Production facility utilization monitoring system and data processing device

Abstract

To provide a production facility utilization monitoring system and a data processing device that can grasp power consumption data for each production facility.SOLUTION: A production facility utilization monitoring system comprises: a plurality of measurement units for measuring current data used in a processing action on a production object, in a plurality of production facilities that sequentially process the production object; and a data processing device connected to each of the plurality of measurement units. The data processing device comprises: a calculation unit that calculates power consumption data consumed during the processing action on the production object for each of the plurality of production facilities based on the current data; and a storage unit for storing the power consumption data of each of the plurality of production facilities in association with the production object.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a production facility operation monitoring system and a data processing device. [Background technology]

[0002] In order to reduce greenhouse gas emissions, the manufacturing industry is also hoping to build a management system for managing power consumption data in production activities. For example, Patent Document 1 discloses a management system equipped with an emission calculation means for calculating greenhouse gas emissions from production records such as the electricity used in each lot. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2010-191832 A Summary of the Invention [Problem to be solved by the invention]

[0004] At production sites, products and other production targets may be produced through various processing steps using multiple production equipment. In order to understand the electricity consumption situation at the production site, it is desirable to be able to obtain the power consumption data for each production equipment from the management system.

[0005] The present disclosure provides a production facility operation monitoring system and a data processing device that can grasp power consumption data for each production facility. [Means for solving the problem]

[0006] In a first aspect, each of a plurality of production equipment which sequentially processes production objects comprises a plurality of measuring units which measure current data used during processing of the production objects, and a data processing device connected to each of the plurality of measuring units, and the data processing device comprises a calculation unit which calculates power consumption data for each of the plurality of production equipment consumed during processing of the production objects based on the current data, and a memory unit which stores the power consumption data for each of the plurality of production equipment relating to the production objects in association with each other. Effect of the Invention

[0007] According to the technology disclosed herein, it is possible to grasp power consumption data for each production facility. [Brief description of the drawings]

[0008] [Figure 1] 1 is a block diagram showing an example of an overall configuration of a production facility operation monitoring system according to a first embodiment. [Diagram 2] 1 is a block diagram showing an example of the configuration of a production facility in a production facility operation monitoring system according to a first embodiment. [Diagram 3] 1 is a block diagram showing an example of the configuration of a data processing device in a production facility operation monitoring system according to a first embodiment; [Figure 4] 4 is a diagram showing an example of a data table including power consumption data of production facilities, which is stored in a storage unit of the data processing device according to the first embodiment; FIG. [Diagram 5] FIG. 2 is a system block diagram showing an example of an overall configuration of a production facility operation monitoring system according to a first modified example of the first embodiment. [Figure 6] FIG. 13 is a diagram showing an example of a data table including power consumption data of the production facility, which is stored in a storage unit of a data processing device in the production facility operation monitoring system according to Modification 1 of the first embodiment. [Figure 7] FIG. 11 is a system block diagram showing an example of an overall configuration of a production facility operation monitoring system according to a second modified example of the first embodiment. [Figure 8]FIG. 11 is a diagram showing an example of a data table including power consumption data of the production facility, which is stored in a storage unit of a data processing device in the production facility operation monitoring system according to Modification 2 of the first embodiment. [Figure 9] FIG. 11 is a system block diagram showing an example of an overall configuration of a production facility operation monitoring system according to a second embodiment. [Figure 10] FIG. 11 is a block diagram showing an example of the configuration of a data processing device in a production facility operation monitoring system according to a second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] A production facility operation monitoring system according to an embodiment will be described below with reference to the drawings. For ease of understanding, the scale of each part in the drawings may differ from the actual scale. In directions such as parallel, right angle, orthogonal, horizontal, vertical, up / down, left / right, deviations are permitted to a degree that does not impair the effects of the embodiment. The shape of the corners is not limited to right angles. For example, the shape of the corners may be rounded. Parallel, right angle, orthogonal, horizontal, and vertical may include approximately parallel, approximately right angle, approximately orthogonal, approximately horizontal, and approximately vertical.

[0010] In this specification, "connection" is not limited to physical connection, but may also include electrical connection. For example, connecting an object A to an object B is not limited to conductive connection of the object A to the object B, but may include conductive connection of the object A to the object B via the object C.

[0011] [First embodiment] <Overall configuration of production equipment operation monitoring system 1 and processing flow for production object 15a> An example of the overall configuration of a production facility operation monitoring system 1 according to the first embodiment and an overview of the flow of processing of a production object 15a will be described with reference to Fig. 1. Fig. 1 is a system block diagram showing an example of the overall configuration of a production facility operation monitoring system 1 according to the first embodiment.

[0012] FIG. 1 shows a production facility operation monitoring system 1, a power source 2, a plurality of production facilities 10a, 10b, 10c, and 10d, a detection unit 30, and an external information processing device 100. The production facility operation monitoring system 1 includes a plurality of measurement units 20a, 20b, 20c, and 20d, and a data processing device 40. The data processing device 40 is connected to the external information processing device 100 via a communication line NW. In FIG. 1, the detection unit 30 is not shown as a component included in the production facility operation monitoring system 1, but may be a component included in the production facility operation monitoring system 1. When it is not necessary to distinguish between the production facilities 10a, 10b, 10c, and 10d, the production facilities 10a, 10b, 10c, and 10d are collectively referred to as "production facilities 10." Furthermore, when there is no need to distinguish between the multiple measurement units 20a, 20b, 20c, and 20d, the multiple measurement units 20a, 20b, 20c, and 20d will be collectively referred to as "measurement unit 20."

[0013] Each of the production facilities 10a, 10b, 10c, and 10d in this embodiment constitutes a production line 50 for producing the production objects 15a. The production line 50 further includes a transport means 51 such as a conveyor for transporting the production objects 15a. However, the number of the production facilities 10 is not limited to four. The number of the production facilities 10 may be any number equal to or greater than two.

[0014] The production line 50 sequentially performs a plurality of processing steps divided into stages on the production object 15a transported by the transport means 51 to turn the production object 15a into a finished product. Each of the production equipment 10a, 10b, 10c, and 10d is equipment for performing each processing step. Examples of the production equipment 10a, 10b, 10c, and 10d include machine tools such as NC (Numerical Control) processing machines. However, the production equipment 10a, 10b, 10c, and 10d are not limited to this.

[0015] As shown in FIG. 1, the production equipment 10a is connected to the power source 2 through a power feeder 11a. The production equipment 10b is connected to the power source 2 through a power feeder 11b. The production equipment 10c is connected to the power source 2 through a power feeder 11c. The production equipment 10d is connected to the power source 2 through a power feeder 11d. When each of the production equipment 10a, 10b, 10c, and 10d performs a processing operation on the production object 15a, power is supplied from the power source 2. The power source 2 in this embodiment is a power system that transmits commercial AC power. However, the power source 2 may be one that transmits DC power, such as a solar cell or a fuel cell.

[0016] The production line 50 performs, for example, a first process, a second process, a third process, and a fourth process on the production object 15a. Examples of the first process, the second process, the third process, and the fourth process include various processing steps such as cutting, drilling, machining, and polishing.

[0017] The production equipment 10a performs a first processing on the production object 15a. The production equipment 10b performs a second processing on the production object 15a. The production equipment 10c performs a third processing on the production object 15a. The production equipment 10d performs a fourth processing on the production object 15a.

[0018] The combination of the first process, the second process, the third process, and the fourth process can be appropriately selected depending on the type of the production object 15a flowing through the production line 50. The combination of the first process, the second process, the third process, and the fourth process may be a combination of different process steps, or a combination including the same type of process step. One example is a combination in which the first process and the second process are cutting processes for cutting different parts of the production object 15a, the third process is a drilling process for drilling holes in the production object 15a, and the fourth process is a polishing process for polishing the production object 15a.

[0019] Examples of the production objects 15a include automobile parts such as engine blocks, cylinder heads, camshafts, and crankshafts. However, the production objects 15a are not limited to automobile parts. The production objects 15a may be industrial products other than automobile parts, such as electrical equipment such as personal computers.

[0020] The same kind of production objects as the production object 15a are sequentially supplied to the production line 50 at a predetermined time interval. The same kind of production objects as the production object 15a are subjected to a first process, a second process, a third process, and a fourth process by the production equipment 10a, 10b, 10c, and 10d.

[0021] <Production Equipment 10> Next, a configuration example of the production facility 10 will be described with reference to Fig. 2. Fig. 2 is a block diagram showing a configuration example of the production facility 10.

[0022] 2, the production equipment 10 includes a main unit 10M, an auxiliary unit 10H, and a control board 10S. The production equipment 10 further includes a housing that houses at least the main unit 10M. The housing includes an entrance for carrying the production object 15a therein, and an exit for carrying the production object 15a that has completed processing in the production equipment 10 out of the housing.

[0023] The main machine 10M is a device used to process the production object 15a in the production facility 10. The main machine 10M includes a processing machine 11P and a loader 11L. The processing machine 11P is a machine that processes the production object 15a by cutting, drilling, milling, polishing, etc. The loader 11L is a machine that moves the production object 15a brought into the production facility 10 to a position where the processing machine 11P can process the production object 15a.

[0024] The auxiliary machine 10H is a device for operating the main machine 10M. The auxiliary machine 10H is, for example, an air compressor, a hydraulic pump, a blower, or other such device. The auxiliary machine 10H may be housed in a housing of the production equipment 10, or may be disposed outside the housing. The main machine 10M and the auxiliary machine 10H are connected to each other via connecting members such as piping and mechanical elements.

[0025] The control board 10S is an electric circuit or the like for controlling the operation of each of the main machine 10M and the auxiliary machine 10H. The control board 10S is provided on the outer surface of the housing of the production equipment 10. The control board 10S may include a communication circuit. The control board 10S may be communicatively connected to the data processing device 40 via the communication circuit.

[0026] Here, the "processing operation on the production object 15a" in the production equipment 10 refers to the operation of each of the main machine 10M, the auxiliary machine 10H, and the control board 10S of the production equipment 10 when processing the production object 15a. The power consumption of the production equipment 10 during the processing operation on the production object 15a corresponds to the total of the power consumption of each of the main machine 10M, the auxiliary machine 10H, and the control board 10S.

[0027] <Measurement section 20> Next, the measurement unit 20 will be described. The measurement unit 20 measures current data used by the production equipment 10 when processing the production object 15a. The measurement unit 20 includes a current detection unit and a measurement unit that measures the current data based on a detection signal of the current detected by the detection unit.

[0028] The measuring unit 20a is a sensor provided on the power supply line 11a. The measuring unit 20a measures current data used by the production equipment 10a when the production equipment 10a processes the production object 15a. The current data used by the production equipment 10a when the production object 15a is processed is hereinafter referred to as "current data used by the production equipment 10a."

[0029] The measuring unit 20b is a sensor provided on the power supply line 11b. The measuring unit 20b measures current data used by the production equipment 10b when the production equipment 10b processes the production object 15a. The current data used by the production equipment 10b when the production object 15a is processed is hereinafter referred to as "current data used by the production equipment 10b."

[0030] The measuring unit 20c is a sensor provided on the power supply line 11c. The measuring unit 20c measures the current data used by the production equipment 10c when the production equipment 10c processes the production object 15a. The current data used by the production equipment 10c when the production object 15a is processed is hereinafter referred to as "current data used by the production equipment 10c."

[0031] The measuring unit 20d is a sensor provided on the power supply line 11d. The measuring unit 20d measures the current data used by the production equipment 10d when the production equipment 10d processes the production object 15a. The current data used by the production equipment 10d when the production object 15a is processed is hereinafter referred to as "current data used by the production equipment 10d."

[0032] Each of the measurement units 20a, 20b, 20c, and 20d is provided on a distribution board 3 that is arranged between the power source 2 and the production equipment 10. In addition, each of the measurement units 20a, 20b, 20c, and 20d is connected via a bus 21 to a data processing device 40 that is also provided on the distribution board 3.

[0033] The measurement unit 20a transmits the current measurement results to the data processing device 40 as the current data used by the production equipment 10a. The measurement unit 20b transmits the current measurement results to the data processing device 40 as the current data used by the production equipment 10b. The measurement unit 20c transmits the current measurement results to the data processing device 40 as the current data used by the production equipment 10c. The measurement unit 20d transmits the current measurement results to the data processing device 40 as the current data used by the production equipment 10d.

[0034] Each of the measuring units 20a, 20b, 20c, and 20d transmits the measured current data to the data processing device 40 at intervals of, for example, 100 milliseconds. The number of measuring units 20 is not limited to four. When the measuring units 20 are provided according to the number of production facilities 10, the number of measuring units 20 increases or decreases according to the number of production facilities 10.

[0035] The measurement unit 20 may further include a function of measuring voltage data of an AC voltage used by the production equipment 10 when the production equipment 10 performs a processing operation on the production object 15a.

[0036] Specifically, the measurement unit 20a transmits the result of the voltage measurement to the data processing device 40 as voltage data used by the production equipment 10a when processing the production object 15a. The voltage data used by the production equipment 10a when processing the production object 15a will be referred to as "voltage data used by the production equipment 10a" hereinafter.

[0037] The measuring unit 20b transmits the result of the voltage measurement to the data processing device 40 as voltage data used by the production equipment 10b when processing the production object 15a. The voltage data used by the production equipment 10b when processing the production object 15a will hereinafter be referred to as "voltage data used by the production equipment 10b."

[0038] The measuring unit 20c transmits the result of the voltage measurement as voltage data used by the production equipment 10c when processing the production object 15a to the data processing device 40. The voltage data used by the production equipment 10c when processing the production object 15a is hereinafter referred to as "voltage data used by the production equipment 10c."

[0039] The measuring unit 20d transmits the result of the voltage measurement as voltage data used by the production equipment 10d when processing the production object 15a to the data processing device 40. The voltage data used by the production equipment 10d when processing the production object 15a will be hereinafter referred to as "voltage data used by the production equipment 10d."

[0040] <Detection unit 30> Next, the detection unit 30 will be described. The detection unit 30 detects the identification data ID1 of the production object 15a from the identification mark applied to the production object 15a. The identification mark is applied to the production object 15a by a laser marking device or the like. There are no limitations on the identification mark as long as it is a mark that can be detected by the detection unit 30. Examples of the identification mark include a one-dimensional barcode or a two-dimensional barcode engraved on the surface of the production object 15a.

[0041] The detection unit 30 includes an imaging unit such as a camera that captures an image of the identification mark applied to the production object 15a, a detection unit that detects identification data ID1 based on the pattern of the identification mark captured by the imaging unit, and a communication unit that transmits the identification data ID1.

[0042] As shown in FIG. 1, the detection unit 30 of this embodiment is provided in the production equipment 10a arranged at the most upstream of the production line 50. Specifically, the detection unit 30 is provided near the entrance of the production equipment 10a. The production object 15a is in an unprocessed state when it is carried into the production equipment 10a. Therefore, foreign matter such as cutting chips and oil generated during processing does not adhere to the identification mark. Therefore, the identification mark is accurately detected by the detection unit 30 provided near the entrance of the production equipment 10a. However, the detection unit 30 may be provided in the production equipment 10b, 10c, and 10d. Moreover, the number of detection units 30 is not limited to one, and may be two or more.

[0043] 1, the detection unit 30 is communicatively connected to the data processing device 40 through a communication unit of the detection unit 30. The detection unit 30 transmits identification data ID1 of the production object 15a to the data processing device 40 through the communication unit of the detection unit 30.

[0044] <Data processing device 40> Next, a configuration example of the data processing device 40 will be described with reference to Fig. 3 and Fig. 4. Fig. 3 is a block diagram showing a configuration example of the data processing device 40. Fig. 4 is a diagram showing an example of a data table TB1 stored in the storage unit 42 of the data processing device 40, the data table TB1 including power consumption data W11, W21, W31, and W41 of the production equipments 10a, 10b, 10c, and 10d.

[0045] The data processing device 40 is connected to each of the measurement units 20a, 20b, 20c, and 20d. The data processing device 40 is connected to the detection unit 30. The data processing device 40 is an information processing device such as a computer that processes various data output from each of the measurement units 20a, 20b, 20c, and 20d and the detection unit 30.

[0046] The data processing device 40 of this embodiment is provided on the distribution board 3 together with each of the measurement units 20a, 20b, 20c, and 20d. However, the location of the data processing device 40 is not limited thereto.

[0047] 3, the data processing device 40 includes a calculation unit 41, a storage unit 42, and a communication unit 43. The calculation unit 41, the storage unit 42, and the communication unit 43 are connected to each other via a bus 48.

[0048] The calculation unit 41 calculates the power consumption data of each of the production equipments 10a, 10b, 10c, and 10d. Moreover, the calculation unit 41 of this embodiment controls and processes various operations in the data processing device 40. An example of the calculation unit 41 is a processor such as a CPU (Central Processing Unit). The calculation unit 41 may be composed of other electronic circuits that perform the same function as a processor.

[0049] The storage unit 42 is a non-volatile storage medium that stores various data such as current data and voltage data used by each of the production equipments 10a, 10b, 10c, and 10d, and identification data ID1 of the production target object 15a. The storage unit 42 also stores the programs executed by the calculation unit 41 and various data required for executing the programs. An example of the storage unit 42 is a flash memory. However, the storage unit 42 may be another storage medium such as a hard disk drive (HDD) or a solid state drive (SSD).

[0050] The communication unit 43 is a communication interface equipped with a communication circuit for communicating with the measurement unit 20, the detection unit 30, and the external information processing device 100. For example, the communication unit 43 receives current data and voltage data of the production equipment 10 transmitted from the measurement unit 20. The communication unit 43 also receives identification data ID1 of the production object 15a transmitted from the detection unit 30.

[0051] Next, a description will be given of the functional configuration of the calculation unit 41. As shown in Fig. 3, the calculation unit 41 functions as a data acquisition unit 411, a calculation processing unit 412, a data storage unit 413, etc. Furthermore, the calculation unit 41 may have other functional components.

[0052] The data acquisition unit 411 sequentially acquires, via the communication unit 43, the identification data ID1 of the production object 15a, and the current data and voltage data used by each of the production equipments 10a, 10b, 10c, and 10d.

[0053] The data acquiring unit 411 outputs the identification data ID1 of the production object 15a to the data storage unit 413. In addition, the data acquiring unit 411 outputs the current data and voltage data used by each of the production equipments 10a, 10b, 10c, and 10d to the calculation processing unit 412.

[0054] The calculation processing unit 412 calculates the power consumption data W11 consumed by the production equipment 10a when processing the production target 15a based on the current data and voltage data used by the production equipment 10a. The power consumption data W11 consumed by the production equipment 10a when processing the production target 15a will be hereinafter referred to as "power consumption data W11 consumed by the production equipment 10a."

[0055] The calculation processing unit 412 may generate time data T11 indicating the calculation time of the power consumption data W11 of the production equipment 10a. The time data T11 may be regarded as time data of the time when the production object 15a passed through the production equipment 10a. The time data T11 may be a time stamp added to the power consumption data W11 of the power consumption by the production equipment 10a.

[0056] The calculation processing unit 412 outputs to the data storage unit 413 the power consumption amount data W11 of the production equipment 10a and the time data T11.

[0057] The calculation processing unit 412 calculates the power consumption data W21 of the production equipment 10b consumed during the processing of the production object 15a based on the current data and voltage data used by the production equipment 10b. The power consumption data W21 of the production equipment 10b consumed during the processing of the production object 15a is hereinafter referred to as "power consumption data W21 consumed by the production equipment 10b."

[0058] The calculation processing unit 412 may generate time data T21 indicating the calculation time point of the power consumption data W21 consumed by the production equipment 10b. The time data T21 may be regarded as time data when the production object 15a passes through the production equipment 10b. The time data T21 may be a time stamp added to the power consumption data consumed by the production equipment 10b.

[0059] The calculation processing unit 412 outputs to the data storage unit 413 the power consumption amount data W21 of the production equipment 10b and the time data T21.

[0060] The calculation processing unit 412 calculates the power consumption data W31 of the production equipment 10c consumed during the processing of the production object 15a based on the current data and voltage data used by the production equipment 10c. The power consumption data W31 of the production equipment 10c consumed during the processing of the production object 15a is hereinafter referred to as "power consumption data W31 consumed by the production equipment 10c."

[0061] The calculation processing unit 412 may generate time data T31 indicating the calculation time of the power consumption data W31 of the production equipment 10c. The time data T31 may be regarded as time data when the production object 15a passes through the production equipment 10c. The time data T31 may be a time stamp added to the power consumption data W31 of the production equipment 10c.

[0062] The calculation processing unit 412 outputs to the data storage unit 413 the power consumption amount data W31 of the production facility 10c and the time data T31.

[0063] The calculation processing unit 412 calculates the power consumption data W41 of the production equipment 10d consumed during the processing of the production object 15a based on the current data and voltage data used by the production equipment 10d. The power consumption data W41 of the production equipment 10d consumed during the processing of the production object 15a is hereinafter referred to as "power consumption data W41 consumed by the production equipment 10d."

[0064] The calculation processing unit 412 may generate time data T41 indicating the calculation time point of the power consumption data W41 of the production equipment 10d. The time data T41 may be regarded as time data of the production target object 15a passing through the production equipment 10d. The time data T41 may be a time stamp added to the power consumption data W41 of the power consumption of the production equipment 10d.

[0065] The calculation processing unit 412 outputs the power consumption data W41 and time data T41 of the production equipment 10d to the data storage unit 413. The calculation processing unit 412 calculates total power consumption data WT1 of the power consumption data W11, W21, W31, and W41 consumed by each of the production equipments 10a, 10b, 10c, and 10d. The total power consumption data WT1 corresponds to the total amount of power consumed in the production line 50 until the production object 15a is completed. The calculation processing unit 412 outputs the total power consumption data WT1 to the data storage unit 413.

[0066] The calculation processing unit 412 may convert the power consumption data W11, W21, W31, and W41 consumed by each of the production facilities 10a, 10b, 10c, and 10d into the amount of greenhouse gas emitted by each of the production facilities 10a, 10b, 10c, and 10d in processing the production target 15a. The calculation processing unit 412 may also convert the total power consumption data WT1 into the amount of greenhouse gas emitted by the production line 50 in processing the production target 15a. The calculation processing unit 412 outputs the converted data on the amount of greenhouse gas to the data storage unit 413.

[0067] 4, the data storage unit 413 stores the identification data ID1, the power consumption data W11, W21, W31, W41, the time data T11, T21, T31, T41, and the total power consumption data WT1 of the production target object 15a in the same column of the data table TB1 in the memory unit 42. As a result, the memory unit 42 stores the power consumption data W11, W21, W31, W41 of each of the production facilities 10a, 10b, 10c, 10d in association with the production target object 15a.

[0068] The data storage unit 413 stores the identification data ID2 of the other production objects, the power consumption data W12, W22, W32, W42 consumed by the production equipment 10a, 10b, 10c, 10d in the processing operations of the other production objects, the time data T12, T22, T32, T42, and the total power consumption data WT2 in another row of the data table TB1. The data storage unit 413 executes these processes for each production object supplied to the production line 50.

[0069] <Action and effect> According to the first embodiment, the calculation unit 41 of the data processing device 40 calculates the power consumption data W11, W21, W31, and W41 of the production equipment 10a, 10b, 10c, and 10d for the production object 15a, and the storage unit 42 stores the power consumption data W11, W21, W31, and W41 in association with each other. This makes it possible to quantitatively grasp the power consumption data W11, W21, W31, and W41 consumed by each of the production equipment 10a, 10b, 10c, and 10d in the processing step for each production object. As a result, environmental information such as greenhouse gas emissions for each of the production equipment 10a, 10b, 10c, and 10d can be visualized, and can be used as countermeasure information for reducing the environmental load in the production line 50. Furthermore, the data processing device 40 stores the time data T11, T21, T31, and T41 in association with the power consumption data W11, W21, W31, and W41, respectively. This makes it easy to refer to the operating status of the production equipment 10a, 10b, 10c, and 10d in chronological order based on the power consumption data W11, W21, W31, and W41.

[0070] [Modification 1 of the first embodiment] Next, a production facility operation monitoring system 1A according to Modification 1 of the first embodiment will be described with reference to Fig. 5 and Fig. 6. Fig. 5 is a system block diagram showing an example of the overall configuration of the production facility operation monitoring system 1A according to Modification 1 of the first embodiment. Fig. 6 is a diagram showing an example of a data table TB2 including power consumption data W11, W21, W31, and W41 of the production facilities 10a, 10b, 10c, and 10d stored in the storage unit 42 of the data processing device 40. Note that in the production facility operation monitoring system 1A, descriptions of components similar to those in the first embodiment will be omitted as appropriate.

[0071] 5 shows a production facility operation monitoring system 1A, a power source 2, a plurality of production facilities 10a, 10b, 10c, and 10d, a detection unit 31, and an external information processing device 100. As shown in FIG. 5, the production facility operation monitoring system 1A includes a plurality of measurement units 20a, 20b, 20c, and 20d, and a data processing device 40, as in the first embodiment. Each of the production facilities 10a, 10b, 10c, and 10d constitutes a production line 50 that processes a production object 15a. The detection unit 31 is provided in the production facility 10d arranged at the most downstream of the production line 50. In FIG. 5, the detection unit 31 is not shown as a component included in the production facility operation monitoring system 1A, but may be a component included in the production facility operation monitoring system 1A.

[0072] The detection unit 31 detects the identification data ID1 of the production object 15a from the identification mark applied to the production object 15a. That is, after the production object 15a is completed in the production line 50 of the production equipment operation monitoring system 1A, the identification data ID1 is detected.

[0073] The identification mark is not applied to the production object 15a at the time of supply to the production line 50, and is applied when the processing by the production equipment 10d is completed and the production object 15a is completed. The production equipment 10d is separately equipped with a component such as a laser marking device that applies an identification mark to the production object 15a.

[0074] When the production object 15a passes through the production equipment 10a arranged at the most upstream of the production line 50, the calculation unit 41 of the data processing device 40 generates provisional identification data PID1 for identifying the production object 15a.

[0075] Specifically, the calculation processing unit 412 of the calculation unit 41 generates provisional identification data PID1 of the production object 15a in synchronization with the calculation of the power consumption data W11 of the production equipment 10a, for example. The calculation processing unit 412 outputs the provisional identification data PID1 of the production object 15a to the data storage unit 413 in addition to the power consumption data W11 and time data T11.

[0076] Next, the calculation processing unit 412 calculates the power consumption data W21 of the production equipment 10b, the power consumption data W31 of the production equipment 10c, and the power consumption data W41 of the production equipment 10d in sequence in accordance with the passage of the production equipment 10b, 10c, and 10d of the production object 15a. The calculation processing unit 412 also generates the time data T21, T31, and T41 in sequence in accordance with the passage of the production equipment 10b, 10c, and 10d of the production object 15a. The calculation processing unit 412 sequentially outputs the power consumption data W21, W31, and W41, the time data T21, T31, and T41, and the total power consumption data WT1 to the data storage unit 413.

[0077] Next, the detection unit 31 detects the identification data ID1 of the production object 15a applied by the production equipment 10d. The data acquisition unit 411 of the calculation unit 41 acquires the identification data ID1 of the production object 15a output from the detection unit 31. Next, the data acquisition unit 411 outputs the identification data ID1 of the production object 15a to the data storage unit 413.

[0078] The data storage unit 413 replaces the provisional identification data PID1 with the identification data ID1. Then, as shown in Fig. 6, the data storage unit 413 stores the identification data ID1, the power consumption data W11, W21, W31, W41, the time data T11, T21, T31, T41, and the total power consumption data WT1 in the same column of the data table TB2 in the memory unit 42. As a result, the memory unit 42 stores the power consumption data W11, W21, W31, W41 of the production equipments 10a, 10b, 10c, and 10d in association with the production object 15a. The data storage unit 413 also performs these processes on other production objects supplied to the production line 50.

[0079] <Action and effect> According to the first modification of the first embodiment, an identification mark is applied to the object of production when all processing steps in the production line 50 are completed. In addition, a detection unit 31 that detects identification data of the object of production is provided in the production equipment 10d that performs the final processing step in the production line 50. This makes it possible to accurately detect identification data even for objects of production whose identification data is difficult to detect due to, for example, the surface morphology (degree of surface unevenness, etc.) before processing. As a result, the power consumption data consumed by each of the production equipments 10a, 10b, 10c, and 10d can be stored in association with the identification data.

[0080] [Modification 2 of the First Embodiment] Next, a production facility operation monitoring system 1B according to Modification 2 of the first embodiment will be described with reference to Figs. 7 and 8. Fig. 7 is a system block diagram showing an example of the overall configuration of the production facility operation monitoring system 1B according to Modification 2 of the first embodiment. Fig. 8 is a diagram showing an example of a data table TB3 including power consumption data W11, W21, W31, and W41 of the production facilities 10a, 10b, 10c, and 10d stored in the storage unit 42 of the data processing device 40. Note that in the production facility operation monitoring system 1B, descriptions of components similar to those of the first embodiment and Modification 1 of the first embodiment will be omitted as appropriate.

[0081] 7 shows a production equipment operation monitoring system 1B, a power source 2, a plurality of production equipments 10a, 10b, 10c, and 10d, and an external information processing device 100. As shown in FIG. 7, the production equipment operation monitoring system 1B includes a plurality of measuring units 20a, 20b, 20c, and 20d, and a data processing device 40, as in the first embodiment. Each of the production equipments 10a, 10b, 10c, and 10d constitutes a production line 50 that processes the production object 15a. In contrast, the production object 15a processed by the production line 50 of the production equipment operation monitoring system 1B does not have an identification mark. That is, the production equipment 10 is not provided with a detection unit such as the detection unit 30 or 31 that detects the identification data of the production object 15a.

[0082] When the production object 15a passes through the production equipment 10a arranged at the most upstream of the production line 50, the calculation unit 41 of the data processing device 40 generates provisional identification data PID1 for identifying the production object 15a.

[0083] Specifically, the calculation processing unit 412 of the calculation unit 41 generates provisional identification data PID1 of the production object 15a in synchronization with the calculation of the power consumption data W11 of the production equipment 10a, for example. The calculation processing unit 412 outputs the provisional identification data PID1 of the production object 15a to the data storage unit 413 in addition to the power consumption data W11 and time data T11.

[0084] Next, the calculation processing unit 412 calculates the power consumption data W21 of the production facility 10b, the power consumption data W31 of the production facility 10c, and the power consumption data W41 of the production facility 10d in sequence according to the passage of the production equipment 10b, 10c, and 10d of the production object 15a. The calculation processing unit 412 also calculates the total power consumption data WT1 by adding up the power consumption data W11, W21, W31, and W41. The calculation processing unit 412 also generates the time data T21, T31, and T41 in sequence according to the passage of the production equipment 10b, 10c, and 10d of the production object 15a. The calculation processing unit 412 sequentially outputs the power consumption data W21, W31, and W41, the time data T21, T31, and T41, and the total power consumption data WT1 to the data storage unit 413.

[0085] 8, the data storage unit 413 stores the provisional identification data PID1, the power consumption data W11, W21, W31, W41, the time data T11, T21, T31, T41, and the total power consumption data WT1 of the production target 15a in the same column of the data table TB3 in the memory unit 42. That is, the memory unit 42 stores the power consumption data W11, W21, W31, W41 of the production equipments 10a, 10b, 10c, and 10d in association with the production target 15a via the provisional identification data PID1. The data storage unit 413 also performs these processes on other production targets supplied to the production line 50.

[0086] <Action and effect> According to the second variant of the first embodiment, for production objects such as rotating shaft members such as camshafts and crankshafts, where applying an identification mark would affect their operation (i.e., it is difficult to apply an identification mark), no identification mark is applied, and temporary identification data is used to associate and store the power consumption data consumed by each of the production equipment 10a, 10b, 10c, and 10d.

[0087] [Second embodiment] Next, a production facility operation monitoring system 1C according to a second embodiment will be described with reference to Fig. 9 and Fig. 10. Fig. 9 is a system block diagram showing an example of the overall configuration of the production facility operation monitoring system 1C according to the second embodiment. Fig. 10 is a block diagram showing an example of the configuration of a data processing device 40C in the production facility operation monitoring system 1C according to the second embodiment. Note that in the production facility operation monitoring system 1C, descriptions of components similar to those in the first embodiment and modified examples 1 and 2 of the first embodiment will be omitted as appropriate.

[0088] 9 shows a production facility operation monitoring system 1C, a power source 2, a plurality of production facilities 10a, 10b, 10c, and 10d, a detection unit 30, and an external information processing device 100. As shown in FIG. 9, the production facility operation monitoring system 1C according to the second embodiment includes a plurality of measurement units 20a, 20b, 20c, and 20d, and a data processing device 40C. Each of the production facilities 10a, 10b, 10c, and 10d constitutes a production line 50 that processes a production object 15a. In FIG. 9, the detection unit 30 is not shown as a component included in the production facility operation monitoring system 1C, but may be a component included in the production facility operation monitoring system 1C.

[0089] In the production facility operation monitoring system 1C according to the second embodiment, the configuration of a data processing device 40C is different from that of the first embodiment. Specifically, as shown in Fig. 10, a calculation unit 41C of the data processing device 40C functions as a data acquisition unit 411, a calculation processing unit 412, and a data storage unit 413, and also functions as an analysis unit 414.

[0090] The analysis unit 414 analyzes the operating state of each of the production facilities 10a, 10b, 10c, and 10d based on the power consumption data relating to each of the production facilities 10a, 10b, 10c, and 10d.

[0091] Through the processes in the data acquisition unit 411, the calculation processing unit 412, and the data storage unit 413 of the calculation unit 41C, for example, a data table TB1 is stored in the memory unit 42 (see FIG. 4). Here, in the data table TB1, a plurality of pieces of power consumption data classified for each of the production facilities 10a, 10b, 10c, and 10d are stored so as to be able to be referenced in chronological order.

[0092] For example, in the data table TB1, for the production facility 10a, the power consumption data W11, W12, W13, W14, W15, W16, . . . , W1N are stored so as to be able to be referenced in chronological order. For the production facility 10b, the power consumption data W21, W22, W23, W24, W25, W26, . . . , W2N are stored so as to be able to be referenced in chronological order. For the production facility 10c, the power consumption data W31, W32, W33, W34, W35, W36, . . . , W3N are stored so as to be able to be referenced in chronological order. For the production facility 10d, the power consumption data W41, W42, W43, W44, W45, W46, . . . , W4N are stored so as to be able to be referenced in chronological order.

[0093] Incidentally, the current used by the production equipment 10 fluctuates due to deterioration of the main equipment 10M and auxiliary equipment 10H of the production equipment 10. In other words, the amount of power consumed by the production equipment 10 fluctuates due to deterioration of the main equipment 10M and auxiliary equipment 10H of the production equipment 10. In this way, in the transition of a plurality of pieces of power consumption data in the production equipment 10, an abnormality in the operating state of the production equipment 10 can be detected from the variation in the plurality of pieces of power consumption data.

[0094] The analysis unit 414 analyzes the operating conditions of the production facilities 10a, 10b, 10c, and 10d based on a plurality of pieces of power consumption data stored in a time-series manner so as to be accessible for each of the production facilities 10a, 10b, 10c, and 10d.

[0095] The analysis method executed by the analysis unit 414 is not particularly limited, but may be a method based on an anomaly determination rule using an Xbar-R control chart defined in the JIS standard "Z 9020-2:2016" for multiple power consumption data classified for each of the production equipment 10a, 10b, 10c, and 10d, for example.

[0096] As an example, a case will be described in which the analysis unit 414 analyzes the operating state of the production facility 10a. The analysis unit 414 refers to the power consumption data W11, W12, W13, W14, W15, W16, . . . , W1N when the production facility 10a performs processing operations for each of the production objects 15a to 15n, and determines whether or not the power consumption data equal to or greater than the threshold Th1 corresponding to the upper control limit line in the Xbar-R control chart is equal to or greater than a predetermined number (threshold Th2). If the power consumption data equal to or greater than the threshold Th1 is equal to or greater than the predetermined number (threshold Th2), the analysis unit 414 determines that the operating state of the production facility 10a is abnormal. It is assumed that the production objects 15a to 15n pass through the production facility 10a in this order.

[0097] As another example, the analysis unit 414 refers to the power consumption data W11, W12, W13, W14, W15, W16, ..., W1N when the production equipment 10a performs each processing operation of the production objects 15a to 15n, and judges whether or not the power consumption data equal to or less than the threshold Th3 corresponding to the lower control limit line in the Xbar-R control chart is a predetermined number (threshold Th4) or more. If the power consumption data equal to or less than the threshold Th3 is equal to or more than the predetermined number (threshold Th4) as a result of the judgment, the analysis unit 414 judges that the operating state of the production equipment 10a is abnormal.

[0098] As yet another example, the analysis unit 414 refers to the power consumption data W11, W12, W13, W14, W15, W16, ..., W1N when the production equipment 10a performs processing operations for each of the production objects 15a to 15n, and determines whether the power consumption increases sequentially across a predetermined number (threshold Th5) or more of the plurality of power consumption data. If the power consumption increases sequentially across a predetermined number (threshold Th5) or more of the plurality of power consumption data as a result of the determination, the analysis unit 414 determines that the operating state of the production equipment 10a is abnormal. Conversely, the analysis unit 414 may determine that the operating state of the production equipment 10a is abnormal if the power consumption decreases sequentially across a predetermined number (threshold Th6) or more of the plurality of power consumption data.

[0099] The analysis unit 414 executes these processes for each of the production facilities 10b, 10c, and 10d, and analyzes the operating state of each of the production facilities 10b, 10c, and 10d.

[0100] <Action and effect> According to the second embodiment, the calculation unit 41C (analysis unit 414) of the data processing device 40C refers to a plurality of pieces of power consumption data for each of the production facilities 10a, 10b, 10c, and 10d in chronological order, and analyzes the operating state of each of the production facilities 10a, 10b, 10c, and 10d. The plurality of pieces of power consumption data reflect the operating states of the production facilities 10a, 10b, 10c, and 10d. Since such power consumption data can be referred to in chronological order, it is possible to improve the accuracy of detecting an abnormal operating state for each of the production facilities 10a, 10b, 10c, and 10d.

[0101] As described above, the embodiment has been described, but the above embodiment is presented as an example, and the present invention is not limited to the above embodiment. The above embodiment can be implemented in various other forms, and various combinations, omissions, substitutions, modifications, etc. can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0102] 1,1A,1B,1C Production equipment operation monitoring system 10, 10a, 10b, 10c, 10d Production equipment 20, 20a, 20b, 20c, 20d Measuring section 30,31 Detector 40,40C Data processing device 41,41C Arithmetic unit 411 Data Acquisition Department 412 Calculation processing unit 413 Data Storage Unit 414 Analysis Department 42 Storage section 43 Communications Department 50 production lines 51 Means of transport

Claims

1. A plurality of measuring units each measuring current data used in a processing operation of a plurality of production equipment that sequentially processes the production objects; A data processing device connected to each of the plurality of measurement units; Equipped with The data processing device includes: a calculation unit that calculates, for each of the plurality of production facilities, power consumption data consumed during a processing operation on the production object based on the current data; A storage unit that stores the power consumption data of each of the plurality of production facilities related to the production object in association with each other; A production equipment operation monitoring system.

2. The storage unit stores the identification data of the production object, which is detected by the detection unit from the identification mark applied to the production object and transmitted to the data processing device, and the power consumption data of each of the plurality of production facilities, in association with each other. The production facility operation monitoring system according to claim 1 .

3. The detection unit is provided in at least one of the production equipment located at the most upstream of a production line that transports the production object and the production equipment located at the most downstream of the production line. The production facility operation monitoring system according to claim 2.

4. The storage unit stores time data when the production object passes through the production facility and the power consumption data in association with each other.

3. The production facility operation monitoring system according to claim 1 or 2.

5. A plurality of measuring units each of which is configured to sequentially process a plurality of production objects, measures current data used in a processing operation on each of the plurality of production objects; A data processing device connected to the measurement unit; Equipped with The data processing device includes: a calculation unit that calculates, for each of the plurality of production equipment, a plurality of pieces of power consumption data consumed during a processing operation for each of the plurality of production objects based on the current data; The calculation unit analyzes an operating state of each of the plurality of production facilities based on the plurality of power consumption data for each of the plurality of production facilities. Production equipment operation monitoring system.

6. A calculation unit that calculates, for each of a plurality of pieces of production equipment that sequentially processes the objects to be produced, data on the amount of power consumed during the processing of the objects to be produced based on current data used during the processing of the objects to be produced; A storage unit that stores the power consumption data of each of the plurality of production facilities related to the production object in association with each other; A data processing device comprising:

7. Each of a plurality of production equipments which sequentially process each of a plurality of production objects includes a calculation unit which calculates, for each of the plurality of production equipments, a plurality of pieces of power consumption data consumed during the processing of each of the plurality of production objects based on current data used during the processing of each of the plurality of production objects; The calculation unit analyzes an operating state of each of the plurality of production facilities based on the plurality of power consumption data related to each of the plurality of production facilities. Data processing device.

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