Power consumption calculation system and power consumption calculation method

Abstract

To enable calculation of power consumption for each operation state even in a facility in which it is difficult to associate a facility operation state with the power consumption.SOLUTION: A power consumption calculation system 100 according to one aspect of the present invention analyzes, on the basis of power consumption information of constituent facilities of a target facility, power consumption states of the constituent facilities, estimates operation states of the target facility corresponding to the power consumption states 1-3 of the constituent facilities based on operating time information of the target facility for each process and the power consumption information of the constituent facilities, and creates a power consumption model 1100 by combining multiple operation states of the target facility and by identifying the operation state of the target facility corresponding to each of the power consumption states 1-3.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a power consumption calculation system and a power consumption calculation method for calculating the power consumption of a target facility. [Background technology]

[0002] In recent years, with growing environmental awareness, production management that takes into account environmental impacts such as reducing power consumption and carbon dioxide (CO2) emissions has become important.

[0003] When proposing methods (measures) for reducing the power consumption of production equipment, it is necessary to identify which operating state (setup, punch processing, laser processing, etc.) has the greatest impact in order to determine the equipment operating state for which measures should be taken.

[0004] However, the conventional method of calculating power consumption by calculating the rated power of production equipment over the equipment operation time does not know the power consumption for each operation state, making it difficult to consider countermeasures. Therefore, in order to identify the factors that increase the power consumption of production equipment and take appropriate measures, it is necessary to analyze the power consumption while the equipment is operating.

[0005] When grasping the power consumption for each equipment operation state, for example, there are (1) easily understood equipment operation states such as setup work in progress (equipment preparation) and (2) equipment operation states that involve a mixture of multiple equipment operations (e.g. material delivery, processing, etc.).

[0006] For example, in the case of the equipment operation status described above in (2), since multiple pieces of equipment are operating simultaneously, it is not possible to classify the equipment operations, making it difficult to associate them with power consumption. In addition, power consumption data tends to vary greatly in power consumption values ​​when there is noise or when power is output instantaneously. Therefore, power consumption data that includes large noise or large transient power consumption values ​​may lead to erroneous judgments when linking equipment operation status with power consumption.

[0007] In this way, accurate correspondence between equipment operation states and power consumption information is required to calculate power consumption for each equipment operation state, but one piece of equipment outputs multiple operation states, and the profile of each operation state often does not match the power consumption profile. For this reason, the challenge is to establish a method for building a model that shows the correspondence between equipment operation states and power consumption.

[0008] For example, Patent Document 1 states that "the power consumption estimation device has a reduced power estimation unit that estimates, for each piece of equipment, the power consumption that can be reduced during the implementation period of energy-saving operation control by referring to air conditioning configuration information that specifies the set of air conditioners that are subject to rotation control and control setting information that includes the settings of rotation control, and by referring to the start time and duration for which energy-saving operation control is actually performed for each air conditioner determined by the control plan determination unit, and the power consumption model that represents the time-series change in power consumption of each air conditioner obtained from the operation record generated by the power consumption model generation unit." As a result, the power consumption estimation device described in Patent Document 1 estimates with high accuracy the power consumption reduction effect when rotation control is performed. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] International Publication No. 2022 / 153534 Summary of the Invention [Problem to be solved by the invention]

[0010] However, the technology described in Patent Document 1 cannot calculate (distinguish) the power consumption state required for defining a power consumption model, and cannot estimate the equipment operation state corresponding to the power consumption.

[0011] In light of the above circumstances, there has been a demand for a method that can calculate power consumption for each operation state, even for equipment in which it is difficult to associate the equipment operation state with the power consumption. [Means for solving the problem]

[0012] In order to solve the above problem, a power consumption calculation system of one embodiment of the present invention comprises an operation time memory unit storing operation time information for each process of a target equipment, a power consumption information memory unit storing power consumption information for each constituent equipment constituting the target equipment, a power consumption state analysis unit analyzing the power consumption state of the constituent equipment from the power consumption information, an operation state estimation unit estimating an operation state of the target equipment corresponding to the power consumption state of the constituent equipment based on the operation time information of the target equipment for each process and the power consumption information of the constituent equipment, a power consumption model creation unit creating a power consumption model of the constituent equipment by matching the operation state of the target equipment with each power consumption state of each constituent equipment, a power consumption calculation unit calculating the power consumption for each power consumption state of the constituent equipment based on the power consumption model, and an information provision unit outputting the calculation results of the power consumption for each power consumption state of the constituent equipment. Effect of the Invention

[0013] According to at least one aspect of the present invention, even for equipment in which it is difficult to associate the equipment operation state with the power consumption, it is possible to calculate the power consumption for each operation state. Problems, configurations and effects other than those described above will become apparent from the following description of the embodiments. [Brief description of the drawings]

[0014] [Figure 1] 1 is a diagram illustrating an example of a functional configuration of a production planning system to which a power consumption calculation system according to an embodiment of the present invention is applied. [Diagram 2] FIG. 2 is a diagram showing an example of a production plan table in the production planning system according to an embodiment of the present invention. [Diagram 3] FIG. 2 is a diagram showing an example of a table of facility information in the production planning system according to an embodiment of the present invention. [Figure 4] FIG. 2 is a diagram showing an example of a table of operation results in the production planning system according to an embodiment of the present invention. [Diagram 5] 1 is a diagram showing an example of a table of power consumption information in a production planning system according to an embodiment of the present invention; [Figure 6] 3 is a diagram showing an example of power consumption information (raw data of power consumption) in the production planning system according to one embodiment of the present invention. FIG. [Figure 7] FIG. 2 is a diagram showing an example of a table of CO2 conversion information in the production planning system according to one embodiment of the present invention. [Figure 8] 10 is a flowchart showing an example of a procedure for a power consumption calculation process performed by the production planning system according to one embodiment of the present invention. [Figure 9] 11 is a diagram illustrating an example of processing by a power consumption state analysis unit in the embodiment of the present invention. FIG. [Figure 10] 13 is a diagram showing an example of association between an equipment operation state and a waveform pattern of power consumption by an operation state estimating unit in one embodiment of the present invention. FIG. [Figure 11] 3 is a diagram showing an example of a combination of power consumption states, equipment operation states, and a power consumption model in the production planning system according to one embodiment of the present invention. FIG. [Figure 12] 1 is a diagram showing an example of power consumption for each power consumption state of each piece of equipment in a production planning system according to an embodiment of the present invention; [Figure 13] FIG. 2 is a diagram showing an example of an output screen in the production planning system according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, examples of modes for carrying out the present invention (hereinafter, referred to as "embodiments") will be described with reference to the accompanying drawings.

[0016] In this specification and the accompanying drawings, identical or similar components are given the same reference numerals, and duplicate explanations may be omitted, or only differences may be explained. In addition, when there are multiple identical or similar components, they may be explained with different subscripts added to the same reference numerals. In addition, when it is not necessary to distinguish between these multiple components, the subscripts may be omitted. The number of each component may be singular or plural, unless otherwise specified.

[0017] In the following embodiment, various information is described in table format, but the various information may be in a data format other than the table format. Also, for example, various names such as "XX information", "XX table", "XX list", and "XX list" are interchangeable. Also, when describing identification information, expressions such as "identification information", "name", and "ID" are used, but these are interchangeable.

[0018] <Functional configuration of the power consumption calculation system> First, an example of the functional configuration of a production planning system to which a power consumption calculation system according to one embodiment of the present invention is applied will be described with reference to Fig. 1. The power consumption calculation system of the present invention realizes calculation of power consumption for each operation state of equipment in order to identify factors that increase power consumption in the production process and estimate the effectiveness of proposed countermeasures.

[0019] Fig. 1 is a diagram showing an example of the functional configuration of a production planning system to which a power consumption calculation system according to this embodiment is applied. As one of the functions for managing a production plan, the production planning system 100 shown in Fig. 1 has a function for calculating power consumption for each piece of equipment constituting a production facility 200 (hereinafter also referred to as "constituent equipment").

[0020] The production planning system 100 is connected to a production facility 200 and a production instruction device 300 via a network N. The production planning system 100 collects operation data including time-series sensor data generated by the production facility 200 via the network N, and provides the collected operation data to the production instruction device 300.

[0021] The production facility 200 is, for example, a production device or a processing device that produces or processes a product according to a production plan. The production facility 200 is a device installed in a control system to be monitored in a factory or a plant, and may be a SCADA (Supervisory Control And Data Acquisition), a DCS (Distributed Control System), a controller, or the like. The number of production facilities 200 is not limited to one, and may be multiple.

[0022] Production instruction device 300 is a device that instructs which product to produce, by which facility (device), and by when. Production instruction device 300 is a terminal used by a user, and corresponds to a general-purpose information processing device such as a personal computer or tablet computer equipped with an input device and a display device. Using the input device of production instruction device 300, a user can display each screen (described later) on the display device, move or click the pointer on each screen, input text, and so on.

[0023] [Production planning system configuration] The production planning system 100 corresponds to a general-purpose computer such as a personal computer, a workstation, etc. The production planning system 100 includes a calculation unit 110, an input / output unit 140, and a storage unit 150, which are connected via a system bus so that they can transmit and receive data to each other.

[0024] The calculation unit 110 includes a calculation processing unit 120 and a memory unit 130. The calculation unit 110 is an example of a computer.

[0025] The arithmetic processing unit 120 is a processing device such as a central processing unit (CPU). The arithmetic processing unit 120 includes a data acquisition unit 121, a power consumption state analysis unit 122, an operation state estimation unit 123, a power consumption model creation unit 124, a power consumption calculation unit 125, and an information provision unit 126. Each of these functional units can be realized by software by the arithmetic processing unit 120 interpreting and executing a computer program that realizes each function. Each of these functional units will be described in detail later.

[0026] The memory unit 130 is a main storage device such as a RAM (Random Access Memory) that temporarily stores an OS (Operating System), computer programs, data, etc. The arithmetic processing unit 120 reads out the program code of the software that realizes each function according to the present embodiment from the storage unit 150 and temporarily stores it in the memory unit 130. In addition, variables, parameters, etc. generated during the arithmetic processing of the arithmetic processing unit 120 are temporarily written in the memory unit 130, and these variables, parameters, etc. are read out by the arithmetic processing unit 120 as appropriate. The program may be recorded in a ROM (Read Only Memory) not shown.

[0027] The calculation unit 110 (hardware module) may include a timer (not shown) for implementing periodic operations such as data collection by software. Periodic information for the periodic operation may be stored in the storage unit 150.

[0028] The input / output unit 140 controls data communication between the production equipment 200 and the production instruction device 300 via the network N. The input / output unit 140 also functions as an input / output interface between the production planning system 100 and the display device 180 or an input device (not shown). For example, when outputting display data from the input / output unit 140 to the display device 180, the input / output unit 140 can use interface standards such as HDMI (High Definition Multimedia Interface) (registered trademark) or DVI (Digital Visual Interface).

[0029] The storage unit 150 stores input information 160 and output information 170 . The input information 160 is information input from an external device to the production planning system 100. In Fig. 1, the input information 160 includes a production plan 161, equipment information 162, operation results 163, power consumption information 164, and CO2 conversion information 165. Each piece of the input information 160 will be described later with reference to Figs. 2 to 6. In this embodiment, each piece of information is stored in a table format, but this is not limited to the example.

[0030] The output information 170 is information that is output from the production planning system 100 to an external device (a display device 180 in this embodiment). In Fig. 1, the output information 170 includes a waveform pattern 171 of power consumption, a number of power consumption states of a power consumption model 172, a power consumption model 173, and a calculation result 174 of power consumption. In this embodiment, each piece of information is stored in a table format, but this is not limited to this example.

[0031] The storage unit 150 is configured with a large-capacity storage device, etc. For example, a hard disk device, a solid state drive (SSD), etc. can be used as the large-capacity storage device. The storage unit 150 stores computer programs and parameters executed by the arithmetic processing unit 120. The arithmetic processing unit 120 reads out program codes of software that realize each function according to this embodiment from the storage unit 150 or a ROM (not shown), executes them, and performs various calculations and controls.

[0032] When the memory unit 150 stores programs, data, etc. necessary for the operation of the calculation processing unit 120, the memory unit 150 is used as an example of a computer-readable non-transitory storage medium that stores a program executed by a computer.

[0033] Next, each functional unit of the arithmetic processing unit 120 will be described. The data acquisition unit 121 acquires data indicating the operating status of equipment constituting the production facility 200 (hereinafter referred to as "constituent equipment") and data indicating power consumption (raw data) from the production facility 200 at regular intervals.

[0034] The power consumption state analysis unit 122 analyzes the power consumption state of the constituent equipment of the production facility 200. For example, the power consumption state analysis unit 122 calculates a waveform pattern of the power consumption of the constituent equipment, and analyzes the power consumption state from the waveform pattern of the power consumption. Here, different power consumption states included in the waveform pattern of the power consumption are detected.

[0035] The operation state estimation unit 123 estimates the operation state of the production facility 200 (hereinafter referred to as the "facility operation state") corresponding to the power consumption state.

[0036] The power consumption model creation unit 124 creates a power consumption model by associating the power consumption states of the constituent equipment of the production equipment 200 with the equipment operation states.

[0037] The power consumption calculation unit 125 calculates the power consumption of the constituent equipment of the production equipment 200 for each power consumption state based on the power consumption model. For example, if the production equipment 200 is a punching device, the power consumption of all the constituent equipment (for example, seven units in the example of FIG. 6) that constitutes the punching device is calculated.

[0038] The information providing unit 126 performs processing to provide each piece of information of the output information 170 of the storage unit 150, such as the results of calculating the power consumption of the components of the production facility 200, to the display device 180 or the production instruction device 300.

[0039] Next, the tables for the production plan 161, the facility information 162, the operation record 163, the power consumption information 164, and the CO2 conversion information 165 will be described with reference to FIGS.

[0040] [Production planning table] 2 is a diagram showing an example of a table of the production plan 161 in the production planning system 100. The table of the production plan 161 stores information related to the production plan of the target product. The table of the production plan 161 has fields for the product, process, equipment, model, and required deadline.

[0041] The "product" field stores information that identifies a product to be produced or processed by a specified deadline. For example, information that identifies a product may include a product name or a product ID (IDentification). The “process” field stores information indicating a process in a series of processes in the production or processing of a product. A process can also be said to be the operating state or operation of a target facility such as the production facility 200. The "equipment" field stores information indicating the equipment (production equipment 200 in FIG. 1) used when producing or processing the product. The "model" field stores information indicating the model of equipment used to produce or process the product. The "required deadline" field stores information indicating a deadline required for the production or processing of a product. In the following, unless otherwise specified, "production of a product" includes processing.

[0042] In the example of FIG. 2, the production plan for product “A” describes that process “1-1” is to be completed by the required deadline “12 / 21” using equipment “(1)” of type “a”. For example, equipment “(1)” is a punching device, and process “1-1” is punching. Similarly, it describes that process “1-1” for product “A” is to be completed by the required deadline “12 / 23” using equipment “(2)” of type “b”. Furthermore, it describes that process “1-1” for product “A” is to be completed by the required deadline “12 / 22” using equipment “(3)” of type “c”. In the following, process “1-1” may be described as “process 1-1”, equipment “(1)” as “equipment (1)”, and type “a” as “type a”.

[0043] [Facility information table] 3 is a diagram showing an example of a table of equipment information 162 in the production planning system 100. The table of equipment information 162 stores information on the process carried out by the equipment and the constituent equipment that constitutes the equipment. The table of equipment information 162 has fields for the process, equipment, model, constituent equipment, and constituent equipment model.

[0044] The "process" field stores the same information as that stored in the process field in the production plan 161 table. The "Facility" field stores the same information as that stored in the facility field in the production plan 161 table. The "Model" field stores the same information as that stored in the model field in the production plan 161 table. The "constituent equipment" field stores information indicating equipment (constituent equipment) that constitutes equipment (eg, production equipment 200) used when producing or processing a product. The "component equipment type" field stores information indicating the type of component equipment.

[0045] In the example of FIG. 3, it is described that equipment (1) of type a that performs process 1-1 is equipped with component equipment (1)-1, whose component equipment type is "(1)-1-α". It is also described that equipment (1) is equipped with component equipment "(1)-1" to "(1)-7", whose component equipment types are "(1)-2-α" to "(1)-7-α". For example, equipment (1) is production equipment 200. It is also described that equipment (2) is equipped with component equipment "(2)-1", whose component equipment type is "(2)-1-β".

[0046] [Operation record table] 4 is a diagram showing an example of a table of operation results 163 in the production planning system 100. The table of operation results 163 stores information related to the operation results of the target equipment. The table of operation results 163 has fields for date, time, and process by equipment.

[0047] The "Date" field stores information about the date on which the target equipment was put into operation. The "time" field stores information about the time when the target equipment started operating. This time may be the time when the equipment started operating. The “Process by Equipment” field stores information about the process (operating status) that was being carried out on the date and time entered in the “Date” and “Time” fields for each piece of target equipment (e.g., equipment (1), (2), ...).

[0048] In the example of FIG. 4, it is recorded that process 1 was carried out at equipment (1) at the time "14:05:30" on December 15th. A flag "1" indicates that the process was carried out, and a flag "0" indicates that the process was not carried out. It is also recorded that processes 1 and 2 were carried out at equipment (1) at the time "14:06:32" on December 15th. It is further recorded that processes 1 to 3 were carried out at equipment (1) at the time "14:06:34" on December 15th, and that processes 1 and 2 were carried out at equipment (1) at the time "14:11:55" on December 15th.

[0049] The table of operation results 163 (an example of an operation time storage unit) stores operation time information of the target equipment based on at least one of the production plan executed by the target equipment or the operation results of the target equipment.

[0050] [Power consumption table] 5 is a diagram showing an example of a table of power consumption information 164 in the production planning system 100. The table of power consumption information 164 stores information on the power consumption of the constituent equipment of the target equipment. The table of power consumption information 164 has fields for time and power consumption by each constituent equipment.

[0051] The "time" field stores information about the time [s] that has passed since a certain reference time. Instead of the time that has passed since a certain reference time, the actual time may be used. The “Power consumption by component equipment” field stores information on the power consumption [kW] (instantaneous value) for each component equipment of the target equipment (e.g., equipment (1)) at the time (hour) entered in the “Time” field.

[0052] In Fig. 5, as an example, it is stated that at time 0 [s], the power consumption of equipment (1)-1 is 1.852 [kW], the power consumption of equipment (1)-2 is 0.134 [kW], and the power consumption of equipment (1)-3 is 11.546 [kW]. It is also stated that at time 0.10 [s], the power consumption of equipment (1)-1 is 1.827 [kW], the power consumption of equipment (1)-2 is 0.129 [kW], and the power consumption of equipment (1)-3 is 11.523 [kW]. It is also stated that at time 0.20 [s], the power consumption of equipment (1)-1 is 1.833 [kW], the power consumption of equipment (1)-2 is 0.133 [kW], and the power consumption of equipment (1)-3 is 11.523 [kW].

[0053] 6 shows an example of power consumption information (raw data of power consumption) for the constituent equipment of the production equipment 200. For example, the production equipment 200 is configured to include seven pieces of equipment, namely, a laser equipment, a punch equipment, a compressor (medium pressure), a compressor (low pressure), an air dryer (medium pressure), an air dryer (low pressure), and a dust collector. For example, the laser equipment corresponds to equipment (1)-1, the punch equipment corresponds to equipment (1)-2, and the compressor (medium pressure) corresponds to equipment (1)-3.

[0054] 5 is obtained for the laser equipment, expanding the power consumption information of the laser equipment onto a two-dimensional plane consisting of time and power consumption will result in a graph such as power consumption raw data 610. Similarly, expanding the power consumption information of the punch equipment onto a two-dimensional plane consisting of time and power consumption will result in power consumption raw data 620.

[0055] The data acquisition unit 121 (FIG. 1) further acquires power consumption information 164, i.e., raw data on power consumption, for a total of seven pieces of component equipment, including a compressor (medium pressure), a compressor (low pressure), an air dryer (medium pressure), an air dryer (low pressure), and a dust collector, and stores the information in the memory unit 150.

[0056] [CO2 conversion information table] CO2 equivalent information is an index that estimates how much CO2 is emitted when a certain amount of electricity is produced or consumed. For example, different electric power companies have contracts with different factories depending on the region in which they are located. Since the power source composition ratio of power generation facilities varies depending on the electric power company, the amount of CO2 generated when generating electricity differs. Therefore, by setting a specific coefficient for each facility such as a factory and applying that coefficient to the power consumption, it is possible to estimate the approximate CO2 emissions at the target facility. For example, nuclear power and renewable energy generate less CO2 than other power sources.

[0057] 7 is a diagram showing an example of a table of CO2 conversion information 165 in the production planning system 100. The table of CO2 conversion information 165 stores information on CO2 emissions from facilities. The table of CO2 conversion information 165 has fields for facilities and coefficients.

[0058] The "facility" field stores information about facilities such as factories. Facility information is linked to the information of the contracted power company. As a result, the following coefficients are set for each facility. The "Coefficient" field stores information about the coefficient applied to the formula that calculates the amount of CO2 emissions from power consumption. The larger the coefficient value, the greater the amount of CO2 emissions. Explanation of the calculation formula is omitted.

[0059] In the example of Figure 7, a coefficient of 0.45 is set for facility "Factory A." Similarly, a coefficient of 0.52 is set for facility "Factory B" in another region, and a coefficient of 0.48 is set for facility "Factory C" in yet another region.

[0060] [Power consumption calculation process] Next, the power consumption calculation process performed by the production planning system 100 will be described with reference to FIG.

[0061] 8 is a flowchart showing an example of the procedure of the power consumption calculation process by the production planning system 100. It is assumed that the input information 160 has already been acquired by the data acquisition unit 121 of the arithmetic processing unit 120 (FIG. 1).

[0062] The power consumption status analysis unit 122 analyzes the power consumption status of the constituent equipment of the target equipment based on the power consumption information 164 (raw data on power consumption) (S1). For example, the power consumption status analysis unit 122 refers to the equipment information 162 and starts the analysis of the power consumption status from the constituent equipment (1)-1 that constitutes the equipment (1) that is the target equipment.

[0063] In step S1, when analyzing the power consumption state of the component equipment, the power consumption state analysis unit 122 first generates a waveform pattern of the power consumption of the component equipment from the power consumption information 164 (raw data of power consumption) (S1a). The power consumption state analysis unit 122 stores the generated waveform pattern of power consumption in the output information 170 of the storage unit 150 as the power consumption waveform pattern 171.

[0064] FIG. 9 shows an example of the processing performed by the power consumption state analysis unit 122. In FIG. For example, when the component equipment is a laser equipment (FIG. 6), the power consumption state analyzer 122 performs waveform processing on the raw power consumption data 610 to remove noise and generate a power consumption waveform pattern 910. Examples of the waveform processing include removing high frequency components using a low pass filter and removing commercial power supply frequency components using a band pass filter.

[0065] Returning to the explanation of the power consumption calculation process in FIG. Next, the power consumption state analysis unit 122 calculates the number of power consumption states from the waveform pattern of power consumption and the equipment information 162 (S1b). The power consumption state analysis unit 122 calculates the type of power consumption state of the constituent equipment based on the waveform pattern of power consumption (an example of information related to the magnitude of time-series power consumption of the constituent equipment) obtained from the power consumption information 164 of the constituent equipment. In the example of FIG. 9, the waveform pattern 910 of power consumption has three power consumption values, so the number of power consumption states is three. Here, the power consumption states are designated "power consumption state 1", "power consumption state 2", and "power consumption state 3" in ascending order of power consumption value. The power consumption state analysis unit 122 stores the calculated number of power consumption states in the output information 170 of the storage unit 150 as the number of power consumption states 172 of the power consumption model.

[0066] After the process of step S1, the operation state estimation unit 123 associates the operation state (equipment operation state) of the target equipment with the waveform pattern of power consumption based on the production plan 161 and the operation record 163, and estimates the equipment operation state (S2). The operation state estimation unit 123 searches for a combination of equipment operation states for each state of the waveform pattern of power consumption to estimate the equipment operation state.

[0067] [Processing of the operating state estimation unit] 10 is a diagram showing an example of the correspondence between the equipment operation states and the waveform patterns of power consumption by the operation state estimation unit 123. In the figure, the vertical direction represents a plurality of equipment operation states, and the horizontal direction represents the flow of time. Here, the power consumption waveform pattern 910 will be described as an example.

[0068] 10 shows example processes such as equipment operation (machine), material supply, punch processing, laser processing, material removal, beam ON, and axis movement as equipment operation states of the production equipment 200. In each operation state, the period displayed in gray indicates that the corresponding process is being performed.

[0069] "Equipment operation (processing machine)" refers to a state in which the target equipment such as the production equipment 200 is in operation, and includes a state in which the processing machine (e.g., punch processing device) is "preparing." A processing machine being "preparing" is also called "during setup work." "Material supply" refers to a state in which a material to be processed is supplied to a target process of a target facility by a transport facility (not shown). "Punching" refers to a state in which punching (perforation) is performed on the supplied material by the punching equipment. "Laser processing" refers to the state in which laser equipment is ready for use, and includes the preparation stage prior to laser irradiation. "Material removal" refers to a state in which the processed material is removed from the target facility by a transport facility (not shown). "Beam ON" is a state in which laser light is output from the laser equipment and the laser light is irradiated onto the material. "Axis moving" is a state in which the axis of the stage on which the material is placed is moved in order to irradiate the laser light to a specified position on the material.

[0070] The operation state estimation unit 123 searches for a combination of equipment operation states corresponding to each type of power consumption state (power consumption states 1 to 3 in FIG. 10) detected from the waveform pattern 910 of power consumption.

[0071] At time 1001 during the power consumption state 1, the production equipment 200 is in the states of equipment operation (machine), punching, and axis movement. In the power consumption state 1, even if the state changes to the axis movement state while punching continues, there is almost no change in the power consumption.

[0072] At time 1002 during power consumption state 2, the production equipment 200 is in a state of equipment operation (machine), laser processing, and axis movement. In power consumption state 2, the production equipment 200 starts laser processing, and at the same time, the power consumption increases significantly from the power consumption in power consumption state 1. Also, in power consumption state 2, there is almost no change whether the axis is moving or not.

[0073] At a certain time 1003 during the power consumption state 3, the production equipment 200 is in the equipment operation (machining machine), laser processing, and beam ON states. Furthermore, the production equipment 200 is in the axis movement state during the laser processing period. In the power consumption state 3, the production equipment 200 is in the beam ON state, and at the same time, the power consumption significantly increases from the power consumption in the power consumption state 2. Thereafter, even when the axis movement is in progress, there is almost no change in the power consumption during the power consumption state 3. Furthermore, when the production equipment 200 is in the beam OFF state during the power consumption state 3, the power consumption significantly decreases and the state changes to the power consumption state 2. Furthermore, when the production equipment 200 is in the beam OFF state during the power consumption state 3 and the laser processing stops, the power consumption rapidly decreases and the state changes to the power consumption state 1.

[0074] Furthermore, in step S2, the operation state estimation unit 123 may estimate, from a combination of the equipment operation states of each power consumption state, an equipment operation state that has a large effect on each power consumption state (change in power consumption) for each power consumption state as the equipment operation state of the cause. For example, the equipment operation state of the cause can be estimated by investigating the change in the equipment operation state immediately before and after the power consumption state changes. Note that multiple equipment operation states may be selected as the equipment operation state of the cause.

[0075] Returning to the explanation of the power consumption calculation process in FIG. After the process of step S2, the power consumption model creation unit 124 creates a power consumption model 1100 as shown in Fig. 11 based on the result of the association between the equipment operation state and the power consumption waveform pattern in step S2 and the operation record 163 (S3). The power consumption model creation unit 124 stores the created power consumption model 1100 in the output information 170 of the storage unit 150 as the number of power consumption states 172 of the power consumption model.

[0076] [Combination of power consumption status, equipment operation status, and power consumption model] Here, the combinations of power consumption states and facility operation states, and the power consumption model will be described with reference to FIG.

[0077] 11 is a diagram showing examples of power consumption states, equipment operation states, and power consumption models. As described above, the operation state estimation unit 123 associates the equipment operation states 1000 with the waveform pattern 910 of power consumption, and searches for a combination of equipment operation states that matches the waveform pattern 910 of power consumption.

[0078] According to FIG. 10 described above, examples of combinations of power consumption states and equipment operation states are as follows: In the case of power consumption state 1, the combination of equipment operation states is equipment operation (machine), punch processing, and axis movement. The equipment operation state of the cause is equipment operation (description of the machine is omitted). In the case of power consumption state 2, the combination of equipment operation states is equipment operation (machine), laser processing, and axis movement. The contributing equipment operation state is laser processing. In the case of power consumption state 3, the combination of equipment operation states is equipment operation (machine), laser processing, beam ON, and axis moving. The equipment operation state of the cause is beam ON.

[0079] The power consumption model creation unit 124 creates data in which equipment, power consumption states, and equipment operation states that are factors are associated with each other as the power consumption model 1100. In other words, the power consumption model creation unit 124 creates the power consumption model 1100 by associating the power consumption states of the constituent equipment with the operation states of the target equipment that are factors of the power consumption states.

[0080] For example, the power consumption model 1100 defines that the laser equipment has three types of power consumption states (power consumption states 1 to 3). The power consumption model 1100 also defines that the equipment operation state causing power consumption state 1 is "equipment operation", the equipment operation state causing power consumption state 2 is "laser processing", and the equipment operation state causing power consumption state 3 is "beam ON".

[0081] Returning to the explanation of the power consumption calculation process in FIG. After the process of step S3, the power consumption calculation unit 125 calculates the unit power consumption of each power consumption state from the unit power consumption of each process (equipment operation state) shown in Fig. 10 (S4). Here, the unit power consumption is the power consumption per unit time [kWh]. It is assumed that information on the unit power consumption of each process is stored in advance in the input information 160 of the storage unit 150. The unit power consumption of each power consumption state can be calculated from the combination of equipment operation states corresponding to each power consumption state and the unit power consumption of each equipment operation state.

[0082] Then, the power consumption calculation unit 125 associates the calculated power consumption unit of each power consumption state with the power consumption model 1100. That is, the power consumption model 1100 may be defined using equipment, a power consumption state, an equipment operation state of a factor, and a power consumption unit of each power consumption state.

[0083] In the above example, the power consumption model 1100 includes the equipment operation state as a factor. However, instead of the equipment operation state as a factor, a combination of the equipment operation states may be used.

[0084] Next, the power consumption calculation unit 125 calculates the power consumption of the component equipment from the power consumption unit of each power consumption state and the operation record 163 (S5). The power consumption calculation unit 125 stores information on the calculated power consumption of the component equipment in the output information 170 of the storage unit 150 as a power consumption calculation result 174.

[0085] In this manner, the present embodiment includes a power consumption unit storage unit (storage unit 150) that stores power consumption information per unit time as power consumption unit information for each component facility. The power consumption calculation unit calculates the power consumption of the component facility for each power consumption state based on the power consumption unit information and the power consumption model.

[0086] Next, the arithmetic processing unit 120 determines whether or not the power consumption calculation process has been completed for all of the component equipment of the target equipment (S6).

[0087] In step S6, if the power consumption calculation process has not been completed for all of the constituent equipment of the target equipment (NO judgment in S6), the process returns to step S1. Then, the calculation processing unit 120 repeats the processing steps of steps S1 to S6 until the power consumption calculation process has been completed for all of the constituent equipment. For example, in the case of the production equipment 200 (punch processing device) shown in Fig. 6, the number of constituent equipment is seven, and the calculation processing unit 120 performs processing for all of the seven constituent equipment.

[0088] On the other hand, when the power consumption calculation process has been completed for all of the constituent equipment of the target equipment (YES determination in S6), the arithmetic processing unit 120 ends this power consumption calculation process.

[0089] When there are multiple pieces of target equipment, the production planning system 100 calculates the power consumption of the constituent equipment for each piece of target equipment in sequence, such as equipment (1), equipment (2), . . . in FIG.

[0090] [Power consumption by power consumption state of each component equipment] Next, the power consumption of each component facility in the production planning system 100 in each power consumption state will be described with reference to FIG. Fig. 12 is a bar graph showing an example of the power consumption state and power consumption for each piece of component equipment in the production planning system 100. Here, the production facility 200 is described as having the component equipment shown in Fig. 6. In Fig. 12, the horizontal axis shows the component equipment, and the vertical axis shows the power consumption for each power consumption state of each piece of component equipment.

[0091] 12, the constituent equipment includes a laser equipment, a punch equipment, a compressor (medium voltage), and a compressor (low voltage). For example, the power consumption of each of the power consumption states 1 to 3 for the laser equipment is piled up. Similarly, the power consumption of each of the power consumption states 1 to 2 for the punch equipment, the power consumption of each of the power consumption states 1 to 2 for the compressor (medium voltage), and the power consumption of the power consumption state 1 for the compressor (low voltage) are piled up.

[0092] Here, power consumption states with the same sign are shown in different components of equipment, such as power consumption states 1 and 2, but even if the signs are the same, the power consumption states will be different if the components of equipment are different. For example, power consumption states 1 and 2 of a laser equipment represent a first type and a second type of power consumption state in the laser equipment. Similarly, power consumption states 1 and 2 of a punch equipment represent a first type and a second type of power consumption state in the punch equipment. The first type and the second type of power consumption state can also be said to be the first and second type of power consumption states detected in the target component equipment.

[0093] As described above, the production planning system 100 of this embodiment (an example of a power consumption calculation system) comprises an operation time memory unit storing operation time information for each process of the target equipment, a power consumption information memory unit storing power consumption information for each component equipment that constitutes the target equipment, a power consumption state analysis unit that analyzes the power consumption state of the component equipment from the power consumption information, an operation state estimation unit that estimates the operation state of the target equipment corresponding to the power consumption state of the component equipment based on the operation time information of the target equipment for each process and the power consumption information of the component equipment, a power consumption model creation unit that creates a power consumption model of the component equipment by matching the operation state of the target equipment with each power consumption state of each component equipment, a power consumption calculation unit that calculates the power consumption for each power consumption state of the component equipment based on the power consumption model, and an information provision unit that outputs the calculation results of the power consumption for each power consumption state of the component equipment.

[0094] Furthermore, in this embodiment, the power consumption state analysis unit distinguishes the power consumption state of the component equipment based on information on the magnitude of the time-series power consumption of the component equipment as power consumption information (waveform pattern of power consumption).

[0095] Furthermore, in this embodiment, the operation state estimation unit associates the operation state of the target equipment with the power consumption state of the constituent equipment, using operation time information of two or more different processes (see FIG. 10) of the target equipment.

[0096] In addition, in this embodiment, the operation status estimation unit estimates the operation status of the target equipment that is a factor of changes in power consumption in the power consumption state of the constituent equipment based on operation time information for each process of the target equipment and power consumption information of the constituent equipment.

[0097] The production planning system 100 (power consumption calculation system) according to the present embodiment described above calculates the number of power consumption states based on the magnitude of power consumption from the power consumption information of the constituent equipment of the target equipment. Then, a power consumption model is created by combining a plurality of equipment operation states and identifying the equipment operation state corresponding to each power consumption state.

[0098] According to this embodiment, even if it is difficult to associate the equipment operation state with the power consumption of the target equipment, it is possible to calculate the power consumption for each operation state, which is necessary to identify the cause of the increase in power consumption. In addition, this makes it possible to calculate the power consumption for each operation state of the target equipment in order to estimate the effect of a countermeasure plan for the cause of the increase in power consumption. For example, this embodiment can be applied to an optimization solution for production planning and production line organization aimed at reducing power consumption.

[0099] [Output screen] Next, the output screen of the production planning system 100 will be described with reference to FIG. 13 is a diagram showing an example of an output screen 1300 in the production planning system 100. The information providing unit 126 (FIG. 1) outputs each piece of information of the output information 170 in the storage unit 150, whereby the output screen 1300 is displayed at an output destination. The output destination of the output information 170 is, for example, the display device 180.

[0100] An output screen 1300 has a display area 1310 for displaying the power consumption pattern and the state number allocation result, a display area 1320 for displaying the power consumption model, and a display area 1330 for displaying the power consumption calculation result.

[0101] A display area 1310 of the power consumption pattern and the state number allocation result includes a selection section 1311 where the user selects a component equipment of the target equipment using a pull-down menu or the like, and a display button 1312 for displaying information about the selected component equipment.

[0102] Moreover, the display area 1310 of the power consumption pattern and the number of states allocation result has an area for displaying power consumption (raw data) 1313 and a consumption waveform pattern 1314. The power consumption (raw data) 1313 corresponds to the power consumption information 164 of the input information 160. The consumption waveform pattern 1314 displays the number of power consumption states. The consumption waveform pattern 1314 corresponds to the power consumption waveform pattern 171 and the number of power consumption states 172 of the power consumption model of the output information 170.

[0103] In the power consumption model display area 1320, information on the power consumption model of the selected component equipment is displayed. This power consumption model corresponds to the power consumption model 173 of the output information 170. In the example of FIG. 13, in addition to the items of equipment, power consumption state, and equipment operation state of the cause, information on the power consumption rate [kWh] is displayed. Also, for the user's reference, original data 1321 of the displayed power consumption model is displayed. As the original data 1321, for example, time [s], selected equipment (1), power consumption state, and equipment operation state of the cause are displayed.

[0104] A power consumption calculation result display area 1330 displays the power consumption [kWh] for each power consumption state of the selected component equipment and a graph 1331 of the total CO2 emissions. The power consumption information corresponds to the power consumption calculation result 174 of the output information 170. In Fig. 13, the power consumption is displayed in a form that allows distinction between power consumption states 1 to 3.

[0105] Incidentally, the calculation processing unit 120 (FIG. 1) has a function (an example of a CO2 emission calculation unit) of calculating the CO2 emission amount of the component equipment based on the CO2 emission amount relative to the power consumption per unit time and the power consumption calculated by the power consumption calculation unit 125. Information on the total CO2 emission amount of the component equipment calculated here is stored in the output information 170 and displayed in the graph 1331. The calculation processing unit 120 can also calculate the CO2 emission amount for each power consumption state of the component equipment.

[0106] According to the present embodiment described above, the user can visually check the power consumption for each operation state, which is necessary to identify the cause of the increase in power consumption. This allows the user to estimate the effectiveness of countermeasures against the cause of the increase in power consumption. For example, the present embodiment can be applied to an optimization solution for production planning and production line organization aimed at reducing power consumption.

[0107] The present invention is not limited to the above-described embodiment, and various other applications and modifications are possible without departing from the gist of the present invention described in the claims. For example, the above-described embodiment is a detailed and specific description of the configuration in order to easily explain the present invention, and is not necessarily limited to the configuration including all of the components described. In addition, it is also possible to add, replace, or delete other components to a part of the configuration of each embodiment.

[0108] In addition, the above-mentioned configurations, functions, processing units, etc. may be realized in part or in whole by hardware, for example, by designing them as integrated circuits. As the hardware, a broad processor device such as an FPGA (Field Programmable Gate Array) or an ASIC (Application Specific Integrated Circuit) may be used.

[0109] Furthermore, each component of the production planning system 100 (power consumption calculation system) according to the above-described embodiment may be implemented in any hardware as long as the respective hardware can transmit and receive information to each other via a network. Furthermore, the processing performed by a certain processing unit may be realized by a single piece of hardware, or may be realized by distributed processing by multiple pieces of hardware.

[0110] In the above-described embodiment, the control lines and information lines are those that are considered necessary for the explanation, and not all control lines and information lines in the product are necessarily shown. In reality, it may be considered that almost all components are connected to each other. [Explanation of symbols]

[0111] 1 to 3...power consumption state, 100...production planning system, 110...calculation unit, 120...calculation processing unit, 121...data acquisition unit, 122...power consumption state analysis unit, 123...operation state estimation unit, 124...power consumption model creation unit, 125...power consumption calculation unit, 126...information provision unit, 130...memory unit, 140...input / output unit, 150...storage unit, 160...input information, 161...production plan, 162...equipment information, 163...operation record, 164...power consumption information, 165...CO2 conversion information, 170...output information, 171...waveform pattern, 172...number of power consumption states, 173...power consumption model, 174...calculation result, 180...display device, 200...production equipment, 300...production instruction device

Claims

1. an operating time storage unit that stores operating time information for each process of the target equipment; a power consumption information storage unit that stores power consumption information for each component facility of the target facility; a power consumption status analysis unit that analyzes the power consumption status of the component equipment based on the power consumption information; an operation state estimation unit that estimates an operation state of the target equipment corresponding to the power consumption state of the component equipment based on the operation time information of the target equipment for each process and the power consumption information of the component equipment; a power consumption model creation unit that creates a power consumption model of the component equipment by associating the operating state of the target equipment with each of the power consumption states of the component equipment; a power consumption calculation unit that calculates the power consumption of the component equipment for each of the power consumption states based on the power consumption model; an information providing unit that outputs a calculation result of the power consumption for each of the power consumption states of the component equipment. Power consumption calculation system.

2. The power consumption state analysis unit distinguishes the power consumption state of the component equipment based on information on the magnitude of the power consumption of the component equipment over time as the power consumption information. The power consumption calculation system according to claim 1 .

3. The operation state estimation unit associates the operation state of the target equipment with the power consumption state of the component equipment by using the operation time information of two or more different processes of the target equipment. The power consumption calculation system according to claim 2 .

4. The operation state estimation unit estimates an operation state of the target equipment that is a factor of a change in power consumption in the power consumption state of the constituent equipment, based on the operation time information for each of the processes of the target equipment and the power consumption information of the constituent equipment. The power consumption calculation system according to claim 3 .

5. The power consumption model creation unit creates the power consumption model by associating the power consumption state of the component equipment with the operation state of the target equipment, which is a cause of the power consumption state. The power consumption calculation system according to claim 4 .

6. The operation time storage unit stores the operation time information of the target equipment based on at least one of a production plan executed by the target equipment or an operation record of the target equipment. The power consumption calculation system according to claim 1 .

7. a power consumption unit storage unit that stores the power consumption information per unit time for each of the component facilities as power consumption unit information; The power consumption calculation unit calculates the power consumption of the component equipment for each of the power consumption states based on the power basic unit information and the power consumption model. The power consumption calculation system according to claim 1 .

8. CO2 per unit of power consumption ２ The CO2 emission of the component equipment is calculated based on the power consumption calculated by the power consumption calculation unit. ２ Calculate CO emissions ２ An emission calculation unit is provided. The power consumption calculation system according to claim 1 .

9. The information providing unit outputs output information including the power consumption information of the component equipment, information on the power consumption model of the component equipment, and a calculation result of the power consumption for each of the power consumption states of the component equipment. The power consumption calculation system according to claim 1 .

10. A power consumption calculation method by a power consumption calculation system that calculates the power consumption of a component facility that constitutes a target facility, A process of analyzing a power consumption state of the component equipment based on the power consumption information of each component equipment; A process of estimating an operating state of the target equipment corresponding to the power consumption state of the component equipment based on operating time information for each process of the target equipment and the power consumption information of the component equipment; creating a power consumption model of the component equipment by associating the operating state of the target equipment with each of the power consumption states of the component equipment; A process of calculating the power consumption of the component equipment for each of the power consumption states based on the power consumption model; and outputting a calculation result of the power consumption for each of the power consumption states of the component equipment. How to calculate power consumption.

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