Production process-based product carbon footprint calculation system and method

Abstract

The application relates to the technical field of management systems, and discloses a product carbon footprint calculation system and method based on production processes. The product carbon footprint calculation system based on production processes comprises an input unit, a database unit, a process unit, a modeling unit, a calculation unit and an output unit. The input unit accesses multi-source heterogeneous data and establishes a virtual data point position model. The database unit stores emission factors and enterprise information. The process unit defines a process and binds a data source. The modeling unit constructs a carbon footprint model, and matches materials for input / output, and sets seven types of attributes, including resources, energy, waste gas, waste, products, byproducts and intermediate products. The calculation unit performs calculation and analysis according to the attribute types by calling built-in formulas or user-defined formulas. The output unit generates a certificate and a report by one key. Through process-level modeling, real-time data integration and a classification calculation system, the application realizes high-precision, real-time and traceable management of product carbon footprints.

Description

Technical Field

[0001] This invention relates to the field of management system technology, and in particular to a product carbon footprint calculation system and method based on production processes. Background Technology

[0002] With the growing global consensus on addressing climate change, product carbon footprint (PCF) has become a key indicator for measuring corporate environmental responsibility and the green performance of products. The British Standards Institution (BSI)'s PAS 2050, published in 2008, marked the transition of product carbon footprint accounting from academic research to commercial practice. Subsequently, the World Resources Institute (WRI) and the World Business Council for Sustainable Development (WBCSD) jointly published the GHG Protocol Product Standard, and the International Organization for Standardization (ISO) published ISO 14067:2018, "Greenhouse gases – Product carbon footprint – Quantification requirements and guidance," jointly establishing an internationally accepted accounting standard system. In recent years, the driving force behind product carbon footprint disclosure has shifted from "voluntary disclosure" to "mandatory compliance." For example, the EU's Battery and Waste Battery Regulation (No. 2023 / 1542) explicitly requires the calculation of the product environmental footprint (PEF) of automotive power batteries and links carbon footprint to carbon tariffs.

[0003] However, current carbon footprint calculation systems on the market generally suffer from technical bottlenecks, making it difficult to meet the urgent needs for refined, real-time, and compliant calculations. The main operating modes of existing systems are typically as follows: Figure 1 As shown, the user first inputs macro- and static data such as the product bill of materials, total energy consumption, and waste through input module A10 (A11); then, through selection module A20, emission factor data is matched from the database (A21); finally, through calculation module A30, the carbon footprint analysis result (A31) is obtained using built-in formulas. This mode has the following inherent defects: (1) The real-time energy consumption and material loss data of the system and the production site are completely separated. It relies on lagging data such as monthly bills and theoretical lists, and cannot capture the dynamic fluctuation of carbon footprint under different production batches and different equipment conditions.

[0004] (2) When multiple products share a production line, it is necessary to rely on manual methods (such as by working hours or output) to preprocess the data. This not only involves a large workload, but also easily leads to serious distortion of the accounting results, overestimating or underestimating the actual carbon footprint of a specific product.

[0005] (3) Existing systems mostly adopt a fixed "total inflow and total outflow" accounting model, which cannot flexibly construct a process-level carbon footprint model according to the actual production process, and it is also difficult to handle the accurate calculation and allocation of complex streams such as waste gas, by-products, and intermediate products generated during the production process.

[0006] Therefore, the existing technical solutions are essentially static accounting tools based on macroscopic and lagging data. Their results cannot truly reflect the real-time carbon emissions in the product manufacturing process, and it is even more difficult to accurately locate the hot processes of carbon footprint. They cannot provide a real-time and accurate data foundation for enterprises to optimize processes, reduce emissions precisely, and achieve efficient compliance.

[0007] To address the aforementioned issues, there is an urgent need for a product carbon footprint calculation system and method that can be deeply integrated with existing enterprise digital systems (such as MES and EMS), automatically acquire real-time production data at the process level, support refined modeling, real-time calculation and traceability by production batch, and flexibly adapt to complex production scenarios. Summary of the Invention

[0008] The technical problem to be solved by this invention is: in order to solve the problems of data lag and coarseness, coarse accounting granularity, rigid models and lack of flexibility in the existing technology mentioned above, a product carbon footprint calculation system and method based on production process is provided. It can be deeply integrated with the existing digital system of the enterprise, automatically acquire real-time production data at the process level, support fine modeling, real-time calculation and traceability by production batch, and flexibly adapt to product carbon footprint calculation in complex production scenarios.

[0009] The technical solution adopted by this invention to solve its technical problem is: a product carbon footprint calculation system based on production processes, comprising the following functional units connected in sequence: The input unit is used to access multi-source heterogeneous raw data and establish a virtual data point model that includes data semantics and business rules corresponding to real devices or scenarios; The database unit is used to store and manage emission factor data, supplier information, product material information, and product BOM information. The process unit, connected to the input unit, is used to customize the product manufacturing process and bind virtual data points to process equipment points; The modeling unit, connected to the database unit and the process unit, is used to build a product carbon footprint model and to match materials and set attribute types for process inputs / outputs. The calculation unit, connected to the modeling unit, is used to call the corresponding carbon footprint calculation method according to the set attribute type, perform calculations, and analyze the results; The output unit, connected to the computing unit, is used to generate carbon footprint certificates and reports with a single click.

[0010] The input unit, serving as a dynamic data entry point, directly connects to the production site, resolving the issue of complete disconnect between existing systems and real-time production data. The database unit, acting as a standardized data hub, ensures the maintainability of accounting factors. The process unit allows users to define and configure production processes corresponding to the actual production line. Based on this, the modeling unit constructs a carbon footprint model that maps to the actual flow of materials and energy, providing a structural foundation for capturing process-level carbon footprint fluctuations and achieving production batch traceability. The calculation unit works in conjunction with the modeling unit to ensure that calculations can respond to changes in the model. The output unit directly transforms the analysis results into visualized certificates and actionable reports, upgrading carbon footprint management from post-event statistics to an intelligent cycle of process monitoring, real-time analysis, and decision support, enabling carbon data to drive production optimization and emission reduction decisions.

[0011] Furthermore, the input unit includes a data access device and a data modeling device. The data access device is equipped with at least three access methods among Excel, CSV, TXT, IoT device signals, database interfaces, and application programming interfaces (APIs). The data modeling device performs business-oriented processing on the raw data through at least one of the following methods: usage analysis, year-on-year analysis, month-on-month analysis, mean analysis, or standard deviation analysis, in order to establish the virtual data point model.

[0012] The traditional static data interface, which relies on manual data entry, is transformed into an intelligent entry point that can automatically and in real time capture raw data from systems such as field instruments, equipment gateways, and MES / ERP, and transform it into a virtual data point model that is understandable to the business, thus ensuring the real-time performance and accuracy of the basic data for calculation.

[0013] Furthermore, the database unit includes: Emission factor editing device for maintaining fossil fuel factor database and carbon footprint factor database; Enterprise information editing device, used to maintain supplier information, product material information, and product BOM information; Each of the supplier information entries, each of the product material information entries, and each of the product BOMs is assigned a unique identification code.

[0014] By establishing a structured database that includes an emission factor library and an enterprise information library, and assigning a unique identification code to all information, a standardized and traceable data foundation is provided for the entire system. This solves the problems of data matching errors and traceability difficulties caused by chaotic material and supplier information in traditional accounting, and ensures the consistency and callability of data throughout the entire chain from raw material acquisition to product production.

[0015] Furthermore, the supplier information includes at least the mode of transportation, the transportation distance, and the corresponding carbon footprint factor value of the transportation mode; The product material information includes at least the default unit, the supplier code, and the corresponding material carbon footprint factor value. The product BOM information includes at least the product quantity, product unit, and a BOM list consisting of at least one of the product material information.

[0016] The data structure of supplier, material, and BOM information is refined, and key attributes such as transportation mode, distance, and carbon footprint factor value are clearly included. This enables the system to accurately calculate the carbon emissions generated by each unit of material in its upstream life cycle, rather than using industry averages or estimates, thus significantly improving the accuracy of carbon footprint calculation in the supply chain.

[0017] Furthermore, the modeling unit includes a model creation device and a matching device; the model creation device provides the function of calling product BOM information through a unique identification code, and provides the function of selecting the life cycle boundary of "cradle to gate" or "cradle to grave", as well as the function of selecting the time boundary at the hour level; the matching device realizes the matching of materials in the BOM list with the input / output equipment points of the process through drag-and-drop or selection operations.

[0018] By supporting lifecycle boundary selection, hourly time boundary setting, and drag-and-drop material matching, users can flexibly and intuitively build carbon footprint models that correspond one-to-one with actual production processes, solving the problem that existing models cannot reflect actual production processes and cannot perform process-level traceability.

[0019] Furthermore, the matching device is also used to manually enter material information, energy information, or supplier information for input / output device points, and to set attributes for all inputs / outputs, the attributes including at least one of resources, energy, exhaust gas, waste, products, by-products, and intermediate products.

[0020] By setting seven categories of attributes, including resources, energy, exhaust gas, waste, products, by-products, and intermediate products, for each input / output point of the process, a complete representation of the complex material and energy flows in the production process is achieved at the system level. This provides a foundation for accurately calculating the direct emissions, indirect emissions, waste treatment impacts, and carbon footprint allocation between main and by-products in the production process.

[0021] Furthermore, the calculation unit has a built-in carbon footprint calculation method corresponding to the attribute, wherein the carbon footprint calculation method for the exhaust gas attribute supports user-defined calculation parameters and calculation formulas.

[0022] It has built-in classification calculation methods for different attributes and gives user-defined calculation flexibility to waste gas attributes. This ensures the standardization and automation of calculations for conventional items such as resources and energy, while also taking into full account the complexity and diversity of waste gas generation scenarios in industrial production, so as to adapt to different industries and different process characteristics.

[0023] Furthermore, the carbon footprint calculation method specifically includes: (a) The formula for calculating the carbon footprint of a resource is as follows: ; Among them, among them, This represents the carbon footprint result for the i-th resource, in kgCO2eq. This represents the consumption of the i-th type of resource; This represents the carbon footprint factor value of the i-th resource. This represents the weight conversion coefficient of the i-th resource, expressed in tons per unit of resource. This represents the transportation distance of the j-th mode of transport for the i-th resource, in km. This represents the carbon footprint factor value for the j-th mode of transportation, expressed in kgCO2eq / tkm; (b) The carbon footprint of energy is calculated as follows: ; in, This represents the carbon footprint result for the nth energy source, expressed in kgCO2eq. This represents the consumption of the nth energy source, expressed in MJ. This represents the carbon footprint factor value of the nth energy source, expressed in kgCO2eq / MJ. (c) The carbon footprint of exhaust gas is calculated by the user using customized calculation parameters and formulas based on the generation scenario; (d) The formula for calculating the carbon footprint of waste is as follows: ; in, The carbon footprint result for the treatment of waste type α is expressed in kgCO2eq; This indicates the amount of waste generated of type α; This represents the weight conversion factor of the αth type of waste, expressed in t / unit of waste. The transport distance for the j-th mode of transport of the α-th type of waste is expressed in km. This represents the carbon footprint factor value for the j-th mode of transportation, expressed in kgCO2eq / t·km; This represents the carbon footprint factor value for the αth type of waste treatment, expressed in kgCO2eq / waste unit; (e) The formula for calculating the carbon footprint of a product is as follows: ; ; in, The carbon footprint result of the product's PR is expressed in kgCO2eq; This indicates the proportion of product PR allocation; Indicates the production volume of product PR; This represents the yield of the βth byproduct, BP. (f) The carbon footprint of by-products is calculated as follows: ; in, The carbon footprint of the byproduct BP is expressed in kgCO2eq. (g) Intermediate products are used to summarize the carbon footprint results of a single process and to transfer the carbon footprint results between processes. The calculation is based on the output and usage ratio of intermediate products in each process.

[0024] Transportation emissions are embedded in resource and waste calculations, enabling full-chain accounting; the carbon footprint allocation between main products and by-products is handled accurately and reasonably through the production ratio allocation method, avoiding the subjectivity and error of manual allocation; and the mechanism for the transfer of carbon footprint between intermediate products is clarified.

[0025] Furthermore, the output unit includes a certificate output device and a report output device; the certificate output device is used to generate a carbon footprint certificate with one click based on a built-in template, and supports export in PNG or JPG format; the report output device is used to generate a carbon footprint report with one click based on a built-in template, supports online modification, and supports export in PDF or WORD format.

[0026] By generating visual certificates and structured reports with a single click, professional carbon footprint data is transformed into an intuitive medium for internal and external communication, compliance submissions, and consumer display, thereby enhancing the system's usability.

[0027] A method for calculating the carbon footprint of a product based on its production process includes the following steps: S1. Identify the target product and, based on the unique identification code, complete its supplier information, product material information, and product BOM information in the database; S2. Collect raw data from the production site through multiple access methods, process it for business purposes, and establish a virtual data point model that corresponds one-to-one with the physical equipment locations. S3. Define the product manufacturing process and bind the virtual data points to the input / output device points of each process; S4. Call up the product BOM information, select the life cycle boundary and time boundary, and build the product carbon footprint model; match the BOM materials with the process equipment locations by dragging or selecting, and set the attribute types for each input / output; S5. Based on the set attribute type, call the corresponding carbon footprint calculation method to perform the calculation; if the attribute is exhaust gas, the user-defined calculation formula is used; if it is other attributes, the corresponding formula built into the system is used for calculation. S6. Classify, summarize, and analyze the calculation results to obtain carbon footprint hotspot information; S7: Based on built-in templates, generate and export carbon footprint certificates and reports with one click.

[0028] Furthermore, in step S4, by integrating the Manufacturing Execution System (MES) or Energy Management System (EMS), real-time process-level data is obtained by production batch to realize real-time calculation and historical traceability of the carbon footprint of the batch of products.

[0029] The beneficial effects of this invention are: The system of this invention, by configuring multi-source heterogeneous data interfaces and integrating with production systems such as MES / EMS, can automatically and in real time collect instrument and equipment data from the production site, completely eliminating the lagging and crude data input methods that rely on monthly bills and manual filling, so that carbon footprint accounting can capture the dynamic fluctuations of different production batches and different equipment states. The system of this invention allows users to customize production processes and bind real-time data with the equipment locations of specific processes, so that the unit of carbon footprint accounting can be refined from the entire product or the entire factory to each specific production process, realizing process-level carbon footprint traceability; when multiple products are produced on the same line, the system can automatically assign based on accurate process data, eliminating the distortion of results caused by manual allocation methods. By providing lifecycle boundary selection, hourly time boundary setting, and drag-and-drop material matching functions, users can flexibly and intuitively build carbon footprint models according to actual production processes. The system sets up a complete classification calculation system for seven types of flows, including resources, energy, exhaust gas, waste, products, by-products, and intermediate products. In particular, the calculation of resources and waste embeds transportation emissions, achieving accurate coverage of the carbon footprint of the entire supply chain. The system employs a scientific production ratio allocation method for products and by-products, addressing the subjectivity and unfairness inherent in manual allocation. Waste gas calculations support user customization, flexibly adapting to the specific calculation needs of complex industrial scenarios such as combustion, chemical reactions, and waste gas treatment. The system supports one-click generation of industry-standard, visualized carbon footprint certificates and structured detailed reports, reducing the workload of compiling compliance reports and enabling convenient use of carbon footprint data for internal management, supply chain communication, consumer communication, and compliance disclosure. Attached Figure Description

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0031] Figure 1 This is a flowchart illustrating the process of an existing carbon footprint calculation system.

[0032] Figure 2 This is a schematic diagram of the architecture of the carbon footprint calculation system of the present invention.

[0033] Figure 3 This is a schematic diagram of the enterprise information boundary device in the carbon footprint calculation system of the present invention.

[0034] Figure 4 This is a schematic diagram of the lifecycle boundary in the carbon footprint calculation system of the present invention. Figure 5 This is a schematic diagram of the input / output attributes in the carbon footprint calculation system of the present invention.

[0035] Figure 6 This is a schematic diagram of the calculation unit in the carbon footprint calculation system of the present invention.

[0036] Figure 7 This is a schematic diagram illustrating an example of the manufacturing process of the carbon footprint calculation system of this invention.

[0037] Figure 8 This is a schematic diagram of an embodiment of the present invention.

[0038] In the diagram: A10, Input module; A11, Macro data; A20, Selection module; A21, Emission factor data; A30, Calculation module; A31, Carbon footprint analysis results; B10, Input unit; B11, Data access device; B12, Data modeling device; B211, Fossil fuel factor library; B212, Carbon footprint factor library; B22, Enterprise information editing device; B221, Supplier information; B2211, Supplier code; B2212, Transportation mode; B2213, Transportation distance; B2214, Transportation mode Carbon footprint factor value; B222, Product material information; B2221, Product material code; B2222, Default unit; B2223, Supplier code; B2224, Carbon footprint factor value of the material called; B223, Product BOM information; B2231, Product BOM code; B2232, Product quantity; B2233, Product unit; B2234, BOM list; B30, Process unit; B31, Process editing device; B32, Data source configuration device; B40, Modeling unit; B41, Model creation device; B411, Life Cycle Boundary; B4111, Cradle to Gate; B4112, Cradle to Grave; C1, Raw Material Acquisition Stage; C2, Product Manufacturing Stage; C3, Product Distribution Stage; C4, Product Use Stage; C5, End-of-Life Stage; B42, Matching Device; B421, Input / Output Attributes; D1, Resources; D2, Energy; D3, Exhaust Gas; D4, Waste; D5, Product; D6, By-product; D7, Intermediate Product; B50, Computing Unit; B51, Computing Device; B511, Product Carbon Footprint Results; B512, Product Lifecycle Inventory; B52, Analytical Device; B521, Process Carbon Emission Analysis; B522, Lifecycle Carbon Emission Analysis; B523, Product Bill of Materials Carbon Emission Analysis; B60, Output Unit; B61, Certificate Output Device; B62, Report Output Device; X11, Resource 1; X12, Resource 2; X13, Energy 1; X15, Exhaust Gas 1; X16, Waste 1; Y11, Intermediate Product 1; Y11, Intermediate Product 1; Y12, Resource 3; Y13, Energy 2; Y14, Product; Y15, By-product; Y16, Exhaust Gas 2. Detailed Implementation

[0039] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0040] like Figure 1 As shown, existing carbon footprint calculation systems typically involve three main steps: Input module A10 allows users to manually input or import macro data of the product A11, such as the product bill of materials (BOM), total energy consumption (e.g., total electricity consumption on the monthly electricity bill), and waste volume. This data is often lagging and aggregated, and is completely decoupled from the real-time situation on the production site. Select module A20, where the user matches the macro data input above with the corresponding emission factor data A21 from a built-in or external database. This process relies on human experience, and the factors may not accurately match specific materials or specific transportation scenarios. The calculation module A30 uses simple formulas (such as total emissions = activity data × emission factor) to perform calculations and output a macroscopic carbon footprint analysis result A31.

[0041] The carbon footprint calculation system is completely disconnected from real-time production line data (such as the instantaneous power of each piece of equipment and the instantaneous material consumption of specific processes), making it unable to reflect the actual emissions under different batches and operating conditions. It adopts a rigid "total in, total out" model, which requires manual allocation of total energy consumption and total material consumption to each product according to rough proportions such as working hours or output when a production line produces multiple products. This can easily lead to serious distortion of the calculation results. The calculation result is only a static number, which cannot locate carbon emission hotspots and is difficult to provide data guidance for precise emission reduction.

[0042] Example 1 like Figure 2 As shown, a product carbon footprint calculation system based on production processes includes the following sequentially connected functional units, forming a dynamic, closed-loop management process: Input unit B10 is responsible for automatically capturing raw production data from multiple channels, including data access device B11 and data modeling device B12. Data access device B11 is equipped with rich interfaces, allowing seamless access to data streams from Excel reports, CSV files, field sensors (IoT), enterprise databases (such as MES and ERP), and third-party system APIs. Data modeling device B12 cleans, transforms, and performs business-oriented processing on the raw data (such as calculating usage and year-on-year / month-on-month analysis), ultimately establishing a virtual data point model. Each virtual data point corresponds one-to-one with a specific piece of equipment, instrument, or scenario in the real world (e.g., "real-time temperature sensor T101 of reactor A-01", "power of conveyor belt motor in production line B"), thus laying the foundation for subsequent process-level data binding.

[0043] Database unit B20 is responsible for storing and managing all basic accounting data, including: The emission factor editing device B21 is used to maintain the fossil fuel factor library B211 and the carbon footprint factor library B212. Users can import international / national standard factor libraries with one click, or manually add enterprise-specific or latest factor data. The enterprise information editing device B22 is used to maintain the enterprise's own static data, forming a dedicated carbon asset data base for the enterprise. Its detailed structure is as follows: Figure 3 As shown, it specifically includes: Supplier information B221 includes supplier code B2211, transportation method B2212, transportation distance B2213, and the carbon footprint factor value of the transportation method used B2214; for example, if supplier "S-001" uses a "32-ton heavy-duty diesel truck" for transportation over a distance of "350 kilometers", the system will automatically match the corresponding factor "0.06446 kgCO2eq / t·km" from the factor library. Product material information B222 includes product material code B2221, default unit B2222, supplier code B2223, and material carbon footprint factor value B2224; for example, the default unit for material "M-steel plate" is "kilogram", the supplier is "S-001", and the material factor is "2.5 kgCO2eq / kg". Product BOM information B223 includes product BOM code B2231, product quantity B2232, product unit B2233, and BOM list B2234. BOM list B2234 consists of the above product material information, which clarifies the various materials required to constitute a unit of product and their quantities.

[0044] Process unit B30 transforms the abstract product BOM into an executable and monitorable production process, which includes: The process editing device B31 allows users to customize product production processes based on the actual production line. For example, for the "car seat" product, processes such as "frame welding → sponge filling → fabric cutting and sewing → final assembly" can be created sequentially. For each process, a name and description must be entered, and its input / output device points must be specified. For example, the input points for the "sponge filling" process might be "foam machine material inlet weighing sensor WT01" and "foam machine energy meter PM01", while the output point is "post-filled seat semi-finished product line position sensor PS01". In the data source configuration device B32, the user binds the virtual data points (such as "real-time weight value of WT01") established by the input unit B10 to the equipment points (such as "material input points of the sponge filling process") defined in the process editing device B31. After binding, the process can automatically read the real-time data of the corresponding equipment during production. Modeling unit B40 is responsible for integrating data, processes, and knowledge to construct a computable carbon footprint model, which includes: The model creation device B41 allows users to select the target product's BOM information B223, define the accounting lifecycle boundary B411, and the pre-created process sequence in process unit B30; for example... Figure 4 As shown, the system offers two standard lifecycle boundary options: "Cradle to Gate B4111" and "Cradle to Grave B4112". The former only includes the raw material acquisition stage C1 and the product production stage C2, while the latter additionally includes the product distribution stage C3, the product use stage C4, and the product end-of-life stage C5. At the same time, users can set time boundaries down to the hour to calculate the carbon footprint of a specific production batch.

[0045] Matching device B42 allows users to match each item in the BOM (Bill of Materials) to the corresponding input / output device point in the process by dragging and dropping; for example, dragging "10kg of steel" from the BOM to the "welding machine material input" point in the "frame welding" process; simultaneously, input / output attributes B421 must be set for each input / output; such as... Figure 5 As shown, the system predefines seven categories of attributes, including resources D1, energy D2, exhaust gas D3, waste D4, products D5, by-products D6, and intermediate products D7. Resources D1 refers to materials or fossil fuels required within the product lifecycle boundary; energy D2 refers to electricity or heat required within the product lifecycle boundary; exhaust gas D3 refers to greenhouse gases emitted by the support structure within the product lifecycle boundary; waste D4 refers to various non-gaseous wastes generated within the product lifecycle boundary; products D5 refers to the target product generated within the product lifecycle boundary (a product carbon footprint model has only one target product); by-products D6 refer to by-products generated within the product lifecycle boundary; and intermediate products D7 refer to intermediate products generated by each process within the product lifecycle boundary. For example, the input steel is a "resource," the consumed electricity is "energy," welding fumes are "exhaust gas," scrap materials are "waste," and the welded frame is an "intermediate product."

[0046] Computational unit B50 performs carbon footprint calculations based on the constructed model, such as... Figure 6 As shown, it includes: The computing device B51 has a built-in differentiated calculation method for different input / output attributes B421. The system automatically calls the corresponding formula to perform calculations based on the attributes and outputs the product carbon footprint result B511 and a detailed product life cycle list B512. Analysis device B52 performs multi-dimensional analysis of the calculation results, generating process carbon emission analysis B521, life cycle carbon emission analysis B522, and product bill of materials carbon emission analysis B523, intuitively displaying carbon emission hotspots.

[0047] Output unit B60 transforms professional calculation results into directly usable outputs, including: The certificate output device B61 can generate beautiful and standardized product carbon footprint certificates with one click based on the built-in templates. It supports exporting in PNG or JPG image format, which is convenient for promotion and display. The report output device B62 can generate a complete and detailed carbon footprint accounting report with one click based on the built-in template. It supports online modification and supplementation, and finally exports the report in PDF or WORD document format for formal submission or archiving.

[0048] To illustrate more clearly how the system works, especially how the computing unit B50 utilizes its built-in methods, a simplified product manufacturing process will be used as an example. Figure 7 As shown, an exemplary production process including process X and process Y is illustrated, which produces a product PR and a by-product BP.

[0049] Product manufacturing process: Process X: Input: Resource 1 x11 (32t truck), Resource 2 x12 (no transport), Energy 1 x13 (e.g., natural gas); Process: In process X, resource 1X11 is consumed and partially burned to produce exhaust gas 1X15, while waste 1X16 is also generated. Output: Intermediate product 1Y11 (Usage Y, i.e., the output of process X, which enters process Y for further processing).

[0050] Process Y: Input: Intermediate product 1Y11 from process X, resource 3 (no transportation)Y12, energy 2Y13 (e.g., electricity); Process: Processing intermediate product 1Y11; Outputs: Product (output Z1) Y14, by-product BP (output Z2) Y15, and waste gas 2Y16.

[0051] Carbon footprint calculation process: Assume that the properties of each input / output have been correctly set and real-time data has been bound through the modeling unit.

[0052] (1) Calculate the carbon footprint of process X (borne by intermediate product Y11) Carbon footprint of Resource 1 (X11) ): Resource calculation formula used: Assuming X11 consumption is 1000 kg, its material carbon footprint factor is... The concentration is 1.5 kgCO2eq / kg, and it is transported using a 32t truck with a weight conversion factor of [missing information]. =1 t / 1000 kg=0.001 t / kg, transport distance The distance is 200 km, and the factor for this mode of transport is... It is 0.06446 kgCO2eq / t·km.

[0053] calculate: =1000×1.5+1000×0.001×200×0.06446 =1500+12.89 = 1512.89 kgCO2eq Carbon footprint of resource 2x12: Assuming a consumption of 500 kg of resource 2x12, no transportation emissions, and a material carbon footprint factor of 0.1 kgCO2eq / kg, then =500×0.1= 50 kgCO2eq.

[0054] Carbon footprint of 1 x 13 energy units: Assuming an energy consumption of 5000 MJ and a material carbon footprint factor of 0.055 kgCO2eq / MJ, then =5000×0.055=275 kgCO2eq.

[0055] Carbon footprint of exhaust gas 1x15: Since exhaust gas calculation supports customization, assuming the user calculates it using a custom formula based on the combustion characteristics of resource 1x11. =80 kgCO2eq.

[0056] Carbon footprint of 1x16 waste: Assuming 200 kg of waste is generated and transported by a 16t truck ( =0.001 t / kg), distance 50 km, transport factor The treatment factor was 0.089 kgCO2eq / tkm. It is 0.05 kg CO2 eq / kg. Therefore... =200×0.001×50×0.089+200× 0.05=0.89+10=10.89 kgCO2eq.

[0057] The total carbon footprint of process X (i.e., the carbon footprint of intermediate product 1Y11 in process X, denoted by its output) ) = + + + + =1512.89+50+275+80+10.89=1928.78 kgCO2eq.

[0058] Assume process X produces intermediate product 1Y11 in total. =950 kg.

[0059] (2) Calculate the carbon footprint of process Y and its allocation to the final product. The carbon footprint from process X: Process Y consumed Y = 800 kg of intermediate product 1Y11. Therefore, the carbon footprint of this portion entering process Y is: = × (Dosage Y / Production) = 1928.78 × (800 / 950) = 1928.78 × 0.8421 ≈ 1623.46 kgCO2eq. The carbon footprint of process Y itself: Resource 3Y12: Assuming the consumption corresponds to =120 kgCO2eq.

[0060] Energy 2Y13: Assuming consumption corresponds to =180 kgCO2eq.

[0061] Exhaust Gas 2Y16: Managing Carbon Footprint =15 kgCO2eq.

[0062] Total carbon footprint of process Y (before allocation): = + + + =1623.46+120+180+15=1938.46kgCO2eq.

[0063] Allocation between product Y14 and by-product Y15 (BP): Assuming this batch of production yields product Y14 (Z1 = 780 kg) and by-product Y15 (BP) (Z2 = 20 kg).

[0064] Calculate the product allocation ratio RA: RA = Z1 / (Z1 + Z2) = 780 / (780+20) = 0.975.

[0065] Carbon footprint of product Y14: = ×RA=1938.46×0.975≈1890.00 kgCO2eq.

[0066] Carbon footprint of byproduct Y15: = × (1-RA) =1938.46×0.025≈48.46kgCO2eq.

[0067] Thus, the carbon footprint of product Y14 (780 kg) is approximately 1890 kgCO2eq, and the carbon footprint per unit product is approximately 2.42 kgCO2eq / kg.

[0068] Example 2 like Figure 8 A method for calculating the carbon footprint of a product based on its production process includes the following steps: S1. Identify target products and prepare basic information: Users determine the target products to be accounted for based on the purpose of product carbon footprint accounting (such as internal process optimization, supply chain carbon information disclosure, compliance requirements such as EU battery regulations). Complete technical data for the product must be collected simultaneously, including: product bill of materials (BOM), production process flow diagram, list of production equipment and corresponding data collection points, list of major raw material suppliers and their transportation information, and relevant energy and resource consumption records.

[0069] S2. Improve database information (data standardization): In the system, the following steps are executed sequentially using the enterprise information editing device: S21. Enter supplier information: Create a unique code for each supplier and record in detail the transportation method and distance of the materials supplied. The system will automatically associate the corresponding transportation carbon footprint factor. S22. Enter product material information: Create a unique material code for each raw material and auxiliary material, associate it with its supplier, and enter or match its material carbon footprint factor value (which can be obtained from the database or manually entered).

[0070] S23. Constructing Product BOM Information: Based on the product's design BOM, create a corresponding BOM model in the system, clarifying each material that makes up the product and its usage. The materials in the BOM will be automatically associated with the entered material information.

[0071] S3. Raw data access and virtual point modeling (real-time data processing): S31. Accessing Field Data: Through various interfaces provided by the system (such as OPC UA, Modbus, API, file import, etc.), access real-time or near real-time data streams from sensors, smart meters, MES systems, and EMS systems in the production field. S32. Establish a virtual data point model: Perform business-oriented processing on the accessed raw data. Each processed data item is defined as a virtual data point and corresponds one-to-one with a specific device, instrument, or production scenario in the physical world.

[0072] S4. Define the process and bind the data (model structuring): S41. Create production process: In the process unit, according to the actual production process flow, define each production process and define its input device point and output device point for each process. S42. Bind data source: Drag or select the virtual data point established in step S32 and bind it to the corresponding input / output device point of the process. After binding, the process will automatically obtain the real-time data of the point during production.

[0073] S5. Constructing a carbon footprint model and matching materials (model instantiation): S51. Create a carbon footprint model: In the modeling unit, select the BOM of the target product and select the life cycle boundary for accounting (e.g., "cradle to gate" for supply chain disclosure, "cradle to grave" for full life cycle assessment); at the same time, you can set the time boundary (e.g., the time period of a specific production batch) to achieve batch-level traceability; S52. Matching Materials and Setting Attributes: Through an intuitive drag-and-drop interface, match each material in the BOM to the corresponding input point in the process. Attributes are determined based on the actual destination of the material / energy. Input raw materials: set as resources; Electricity and heat consumed: Set as energy source; Greenhouse gases directly emitted during the production process: classified as waste gas; Waste residue and waste liquid generated: classified as waste; The final target product: set as the product; Valuable substances produced simultaneously: are designated as byproducts; Intermediate products produced in one process that need to be further processed in the next process: These are designated as intermediate products. When the attribute is set to exhaust gas, the system will provide a parameter input interface or formula editor, allowing users to customize calculation parameters and formulas according to the actual generation mechanism.

[0074] S6. Real-time computing and hotspot analysis (intelligent computing): S61. Triggered Calculation: The system automatically triggers carbon footprint calculation based on the constructed model, the bound real-time data, and the set attributes and formulas. S62. Multi-dimensional analysis: After the calculation is completed, the system automatically analyzes the results and presents them in a visual format: Process carbon emission analysis chart: Displays the ranking of carbon footprint contributions of each process, intuitively identifying carbon hotspot processes; Life cycle stage analysis chart: showing the carbon emission percentage at each stage, including raw material acquisition, production, and transportation; Material Carbon Inventory Analysis Table: Lists the carbon emissions from various materials in the BOM and identifies high-carbon materials.

[0075] S7. One-click output generation (result delivery): S71. Generate carbon footprint certificate: The system automatically generates a visual certificate containing information such as product name, carbon footprint value, accounting standard, and accounting unit based on the built-in template. It supports exporting to PNG / JPG format for product promotion or display. S72. Generate Carbon Footprint Report: The system automatically generates a complete and detailed accounting report, covering accounting objectives, boundaries, data sources, calculation methods, allocation principles, results, and uncertainty analysis. The report supports online preview and modification and can be directly exported as PDF or WORD format for formal submission, archiving, or third-party verification.

[0076] Through the above steps, the product carbon footprint calculation method based on production process in this embodiment realizes a closed loop of the entire process from data standardization, real-time collection, process-level modeling, intelligent calculation to result delivery, upgrading the traditional ex-post static accounting to dynamic, refined, and traceable carbon footprint management synchronized with the production process.

[0077] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A product carbon footprint calculation system based on production processes, characterized in that, It includes the following functional units connected in sequence: The input unit is used to access multi-source heterogeneous raw data and establish a virtual data point model that includes data semantics and business rules corresponding to real devices or scenarios; The database unit is used to store and manage emission factor data, supplier information, product material information, and product BOM information. The process unit, connected to the input unit, is used to customize the product manufacturing process and bind virtual data points to process equipment points; The modeling unit, connected to the database unit and the process unit, is used to build a product carbon footprint model and to match materials and set attribute types for process inputs / outputs. The calculation unit, connected to the modeling unit, is used to call the corresponding carbon footprint calculation method according to the set attribute type, perform calculations, and analyze the results; The output unit, connected to the computing unit, is used to generate carbon footprint certificates and reports with a single click.

2. The product carbon footprint calculation system based on production processes according to claim 1, characterized in that: The input unit includes a data access device and a data modeling device. The data access device is equipped with at least three access methods, including Excel, CSV, TXT, IoT device signals, database interfaces, and application programming interfaces (APIs). The data modeling device performs business-oriented processing on the raw data through at least one of the following methods: usage analysis, year-on-year analysis, month-on-month analysis, mean analysis, or standard deviation analysis, in order to establish the virtual data point model.

3. The product carbon footprint calculation system based on production processes according to claim 1, characterized in that: The database unit includes: Emission factor editing device for maintaining fossil fuel factor database and carbon footprint factor database; Enterprise information editing device, used to maintain supplier information, product material information, and product BOM information; Each of the supplier information entries, each of the product material information entries, and each of the product BOMs is assigned a unique identification code.

4. The product carbon footprint calculation system based on production processes according to claim 3, characterized in that: The supplier information includes at least the mode of transport, the transport distance, and the corresponding carbon footprint factor value of the transport mode. The product material information includes at least the default unit, the supplier code, and the corresponding material carbon footprint factor value. The product BOM information includes at least the product quantity, product unit, and a BOM list consisting of at least one of the product material information.

5. The product carbon footprint calculation system based on production processes according to claim 1, characterized in that: The modeling unit includes a model creation device and a matching device. The model creation device provides the function of calling product BOM information through a unique identification code, and provides the function of selecting the life cycle boundary of "cradle to gate" or "cradle to grave", as well as the function of selecting the time boundary at the hour level. The matching device realizes the matching of materials in the BOM list with the input / output equipment points of the process through drag-and-drop or selection operations.

6. The product carbon footprint calculation system based on production processes according to claim 5, characterized in that: The matching device is also used to manually enter material information, energy information or supplier information for input / output device points, and to set attributes for all inputs / outputs, including at least one of resources, energy, exhaust gas, waste, products, by-products and intermediate products.

7. The product carbon footprint calculation system based on production processes according to claim 6, characterized in that: The calculation unit has a built-in carbon footprint calculation method corresponding to the attribute, wherein the carbon footprint calculation method for the exhaust gas attribute supports user-defined calculation parameters and calculation formulas.

8. The product carbon footprint calculation system based on production processes according to claim 7, characterized in that: The carbon footprint calculation method specifically includes: (a) The formula for calculating the carbon footprint of a resource is as follows: ； Among them, among them, This represents the carbon footprint result for the i-th resource, in kgCO2eq. This represents the consumption of the i-th type of resource; Represents the carbon footprint factor value of the i-th resource; Represents the weight conversion coefficient of the i-th resource, in t / resource unit; This represents the transportation distance of the j-th mode of transport for the i-th resource, in km; This represents the carbon footprint factor value for the j-th mode of transportation, expressed in kgCO2eq / tkm; (b) The carbon footprint of energy is calculated as follows: ； in, This represents the carbon footprint result for the nth energy source, expressed in kgCO2eq. This represents the consumption of the nth energy source, expressed in MJ. This represents the carbon footprint factor value of the nth energy source, expressed in kgCO2eq / MJ. (c) The carbon footprint of exhaust gas is calculated by the user using customized calculation parameters and formulas based on the generation scenario; (d) The formula for calculating the carbon footprint of waste is as follows: ； in, The carbon footprint result for the treatment of waste type α is expressed in kgCO2eq; This indicates the amount of waste generated of type α; This represents the weight conversion factor of the αth type of waste, expressed in t / unit of waste. The transport distance for the j-th mode of transport of the α-th type of waste is expressed in km. This represents the carbon footprint factor value for the j-th mode of transportation, expressed in kgCO2eq / t·km; This represents the carbon footprint factor value for the αth type of waste treatment, expressed in kgCO2eq / waste unit; (e) The formula for calculating the carbon footprint of a product is as follows: ； ； in, The carbon footprint result of the product's PR is expressed in kgCO2eq; Indicates the proportion of product PR allocated; Indicates the production volume of product PR; This represents the yield of the βth byproduct, BP. (f) The carbon footprint of by-products is calculated as follows: ； in, The carbon footprint of the byproduct BP is expressed in kgCO2eq. (g) Intermediate products are used to summarize the carbon footprint results of a single process and to transfer the carbon footprint results between processes. The calculation is based on the output and usage ratio of intermediate products in each process.

9. The product carbon footprint calculation system based on production processes according to claim 1, characterized in that: The output unit includes a certificate output device and a report output device; the certificate output device is used to generate a carbon footprint certificate with one click based on a built-in template, and supports exporting in PNG or JPG format; The report output device is used to generate a carbon footprint report with one click based on a built-in template, supports online editing, and supports export in PDF or WORD format.

10. A method for calculating the carbon footprint of a product based on production processes, characterized in that, Includes the following steps: S1. Identify the target product and, based on the unique identification code, complete its supplier information, product material information, and product BOM information in the database; S2. Collect raw data from the production site through multiple access methods, process it for business purposes, and establish a virtual data point model that corresponds one-to-one with the physical equipment locations. S3. Define the product manufacturing process and bind the virtual data points to the input / output device points of each process; S4. Call up the product BOM information, select the life cycle boundary and time boundary, and build the product carbon footprint model; match the BOM materials with the process equipment locations by dragging or selecting, and set the attribute types for each input / output; S5. Based on the set attribute type, call the corresponding carbon footprint calculation method to perform the calculation; if the attribute is exhaust gas, the user-defined calculation formula is used; if it is other attributes, the corresponding formula built into the system is used for calculation. S6. Classify, summarize, and analyze the calculation results to obtain carbon footprint hotspot information; S7: Based on built-in templates, generate and export carbon footprint certificates and reports with one click.

11. The product carbon footprint calculation method based on production processes according to claim 10, characterized in that: In step S4, by integrating the Manufacturing Execution System (MES) or Energy Management System (EMS), real-time process-level data is obtained by production batch, enabling real-time calculation and historical traceability of the carbon footprint of the batch of products.

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