Power consumption monitoring device, power consumption monitoring method, power consumption monitoring program, and recording medium

Abstract

This enables the simple and rational calculation of the power consumption of monitored devices. [Solution] Steps S106 (first calculation process) and S111 (second calculation process) can be executed to calculate the power consumption of multiple units included in the component mounting machine 4 (monitored device) during the execution period Te. Here, the calculation process in step S106 calculates the power consumption of the units based on the model shown in Figures 5A and 5B (first model), which models the power consumption of the units as constant with respect to time. The calculation process in step S111 calculates the power consumption of the units based on the model shown in Figures 5A and 5C (second model), which models the power consumption of the units as changing with respect to time.

Description

Technical Field

[0001] This invention relates to a technique for monitoring the power consumption of a monitored device.

Background Art

[0002] Patent Document 1 discloses a technique for controlling the operation of a component mounter that mounts components adsorbed by a nozzle onto a substrate, thereby suppressing the power consumption of the component mounter. Thus, the technique for suppressing the power consumption of a device is important from the viewpoints of environmental protection and reduction of running costs.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in order to effectively suppress the power consumption, it may be required to calculate the power consumption of the device. However, the calculation of the power consumption of such a device tends to be complicated in terms of calculation cost.

[0005] This invention has been made in view of the above problems, and an object thereof is to enable simple and reasonable calculation of the power consumption of a monitored device.

Means for Solving the Problems

[0006] The power consumption monitoring device according to the present invention includes a storage unit that stores unit information relating to a plurality of units included in a device to be monitored, and a power consumption calculation unit that performs a first calculation process to calculate the power consumption of a unit based on a first model which models the power consumption of a unit as constant with respect to time, and a second calculation process which calculates the power consumption of a unit based on a second model which models the power consumption of a unit as changing with respect to time. The unit information indicates whether each of the plurality of units belongs to the first model or the second model, and the power consumption calculation unit calculates the power consumption of units belonging to the first model by the first calculation process and calculates the power consumption of units belonging to the second model by the second calculation process.

[0007] The power consumption monitoring method according to the present invention comprises the steps of: acquiring unit information relating to a plurality of units included in a device to be monitored; executing a first calculation process to calculate the power consumption of a unit based on a first model which models the power consumption of a unit as constant with respect to time; and executing a second calculation process to calculate the power consumption of a unit based on a second model which models the power consumption of a unit as changing with respect to time. The unit information indicates whether each of the plurality of units belongs to the first model or the second model, the power consumption of a unit belonging to the first model is calculated by the first calculation process, and the power consumption of a unit belonging to the second model is calculated by the second calculation process.

[0008] The power monitoring program according to the present invention causes a computer to execute the above-described power consumption monitoring method.

[0009] The recording medium according to the present invention records the above-mentioned power consumption monitoring program in a way that can be read by a computer.

[0010] In the present invention (power consumption monitoring device, power consumption monitoring method, power consumption monitoring program, and recording medium) configured as described above, a first calculation process and a second calculation process can be executed to calculate the power consumption of multiple units included in the monitored device. Here, the first calculation process calculates the power consumption of a unit based on a first model that models the power consumption of a unit as constant with respect to time. The second calculation process calculates the power consumption of a unit based on a second model that models the power consumption of a unit as changing with respect to time. Therefore, the power consumption of a unit with a small change in power consumption over time can be calculated by the first calculation process, and the power consumption of a unit with a large change in power consumption over time can be calculated by the second calculation process. In other words, the application of the second calculation process, which requires complex calculations, can be limited to a select number of units. As a result, it becomes possible to calculate the power consumption of the monitored device simply and rationally.

[0011] Alternatively, the power consumption monitoring device may be configured such that the first calculation process calculates the power consumption of the unit by multiplying the unit's operating time by a constant. In such a configuration, the first calculation process can be easily executed to calculate the power consumption.

[0012] Furthermore, the power consumption monitoring device may be configured to store a table showing the correspondence between multiple parameters that define the operations performed by the unit and the amount of power consumed by the unit as a result of performing the operations defined by those multiple parameters, for units belonging to the second model, and the second calculation process calculates the power consumption of the unit based on the multiple parameters that define the operations performed by the unit and the table. In such a configuration, the power consumption of a unit whose power consumption changes with time can be calculated simply and with high accuracy.

[0013] Furthermore, the monitored device may include a motor that drives the object as a unit belonging to the second model, and the power consumption monitoring device may be configured such that multiple parameters define the motor profile that accelerates the object's speed from zero to maximum speed and then decelerates it back to zero. In such a configuration, the power consumption of a motor whose power consumption changes with time can be calculated simply and with high accuracy.

[0014] Furthermore, the power consumption monitoring device may be configured such that multiple parameters include the distance the motor travels to move the object, the maximum speed, the acceleration that the motor uses to accelerate the object from zero to the maximum speed, and the deceleration that the motor uses to decelerate the object from the maximum speed to zero. In such a configuration, the power consumption of a motor whose power consumption changes with time can be calculated simply and with high accuracy.

[0015] Furthermore, the second calculation process calculates the motor's power consumption by calculating the acceleration power consumption, which is the amount of power consumed by the motor during the acceleration period in which the object's speed is accelerated from zero to maximum speed at a predetermined acceleration; the maximum speed power consumption, which is the amount of power consumed by the motor during the maximum speed period in which the object's speed is moved at maximum speed; and the deceleration power consumption, which is the amount of power consumed by the motor during the deceleration period in which the object's speed is reduced from maximum speed to zero at a predetermined deceleration. The power consumption monitoring device may be configured such that multiple parameters include the length of the acceleration period or the distance the object travels during the acceleration period as acceleration period-related information, and the acceleration power consumption is calculated based on the acceleration period-related information and acceleration. Multiple parameters include the length of the maximum speed period or the distance the object travels during the maximum speed period as maximum speed period-related information, and the maximum speed power consumption is calculated based on the maximum speed period-related information and maximum speed. Multiple parameters include the length of the deceleration period or the distance the object travels during the deceleration period as deceleration period-related information, and the deceleration power consumption is calculated based on the deceleration period-related information and deceleration. In this configuration, the power consumption of a motor, whose power consumption changes with time, can be calculated simply and with high accuracy.

[0016] Further, the power consumption monitoring device may be configured to further include a notification unit that notifies the user when the power consumption of the unit calculated by the power consumption calculation unit exceeds a predetermined power consumption. In such a configuration, for example, an abnormality or the like occurring in the unit can be detected by the deviation of the power consumption of the unit from the predetermined power consumption and notified to the user.

Advantages of the Invention

[0017] As described above, according to the present invention, it is possible to simply and reasonably calculate the power consumption of the monitoring target device.

Brief Description of the Drawings

[0018] [Figure 1] A plan view schematically showing the configuration of an example of a component mounter. [Figure 2] A block diagram showing the electrical configuration of the component mounter shown in FIG. 1. [Figure 3] A block diagram showing an example of the power supply system included in the component mounter. [Figure 4] A block diagram showing an example of a management server for monitoring the power consumption of the component mounter. [Figure 5A] A diagram showing in tabular form the basic concept of power consumption monitoring in the present embodiment. [Figure 5B] A diagram schematically showing in a time chart the method for calculating the power consumption of a low-power fluctuation unit. [Figure 5C] A diagram schematically showing in a time chart the method for calculating the power consumption of a high-power fluctuation unit. [Figure 6] A flowchart showing an example of power consumption monitoring executed by the calculation unit of the management server. [Figure 7] A diagram schematically showing in a time chart a modification of the method for calculating the power consumption of a high-power fluctuation unit during the execution period.

Embodiments for Carrying Out the Invention

[0019] FIG. 1 is a plan view schematically showing the configuration of an example of a component mounting machine, and FIG. 2 is a block diagram showing the electrical configuration of the component mounting machine of FIG. 1. In FIG. 1, the X direction which is a horizontal direction, the Y direction which is a horizontal direction orthogonal to the X direction, and the Z direction which is a vertical direction are shown.

[0020] The component mounting machine 4 executes a mounting operation of mounting the component E on the substrate B. As shown in FIG. 2, this component mounting machine 4 includes a control unit 400 that comprehensively controls the entire apparatus. The control unit 400 includes a main control unit 401 composed of a processor or the like, a storage unit 402 composed of an HDD or the like, a drive control unit 403 that controls the drive system of the component mounting machine 4, and an imaging control unit 404 that controls the imaging system of the component mounting machine 4. Then, the main control unit 401 controls the drive control unit 403 according to the program stored in the storage unit 402, and executes component mounting in the procedure specified by the program. In addition, a UI 405 which is a user interface is provided in the component mounting machine 4, and the main control unit 401 displays the operating status of the component mounting machine 4 on the UI 405 and receives commands from the operator input to the UI 405.

[0021] As shown in FIG. 1, the component mounting machine 4 includes a transport unit 41 that transports the substrate B in the X direction (substrate transport direction). This transport unit 41 has a pair of conveyors 411 arranged in parallel in the X direction and a conveyor motor M411 that drives the conveyor 411. When the conveyor motor M411 drives the conveyor 411, the conveyor 411 transports the substrate B in the X direction. The interval between these conveyors 411 can be changed in the Y direction (width direction) orthogonal to the X direction, and the transport unit 41 adjusts the interval between the conveyors 411 according to the width of the substrate B to be transported. The drive control unit 403 controls the conveyor motor M411 to carry the substrate B into a predetermined working position (the position of the substrate B in FIG. 1) from the upstream side in the X direction which is the substrate transport direction, and carry out the substrate B on which the component E is mounted from the working position to the downstream side in the X direction.

[0022] On each side of the transport unit 41 in the Y direction, two component supply units 42 are arranged in the X direction, and in each component supply unit 42, multiple tape feeders 421 are arranged in the X direction. The component supply unit 42 is provided with multiple component supply locations 422 arranged in the X direction, and tape feeders 421 that supply the components E to be supplied to each component supply location 422 are attached to each component supply location 422 in correspondence and are detachably mounted. A component supply reel is arranged for each tape feeder 421, around which a carrier tape containing small pieces of components E such as integrated circuits, transistors, and capacitors at predetermined intervals is wound, and the carrier tape pulled from the component supply reel is loaded into each tape feeder 421. In addition, each tape feeder 421 has a feed motor M421, and the feed motor M421 intermittently drives the carrier tape to supply components E to the component supply locations 422 at the tip of the tape feeder 421.

[0023] Furthermore, the component mounting machine 4 is provided with a pair of Y-axis rails 43 extending in the Y direction, a Y-axis ball screw 44 extending in the Y direction, and a Y-axis motor M44 (servo motor) that rotates the Y-axis ball screw 44. The X-axis rail 45 is supported by the pair of Y-axis rails 43 so as to be movable in the Y direction and is fixed to the nuts of the Y-axis ball screw 44. The X-axis rail 45 is fitted with an X-axis ball screw 46 extending in the X direction and an X-axis motor M46 (servo motor) that rotates the X-axis ball screw 46. The head unit 47 is supported by the X-axis rail 45 so as to be movable in the X direction and is fixed to the nuts of the X-axis ball screw 46. Therefore, the drive control unit 403 can move the head unit 47 in the Y direction by rotating the Y-axis ball screw 44 with the Y-axis motor M44, or move the head unit 47 in the X direction by rotating the X-axis ball screw 46 with the X-axis motor M46.

[0024] The head unit 47 has a plurality of mounting heads 48 arranged linearly in the X direction. Each mounting head 48 is provided with a Z-axis motor M48z (servo motor) that drives the mounting head 48 in the Z direction. The drive control unit 403 lowers the mounting head 48 toward the component E at the component supply location 422 using the Z-axis motor M48z, so that the nozzle at the lower end of the mounting head 48 comes into contact with the component E. In this state, the mounting head 48 generates negative pressure in the nozzle and attracts the component E. Furthermore, the drive control unit 403 lowers the mounting head 48, which is attracting the component E to the nozzle, toward the substrate B, so that the component E comes into contact with the substrate B. In this state, the mounting head 48 generates positive pressure in the nozzle and mounts the component E onto the substrate B.

[0025] Furthermore, the mounting head 48 is provided with an R-axis motor M48r (servo motor) that drives the mounting head 48 in the R direction. Here, the R direction is the rotation angle around a rotation axis parallel to the Z direction. The drive control unit 403 adjusts the angle of the component E that the mounting head 48 mounts to the substrate B, which is rotated in the R direction by the R-axis motor M48r. In this case, the rotation of the mounting head 48 in the R direction is controlled based on the result of the mounting head 48 recognizing the component E that will be attracted by the nozzle.

[0026] In other words, the component mounting machine 4 is equipped with a recognition camera 491 and an illumination 492. The recognition camera 491 is positioned facing upwards, and the illumination 492 irradiates light into the field of view of the recognition camera 491. The drive control unit 403 controls the position of the mounting head 48 before picking up the component E from the component supply point 422 and mounting the component E onto the substrate B, so that the component E is within the field of view of the recognition camera 491. The imaging control unit 404 acquires an image of the component E by irradiating light with the illumination 492 and causing the recognition camera 491 to perform imaging. The imaging control unit 404 then transmits the angle of the recognized component E (recognition angle) based on this image to the drive control unit 403, and the drive control unit 403 adjusts the angle of the mounting head 48 in the R direction based on this recognition angle.

[0027] Figure 3 is a block diagram showing an example of a power supply system for a component mounting machine. As shown in Figure 3, the power supply system 5 of the component mounting machine 4 includes a converter 51. The converter 51 converts the AC power supplied from the facility where the component mounting machine 4 is installed into DC power and outputs DC power.

[0028] The power supply system 5 has a plurality of converters 521, 522, 523, and 524, each connected to converter 51. The plurality of converters 521, 522, 523, and 524 are connected in parallel to each other and output a DC power supply generated by converting the voltage of the DC power supply output from converter 51.

[0029] The DC power output by converter 521 is supplied to the main control unit 401, storage unit 402, drive control unit 403, imaging control unit 404, and UI 405. In other words, each of the main control unit 401, storage unit 402, drive control unit 403, imaging control unit 404, and UI 405 operates using the DC power supplied by converter 521.

[0030] The DC power output by converter 522 is supplied to the X-axis motor M46, Y-axis motor M44, Z-axis motor M48z, and R-axis motor M48r. In other words, each of the X-axis motor M46, Y-axis motor M44, Z-axis motor M48z, and R-axis motor M48r operates using the DC power supplied by converter 522.

[0031] The DC power output by converter 523 is supplied to the conveyor motor M411 and the feed motor M421. In other words, each of the conveyor motor M411 and the feed motor M42 is operated by the DC power supplied from converter 523.

[0032] The DC power output by converter 524 is supplied to the recognition camera 491 and the lighting 492. In other words, each of the recognition camera 491 and the lighting 492 operates using the DC power supplied by converter 524.

[0033] A power meter P401 is inserted between the converter 521 and the main control unit 401. This power meter P401 measures the power (watts) consumed by the main control unit 401.

[0034] A power meter P402 is inserted between the converter 521 and the memory unit 402. This power meter P402 measures the power (watts) consumed by the memory unit 402.

[0035] A power meter P403 is inserted between the converter 521 and the drive control unit 403. This power meter P403 measures the power (watts) consumed by the drive control unit 403.

[0036] A power meter P404 is inserted between the converter 521 and the imaging control unit 404. This power meter P404 measures the power (watts) consumed by the imaging control unit 404.

[0037] A power meter P405 is inserted between converter 521 and UI405. This power meter P405 measures the power (watts) consumed by UI405.

[0038] A power meter P46 is inserted between the converter 522 and the X-axis motor M46. This power meter P46 measures the power (watts) consumed by the X-axis motor M46.

[0039] A power meter P44 is inserted between the converter 522 and the Y-axis motor M44. This power meter P44 measures the power (watts) consumed by the Y-axis motor M44.

[0040] A power meter P48z is inserted between the converter 522 and the Z-axis motor M48z. This power meter P48z measures the power (watts) consumed by the Z-axis motor M48z.

[0041] A power meter P48r is inserted between the converter 522 and the R-axis motor M48r. This power meter P48r measures the power (watts) consumed by the R-axis motor M48r.

[0042] A power meter P411 is inserted between the converter 523 and the conveyor motor M411. This power meter P411 measures the power (watts) consumed by the conveyor motor M411.

[0043] A power meter P421 is inserted between the converter 523 and the feed motor M421. This power meter P421 measures the power (watts) consumed by the conveyor motor M411.

[0044] A power meter P491 is inserted between the converter 524 and the recognition camera 491. This power meter P491 measures the power (watts) consumed by the recognition camera 491.

[0045] A power meter P492 is inserted between the converter 524 and the light fixture 492. This power meter P492 measures the power (watts) consumed by the light fixture 492.

[0046] Furthermore, Figure 3 shows a classification of low-power variable units Ul, which have small fluctuations in power consumption over time, and high-power variable units Uh, which have larger fluctuations in power consumption over time compared to low-power variable units Ul. Specifically, the main control unit 401, memory unit 402, drive control unit 403, imaging control unit 404, UI405, conveyor motor M411, feed motor M421, recognition camera 491, and lighting 492 each correspond to low-power variable units Ul. The X-axis motor M46, Y-axis motor M44, Z-axis motor M48z, and R-axis motor M48r correspond to high-power variable units Uh.

[0047] Figure 4 is a block diagram showing an example of a management server that monitors the power consumption of a component mounting machine. The management server 6 is, for example, a computer and comprises an arithmetic unit 61, a storage unit 62, a UI 63, and a communication unit 64. The arithmetic unit 61 is a processor such as a CPU (Central Processing Unit). The storage unit 62 is a storage device such as an SSD (Solid State Drive). The UI 63 is a user interface and has input devices such as a mouse and keyboard, and output devices such as a display. Note that the input and output devices of the UI 63 do not need to be configured separately; they may be configured as an integrated unit using a touch panel display or the like. The communication unit 64 communicates with the component mounting machine 4 by wire or wireless. For example, the communication unit 64 receives the power consumption measurements from each power meter P (power meters P401, P402, ...) and stores them in the storage unit 62.

[0048] The memory unit 62 stores the production program 621. The production program 621 defines the sequence in which the component mounting machine 4 mounts component E onto the circuit board B. In other words, the main control unit 401 of the component mounting machine 4 executes the production program 621 downloaded from the management server 6, thereby performing the component mounting process to mount component E onto the circuit board B according to the procedure indicated by the production program 621.

[0049] Furthermore, the storage unit 62 stores the power consumption monitoring program 622, attribute data 623, power consumption conversion table 624, and power consumption conversion coefficient data 625. The power consumption monitoring program 622 defines the calculations performed by the calculation unit 61 to monitor the power consumption of the component mounting machine 4. The attribute data 623 indicates whether each unit, such as the main control unit 401 and the X-axis motor M46, is a low-power variable unit Ul or a high-power variable unit Uh. The power consumption conversion table 624 is a table used to calculate the power consumption of the high-power variable unit Uh. The power consumption conversion coefficient data 625 is data used to calculate the power consumption of either the low-power variable unit Ul or the high-power variable unit Uh.

[0050] Next, we will specifically explain the power consumption monitoring performed by the management server 6. Figure 5A is a diagram showing the basic concept of power consumption monitoring in this embodiment in tabular form. As shown in Figure 5A, in the power consumption monitoring of this embodiment, the power consumption of the low-power variable unit Ul and the high-power variable unit Uh is calculated by performing different calculation processes for each of them. Furthermore, the power consumption of the units (low-power variable unit Ul, high-power variable unit Uh) depends on whether the unit is in an "executing state," an "executable state," or a "waiting state."

[0051] "Execution state" refers to the state in which a unit is performing operations for component mounting processing. For example, for the main control unit 401, this corresponds to the state in which production program 621 is being executed, and for the X-axis motor M46, this corresponds to the state in which the mounting head 48 is being driven in the X direction. In the "execution state," the unit consumes the amount of power required to perform operations for component mounting processing. "Ready to run" refers to the standby state in which a unit can immediately start operations for component mounting processing. For example, for a motor, this corresponds to the state in which it is energized. "Waiting state" refers to the sleep state in which the unit waits to transition to the "ready to run" state. For example, for a motor, this corresponds to the state in which it is not energized. The power consumption of a unit in the execution state is greater than the power consumption of a unit in the ready to run state, and the power consumption of a unit in the ready to run state is greater than the power consumption of a unit in the waiting state.

[0052] Figure 5A shows the power consumption and energy consumption for each state of the low-power variable unit Ul and the high-power variable unit Uh. Here, the "numbers" 1, 2, ..., m in the row for "low-power variable unit Ul" are numbers that distinguish the units (main control unit 401, etc.) belonging to the low-power variable unit Ul, and the "numbers" 1, 2, ..., n in the row for "high-power variable unit Uh" are numbers that distinguish the units (main control unit 401, etc.) belonging to the high-power variable unit Uh.

[0053] Figure 5A shows the power consumption and energy consumption values ​​for each unit for each state. In particular, power consumption given as a function that varies with time is marked with "(t)", while power consumption given as a constant that does not vary with time is not marked with "(t)". ​​In the "waiting state" and "running state", the power consumption of the low-power variable unit Ul and the high-power variable unit Uh are modeled as being independent of time. On the other hand, in the running state, the power consumption of the low-power variable unit Ul is modeled as being independent of time, while the power consumption of the high-power variable unit Uh is modeled as being time-dependent.

[0054] A concrete comparison between the m-th low-power variable unit Ul and the nth high-power variable unit Uh is as follows: The power consumption Pecm of the low-power variable unit Ul is a constant that does not depend on time, and the power consumption Wecm of the low-power variable unit Ul is the power consumption Pecm multiplied by the unit's operating time. On the other hand, the power consumption Pevm(t) of the high-power variable unit Uh is a function that depends on time. Therefore, the power consumption Wevm of the high-power variable unit Uh is the value obtained by integrating the power consumption Pevm(t) with respect to the unit's operating time.

[0055] Figure 5B schematically illustrates the calculation method for the power consumption of a low-power variable unit using a time chart. In Figure 5B, a time chart is shown with time on the horizontal axis and power consumption (watts) on the vertical axis. This time chart shows the power consumption of the low-power variable unit Ul during the execution of a component mounting process in which components E are mounted on a single circuit board B according to production program 621. In Figure 5B, the runnable period Tp is the period during which the low-power variable unit Ul is in a runnable state, and the execution period Te is the period during which the low-power variable unit Ul is in an execution state. In other words, the power consumption of the low-power variable unit Ul is modeled to have the time dependence shown in Figure 5B.

[0056] The power consumption (watts) of the low-power variable unit Ul during the feasible period Tp is modeled as constant at power consumption Ppcm, regardless of time. Therefore, for example, the power consumption (watt-hours) during the feasible period Tp is calculated as Ppcm × Tp.

[0057] The calculation unit 61 experimentally obtains the power consumption Ppcm of the low-power variable unit Ul during the executable period Tp. Using the main control unit 401, which is an example of a low-power variable unit Ul, the power consumption when the calculation unit 61 is not executing the production program 621 is measured by the power meter P401. The power consumption measured by the power meter P401 is transmitted from the component mounting machine 4 to the communication unit 64 of the management server 6 and obtained by the calculation unit 61. The calculation unit 61 then calculates the power consumption Ppcm by, for example, averaging the obtained power consumption over time. The power consumption Ppcm thus calculated is stored in the storage unit 62 as energy conversion coefficient data 625.

[0058] The power consumption (watts) of the low-power variable unit Ul during the execution period Te is modeled as constant at power consumption Pecm, regardless of time. Therefore, for example, the power consumption (watt-hours) during the execution period Te is calculated as Pecm × Te.

[0059] The calculation unit 61 experimentally obtains the power consumption Pecm of the low-power variable unit Ul during the execution period Te. Using the main control unit 401, which is an example of a low-power variable unit Ul, the power consumption while the main control unit 401 is executing the production program 621 is measured by the power meter P401. The power consumption measured by the power meter P401 is transmitted from the component mounting machine 4 to the communication unit 64 of the management server 6 and obtained by the calculation unit 61. The calculation unit 61 then calculates the power consumption Pecm by, for example, averaging the obtained power consumption over time. The power consumption Pecm thus calculated is stored in the storage unit 62 as energy conversion coefficient data 625.

[0060] Figure 5C is a schematic diagram illustrating the calculation method for the power consumption of a high-power variable unit using a time chart. In particular, Figure 5C shows the calculation method for the power consumption of a motor, which is an example of a high-power variable unit Uh.

[0061] The lower part of Figure 5C shows a time chart with time on the horizontal axis and motor power consumption (watts) on the vertical axis. This time chart shows the power consumption of the high-power variable unit Uh during the execution of the component mounting process, in which component E is mounted on one board B according to production program 621. The upper part of Figure 5C shows a time chart with time on the horizontal axis and motor speed on the vertical axis. This time chart shows the speed (motor output speed) of the high-power variable unit Uh during the execution of the component mounting process, in which component E is mounted on one board B according to production program 621. In Figure 5C, the runnable period Tp is the period during which the high-power variable unit Uh (motor) is in a runnable state, and the execution period Te is the period during which the high-power variable unit Uh (motor) is in an execution state. In other words, the power consumption of the high-power variable unit Uh is modeled to have the time dependence shown in Figure 5C.

[0062] The power consumption (watts) of the high-power variable unit Uh during the feasible period Tp is modeled as constant at power consumption Ppvm, regardless of time. Therefore, for example, the power consumption (watt-hours) during the feasible period Tp is calculated as Ppvm × Tp.

[0063] The calculation unit 61 experimentally obtains the power consumption Ppvm of the high-power variable unit Uh during the executable period Tp. Using the X-axis motor M46 as an example of the high-power variable unit Uh, the power consumption of the excited X-axis motor M46 when it is stopped is measured by the power meter P46. The power consumption measured by the power meter P46 is transmitted from the component mounting machine 4 to the communication unit 64 of the management server 6 and obtained by the calculation unit 61. The calculation unit 61 then calculates the power consumption Ppvm, for example, by averaging the obtained power consumption over time. The resulting power consumption Ppvm is stored in the storage unit 62 as energy conversion coefficient data 625.

[0064] The power consumption (watts) of the high-power variable unit Uh during the execution period Te is modeled by a time-dependent power consumption Pevm(t). Therefore, for example, the power consumption (watt-hours) during the execution period Te can be calculated by integrating the power consumption Pevm(t) over the execution period Te.

[0065] However, the power consumption of the high-power variable unit Uh during the execution period Te is determined not by actually performing an integral calculation, but based on several parameters that define the operation of the high-power variable unit Uh. In other words, the execution period Te includes the acceleration period Tea, the constant velocity period Tec, and the deceleration period Ted. During the acceleration period Tea, the speed of the high-power variable unit Uh (the speed output by the motor) accelerates from zero to a maximum speed Vx with acceleration Aa. During the constant velocity period Tec following the acceleration period Tea, the speed of the high-power variable unit Uh is constant at the maximum speed Vx. During the deceleration period Ted following the constant velocity period Tec, the speed of the high-power variable unit Uh decelerates from the maximum speed Vx to zero with deceleration Ad. The motor then moves the object (implementation head 48) by a distance D given by the area of ​​the speed profile in the upper part of Figure 5C (i.e., the time integral). In other words, the operation of the high-power variable unit Uh (in other words, the motor's speed profile) is determined by several parameters, including acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D. Note that when the travel distance D is short, there is no constant velocity period Tec, and the speed profile has a triangle. In this case, the speed corresponding to the vertex of the triangle in the speed profile is the maximum speed Vx.

[0066] In response, the calculation unit 61 experimentally calculates a power conversion table 624 showing the relationship between acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D, and the power consumption of the motor, and stores it in the storage unit 62. To illustrate with an example of a high-power variable unit Uh, the X-axis motor M46, the power consumption when the X-axis motor M46 performs an operation defined by acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D is measured by the power meter P46. The power consumption measured by the power meter P46 is transmitted from the component mounting machine 4 to the communication unit 64 of the management server 6 and acquired by the calculation unit 61. The calculation unit 61 then generates the power conversion table 624 by acquiring the power consumption measured by the power meter P46 while changing the combination of acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D. The power conversion table 624 thus generated is stored in the storage unit 62. Therefore, the calculation unit 61 can determine the power consumption of the high-power variable unit Uh by obtaining the power consumption corresponding to the combination of acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D from the power consumption conversion table 624.

[0067] The power consumption monitoring program 622 stored in the memory unit 62 of the management server 6 predicts the power consumption of the component mounting machine 4 based on a power consumption model that models the power consumption of the low-power variable unit Ul and the high-power variable unit Uh, as described above. This point will be explained next.

[0068] Figure 6 is a flowchart showing an example of power consumption monitoring performed by the arithmetic unit of the management server. The power consumption monitoring in Figure 6 is performed by the arithmetic unit 61 according to the power consumption monitoring program 622. In particular, a simulation is performed in which a component mounting process is carried out on the component mounting machine 4 according to the production program 621, and the power consumption of each unit of the component mounting machine 4 associated with the execution of the component mounting process is calculated.

[0069] In step S101, the count value N used to distinguish units is reset to zero, and in step S102, the count value N is incremented by 1. This count value N sets the units that will be used for energy calculation. In step S103, it is determined whether the unit indicated by the count value N is a low-power variable unit Ul or not. Specifically, the determination in step S103 is made based on attribute data 623 that indicates whether each unit is a low-power variable unit Ul or a high-power variable unit Uh.

[0070] If the unit with count value N is a low-power variable unit Ul (if the answer is "YES" in step S103), the calculation unit 61 estimates the power consumption of the unit with count value N by steps S104 to S107 (low-variability calculation processing).

[0071] Specifically, the calculation unit 61 obtains the executable period Tp and the execution period Te of the low-power variable unit Ul based on the production program 621 (step S104). This provides the information shown in the time chart illustrated in Figure 5B.

[0072] In step S105, the calculation unit 61 obtains the power consumption Ppcm stored as energy conversion coefficient data 625 in the storage unit 62, and calculates the power consumption for each executable period Tp by multiplying the power consumption Ppcm by the executable period Tp.

[0073] In step S106, the calculation unit 61 obtains the power consumption Pecm stored as power consumption conversion coefficient data 625 in the storage unit 62, and calculates the power consumption for each execution period Te by multiplying the power consumption Pecm by the execution period Te.

[0074] In step S107, the calculation unit 61 calculates the total power consumption of the unit by adding the power consumption for each executable period Tp and the power consumption for each execution period Te. Then, the process proceeds to step S108.

[0075] If the unit with count value N is a high-power variable unit Uh (if the answer is "NO" in step S103), the calculation unit 61 estimates the power consumption of the unit with count value N by steps S109 to S112 (high-power variable calculation processing).

[0076] Specifically, the calculation unit 61 obtains the executable period Tp and the execution period Te of the high-power variable unit Uh based on the production program 621 (step S109). This provides the information shown in the time chart illustrated in the lower part of Figure 5A.

[0077] In step S110, the calculation unit 61 obtains the power consumption Ppvm stored as energy conversion coefficient data 625 in the storage unit 62, and calculates the power consumption for each executable period Tp by multiplying the power consumption Ppvm by the executable period Tp.

[0078] In step S111, the calculation unit 61 obtains several parameters that define the operation performed by the high-power variable unit Uh during the execution period Te. Then, the calculation unit 61 obtains the power consumption amount associated with these several parameters in the power consumption conversion table 624. In this way, the power consumption amount for each execution period Te is determined.

[0079] In step S112, the calculation unit 61 calculates the total power consumption of the unit by adding the power consumption for each executable period Tp and the power consumption for each execution period Te. Then, the process proceeds to step S108.

[0080] In step S108, the calculation unit 61 determines whether the count value N has reached the maximum value Nx. Here, the maximum value Nx is the number of units provided by the component mounting machine 4. If the count value N is less than the maximum value Nx (i.e., "NO" in step S108), the process returns to step S102. This calculates the power consumption for the Nx units provided by the component mounting machine 4.

[0081] When the count value N reaches the maximum value Nx (YES in step S108), the calculation unit 61 determines whether there are any abnormal units among the Nx units. Specifically, it compares the calculated power consumption of the unit with the upper limit power consumption set for that unit to determine whether the power consumption exceeds the upper limit power consumption. Units whose power consumption is less than or equal to the upper limit power consumption are determined to be normal, while units whose power consumption exceeds the upper limit power consumption are determined to be abnormal.

[0082] If there is an abnormal unit among the Nx units (if the answer is "YES" in step S113), the arithmetic unit 61 causes the UI 63 to notify the error. For example, an error notification is displayed on the UI 63's display.

[0083] If there are no abnormal units among the Nx units (if the answer is "NO" in step S113), the calculation unit 61 calculates the total power consumption of the Nx units and calculates the power consumption of the component mounting machine 4 (step S114). Then, the calculation unit 61 displays the power consumption of the component mounting machine 4 on the UI 63 display (step S115).

[0084] In the embodiment described above, steps S106 (first calculation process) and S111 (second calculation process) can be executed to calculate the power consumption of multiple units included in the component mounting machine 4 (monitored device) during the execution period Te. Here, the calculation process in step S106 calculates the power consumption of a unit based on the model shown in Figures 5A and 5B (first model), which models the power consumption of a unit as constant with respect to time. The calculation process in step S111 calculates the power consumption of a unit based on the model shown in Figures 5A and 5C (second model), which models the power consumption of a unit as changing with respect to time. Therefore, among the multiple units, the power consumption of the low-power variable unit Ul, whose power consumption changes little over time, can be calculated by the calculation process in step S106, and the power consumption of the unit whose power consumption changes large over time can be calculated by the calculation process in step S111. In other words, the application of the calculation process in step S111, which requires complex calculations, can be limited to the high-power variable unit Uh among the multiple units. As a result, it becomes possible to calculate the power consumption of the component mounting machine 4 simply and rationally.

[0085] Furthermore, the calculation process in step S106 calculates the power consumption of the unit by multiplying the unit's operating time by a constant. In this configuration, the calculation process in step S106 can be easily performed to calculate the power consumption.

[0086] Furthermore, a power consumption conversion table 624 is stored that shows the correspondence between multiple parameters that define the operation performed by the unit and the amount of power consumed by the unit as a result of performing the operation defined by these multiple parameters, for units belonging to the high-power variable unit Uh. Based on this, the calculation process in step S111 calculates the power consumption of the unit based on the multiple parameters that define the operation performed by the unit and the power consumption conversion table 624. With this configuration, the power consumption of a unit whose power consumption changes with time can be calculated simply and with high accuracy.

[0087] Furthermore, the component mounting machine 4 includes a motor (such as the X-axis motor M46) that drives the mounting head 48 (object) as a high-power variable unit Uh. In contrast, multiple parameters define the motor profile that accelerates the speed of the mounting head 48 from zero to a maximum speed Vx and then decelerates it back to zero. With this configuration, the power consumption of the motor, which changes with time, can be calculated simply and with high accuracy.

[0088] Furthermore, the parameters include the distance D the motor moves the mounting head 48 (object), the maximum speed Vx, the acceleration Aa the motor uses to accelerate the mounting head 48 from zero to the maximum speed Vx, and the deceleration Ad the motor uses to decelerate the mounting head 48 from the maximum speed Vx to zero. With this configuration, the power consumption of the motor, which changes with time, can be calculated simply and with high accuracy.

[0089] Furthermore, if the power consumption of the unit calculated by the calculation unit 61 exceeds the upper limit power consumption (predetermined power consumption), the UI 63 (notification unit) notifies the user (step S116). In this configuration, for example, an abnormality in the unit can be detected by the deviation of the unit's power consumption from the predetermined power consumption, and the user can be notified.

[0090] As described above, in this embodiment, the component mounting machine 4 corresponds to an example of the "monitored device" of the present invention, the main control unit 401 or the X-axis motor M46 etc. corresponds to an example of the "unit" of the present invention, attribute data 623 corresponds to attribute data 623 of the present invention, storage unit 62 corresponds to an example of the "storage unit" of the present invention, step S106 corresponds to an example of the "first calculation process" of the present invention, step S111 corresponds to an example of the "second calculation process" of the present invention, calculation unit 61 corresponds to an example of the "power consumption calculation unit" of the present invention, management server 6 corresponds to an example of the "power consumption monitoring device" of the present invention, power consumption conversion table 624 corresponds to an example of the "table" of the present invention, UI 63 corresponds to an example of the "notification unit" of the present invention, management server 6 corresponds to an example of the "computer" of the present invention, power consumption monitoring program 622 corresponds to an example of the "power consumption monitoring program" of the present invention, and storage unit 62 corresponds to an example of the "recording medium" of the present invention.

[0091] It should be noted that the present invention is not limited to the embodiments described above, and various modifications can be made to those described above without departing from the spirit of the invention. For example, examples of multiple parameters that define the operation of the motor are not limited to the acceleration Aa, maximum speed Vx, deceleration Ad, and travel distance D described above. In other words, multiple parameters that uniquely define the operation (in other words, the profile) of the motor can be arbitrarily selected.

[0092] Furthermore, various methods can be considered for calculating the power consumption of the high-power variable unit Uh during the execution period Te. For example, as shown in Figure 7, the power consumption of the high-power variable unit Uh during the execution period Te may be calculated by adding up the power consumption obtained for each of the acceleration period Tea, constant velocity period Tec, and deceleration period Ted. Here, Figure 7 is a diagram schematically showing a modified example of the method for calculating the power consumption of the high-power variable unit during the execution period in a time chart.

[0093] Furthermore, in the calculation process shown in the example in Figure 7 (step S111), the motor power consumption Wa (acceleration power consumption) during the acceleration period Tea, the motor power consumption Wc (maximum speed power consumption) during the constant speed period Tec (maximum speed period), and the motor power consumption Wd (deceleration power consumption) during the deceleration period Ted are calculated.

[0094] In particular, an acceleration power table showing the relationship between the length of the acceleration period Tea and the acceleration Aa, and the amount of power consumed during the acceleration period Tea, is pre-stored in the storage unit 62. The calculation unit 61 then obtains the amount of power consumed corresponding to the combination of the length of the acceleration period Tea and the acceleration Aa, which was acquired based on the production program 621, from the acceleration power table to determine the power consumption of the unit during the acceleration period Tea. Incidentally, instead of the acceleration period Tea, the travel distance of the mounting head 48 during the acceleration period Tea can also be used to calculate the power consumption during the acceleration period Tea.

[0095] Furthermore, a constant-speed power table showing the relationship between the length of the constant-speed period Tec and the maximum speed Vx, and the amount of power consumed during the constant-speed period Tec, is pre-stored in the storage unit 62. The calculation unit 61 then obtains the amount of power consumed corresponding to the combination of the length of the constant-speed period Tec and the maximum speed Vx, which was acquired based on the production program 621, from the constant-speed power table to determine the power consumption of the unit during the constant-speed period Tec. Incidentally, instead of the constant-speed period Tec, the travel distance of the mounting head 48 during the constant-speed period Tec can also be used to calculate the power consumption during the constant-speed period Tec.

[0096] Furthermore, a power table for deceleration, showing the relationship between the length of the deceleration period Ted and the deceleration rate Ad, and the amount of power consumed during the deceleration period Ted, is pre-stored in the storage unit 62. The calculation unit 61 then obtains the amount of power consumed corresponding to the combination of the length of the deceleration period Ted and the deceleration rate Ad, which was acquired based on the production program 621, from the power table for deceleration, thereby determining the power consumption of the unit during the deceleration period Ted. Incidentally, instead of the deceleration period Ted, the travel distance of the mounting head 48 during the deceleration period Ted can also be used to calculate the power consumption during the deceleration period Ted.

[0097] Furthermore, it is not essential to use a table to calculate the amount of power consumed during the execution period Te of the high-power variable unit Uh. In other words, the amount of power consumed can be calculated by having the calculation unit 61 perform a time integral of the power consumption Pevm(t).

[0098] Furthermore, the units classified as high-power variable units Uh are not limited to the examples above. Therefore, conveyor motor M411 or lighting 492, etc., may also be classified as high-power variable units Uh.

[0099] Furthermore, the devices subject to power consumption monitoring are not limited to the component mounting machine 4. Therefore, the above embodiment can be applied to monitor the power consumption of printing machines that print solder onto circuit boards, or inspection machines that inspect circuit boards with components mounted on them. [Explanation of Symbols]

[0100] 4…Component mounting machine 401...Main Control Unit 6…Management Server 61...Arithmetic section 62...Storage section 622...Electricity monitoring program 623... Attribute data 624...Electricity Conversion Table 63…UI

Claims

1. A storage unit that stores unit information for multiple units included in the monitored device, A power consumption calculation unit that performs a first calculation process to calculate the power consumption of the unit based on a first model which models the power consumption of the unit as constant with respect to time, and a second calculation process which calculates the power consumption of the unit based on a second model which models the power consumption of the unit as changing with respect to time. Equipped with, The unit information indicates whether each of the plurality of units belongs to the first model or the second model. The power consumption calculation unit is a power consumption monitoring device that calculates the power consumption of the unit belonging to the first model by the first calculation process and calculates the power consumption of the unit belonging to the second model by the second calculation process.

2. The power consumption monitoring device according to claim 1, wherein the first calculation process calculates the power consumption of the unit by multiplying the operating time of the unit by a constant.

3. A table is stored showing the correspondence between a plurality of parameters that define the operation performed by the unit and the amount of power consumed by the unit as a result of performing the operation defined by the plurality of parameters, for the unit belonging to the second model. The power consumption monitoring device according to claim 1 or 2, wherein the second calculation process calculates the power consumption of the unit based on the plurality of parameters that define the operation performed by the unit and the table.

4. The monitored device, as the unit belonging to the second model, includes a motor that drives the object, The power consumption monitoring device according to claim 3, wherein the plurality of parameters define the profile of the motor that accelerates the speed of the object from zero to a maximum speed and then decelerates it to zero.

5. The power consumption monitoring device according to claim 4, wherein the plurality of parameters include the distance traveled by the motor to move the object, the maximum speed, the acceleration by which the motor accelerates the object from zero to the maximum speed, and the deceleration by which the motor decelerates the object from the maximum speed to zero.

6. The second calculation process calculates the motor's power consumption by determining the acceleration power consumption, which is the power consumption of the motor during the acceleration period in which the object's speed is accelerated from zero to the maximum speed at a predetermined acceleration; the maximum speed power consumption, which is the power consumption of the motor during the maximum speed period in which the object is moved at the maximum speed; and the deceleration power consumption, which is the power consumption of the motor during the deceleration period in which the object's speed is reduced from the maximum speed to zero at a predetermined deceleration. The aforementioned multiple parameters include the length of the acceleration period or the distance the object travels during the acceleration period as acceleration period-related information. The acceleration power consumption is calculated based on the acceleration period-related information and the acceleration. The aforementioned plurality of parameters include the length of the maximum speed period or the distance the object travels during the maximum speed period as maximum speed period-related information. The aforementioned maximum speed power consumption is calculated based on the aforementioned maximum speed period-related information and the aforementioned maximum speed. The aforementioned multiple parameters include the length of the deceleration period or the distance the object travels during the deceleration period as deceleration period-related information. The power consumption monitoring device according to claim 4, wherein the deceleration power consumption is calculated based on the deceleration period-related information and the deceleration speed.

7. The power consumption monitoring device according to claim 1 or 2, further comprising a notification unit that notifies the user when the power consumption of the unit calculated by the power consumption calculation unit exceeds a predetermined power amount.

8. A process of acquiring unit information for multiple units included in the monitored device, A first calculation process is performed to calculate the amount of power consumed by the unit based on a first model that models the power consumption of the unit as constant with respect to time. A second calculation process is performed to calculate the amount of power consumed by the unit based on a second model that models the power consumption of the unit as changing with time. Equipped with, The unit information indicates whether each of the plurality of units belongs to the first model or the second model. The power consumption of the unit belonging to the first model is calculated by the first calculation process, The power consumption of the unit belonging to the second model is calculated by the second calculation process, and this is the power consumption monitoring method.

9. A power consumption monitoring program that causes a computer to execute the power consumption monitoring method described in claim 8.

10. A recording medium for recording the power consumption monitoring program described in claim 9 in a manner readable by a computer.

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