Safety and reliability analysis method of production equipment system based on energy effect

Abstract

An embodiment of the present invention provides a method for analyzing the safety and reliability of a production equipment system under energy action, which belongs to the field of system reliability and production safety. The method includes: constructing an energy activity model based on the energy carried by equipment in the production system, analyzing the activity rules of the energy activity model to obtain energy impact parameters; based on the energy impact parameters, performing a safety and reliability analysis on the production system from the perspective of self-stability, internal stability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and external stability parameters; determining the functional requirements of the production system based on the safety and reliability parameters to ensure the safety and reliability of the system. This method solves the problem of safety and reliability evaluation of the production system during the production process, and provides an effective way to improve the safety and reliability of the production system.

Description

Technical Field

[0001] The present invention relates to the field of system reliability and production safety, and in particular to a method for analyzing the safety reliability of a production equipment system under energy action. Background Art

[0002] The safe and reliable operation of production systems is the foundation and prerequisite for an enterprise's production activities. According to energy transfer theory, the essence of an accident is the abnormal interaction of energy. The root cause of a large number of production safety accidents is often related to abnormalities and failures in energy transfer during production system operation. Existing research rarely analyzes the safety and reliability of production systems from the perspective of energy activities, neglecting the driving role of energy activities in production system functions and the root causes of production safety accidents, resulting in incomplete control measures for production safety. Summary of the Invention

[0003] The purpose of the embodiment of the present invention is to provide a method for analyzing the safety and reliability of a production equipment system under energy action, which solves the problem of safety and reliability evaluation and grading during the production process and improves the safety and reliability of subsequent production activities.

[0004] The present invention proposes a method for analyzing the safety and reliability of a production system under energy effects, the method comprising:

[0005] Constructing an energy activity model based on the energy carried by the equipment in the production system, and analyzing the activity patterns of the energy activity model to obtain energy impact parameters;

[0006] According to the energy impact parameter, the safety and reliability of the production system is analyzed from the perspective of self-stability, anti-stability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and anti-stability parameters;

[0007] The functional requirements of the production system are determined based on the safety and reliability parameters to ensure the safety and reliability of the system.

[0008] Optionally, the energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow;

[0009] The energy activity model is:

[0010]

[0011] in, For energy, Convert materials into energy, Absorb energy for the device; To diffuse energy; It is a dynamic energy flow.

[0012] Optionally, the material conversion energy is:

[0013]

[0014] The energy absorbed by the device is:

[0015]

[0016] The diffusion energy is:

[0017]

[0018] in, The quality of the material, is the specific heat capacity of the material,

[0019] is the temperature change of the material,

[0020] is the power consumption of the device, t is the working time of the device,

[0021] represents the heat transfer coefficient, Represents surface area.

[0022] Optionally, the step of performing a safety and reliability analysis on the production system from the perspectives of self-stability, other-stability, and anti-stability based on the energy impact parameter to obtain a safety and reliability parameter includes:

[0023] The energy impact parameters include equipment reliability, equipment availability, equipment fault detection rate, maximum energy that the equipment can withstand, external disturbance recovery time, energy margin and energy leakage;

[0024] Determining a self-stabilization parameter based on the equipment reliability, equipment availability, and equipment failure detection rate;

[0025] Determine the interference immunity parameters based on the maximum energy that the device can withstand and the external disturbance recovery time;

[0026] The stability parameters are determined according to the energy margin and the energy leakage situation.

[0027] Optionally, determining the self-stabilization parameter according to the device reliability, device availability, and device fault detection rate includes:

[0028]

[0029] Among them, S is the self-stabilization parameter,

[0030] For reliability,

[0031] is availability,

[0032] is the fault detection rate,

[0033] is the redundancy,

[0034] is the i-th factor affecting the system's self-stability,

[0035] Factor The upper threshold value of .

[0036] Optionally, determining the interference immunity parameter according to the maximum energy that the device can withstand and the external disturbance recovery time includes:

[0037]

[0038] Where I is the immunity parameter,

[0039] is the maximum energy the device can withstand,

[0040] is the external disturbance recovery time,

[0041] is each factor that affects the system immunity,

[0042] Factor The upper threshold value of .

[0043] Optionally, determining the stability parameter according to the energy margin and the energy leakage situation includes:

[0044]

[0045] Among them, H is the stability parameter,

[0046] is the energy margin,

[0047] For energy leakage,

[0048] is the i-th factor affecting the stability of the system,

[0049] Factor The upper threshold value of .

[0050] Optionally, determining the functional requirements of the production system according to the safety and reliability parameters includes:

[0051] When the self-stability parameters, the anti-interference parameters and the hetero-stability parameters exceed the safety threshold range, the energy carrying capacity, production capacity, environmental conditions and monitoring and control safety of the equipment in the production system are analyzed.

[0052] The present invention also proposes a device for analyzing the safety and reliability of a production equipment system under energy action, the device comprising:

[0053] A first processing module is used to construct an energy activity model based on the energy carried by the equipment in the production system, and to analyze the activity patterns of the energy activity model to obtain energy impact parameters;

[0054] A second processing module is configured to perform a safety and reliability analysis on the production system from the perspectives of self-stability, other-stability, and anti-stability according to the energy impact parameter to obtain safety and reliability parameters;

[0055] The third processing module is used to determine the functional requirements of the production system according to the safety and reliability parameters, so as to ensure the safety and reliability of the system.

[0056] Optionally, the energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow;

[0057] The energy activity model is:

[0058]

[0059] in, For energy, Convert materials into energy, Absorb energy for the device; To diffuse energy; It is a dynamic energy flow.

[0060] The present invention provides a method for analyzing the safety and reliability of a production equipment system under the action of energy. The method includes: constructing an energy activity model based on the energy carried by the equipment in the production system, analyzing the activity rules of the energy activity model to obtain energy impact parameters; based on the energy impact parameters, analyzing the safety and reliability of the production system from the perspective of self-stability, heterostability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and heterostability parameters; and determining the functional requirements of the production system based on the safety and reliability parameters to ensure the safety and reliability of the system. This method analyzes the interactive operation mechanism of the production system operating factors of energy transmission by considering the effect of the energy activity of the production system, analyzes the failure mode and safety of the production system from the perspective of all production factors, and constructs an index system of self-stability, heterostability, and anti-interference for evaluating the safety and reliability of the operation. This solves the problem of safety and reliability evaluation grading in the production process and improves the safety and reliability of subsequent production activities. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] The accompanying drawings are used to provide a further understanding of the embodiments of the present invention and constitute a part of the specification. Together with the following detailed description, they are used to explain the embodiments of the present invention, but do not constitute a limitation of the embodiments of the present invention. In the accompanying drawings:

[0062] Figure 1 This is a flow chart of a method for analyzing the safety and reliability of a production equipment system under energy action according to the present invention;

[0063] Figure 2 It is a schematic diagram of material flow classification of the present invention;

[0064] Figure 3 It is a schematic diagram of the double chain model of energy equipment and materials of the production system of the present invention;

[0065] Figure 4 It is a schematic diagram of a process of an embodiment of the present invention;

[0066] Figure 5 is a schematic diagram of comprehensive safety analysis of a production system considering energy activities according to the present invention;

[0067] Figure 6 This is a schematic diagram of production safety analysis of a typical chemical plant considering energy activities according to the present invention;

[0068] Figure 7 is a schematic diagram of the comprehensive analysis results of the production system safety considering energy activities of the present invention;

[0069] Figure 8 This is the intention of the present invention to provide a safety and reliability analysis device for a production equipment system under energy action.

[0070] Description of Reference Numerals

[0071] 100-Production equipment system safety and reliability analysis device based on energy action;

[0072] 200-first processing module;

[0073] 300-second processing module;

[0074] 400-third processing module. DETAILED DESCRIPTION

[0075] The following describes the specific implementation of the embodiment of the present invention in detail with reference to the accompanying drawings. It should be understood that the specific implementation described herein is only used to illustrate and explain the embodiment of the present invention and is not used to limit the embodiment of the present invention.

[0076] It should be noted that the acquisition, transmission, storage, use, and processing of data in the technical solution of this application are in compliance with the relevant provisions of laws and regulations. In the embodiments of this application, certain software, components, models, and other existing solutions in the industry may be mentioned. These should be considered as exemplary. Their purpose is only to illustrate the feasibility of implementing the technical solution of this application, but it does not mean that the applicant has or will necessarily use such solutions.

[0077] Example 1

[0078] The present invention is a method for analyzing the safety and reliability of production equipment systems under energy action, such as Figure 1 As shown, the method includes: step S101 is to construct an energy activity model according to the energy carried by the equipment in the production system, and analyze the activity rules of the energy activity model to obtain energy impact parameters.

[0079] According to a specific embodiment, the energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow; the energy activity model is: ,in, is energy, i is the process number, Convert materials into energy, Absorb energy for the device; To diffuse energy; is a dynamic energy flow. The material conversion energy is: ; The energy absorbed by the device is: ; The diffusion energy is: ;in, The quality of the material, is the specific heat capacity of the material, is the temperature change of the material, is the power consumption of the device, t is the working time of the device, represents the heat transfer coefficient, Represents surface area.

[0080] The present invention analyzes the importance and complexity of the interaction between matter and energy in production systems, refines the energy activity model, and visualizes energy activities in the form of energy flows, laying the foundation for abnormal activity energy analysis and safety and reliability analysis.

[0081] Specifically, production equipment, as a production tool, relies on energy to function. During the production process, materials and energy interact through multiple steps, following the production process requirements, to complete various production tasks. This process requires external material and energy input. Through these multiple steps, as materials and energy are transmitted, transformed, and output within the production system, various materials and energy bodies form material flows and energy flows, respectively.

[0082] The production process includes multiple production process links. After external energy is input into the system, in each process link, it receives the transferred energy and material conversion energy from the previous link and consumes energy to carry out the process.

[0083] Generally speaking, in each process link, energy activities are divided into four parts: driving equipment to do work on materials and conducting energy exchange and conversion with materials; part of the energy is absorbed by the equipment, generating heat, vibration, noise, etc.; it diffuses into the spatial environment in the form of energy such as heat energy; and it is transmitted to the next link of the system, forming an interconnected dynamic energy flow to maintain continuous production operations.

[0084] According to a specific embodiment, The energy activity model of the process is: .in, It represents the energy input to the process, which usually includes the power consumption of the drive motor, heat source, power source, etc. It can be obtained by multiplying power by time: ; Indicates the energy of material conversion. If the material absorbs energy, it is represented by a positive value. If the material releases energy, it is represented by a negative value. The temperature change, phase change, chemical reaction, etc. of the material will involve the absorption or release of energy, which can be calculated through thermodynamics and process flow: , Indicates quality, represents the specific heat capacity, Indicates temperature change; Indicates the energy absorbed by the device, which can usually be calculated by the efficiency and power consumption of the device: , Indicates the power consumption of the device; It represents the energy diffused into space, which can be estimated by ambient temperature changes, equipment surface temperature, radiation and convection losses, etc. The specific calculation method can use processes including heat conduction, convection and radiation: , represents the heat transfer coefficient, represents surface area; Indicates the energy transferred to the next link, which can be calculated by the transfer of materials in the system; Indicates the process link.

[0085] The energy activity model of the entire production system is: .in, represents exogenous energy (i.e., the energy input into the production system, which is the sum of the energy of all process links), , As recyclable surplus energy, the surplus energy can be reused through a recovery system (such as waste heat recovery), reducing the system's demand for external energy. , since the remaining energy can be reused, it is represented by a negative sign, Indicates the total number of processes, Indicates the material conversion energy, Indicates that the device absorbs energy, Represents the energy diffused into space.

[0086] In addition, the production system is in a certain environment, and its state during operation is affected by the surrounding environment. The environmental impact includes two aspects: physical environment and spatial environment.

[0087] The physical environment refers to the set of environmental conditions that affect the production system, including temperature, humidity, vibration, etc., which will have a certain impact on the manufacturing process and operators. These environmental factors depend on the natural environment and the design of the production system itself. Therefore, the energy activity model of environmental changes is obtained: .in, is the energy change within the production system, It is the energy input of the external environment to the manufacturing system. Through environmental changes, it affects the operating efficiency of the equipment, the conversion efficiency of materials and the overall energy balance of the system. The energy input of the external environment increases the energy consumption of the production system, which may be manifested as additional heat energy or power consumed by the equipment. However, it should be pointed out that this formula represents the energy process and cannot directly reflect the specific effect of the environment on the production system. Represents the energy diffused into space.

[0088] The spatial environment is a collection of factors such as the production system structure and spatial layout, including three-dimensional space, personnel gaps, material flow, etc., which will make the operation of production equipment complicated.

[0089] The core of production activities lies in the acquisition, processing, manufacturing and transportation of material objects, thus forming a material flow consisting of raw materials, semi-finished products, products and waste. Each production industry has formed its own unique material flow type according to its specific production objects and products (such as Figure 2 The production system can restore the material and energy flows to a relatively stable state through its own regulatory mechanisms, such as the automatic feedback control system's adjustment of equipment power and adaptive changes in material transmission speed, thereby ensuring the continuity and stability of the production process.

[0090] In summary, the material flow and energy flow in the production system are analyzed to form the following Figure 3 The energy, equipment and material dual-chain model of the production system shown lays the foundation for subsequent theoretical modeling analysis and control methods of production system safety and reliability.

[0091] This application discloses a categorized analysis of different types of abnormal energy activity associated with failure modes. While traditional equipment failure analysis often focuses on a single type or a few related failures, this method conducts a deep, bidirectional correlation between energy and failures, further integrating energy with production equipment functional failures to more comprehensively reveal the complex relationships underlying these events.

[0092] By analyzing abnormal energy activities and failure modes in production systems, the safety and reliability of production systems have been improved. The inherent relationship between abnormal energy activities and failure modes has been innovatively and deeply analyzed from multiple dimensions. With the help of advanced technical means and analysis methods, a more accurate, comprehensive and forward-looking risk prevention and control system has been built.

[0093] Energy activities in production systems include thermal energy, mechanical energy, electrical energy, kinetic energy, chemical energy, radiation energy, and potential energy. The corresponding abnormal energy activities include abnormal temperature increases or decreases in equipment or systems, causing abnormal changes in related energy; abnormal energy changes in equipment or systems due to loss of control, excessive vibration, or unexpected impact; abnormal energy changes caused by abnormal changes in current or voltage; abnormal energy changes caused by the sudden release or suppression of kinetic energy in the system; abnormal energy changes caused by abnormal energy release related to chemical substances or reactions; abnormal energy release of light radiation and electromagnetic radiation; and abnormal energy release caused by factors such as gravity and pressure. In general, the binary attributes of energy can be expressed as follows: ,in, Indicates the intensity, represents an extensive quantity. As can be seen from the above expression, energy is the cumulative effect of intensity quantities on corresponding extensive quantities. By combining intensity and extensive quantities, abnormal energy activity can be effectively quantified, allowing for in-depth analysis of various energy activities in production systems. Each energy activity has a corresponding intensity and extensive quantity. This combination of binary attributes enables precise energy monitoring and anomaly detection, providing a scientific basis for the safety, reliability, and efficiency of production systems.

[0094] The above-mentioned abnormal energy activity is an internal factor that leads to production accidents. It may be generated, stored or released within the production equipment system, or it may be input from the external environment. In the production process, reasonable control of energy is crucial to ensure the stable operation of the equipment system and reliable and safe production. A typical production system can be divided into the following main parts according to its function:

[0095] (1) Production function: Through a combination of specific equipment and process, core production tasks are efficiently performed, raw materials are converted into products that meet the requirements, and the orderly advancement and precise implementation of the product production process are ensured.

[0096] (2) Energy supply function: Build a complete energy security system covering multiple energy supply channels such as electricity, heat, and gas, accurately match and continuously meet the diverse needs of various links in the production process for various types of energy, and provide a solid power foundation for the stable development of production activities.

[0097] (3) Monitoring function: With the help of advanced monitoring and control systems, real-time and accurate data collection and in-depth analysis of key parameters in the production process are carried out, abnormal conditions are detected in time and the alarm mechanism is triggered. At the same time, based on the data analysis results, the system operation is optimized and adjusted to achieve refined management and efficient control of the production process, ensuring that production operations are always in the best operating state.

[0098] The production equipment system must have a complete abnormal energy activity carrying capacity to keep the energy in the production system in a stable and controlled state. The failure modes of the abnormal energy activity carrying capacity of the general production system are divided into the following categories:

[0099] (1) Functional deficiency: In terms of design, the production equipment system does not have complete abnormal energy activity carrying function, environmental function, protection function, monitoring function, control function, etc., and does not meet the safety and reliability requirements.

[0100] (2) Functional failure: Although the abnormal energy activity carrying function has been taken into account during the design stage, these functions may be weakened or fail due to manufacturing or use reasons and may not be able to effectively play the expected role.

[0101] (3) Function not put into operation: During the operation stage of the equipment system, due to reasons such as process and operating procedures, when production changes, certain abnormal energy activity carrying functions within the system fail to be correctly started, used or function, and may even cause malfunctions.

[0102] Generally speaking, the most fundamental cause of functional failure is design issues. Due to existing technological levels, designer capabilities, and resource constraints, the operating principles are not scientifically sound or the system architecture is flawed. Functional failure occurs during the production phase, when factors such as equipment maintenance, production load, and environmental conditions affect the performance of system components, leading to reduced performance or failure, manifesting as functional failure or performance degradation. Functions are not implemented due to technical limitations or equipment performance issues, resulting in the inability of these functions to activate or function properly under specific circumstances.

[0103] By analyzing the transmission and transformation processes of matter and energy in the production system, we help determine the boundary conditions for stable operation of the system; by analyzing the physical and spatial environment of the production system, we clarify the impact of external interference factors on the interaction between matter and energy; by studying the changes in the interaction between matter and energy under external interference, we quantify the relationship between interference intensity and system response; by classifying abnormal energy activities and functional failure modes, we clarify the possible unstable states of the system.

[0104] Step S102 is to perform a safety and reliability analysis on the production system based on the energy impact parameters from the perspectives of self-stability, anti-stability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and anti-stability parameters.

[0105] According to a specific implementation method, the safety and reliability parameters of the production system are analyzed from the perspective of self-stability, external stability, and anti-stability based on the energy impact parameters, including: the energy impact parameters include equipment reliability, equipment availability, equipment fault detection rate, the maximum energy that the equipment can withstand, external disturbance recovery time, energy margin and energy leakage; self-stability parameters are determined based on the equipment reliability, equipment availability, and equipment fault detection rate; anti-disturbance parameters are determined based on the maximum energy that the equipment can withstand and the external disturbance recovery time; and anti-stability parameters are determined based on the energy margin and energy leakage.

[0106] Specifically, determining the self-stabilization parameter according to the equipment reliability, equipment availability, and equipment fault detection rate includes:

[0107]

[0108] Among them, S is the self-stabilization parameter, For reliability, is availability, is the fault detection rate, is the redundancy, is the i-th factor affecting the system's self-stability, Factor The upper threshold value of .

[0109] Determining the anti-interference parameter according to the maximum energy that the device can withstand and the external disturbance recovery time includes:

[0110]

[0111] Where I is the immunity parameter, is the maximum energy the device can withstand, is the external disturbance recovery time, is each factor that affects the system immunity, Factor The upper threshold value of .

[0112] The determining of the stability parameter according to the energy margin and the energy leakage condition includes:

[0113]

[0114] Among them, H is the stability parameter, is the energy margin, For energy leakage, is the i-th factor affecting the stability of the system, Factor The upper threshold value of .

[0115] Specifically, based on the understanding of the functional structure of the production system and the consideration of the interactive relationship between energy activities and the production system and the potential abnormal release of energy, the connotation of the safety and reliability of the production system considering energy activities is analyzed and its theoretical model is constructed.

[0116] The safety and reliability of a production system that takes energy activities into consideration refers to its ability to maintain safe and stable operation during operation, including the ability of the production system to avoid accidents or failures under normal operating conditions, the ability to promptly identify, respond to and recover from abnormal situations, and the ability to ensure that the system energy is not output to the outside to cause accidents.

[0117] The stability, robustness, and safety of an equipment system are important indicators of its safety and reliability. They respectively assess the system's ability to maintain stability under normal operating conditions, its ability to resist external interference and disruption, and its ability to maintain stability under abnormal circumstances. The production capacity of an equipment system reflects its stability, namely its ability to consistently achieve expected production goals and indicators during the production process. The environmental function reflects the robustness of the equipment system, namely its ability to maintain a stable operating state under different environmental conditions. The protection function reflects the safety of the equipment system, namely its ability to effectively prevent damage from external destructive factors.

[0118] Based on this, the safety and reliability of the production system are mainly reflected in three aspects: self-stability, anti-interference and heterostability. Specifically, the self-stability refers to the ability of the production system to self-regulate and operate stably, preventing internal causes such as failure of the carrying function of abnormal energy activities from causing equipment damage and production interruptions. High self-stability means that it can effectively prevent production stoppages caused by fluctuations within the system, so that the system can recover quickly when faults such as failure of the carrying function of abnormal energy activities occur within the system, and avoid minor faults from rapidly expanding into safety accidents due to energy anomalies. The self-stability of the production system is affected by multiple factors and can be evaluated based on indicators related to system health detection. The theoretical model of the self-stability indicator is as follows:

[0119]

[0120] in, Reliability refers to the ability of a device to complete its intended function without failure under specified conditions and within a specified time. It is an important indicator for measuring the stability and sustainability of a device during actual use. It is usually described by a failure probability distribution. Common distributions include exponential distribution and Weibull distribution. Availability refers to the ability of a system or device to operate normally and provide the intended service when needed. It is used to measure the proportion of normal operation of a device or system over a period of time. It is usually expressed as the ratio of the mean time between failures to the sum of the mean time between failures and the mean time to repair. Fault detection rate refers to the proportion of faults that can be effectively identified and detected during the operation of a system or device, and measures the speed and accuracy of the detection system's response to potential faults. Indicates each factor that affects the self-stability of the system; Redundancy reflects the proportion of redundant resources added to the system to achieve reliability or fault tolerance; The corresponding factor The upper threshold value of The larger the value, the higher the self-stability.

[0121] Interference immunity is the ability of a production system to effectively resist external risks and influences, preventing production interruptions and equipment damage caused by human error, external environmental factors, and other factors, indicating the system's robustness. It can maintain normal operation in the face of uncontrollable factors, reduce excessive wear or damage to equipment caused by emergencies, effectively respond to sudden external changes, avoid costly downtime and production delays, and protect personnel and property. The theoretical model for interference immunity is as follows:

[0122]

[0123] in, Indicates the maximum energy the device can withstand. The larger the value, the more effective the system is in preventing the impact of external energy and reducing risks. The external disturbance recovery time refers to how long it takes for the production system to resume normal operation after a risk event occurs; Indicates each factor that affects the self-stability of the system; The corresponding factor The upper threshold value of .

[0124] The aforementioned stability refers to the ability of the production system to ensure that it does not output risks to the outside world, preventing problems such as personal injury, property loss, and environmental damage caused by abnormal release of system energy. It reflects the safety design of the system and ensures that all unstable factors of the system can be controlled within the system without affecting the surrounding environment or personnel. The theoretical model of the stability index is as follows:

[0125]

[0126] in, Energy margin refers to the gap between the additional energy (such as electricity, heat, mechanical energy, etc.) that the production system can withstand when working and the maximum safe load of the system; Indicates the energy leakage situation, which means that the energy of the leaked part does not exceed the limit value of other equipment protection; Indicates factors that affect the self-stability of the system; The corresponding factor The upper threshold value of The larger the value, the higher the stability. In summary, the conceptual evaluation formula for the safety and reliability of the production system is given as: .

[0127] Step S103 is to determine the functional requirements of the production system according to the safety and reliability parameters, so as to ensure the safety and reliability of the system.

[0128] According to a specific embodiment, the determination of the functional requirements of the production system based on the safety and reliability parameters includes: analyzing the energy carrying capacity, environmental conditions, and monitoring and control safety of the equipment in the production system based on the self-stability parameters, the anti-interference parameters, and the hetero-stability parameters, to provide the functional requirements of the production system. Based on the compliance of the system's self-stability parameters, the functional requirements of the production system's safety and reliability evaluation indicators when they are within the range of the self-stability parameters are determined from the two aspects of monitoring and control; based on the compliance of the system's anti-interference parameters, the functional requirements of the production system's safety and reliability evaluation indicators when they are within the range of the anti-interference parameters are determined from the aspect of environmental conditions; based on the compliance of the system's hetero-stability parameters, the functional requirements of the production system's safety and reliability evaluation indicators when they are within the range of the hetero-stability parameters are determined from the aspect of energy carrying capacity.

[0129] Specifically, from the perspective of the safety and reliability of the production system, this application proposes the production system safety and reliability function assurance requirements. This method systematically integrates self-stability, anti-interference and heterostability into the production system safety and reliability function protection analysis framework for the first time, providing an innovative theoretical basis for building comprehensive safety and reliability protection requirements. In addition, a comprehensive consideration of the risks brought by functional integrity and abnormal energy activity carrying functions proposes a new protection method for balancing energy transmission and constraints. The production system safety and reliability function protection requirements mainly include the following aspects.

[0130] (1) Monitoring reliability requirements: Through real-time and regular monitoring, the production situation can be fully understood, especially the changes in the system operating status and performance parameters, and timely feedback can be given to the control system to deal with possible accidental release of energy or substances reaching a critical state, thereby achieving timely early warning and risk control, and effectively improving self-stability. The monitoring objects cover the following points:

[0131] 1) Material, connection, shape, and appearance of equipment components. Monitor the material condition and connection status of equipment components, as well as changes in their shape and appearance, to promptly identify potential wear, corrosion, looseness, and other issues. For components susceptible to wear, such as gears and chains in mechanical transmissions, wear-resistant coatings or regular replacement can be used as protective measures. For areas susceptible to corrosion, such as the metal casing of chemical equipment, anti-corrosion paint can be applied or corrosion-resistant materials can be used. For connection points, use locknuts, spring washers, and other methods to ensure secure connections and ensure the safe and stable operation of equipment components.

[0132] 2) Key operating indicators of system equipment. Monitoring key operating indicators of system equipment, including parameters such as flow, temperature, and pressure, reflects the operating status and performance of the system equipment, allowing for timely detection of abnormalities and implementation of adjustments and controls. For example, for temperature monitoring, high-precision temperature sensors are installed at key heat-generating parts of the equipment, along with temperature alarms. When the temperature exceeds the set threshold, cooling devices such as cooling fans and water cooling systems are automatically activated. For pressure monitoring, pressure sensors and safety valves are installed. Once the pressure rises abnormally, the safety valve automatically opens to release pressure, ensuring safe operation of the equipment.

[0133] 3) Changes in environmental conditions. Monitor changes in environmental conditions, including temperature, humidity, and air pressure. Promptly identify any potential impacts of these changes on equipment and production processes, and implement appropriate adjustments and responses. For example, in high-temperature environments, equip equipment with heat shields to reduce heat transfer into the equipment. In humid environments, moisture-proof the equipment's internal circuits, such as using sealants or installing desiccant cartridges, to prevent short circuits.

[0134] (2) Control reliability analysis: To ensure the coordination, safety and reliability of the production system, the production system needs to have the ability to control changes in production conditions and effectively improve self-stability. This control capability is mainly reflected in the following three aspects:

[0135] 1) Change-Based Control Capabilities. Production conditions may fluctuate over time, depending on raw materials, the environment, and other factors. Equipment systems should be able to adapt to these changes, including effectively adjusting dynamic indicators such as energy flow, material flow, and environmental conditions. For example, when the properties of raw materials change, the equipment's control system automatically adjusts processing parameters, such as heating temperature and processing speed. Energy flow changes are monitored in real time using monitoring devices such as smart meters and flow meters, and then frequency converters are used to adjust motor speed to ensure optimal energy distribution and utilization, ensuring stable equipment operation.

[0136] 2) Emergency response capabilities based on dangerous situations. When unexpected situations or dangerous situations arise during production, the equipment system should have emergency response capabilities to safely release energy in the system through diversion, unloading, and other methods, thereby eliminating potential dangerous situations and ensuring the safety of personnel and equipment. For example, short-circuit protection devices and overload protection relays should be installed in the electrical system. In the event of a short circuit or overload, the circuit will be quickly disconnected to prevent damage to electrical equipment due to excessive current. For hydraulic systems, relief valves should be installed. When the pressure exceeds the set value, the relief valve opens, allowing excess hydraulic oil to flow back to the tank, avoiding dangerous situations caused by excessive system pressure.

[0137] 3) Problem-based compensation capabilities. Equipment systems must possess appropriate compensation capabilities for abnormal situations or problems that may arise during production. For example, if a sensor fails, the equipment's control system automatically switches to a backup sensor or employs an estimation algorithm to compensate for the missing sensor data based on other relevant parameters, ensuring continued normal operation of the equipment. For equipment with reduced accuracy due to wear of mechanical components, automatic compensation devices can be used to adjust the processing position or employ error correction algorithms to ensure that product quality is not significantly affected.

[0138] (3) Environmental Condition Stability Reliability Analysis: Environmental condition stability reliability refers to the ability of the production system to continue to operate normally under different environmental conditions. The safety of the production system is largely affected by various energies in the environment. The physical environment affects the state of the production system, which is essentially the effect of energy, including thermal energy, mechanical energy, electromagnetic energy, etc. The spatial environment affects the operating activities of equipment and personnel and is an important condition factor affecting energy activities. Therefore, environmental condition reliability analysis is the ability of the production system to withstand various energy changes after environmental changes. It is determined by using various tools to calculate the degradation of equipment, thereby effectively improving the anti-interference performance.

[0139] In the environmental stability and reliability analysis of production systems, energy encompasses multiple forms, each intertwined with the other, impacting equipment operation. High and low temperature fluctuations in thermal energy test equipment's heat and cold resistance, respectively. At high temperatures, heat dissipation and insulation measures ensure equipment does not overheat and fail, while at low temperatures, heating and appropriate lubricants ensure proper operation. Strong electromagnetic interference and electromagnetic compatibility issues between devices require shielding and packaging, rational layout, filtering circuits, and rigorous testing to maintain the stability of electronic components and accurate signal transmission. Chemical energy, in environments with varying humidity and corrosiveness, addresses risks such as short circuits, corrosion, and static electricity accumulation through dehumidification, humidification, the use of corrosion-resistant materials, anti-corrosion coatings, and regular maintenance, thereby maintaining equipment reliability and lifespan in chemical environments. Multiple energy factors interact with equipment, and the coordinated and complementary response measures are key to ensuring the stable operation of production systems in complex energy environments.

[0140] The spatial environment plays an indispensable role in analyzing the environmental stability and reliability of a production system. The three-dimensional spatial layout determines the installation height, location, and spacing of equipment. Proper planning can prevent maintenance difficulties, operator discomfort, and collision risks, while also creating an appropriate space for high-precision equipment to maintain accurate operation. The strategic design of personnel clearances and work paths ensures ample and unobstructed space for movement and operation between equipment. This creates a safe and efficient network of access paths within multi-equipment areas, and allows for collaborative operations without interference, improving both efficiency and safety. Material flow path planning effectively separates material transportation routes from personnel and equipment operating areas. Dedicated conveying methods and access paths, combined with protection and inspection at key nodes, ensure safe and orderly material transportation. Material storage areas are strategically arranged based on material characteristics and aligned with the production system's capacity. These multiple aspects work together to ensure the stable and reliable operation of the production system in the spatial dimension. These interrelated and mutually influential elements of the spatial environment contribute to the spatial infrastructure that ensures the stable operation of the production system.

[0141] (4) Energy carrying reliability analysis: In the production system, components are interconnected to form a complex structure, which can be divided into two categories according to their functions: energy bodies and constraint bodies. Among them, energy bodies are responsible for the transmission, conversion and storage of energy, while constraint bodies ensure that energy flows safely along a specific path within the system. The input of external energy sources must meet the needs of processing raw materials into products, but cannot exceed the rated design value of the system. Under normal circumstances, there is an optimal value for the input of external energy, and this optimal value is equal to the rated design value of the equipment, which puts the equipment in the best operating state, thereby effectively improving its stability. Specifically including:

[0142] 1) Energy-carrying capacity. The energy-carrying capacity of a production system determines its production capacity, which in turn depends on the structural (strength) performance and reliability of its hardware. To improve energy-carrying capacity, key structural components of equipment are manufactured using high-strength materials, such as alloy steel for container walls designed to withstand high pressures. Energy transmission components, such as cables and drive shafts, are selected with appropriate specifications and materials based on their energy-carrying requirements. Regular strength testing and maintenance are performed to ensure safe and reliable energy transmission.

[0143] 2) Energy activity constraint capability. Safe production requires coordination between energy flow, system, and material flow during system operation, maximizing external energy utilization and constraining it to maintain optimal equipment operation. For example, in electrical systems, devices such as current limiters and voltage stabilizers are installed to limit excessive current and stabilize voltage, ensuring the safe transmission and proper utilization of electrical energy within the equipment. In hydraulic systems, throttle valves and speed control valves are used to control the flow and velocity of hydraulic oil, ensuring that hydraulic energy is transmitted along predetermined paths and parameters, ensuring smooth and reliable equipment operation.

[0144] Example 2

[0145] like Figure 4 As shown, the present invention proposes an example of a chemical system, the steps of which include: Step 1 is the analysis of material interactions and energy interactions in the production system. Chemical production systems are classified into core production systems and auxiliary systems, and are further subdivided into multiple subsystems. The core production system of the chemical system is the key part, which is directly related to the core production process of the product, and mainly includes the following subsystems: Reaction system: responsible for the chemical reaction, including reactors, catalysts and their control systems. The design and optimization of the reaction system directly affects the quality and yield of the product; separation system: used to separate the desired products and by-products from the reaction mixture. Commonly used separation technologies include distillation, extraction, filtration, etc.; processing system: post-processing of the separated products, such as drying, mixing, packaging, etc., to meet market demand. Auxiliary systems provide support and assurance for the core production system, ensuring the smooth progress of the production process. They primarily include the following subsystems: Energy supply system: Responsible for providing the required electricity, heat, and gas, including boilers, generators, compressors, and other equipment to ensure that energy needs are met during the production process; Control and automation system: Used to monitor key parameters in the production process in real time, conduct data collection, alarm management, and system optimization to achieve efficient control of the production process; Maintenance and support system: Responsible for the daily maintenance and overhaul of equipment to ensure the reliability and stability of production equipment. It also provides necessary safety measures to reduce accident risks; Logistics and material management system: Responsible for the procurement, storage, transportation, and distribution of raw materials, ensuring the timely supply of raw materials required for production and the smooth flow of products.

[0146] The energy activity of a heat exchanger includes the heat released by the heat source fluid and the energy absorbed by the cold source fluid in the heat exchanger. The energy activity of a reactor comes from external energy input, including the energy required for heating, cooling or stirring, absorbing energy, generating heat, vibration, etc. During the reaction, heat or other forms of energy are diffused to the surrounding environment. The energy activity of a storage tank is usually the energy brought by the fluid flowing from the reactor into the storage tank. In addition, the temperature and humidity of the surrounding environment may affect the energy efficiency of the reactor and the energy storage capacity of the storage tank. The layout and design of the reactor and storage tank will affect the energy flow path and efficiency. An optimized layout can reduce energy loss and improve energy utilization. For example, higher temperatures may lead to faster reaction rates, thereby affecting the energy input and output of the reactor.

[0147] Step 2 involves analyzing abnormal energy activity and failure modes in the production system. In chemical reactors, conductive energy activity primarily manifests itself in the transfer of heat and the movement of fluids during reactions. For example, in a reactor, heat is transferred from a heater to reactants, or heat generated by a reaction is transferred to a cooling medium through a cooling system. In the reactor, catalysts promote reactions, converting input chemical energy into thermal and chemical energy. Reactants are converted into products during the reaction, with energy stored and released in various forms. The gases or heat generated by the reactions can be utilized or converted into other forms of energy. In storage tanks, stored liquid ammonia releases heat through exothermic reactions or absorbs heat through endothermic reactions. Pumps convert electrical energy into mechanical energy to drive operation. These energy activity locations require special attention, as they can all potentially lead to corresponding failures. Therefore, verification of the corresponding functions is necessary to ensure the safe operation of the production system.

[0148] Step 3 is to analyze the safety and reliability of the production system considering energy activities. A comprehensive analysis of the production system safety is conducted from the dimensions of self-stability, anti-interference and hetero-stability. The energy constraints in the safety and reliability function are analyzed from the four aspects of monitoring reliability, control reliability, environmental stability reliability and energy carrying reliability, and the corresponding guarantee requirements are given (the analysis results are shown in the figure). Figure 5 shown).

[0149] Step 4 is to analyze the safety and reliability function assurance requirements of the production system. A process in the chemical system including reactors, heat exchangers, pumps and storage tanks is selected for practical analysis (the results are as follows Figure 6 shown).

[0150] Based on this, the application of the safety and reliability analysis method of a production system under a certain energy effect in a certain process of a chemical system is completed (the analysis results are as follows Figure 7 shown).

[0151] Example 3

[0152] The present invention also proposes a production equipment system safety reliability analysis device based on energy action, such as Figure 8 As shown, the device 100 for analyzing the safety and reliability of a production equipment system under energy action includes: a first processing module 200, which is used to construct an energy activity model according to the energy carried by the equipment in the production system, and analyze the activity rules of the energy activity model to obtain energy impact parameters; a second processing module 300, which is used to analyze the safety and reliability of the production system from the perspective of self-stability, other-stability, and anti-stability according to the energy impact parameters to obtain safety and reliability parameters; a third processing module 400, which is used to determine the functional requirements of the production system according to the safety and reliability parameters, so as to ensure the safety and reliability of the system.

[0153] The energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow; the energy activity model is: ,in, For energy, Convert materials into energy, Absorb energy for the device; To diffuse energy; It is a dynamic energy flow.

[0154] The device considers the role of energy activities in the production system, analyzes the interactive operation mechanism of the production system operating factors of energy transfer, analyzes the failure mode and safety of the production system from the perspective of all production factors, and constructs an indicator system such as self-stability, hetero-stability and anti-interference for evaluating the safety and reliability of operation. It solves the problem of safety and reliability evaluation grading in the production process and improves the safety and reliability of subsequent production activities.

[0155] The present invention provides a method for analyzing the safety and reliability of a production equipment system under the action of energy. The method includes: constructing an energy activity model based on the energy carried by the equipment in the production system, analyzing the activity rules of the energy activity model to obtain energy impact parameters; based on the energy impact parameters, analyzing the safety and reliability of the production system from the perspective of self-stability, heterostability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and heterostability parameters; determining the functional requirements of the production system based on the safety and reliability parameters to ensure the safety and reliability of the system. This method analyzes the interactive operation mechanism of the production system operating factors of energy transmission by considering the effect of the energy activity of the production system, analyzes the failure mode and safety of the production system from the perspective of all production factors, and constructs an index system of self-stability, heterostability, and anti-interference for evaluating the safety and reliability of the operation. It solves the problem of safety and reliability evaluation grading in the production process and improves the safety and reliability of subsequent production activities.

[0156] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0157] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0158] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0159] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0160] In a typical configuration, a computing device includes one or more processors (CPUs), input / output interfaces, network interfaces, and memory.

[0161] The memory may include non-permanent memory in a computer-readable medium, random access memory (RAM) and / or non-volatile memory in the form of read-only memory (ROM) or flash RAM. The memory is an example of a computer-readable medium.

[0162] Computer-readable media includes both permanent and non-permanent, removable and non-removable media that can be implemented using any method or technology for information storage. Information can be computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include, but are not limited to, phase-change RAM (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, compact disc read-only memory (CD-ROM), digital versatile disc (DVD) or other optical storage, magnetic cassettes, magnetic disk storage or other magnetic storage devices, or any other non-transmission media that can be used to store information that can be accessed by a computing device. As defined herein, computer-readable media does not include transitory computer-readable media, such as modulated data signals and carrier waves.

[0163] It should also be noted that the terms "comprises," "includes," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, commodity, or apparatus that includes a series of elements includes not only those elements but also other elements not explicitly listed, or includes elements inherent to such process, method, commodity, or apparatus. In the absence of further limitations, an element defined by the phrase "comprises a ..." does not exclude the presence of other identical elements in the process, method, commodity, or apparatus that includes the element.

[0164] The above are merely embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should all be included within the scope of the claims of the present application.

Claims

1. A safety and reliability analysis method for production equipment systems based on energy, characterized by: The method includes: Constructing an energy activity model based on the energy carried by the equipment in the production system, and analyzing the activity patterns of the energy activity model to obtain energy impact parameters; According to the energy impact parameter, the safety and reliability of the production system is analyzed from the perspective of self-stability, anti-stability, and anti-stability to obtain safety and reliability parameters, wherein the safety and reliability parameters include self-stability parameters, anti-interference parameters, and anti-stability parameters; Determine the functional requirements of the production system based on the safety and reliability parameters to ensure the safety and reliability of the system; The energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow; The energy activity model is: in, For energy, Convert materials into energy, Absorb energy for the device; To diffuse energy; It is a dynamic energy flow; The safety and reliability parameters obtained by performing a safety and reliability analysis on the production system from the perspectives of self-stability, other-stability, and anti-stability according to the energy impact parameters include: The energy impact parameters include equipment reliability, equipment availability, equipment fault detection rate, maximum energy that the equipment can withstand, external disturbance recovery time, energy margin and energy leakage; Determining a self-stabilization parameter based on the equipment reliability, equipment availability, and equipment failure detection rate; Determine the interference immunity parameters based on the maximum energy that the device can withstand and the external disturbance recovery time; The stability parameters are determined according to the energy margin and the energy leakage situation.

2. The method according to claim 1, characterized in that The material conversion energy is: The energy absorbed by the device is: The diffusion energy is: in, The quality of the material, is the specific heat capacity of the material, is the temperature change of the material, is the power consumption of the device, t is the working time of the device, represents the heat transfer coefficient, Represents surface area.

3. The method according to claim 1, characterized in that The determining of the self-stabilization parameter according to the equipment reliability, equipment availability, and equipment fault detection rate includes: Among them, S is the self-stabilization parameter, For reliability, is availability, is the fault detection rate, is the redundancy, is the i-th factor affecting the system's self-stability, Factor The upper threshold value of .

4. The method according to claim 1, wherein Determining the anti-interference parameter according to the maximum energy that the device can withstand and the external disturbance recovery time includes: Where I is the immunity parameter, is the maximum energy the device can withstand, is the external disturbance recovery time, is each factor that affects the system immunity, Factor The upper threshold value of .

5. The method according to claim 1, wherein The determining of the stability parameter according to the energy margin and the energy leakage condition includes: Among them, H is the stability parameter, is the energy margin, For energy leakage, is the i-th factor affecting the stability of the system, Factor The upper threshold value of .

6. The method according to claim 1, characterized in that Determining the production system functional requirements according to the safety and reliability parameters includes: The energy carrying capacity, environmental conditions and monitoring and control safety of the equipment in the production system are analyzed based on the self-stability parameters, anti-interference parameters and hetero-stability parameters.

7. A production equipment system safety and reliability analysis device based on energy, characterized in that: The device includes: A first processing module is used to construct an energy activity model based on the energy carried by the equipment in the production system, and to analyze the activity patterns of the energy activity model to obtain energy impact parameters; A second processing module is configured to perform a safety and reliability analysis on the production system from the perspectives of self-stability, other-stability, and anti-stability according to the energy impact parameter to obtain safety and reliability parameters; A third processing module is used to determine the functional requirements of the production system according to the safety and reliability parameters, so as to ensure the safety and reliability of the system; The energy includes material conversion energy, equipment absorption energy, diffusion energy, and dynamic energy flow; The energy activity model is: in, For energy, Convert materials into energy, Absorb energy for the device; To diffuse energy; It is a dynamic energy flow; The safety and reliability parameters obtained by performing a safety and reliability analysis on the production system from the perspectives of self-stability, other-stability, and anti-stability according to the energy impact parameters include: The energy impact parameters include equipment reliability, equipment availability, equipment fault detection rate, maximum energy that the equipment can withstand, external disturbance recovery time, energy margin and energy leakage; Determining a self-stabilization parameter based on the equipment reliability, equipment availability, and equipment failure detection rate; Determine the interference immunity parameters based on the maximum energy that the device can withstand and the external disturbance recovery time; The stability parameters are determined according to the energy margin and the energy leakage situation.

8. The device according to claim 7, characterized in that The material conversion energy is: The energy absorbed by the device is: The diffusion energy is: in, The quality of the material, is the specific heat capacity of the material, is the temperature change of the material, is the power consumption of the device, t is the working time of the device, represents the heat transfer coefficient, Represents surface area.

9. The device according to claim 7, characterized in that The determining of the self-stabilization parameter according to the equipment reliability, equipment availability, and equipment fault detection rate includes: Among them, S is the self-stabilization parameter, For reliability, is availability, is the fault detection rate, is the redundancy, is the i-th factor affecting the system's self-stability, Factor The upper threshold value of .

10. The device according to claim 7, characterized in that Determining the anti-interference parameter according to the maximum energy that the device can withstand and the external disturbance recovery time includes: Where I is the immunity parameter, is the maximum energy the device can withstand, is the external disturbance recovery time, is each factor that affects the system immunity, Factor The upper threshold value of .

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