production equipment 1 is an energy-saving control object.

[0111] The sensor 2 is used to collect information of the non-intelligent production equipment 1, including a photoelectric sensor, a current sensor, a flow meter and a meter.

[0112] The photoelectric sensor is used for a 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 forced reflow oven hibernation when the reflow oven still has the PCB board.

[0113] The current sensor is used to detect the working current of the non-intelligent production equipment 1, so as to judge whether the non-intelligent production equipment 1 hibernates successfully or is in which state of hibernation, startup or shutdown by comparison with a threshold value.

[0114] In order to evaluate the energy-saving effect of the technical scheme of the application, the energy consumption needs to be collected before the implementation of the scheme, and the energy consumption needs to be continuously collected after the implementation of the scheme, so as to compare the energy consumption and evaluate the energy-saving and consumption-reducing effect of the scheme.

[0115] The control executor 3 is used to realize energy channel control and startup / shutdown control of the non-intelligent production equipment 1, including a solenoid valve, an electric / pneumatic valve and remote control software installed on a workbench computer of the non-intelligent production equipment.

[0116] The solenoid valve and the electric / pneumatic valve are used to control the water, electricity and gas energy channels of the non-intelligent production equipment, and the remote control software installed on the workbench computer of the non-intelligent production equipment executes control instructions by simulating manual operation of an employee, which is used in the case that the non-intelligent production equipment 1 has no control instruction communication interface.

[0117] The energy consumption server 4 is configured to receive the device information reported by the energy consumption collection control terminal 5 and the instruction issued by the production management system 6, and issue a control instruction for the non-intelligent production device 1 according to the instruction of the production management system 6 and the state of the non-intelligent production device 1.

[0118] The energy consumption collection control terminal 5 is connected with the sensor 2 in a wired mode, configured to collect the information of the non-intelligent production device 1 detected by the sensor 2, and one energy consumption collection control terminal 5 can access three sensors 2; the energy consumption collection control terminal 5 is connected with the energy consumption server 4 in a wireless mode, configured to receive the control instruction sent by the energy consumption server 4; the energy consumption collection control terminal 5 is connected with the non-intelligent production device 1 in a wired mode, configured to execute the control instruction sent by the energy consumption server 4.

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

[0120] The production management system 6 schedules production according to the production capacity and sends the line body switch line state information to the energy consumption server 4; the energy consumption server 4 analyzes the line body switch line state information issued by the production management system 6, locates the line body that needs to be switched off, judges whether the non-intelligent production device 1 can be switched off according to the sensor information of the non-intelligent production device 1, sends a control instruction to the energy consumption collection control terminal 5 bound to the non-intelligent production device 1 if the non-intelligent production device 1 can be switched off, and sends the control instruction to the non-intelligent production device 1 through the communication interface or the remote control software on the industrial computer of the non-intelligent production device 1 by the energy consumption collection control terminal 5.

[0121] For the non-intelligent production device 1 that does not need manual intervention in the start-up process, the energy consumption server 4 sends a start-up instruction to the non-intelligent production device 1 through the energy consumption collection control terminal 5; for the non-intelligent production device 1 that needs manual intervention in the start-up process, the energy consumption server 4 sends a start-up notification to the manager of the non-intelligent production device 1.

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

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

[0124] The energy consumption collection control terminal 5 is connected with the energy consumption server 4 in a wireless mode such as WIFI, LoRa and LAN.

[0125] The energy consumption server 4 is connected with the production management system 6 through HTTP API, HTTP, MQTT, TCP / IP, CoAP and the like.

[0126] As shown in the figure, the energy consumption collection control terminal 5 is connected with the sensor 2 and the non-intelligent production equipment 1 through the RS485 interface. Figure 9 The circuit diagram of the energy consumption collection control terminal 5 is shown in the figure, the MCU of the energy consumption collection control terminal 5 adopts the GD32 series MCU, in the circuit diagram, A+, 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 reconstruction system further comprises a WEB server 7 for providing a page for binding the energy consumption collection control terminal 5 with the sensor 2 and the non-intelligent production equipment 1 and creating and managing a line body.

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

[0129] The technical scheme of the present application detects the working state of the non-intelligent production equipment through sensing technology, collects sensor data through the energy consumption collection control terminal and reports to the energy consumption server, the energy consumption server establishes a self-defined sleep or shutdown strategy based on the line body switch line instruction of the production management system and the state of the non-intelligent production equipment, executes the sleep or shutdown action through the energy consumption collection control terminal and the non-intelligent production equipment communication or through software simulation of manual operation, closes or adjusts the energy channel of the non-intelligent production equipment through the valve, realizes the comprehensive control of the valve, equipment communication and line body management in multiple levels and multiple modes, and realizes the equipment energy-saving and consumption-reducing reconstruction.

[0130] The above is only a specific embodiment of the present application, which cannot limit the scope of the present application, and the equivalent changes made by the general technical personnel in the technical field according to the present application, and the changes well known by the technical personnel in the field, should still belong to the scope covered by the present application.

Claims

1. A method for energy-saving and consumption-reducing retrofitting of non-intelligent production equipment, characterized in that, Includes the following steps: S1, an energy consumption acquisition and control terminal (5) and a current sensor (2) are installed on the non-intelligent production equipment (1) which is the object of energy saving. Remote control software is installed on the industrial control computer of the non-intelligent production equipment (1) which does not have a control command communication interface. The energy consumption acquisition and control terminal (5) is connected to the current sensor (2) and the non-intelligent production equipment (1) via a wired connection. The energy consumption acquisition and control terminal (5) is used to collect the working current of the non-intelligent production equipment (1) detected by the current sensor (2). The energy consumption server (4) is used to determine the working status of the non-intelligent production equipment (1) based on the working current detected by the current sensor (2). S2, on the background page of the energy consumption server (4), bind the energy consumption acquisition and control terminal (5) with the corresponding sensor (2) and non-intelligent production equipment (1), then create a production line and bind the production line name with all the energy consumption acquisition and control terminals (5) in the production line; S3, the production management system (6) schedules production according to the output based on the PPC plan and sends the line switch status information to the energy consumption server (4); S4, the energy consumption server (4) parses 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. S5, the energy consumption server (4) determines whether the non-intelligent production equipment (1) in the production line can hibernate or be shut down based on the equipment information collected by the sensor. If so, it sends a hibernation or shutdown command to the energy consumption collection and control terminal (5) bound to the non-intelligent production equipment (1). S6. For non-intelligent production equipment (1) with a control command communication interface, the energy consumption acquisition and control terminal (5) sends a hibernation 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). S7, for non-intelligent production equipment (1) without a control command communication interface, the energy consumption acquisition and control terminal (5) sends a hibernation or shutdown command to the remote control software installed on the non-intelligent production equipment (1). The remote control software executes the hibernation or shutdown command by simulating the manual operation of the employee. The energy consumption acquisition and 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 acquisition 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 acquisition and control terminal (5), compares it with the set sleep threshold, and determines whether the non-intelligent production equipment (1) has successfully gone into sleep.

2. The energy-saving and consumption-reducing retrofit method for non-intelligent production equipment according to claim 1, characterized in that, For reflux furnace equipment, the following steps are included after step S1: S1A, photoelectric sensors are installed on the inlet and outlet tracks of the reflow oven. The energy consumption acquisition and control terminal (5) continuously detects whether there are PCB boards on the front and rear docking tracks of the reflow oven equipment in real time through the photoelectric sensors, and sends the detection results to the energy consumption server (4). Following step S4, the following is also included: S4A, after the energy consumption server (4) receives the reflow oven equipment shutdown command issued by the production management system (6), it determines whether the photoelectric sensor is abnormal. If there is no abnormality, it continuously reads the output data of the photoelectric sensor of the current reflow oven equipment within time T1 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 wrong and does not perform hibernation or shutdown operation. The value of T1 is a preset value.

3. The energy-saving and consumption-reducing retrofit method for non-intelligent production equipment according to claim 2, characterized in that, In step S1A, the photoelectric sensor is installed on the reflux furnace inlet and outlet tracks. One photoelectric sensor is installed on each of the inlet and outlet tracks, or two are installed on the inlet track and one on the outlet track.

4. The energy-saving and consumption-reducing retrofit method for non-intelligent production equipment according to claim 1, characterized in that, In step S4, the energy consumption acquisition and 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. The energy consumption acquisition and control terminal (5) establishes communication with the non-intelligent production equipment (1) and sends control commands through the communication interface in accordance with the communication protocol of the non-intelligent production equipment (1).

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

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

7. A system for energy-saving and consumption-reducing retrofitting of non-intelligent production equipment, characterized in that, include: Non-intelligent production equipment (1), sensors (2), control actuators (3), energy consumption server (4), energy consumption acquisition and control terminal (5), production management system (6), wherein: Non-intelligent production equipment (1) is the target of energy-saving control; Sensor (2) is used to collect information from non-intelligent production equipment (1), including photoelectric sensors, current sensors, flow meters, and meters. Among them, flow meters and meters are used to collect energy consumption and evaluate the energy saving and consumption reduction effect. The control actuator (3) is used to realize the energy channel control and start-up control of the non-intelligent production equipment (1), including solenoid valves, electric / pneumatic valves and remote control software installed on the industrial control computer of the production equipment; The energy consumption server (4) is used to receive the equipment information reported by the energy consumption acquisition and control terminal (5) and the instructions issued by the production management system (6). Based on the instructions of the production management system (6) and the status of the non-intelligent production equipment (1), it issues control instructions to the non-intelligent production equipment (1). The energy consumption acquisition and control terminal (5) is connected to the sensor (2) via a wired connection and is used to collect information of the non-intelligent production equipment (1) detected by the sensor (2). One energy consumption acquisition and control terminal (5) can connect to multiple sensors (2). The energy consumption acquisition and control terminal (5) is connected to the energy consumption server (4) via a wireless connection and is used to receive control commands sent by the energy consumption server (4). The energy consumption acquisition and control terminal (5) is connected to the non-intelligent production equipment (1) via a wired connection and is used to execute the control commands sent by the energy consumption server (4). The production management system (6) is used for production management control and sends switch line instructions to the energy consumption server (4); The production management system (6) schedules production according to output and sends the 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, it sends a control command to the energy consumption acquisition and control terminal (5) bound to the non-intelligent production equipment (1). The energy consumption acquisition and control terminal (5) sends the control command to the non-intelligent production equipment (1) through the communication interface or the remote control software on the industrial control computer of the non-intelligent production equipment (1).

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

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