Energy efficiency evaluation support system

Abstract

To provide an energy efficiency evaluation support system capable of determining occurrence of a waste in energy consumption derived from production of manufactures.SOLUTION: The present system is adapted to a manufacturing apparatus 10 that produces manufactures using plural types of process apparatuses. Plural evaluation object periods are designated in order to determine energy consumption of the manufacturing apparatus 10 for a series of manufacturing processes for producing manufactures. A time length detection unit 45 of a computer 40 detects a time length of each of the evaluation object periods as an actual time length. A memory unit 41 of the computer 40 stores in advance a reference value for the time length of each of the evaluation object periods. A determination unit 46 of the computer 40 determines occurrence of a waste of energy consumption over each of the evaluation object periods on the basis of a result of comparison of the actual time length of the evaluation object period with the reference value.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an energy efficiency evaluation support system for supporting the evaluation of energy efficiency in a manufacturing apparatus.

Background Art

[0002] Generally, a manufacturing apparatus for manufacturing a product has a plurality of different types of process apparatuses for each process. As such a manufacturing apparatus, a manufacturing apparatus for manufacturing beverage products such as tea in a PET bottle is known (see, for example, Patent Document 1). This manufacturing apparatus includes, as process apparatuses, an extractor used in an extraction process for extracting tea extract, a blending apparatus used in a blending process, a filling apparatus used in a filling process for filling tea into a PET bottle, and the like.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In response to the growing awareness of energy conservation in recent years, in the manufacture of products by manufacturing apparatuses, further reduction of manufacturing costs is required in order to improve manufacturing efficiency.

[0005] In manufacturing a product by a manufacturing apparatus, in order to eliminate its waste, it is necessary to determine where waste occurs in the manufacturing process. The fact is that a method for evaluating the energy efficiency in a manufacturing apparatus, including a method for determining a portion where such waste occurs, has not yet been established.

Means for Solving the Problems

[0006] This section describes various aspects of an energy efficiency evaluation support system designed to address the above-mentioned challenges. [Aspect 1] An energy efficiency evaluation support system applicable to a manufacturing apparatus that manufactures products using multiple types of process equipment, wherein multiple evaluation target periods are defined for a series of manufacturing processes that manufacture the products, and the system comprises: a time length detection unit that individually detects the time length of each of the multiple evaluation target periods as the actual time length; a reference storage unit that stores reference values ​​for the time lengths of the multiple evaluation target periods in advance; and a determination unit that determines the occurrence of wasted energy consumption during the evaluation target period based on the result of comparing the actual time length corresponding to the same evaluation target period with the reference value.

[0007] Typically, there is an optimal length for the manufacturing process of a manufacturing device to minimize energy consumption during production. Therefore, in manufacturing devices, both when the manufacturing process length is too long and when it is too short, there is a possibility of wasted energy consumption.

[0008] In the above configuration, the actual time length, which is the detected value for the duration of each evaluation period in the manufacturing process, is compared with a pre-stored reference value for the duration of the same evaluation period. According to the above configuration, it is possible to determine whether the evaluation period has become longer (or shorter) from the comparison result between the actual time length and the reference value. Therefore, based on this determination, it is possible to determine whether there is a possibility of wasted energy consumption during the evaluation period. Thus, according to the above configuration, it is possible to determine whether there is wasted energy consumption in the manufacturing of the product.

[0009] [Aspect 2] The manufacturing apparatus manufactures a plurality of products through a series of manufacturing processes, the reference storage unit stores a first relationship between the number of products manufactured in the series of manufacturing processes and the reference value corresponding to that number, the energy efficiency evaluation support system has a production quantity detection unit that detects the number of products manufactured in the series of manufacturing processes, the determination unit calculates the reference value from the first relationship based on the number of products detected by the production quantity detection unit, and uses the calculated reference value as a comparison target with the actual time length, the energy efficiency evaluation support system as described in [Aspect 1].

[0010] As the number of products manufactured in a series of manufacturing processes increases, the duration of those processes also increases. Consequently, the duration of each evaluation period and the benchmark values ​​for those durations also change in accordance with these changes in the duration of the manufacturing processes.

[0011] According to the above configuration, a standard value for the duration of each evaluation period can be determined according to the number of products manufactured. Therefore, based on this standard value, it is possible to accurately determine the amount of waste in energy consumption related to the manufacturing of a product, in accordance with the number of products manufactured.

[0012] [Aspect 3] The manufacturing apparatus manufactures multiple types of the manufactured products, the reference storage unit stores a second relationship between the types of the manufactured products manufactured in the series of manufacturing processes and the reference value corresponding to the same type, and the determination unit calculates the reference value from the second relationship based on the types of the manufactured products manufactured in the series of manufacturing processes, and uses the calculated reference value as a comparison target with the actual time length, the energy efficiency evaluation support system according to [Aspect 1] or [Aspect 2].

[0013] When the type of product manufactured in a series of manufacturing processes differs, the duration of those processes also differs. Consequently, the duration of each evaluation period and the benchmark values ​​for those durations also change in accordance with these changes in the duration of the manufacturing processes.

[0014] According to the above configuration, a standard value for the length of the evaluation period can be determined according to the type of product. Therefore, based on this standard value, it is possible to accurately determine the amount of waste in energy consumption related to the manufacturing of the product, in a manner appropriate to the type of product.

[0015] [Aspect 4] The determination unit determines that waste has occurred when the actual time length is greater than the reference value, an energy efficiency evaluation support system according to any one of [Aspect 1] to [Aspect 3].

[0016] [Aspect 5] The energy efficiency evaluation support system according to any one of [Aspect 1] to [Aspect 4], wherein the manufactured product is a beverage product in a beverage container, the plurality of process equipment includes a filling equipment for filling the beverage container with the beverage, and the plurality of evaluation periods include a start-up period which is the period from when the operation of the manufacturing equipment for manufacturing the beverage product is started until the filling of the beverage by the filling equipment is started, a filling period which is the period during which the filling of the beverage by the filling equipment is performed, and a stop period which is the period from when the filling of the beverage by the filling equipment is completed until the operation of the manufacturing equipment for manufacturing the beverage product is stopped.

[0017] According to the above configuration, the series of manufacturing processes can be divided into a "startup period" for starting up the manufacturing equipment, a "filling period" for filling beverage containers with beverages using a filling device to manufacture beverage products, and a "shutdown period" for stopping the manufacturing equipment after the beverage products have been manufactured. This makes it possible to accurately determine the amount of energy waste generated during each of these periods.

[0018] [Aspect 6] The manufacturing apparatus has a cleaning device that cleans the inside of the process apparatus by driving the same cleaning pump before and after using the plurality of types of process apparatus, and manufactures the product using the plurality of types of process apparatus and the cleaning device. The energy efficiency evaluation support system has a pump detection unit that detects an index value of the power consumption of the cleaning pump, a condition storage unit that stores in advance conditions for identifying the process apparatus to be cleaned when the cleaning device is in operation, and a target device identification unit that identifies the process apparatus to be cleaned and the operating period of the cleaning pump for cleaning the process apparatus based on the index value of power consumption when the change in the index value of power consumption detected by the pump detection unit satisfies the conditions, and determines the plurality of evaluation target periods based on the process apparatus to be cleaned and the operating period identified by the target device identification unit, the energy efficiency evaluation support system according to any one of [Aspect 1] to [Aspect 5].

[0019] In the above configuration, the cleaning equipment is driven by a shared cleaning pump. However, if the process equipment being cleaned is different, the cleaning method of the process equipment will also be different, and therefore the driving method of the cleaning pump will also be different. With the above configuration, the characteristic movement of the cleaning pump during the operation of the cleaning device (specifically, the change in the power index value) can be known in advance for each process device, and the conditions that allow for the identification of this characteristic movement can be stored as conditions for identifying the process device to be cleaned. Therefore, based on the above conditions, the characteristic movement of the power consumption index value of the cleaning pump can be captured, and the process device to be cleaned by the cleaning device can be identified. Moreover, the operating period of the cleaning pump for cleaning the process device to be cleaned can also be determined from the change in the power consumption index value of the cleaning pump.

[0020] In manufacturing equipment equipped with a cleaning device, the evaluation period for assessing energy efficiency is determined by the period during which the process equipment is operated and the period during which the cleaning device is operated for cleaning the process equipment before or after use. With the above configuration, the target equipment identification unit can identify the operating period of the cleaning pump for cleaning the process equipment to be cleaned, and this operating period can be used as a parameter for setting the evaluation period.

[0021] [Aspect 7] An energy efficiency evaluation support system according to [Aspect 6], comprising a process detection unit that separately detects an index value of the power consumption of each of the multiple types of process equipment, wherein the target equipment identification unit identifies the process equipment to be cleaned and the operating period based on the index value of the power consumption of the cleaning pump and the index value of the power consumption of any of the process equipment detected by the pump detection unit when both the trend of the index value of the power consumption detected by the pump detection unit and the trend of the index value of the power consumption of any of the multiple types of process equipment detected by the process detection unit satisfy the above conditions.

[0022] Some manufacturing equipment operates when a cleaning device is run to clean the process equipment. With the above configuration, in such manufacturing equipment, in addition to using an index value for the power consumption of the cleaning pump, an index value for the power consumption of the process equipment can be used as a parameter to define the conditions for identifying the process equipment to be cleaned. This allows for fine-tuning of the above conditions, making it possible to accurately identify the process equipment to be cleaned and the operating period of the cleaning pump for cleaning that process equipment.

[0023] [Aspect 8] An energy efficiency evaluation support system according to any one of [Aspect 1] to [Aspect 7], comprising a process detection unit that separately detects an index value of the power consumption of the multiple types of process equipment, and determining the multiple evaluation target periods based on the changes in the index value detected by the process detection unit.

[0024] According to the above configuration, by adding a process detection unit, which is a configuration for detecting an index value of power consumption of a process device, it is possible to accurately define an evaluation target period according to the actual operation mode of the process device.

[0025] [Aspect 9] An energy efficiency evaluation support system according to any one of [Aspect 1] to [Aspect 8], comprising: a standard value storage unit that stores in advance standard values for the time lengths of the plurality of evaluation target periods; and a notification unit that notifies, during the manufacturing of the product by the manufacturing device, a standard period that is the evaluation target period determined by the standard value.

[0026] According to the above configuration, during the manufacturing of a product by a manufacturing device, a user can grasp a standard period, which is a standard period for the evaluation target period, based on the information notified by the notification unit. Thereby, the user can grasp the deviation between the standard period and the actual evaluation target period, or control the operations of a plurality of types of process devices while confirming the standard period. According to the above configuration, it is thus possible to support the efficient operation of the manufacturing device by the user.

[0027] [Aspect 10] An energy efficiency evaluation support system applied to a manufacturing device that manufactures a product using a plurality of types of process devices, wherein a first evaluation target period for evaluating the energy efficiency of the manufacturing device for a series of manufacturing processes for manufacturing the product is defined, and includes: a time length detection unit that detects the time length of the first evaluation target period as an actual time length; a time length reference storage unit that stores in advance a first reference value for the time length of the first evaluation target period; and a time length determination unit that determines the occurrence of wasted energy consumption in the first evaluation target period based on the result of comparing the actual time length corresponding to the first evaluation target period with the first reference value.

[0028] Typically, there is an optimal length for the manufacturing process of a manufacturing device to minimize energy consumption during production. Therefore, in manufacturing devices, both when the manufacturing process length is too long and when it is too short, there is a possibility of wasted energy consumption.

[0029] In the above configuration, the actual time length, which is the detected value for the manufacturing process, or more specifically, the length of the first evaluation period, is compared with a pre-stored first reference value for the same first evaluation period. According to the above configuration, it is possible to determine whether the first evaluation period has become longer (or shorter) from the comparison result between the actual time length and the first reference value. Therefore, based on this determination, it is possible to determine whether there is a possibility of wasted energy consumption during the first evaluation period. Thus, according to the above configuration, it is possible to determine whether there is wasted energy consumption in the manufacturing of a product.

[0030] [Aspect 11] The energy efficiency evaluation support system according to [Aspect 10], wherein the time length reference storage unit stores a third relationship between the amount of the product manufactured in the series of manufacturing processes and the first reference value corresponding to the amount manufactured, and the time length determination unit calculates the first reference value from the third relationship based on the amount manufactured, and uses the calculated first reference value as a comparison target with the actual time length.

[0031] As the volume of products manufactured in a series of manufacturing processes increases, the duration of those processes also increases. Consequently, the duration of the first evaluation period and the first baseline value for that duration also change in accordance with these changes in the duration of the manufacturing processes.

[0032] According to the above configuration, a first reference value for the length of the first evaluation period can be determined according to the above production volume. Therefore, based on this first reference value, it is possible to accurately determine the amount of waste in energy consumption related to the production of the product, in accordance with the production volume of the product.

[0033] [Aspect 12] The manufacturing apparatus manufactures a plurality of types of the manufactured products, the time length reference storage unit stores a fourth relationship between the types of the manufactured products manufactured in the series of manufacturing processes and the first reference value corresponding to the same type, and the time length determination unit calculates the first reference value from the fourth relationship based on the types of the manufactured products manufactured in the series of manufacturing processes, and uses the calculated first reference value as a comparison target with the actual time length, the energy efficiency evaluation support system according to [Aspect 10] or [Aspect 11].

[0034] When the type of product manufactured in a series of manufacturing processes differs, the duration of those processes also differs. Consequently, the duration of the first evaluation period and the first baseline value for that duration also change in accordance with these changes in the duration of the manufacturing processes.

[0035] According to the above configuration, a first reference value for the length of the first evaluation period can be determined according to the type of product. Therefore, based on this first reference value, it is possible to accurately determine the amount of waste in energy consumption related to the manufacturing of the product, in a manner appropriate to the type of product.

[0036] [Aspect 13] The energy efficiency evaluation support system according to any one of [Aspect 10] to [Aspect 12], wherein the time length determination unit determines that waste has occurred when the actual time length is greater than the first reference value.

[0037] [Aspect 14] An energy efficiency evaluation support system according to any one of [Aspect 10] to [Aspect 13], comprising a process detection unit that separately detects an index value of the power consumption of the multiple types of process equipment, and determining the first evaluation period based on the trend of the index value detected by the process detection unit.

[0038] With the above configuration, by adding a process detection unit, which is configured to detect an indicator value of the power consumption of the process equipment, the first evaluation period can be accurately defined according to the actual operating mode of the process equipment.

[0039] [Aspect 15] An energy efficiency evaluation support system according to any one of [Aspect 10] to [Aspect 14], comprising: a standard value storage unit that stores a standard value in advance for the length of the first evaluation period; and a notification unit that notifies the standard period, which is the first evaluation period determined by the standard value, during the manufacturing of the product by the manufacturing apparatus.

[0040] With the above configuration, the user can understand the standard period, which is the typical period for the evaluation target period, based on the information notified by the notification unit during the manufacturing of products by the manufacturing equipment. This allows the user to understand the difference between the standard period and the actual evaluation target period, and to control the operation of multiple types of process equipment while checking the standard period. With the above configuration, it is possible to support the efficient operation of the manufacturing equipment by the user in this way.

[0041] [Aspect 16] An energy efficiency evaluation support system according to any one of [Aspect 10] to [Aspect 15], comprising: a second evaluation period for evaluating the energy efficiency of the manufacturing equipment for a series of manufacturing processes for producing the product; a process detection unit for detecting an index value of the power consumption of each of the multiple types of process equipment; and a unit cost calculation unit that determines the second evaluation period based on the trend of the index value detected by the process detection unit, and calculates the energy cost for producing the product based on the energy consumption of the manufacturing equipment and the amount of the product produced by the manufacturing equipment during the second evaluation period.

[0042] In the above-described manufacturing apparatus, products are manufactured through the operation of multiple types of process equipment in a series of manufacturing processes. Therefore, with the above configuration, it becomes possible to identify the operating state of the manufacturing apparatus based on the relationship between the operating state of each process equipment, specifically the indicator values ​​of the power consumption of each process equipment. Based on the operating state of the manufacturing apparatus identified in this way, a second evaluation period, which is a specific period in the series of manufacturing processes for manufacturing products, can be determined. By determining the second evaluation period in this way, the energy intensity required for manufacturing products during the second evaluation period can be calculated based on the energy consumption of the manufacturing apparatus and the amount of products manufactured during that period. Then, the energy efficiency of the manufacturing apparatus can be evaluated based on this energy intensity.

[0043] [Aspect 17] The manufacturing apparatus manufactures a plurality of types of the manufactured products, and has a management system in which information including the types, quantities, and periods of the manufactured products manufactured in the series of manufacturing processes are stored for each of the series of manufacturing processes, and the energy efficiency evaluation support system identifies the types and quantities of the manufactured products during the first evaluation period from the information stored in the management system based on the first evaluation period, the energy efficiency evaluation support system as described in [Aspect 16].

[0044] Manufacturing equipment may be equipped with a management system that stores and manages various information related to the manufacturing of products, such as the production plan for the products (e.g., the type and quantity of products to be manufactured, and the manufacturing period). According to the above configuration, the type and quantity of products to be manufactured during the first evaluation period can be identified from the information stored in such a management system, based on the first evaluation period. Then, using the type and quantity of products to be manufactured, it is possible to calculate the energy intensity required for manufacturing the products and to determine whether any waste occurs in the energy consumption related to manufacturing the products.

[0045] [Aspect 18] An energy efficiency evaluation support system applicable to a manufacturing apparatus that uses multiple types of process equipment to manufacture a product, wherein a second evaluation period is defined for a series of manufacturing processes for manufacturing the product, and the system comprises: a process detection unit that detects an index value of the power consumption of each of the multiple types of process equipment; and a unit cost calculation unit that determines the second evaluation period based on the trend of the index value detected by the process detection unit, and calculates the energy cost for manufacturing the product based on the energy consumption of the manufacturing apparatus and the amount of the product manufactured by the manufacturing apparatus during the second evaluation period.

[0046] According to the above configuration, it becomes possible to identify the operating state of the manufacturing equipment based on the relationship between the operating state of each process device, specifically the indicator values ​​of the power consumption of each process device. Then, based on the operating state of the manufacturing equipment identified in this way, a second evaluation period, which is a specific period in the series of manufacturing processes for producing a product, can be determined. By determining the second evaluation period in this way, the energy intensity required for producing the product during the second evaluation period can be calculated based on the energy consumption of the manufacturing equipment and the amount of product produced during that period. Then, the energy efficiency of the manufacturing equipment can be evaluated based on this energy intensity.

[0047] [Aspect 19] An energy efficiency evaluation support system according to [Aspect 16] or [Aspect 18], comprising: a unit intensity reference storage unit that stores in advance a second reference value for energy intensity during the second evaluation period; and a unit intensity determination unit that determines the occurrence of energy waste during the second evaluation period when the energy intensity calculated by the unit intensity calculation unit is greater than the second reference value stored in the unit intensity reference storage unit.

[0048] According to the above configuration, by comparing the energy intensity for the second evaluation period with the second baseline value for that energy intensity, it is possible to determine if the energy intensity for the second evaluation period has increased. Based on this determination, it is possible to conclude that there is a possibility of wasted energy consumption during the second evaluation period. Thus, according to the above configuration, it is possible to determine the occurrence of waste in energy consumption related to the manufacturing of products based on the energy intensity during the second evaluation period.

[0049] [Aspect 20] The manufacturing apparatus manufactures a plurality of types of the manufactured goods and has a management system which stores information including the types and quantities of the manufactured goods, the unit cost reference storage unit stores a fifth relationship between the types of the manufactured goods manufactured in the series of manufacturing processes and the second reference value corresponding to the same type, the unit cost calculation unit calculates the energy cost based on the quantities of goods manufactured stored in the management system, and the unit cost determination unit calculates the second reference value from the fifth relationship based on the types stored in the management system, and uses the calculated second reference value as a comparison target with the energy cost, the energy efficiency evaluation support system according to [Aspect 19].

[0050] Manufacturing equipment may be equipped with a management system that stores and manages various information related to the manufacturing of products, such as the production plan for the products (e.g., the type and quantity of products to be manufactured). With the above configuration, the type and quantity of products to be manufactured stored in such a management system can be used to calculate the energy intensity required for manufacturing the products and to determine whether any energy waste occurs in the energy consumption related to manufacturing the products.

[0051] [Aspect 21] The management system stores information for each of the series of manufacturing processes, including the type, quantity, and duration of the products manufactured in the series of manufacturing processes. The energy efficiency evaluation support system, according to [Aspect 20], identifies the type and quantity of the manufactured product during the second evaluation period from the information stored in the management system, based on the second evaluation period.

[0052] According to the above configuration, the type and quantity of products manufactured during the second evaluation period can be identified from the information stored in the management system, based on the second evaluation period. Then, using the type and quantity of products manufactured, it is possible to calculate the energy intensity required for manufacturing the products and to determine whether any waste occurs in the energy consumption related to manufacturing the products.

[0053] [Aspect 22] The manufacturing apparatus manufactures a plurality of types of the manufactured products, the unit cost reference storage unit stores a fifth relationship between the types of the manufactured products manufactured in the series of manufacturing processes and the second reference value corresponding to those types, the energy efficiency evaluation support system has a manufactured product detection unit that detects the types and quantities of the manufactured products manufactured in the series of manufacturing processes, the unit cost calculation unit calculates the energy cost based on the quantities of products detected by the manufactured product detection unit, and the unit cost determination unit calculates a second reference value from the fifth relationship based on the types detected by the manufactured product detection unit, and uses the calculated second reference value as a comparison target with the energy cost, the energy efficiency evaluation support system according to [Aspect 19].

[0054] According to the above configuration, the type and quantity of manufactured goods detected by the manufactured goods detection unit, such as an image processing device or a detection sensor, can be used to calculate the energy intensity required for manufacturing the goods and to determine whether any energy waste occurs in the energy consumption required for said manufacturing.

[0055] [Aspect 23] The manufacturing apparatus manufactures multiple types of the manufactured products, the unit cost reference storage unit stores a fifth relationship between the types of the manufactured products manufactured in the series of manufacturing processes and the second reference value corresponding to those types, the energy efficiency evaluation support system has a type identification unit that identifies the types of the manufactured products manufactured in the series of manufacturing processes based on the power consumption index value detected by the process detection unit, the unit cost determination unit calculates a second reference value from the fifth relationship based on the types identified by the type identification unit, and uses the calculated second reference value as a comparison target with the energy cost, the energy efficiency evaluation support system as described in [Aspect 19].

[0056] In the above-described manufacturing apparatus, the power consumed by the process equipment may differ depending on the type of product being manufactured, such as the load on the electric actuator, which is the drive source for the process equipment. With the above configuration, it is possible to identify the type of product manufactured by the manufacturing apparatus by capturing these differences in the power consumption of the process equipment. Based on the identified type of product, it is possible to determine whether any energy waste has occurred in the energy consumption involved in the manufacturing of the product. [Effects of the Invention]

[0057] According to the energy efficiency evaluation support system of the present invention, it is possible to determine the occurrence of waste in energy consumption related to the manufacturing of products. [Brief explanation of the drawing]

[0058] [Figure 1] This is a schematic diagram of an energy efficiency evaluation support system according to one embodiment. [Figure 2] This is a flowchart showing the manufacturing process of beverage products using manufacturing equipment to which an energy efficiency evaluation support system is applied. [Figure 3] This table shows the relationship between the evaluation period and the evaluation criteria. [Figure 4] This is a schematic diagram of an energy efficiency evaluation support system in another embodiment. [Figure 5] This is a schematic diagram of the energy efficiency evaluation support system according to the second embodiment. [Figure 6] This table shows the relationship between the evaluation period and the evaluation criteria. [Figure 7] This table shows the relationship between the operating rate of the extraction machine and the criteria for evaluation. [Figure 8] This table shows the relationship between the energy consumption per unit of equipment and the criteria for evaluation. [Modes for carrying out the invention]

[0059] (First Embodiment) The following describes one embodiment of an energy efficiency evaluation support system. First, let's describe the manufacturing apparatus to which the energy efficiency evaluation support system is applied. The manufacturing apparatus in this embodiment is for producing beverage products (for example, tea products). More specifically, multiple types of beverage products are produced by using this manufacturing apparatus in sequence.

[0060] As shown in Figures 1 and 2, the manufacturing apparatus 10 has multiple types of process equipment, including an extractor 11, a centrifuge 12, a storage tank 13, a mixing device 14, a sterilization device 15, a sterile tank 16, a filling device 17, a labeling device 18, a packaging device 19, and a boxing device 20.

[0061] (extraction process) In the manufacturing of beverage products, the extraction process is performed first (Step S1 in Figure 2). This extraction process utilizes process equipment such as an extractor 11, a centrifuge 12, and a storage tank 13. In the extraction process, first, an extract (tea leaf extract) is extracted from the raw material (tea leaves) by the extractor 11. Then, this extract is clarified by the centrifuge 12 and sent to the storage tank 13 for temporary storage.

[0062] (Mixing process) After the extraction process is completed, the blending process is performed (step S2 in Figure 2). In the blending process, a blending device 14 is used as the process equipment. In the blending process, the blending device 14 mixes (blends) the extract and other raw materials in a predetermined ratio to produce a blended liquid (beverage).

[0063] (filling process) After the mixing process is completed, the filling process is performed (step S3 in Figure 2). In the filling process, process equipment such as a sterilization device 15, a sterile tank 16, and a filling device 17 are used. In the manufacturing apparatus 10 of this embodiment, steam can be supplied to the sterilization device 15 and the sterile tank 16 from a boiler 21 (Figure 1) installed in the factory. The sterilization device 15 is structured to heat and sterilize the mixture using this steam. The sterile tank 16 is also structured to maintain an aseptic state inside using steam supplied from the boiler 21.

[0064] In the filling process, the prepared liquid is first sent from the mixing device 14 to the sterilization device 15, where it is sterilized, and then sent to the sterile tank 16 for temporary storage. This prepared liquid is then sent from the sterile tank 16 to the filling device 17, where it is filled into beverage containers (e.g., PET bottles).

[0065] (Finishing process) After the filling process is completed, the finishing process is performed (step S4 in Figure 2). In the finishing process, a labeling device 18, a packaging device 19, and a boxing device 20 are used. In the finishing process, first, the labeling device 18 affixes product labels to the outside of beverage containers that are filled with the prepared liquid. Then, the packaging device 19 packages the beverage products, and the boxing device 20 boxes the beverage products.

[0066] In the manufacturing apparatus 10 of this embodiment, beverage products are manufactured through an extraction process, a blending process, a filling process, and a finishing process. In the manufacturing apparatus 10 of this embodiment, in order to efficiently manufacture beverage products, each process is executed in such a manner that some of the preceding and succeeding processes overlap. Furthermore, in the manufacturing apparatus 10 of this embodiment, the series of processes consisting of the extraction process, the blending process, the filling process, and the finishing process are also executed in such a manner that some of the preceding and succeeding "series of processes" overlap.

[0067] (Cleaning device) As shown in Figure 1, the manufacturing apparatus 10 of this embodiment has a cleaning device 30 that performs internal cleaning of the process equipment. The cleaning device 30 is a device that performs stationary cleaning, also known as CIP (Cleaning in Place). Specifically, the cleaning device 30 has equipment (cleaning liquid tank, piping, pump, etc.) that is pre-installed in the manufacturing apparatus 10. The cleaning device 30 then automatically cleans the inside of the process equipment by sending cleaning liquid into the process equipment and recovering it using the above equipment.

[0068] The cleaning device 30 includes a cleaning liquid tank 31, a first pipe 32, a first pump 33, a second pipe 34, and a second pump 35. The cleaning solution tank 31 is a tank that stores cleaning solution used for cleaning the process equipment. In this embodiment, the cleaning solution tank 31 includes multiple tanks for storing different types of cleaning solutions, such as a tank for storing hot water as the cleaning solution, a tank for storing alkaline cleaning solution, and a tank for storing acidic cleaning solution. When cleaning the inside of the process equipment, the cleaning solution is supplied to the process equipment from one of the multiple cleaning solution tanks through the operation of the cleaning device 30 by an operator. Note that Figure 1 shows only one cleaning solution tank 31.

[0069] The first piping 32 extends in such a manner that it selectively connects the cleaning solution tank 31 to either the extractor 11 or the mixing device 14. The first piping 32 is provided with the first pump 33 and a switching valve (not shown). The first pump 33 is an electric pump that pumps the cleaning solution in the cleaning solution tank 31 to either the extractor 11 or the mixing device 14. The switching valve provided in the first piping 32 is a valve for switching between a state in which the cleaning solution tank 31 and the extractor 11 are connected by the first piping 32, and a state in which the cleaning solution tank 31 and the mixing device 14 are connected by the first piping 32.

[0070] In the cleaning device 30, by operating the switching valve of the first pipe 32 and then driving the first pump 33, cleaning solution is selectively supplied to either the extractor 11 or the mixing device 14, thereby automatically cleaning the inside of the extractor 11 or the mixing device 14. In this way, the cleaning device 30 of this embodiment performs internal cleaning of both the extractor 11 and the mixing device 14 through the driving of the same cleaning pump (specifically, the first pump 33).

[0071] Meanwhile, the second piping 34 extends from the cleaning solution tank 31 to the sterilization device 15, the sterile tank 16, and the filling device 17. The second piping 34 is equipped with a second pump 35. The second pump 35 is an electric pump that pumps the cleaning solution in the cleaning solution tank 31 to the sterilization device 15, the sterile tank 16, and the filling device 17. In the cleaning device 30, by driving the second pump 35, the cleaning solution is sent through the second piping 34 to the sterilization device 15, the sterile tank 16, and the filling device 17, and the insides of the sterilization device 15, the sterile tank 16, and the filling device 17 are automatically cleaned.

[0072] Each process device, such as the extractor 11, centrifuge 12, storage tank 13, mixing device 14, sterilization device 15, sterile tank 16, filling device 17, labeling device 18, packaging device 19, and boxing device 20, as well as the washing device 30, is equipped with an operation panel. When manufacturing beverage products using the manufacturing apparatus 10, the operation control of the process device corresponding to each operation panel is performed through the operation of each operation panel by the worker.

[0073] (Energy efficiency evaluation support system) The energy efficiency evaluation support system of this embodiment includes a computer 40. The computer 40 includes input devices operated by the user and display devices that display information to the user. The computer 40 could be a personal computer such as a desktop, notebook, or tablet, or a portable computer such as a smartphone.

[0074] The computer 40 is capable of running support programs to help calculate the energy intensity of beverage products manufactured by the manufacturing equipment 10, and evaluation programs to evaluate the energy efficiency of the manufacturing equipment 10.

[0075] (Storage part) The computer 40 is equipped with a storage unit 41 for storing various data. The storage unit 41 stores support programs, evaluation programs, and various calculation results from the computer 40. The storage unit 41 also stores conditions for identifying the process equipment to be cleaned during the operation of the cleaning device 30, specifically conditions A1 to A3, conditions B1 to B4, and conditions C1 and C2, which will be described later. In this embodiment, the storage unit 41 corresponds to the condition storage unit.

[0076] (Target device identification section) The computer 40 includes, as functional units, a target device identification unit 43 and a unit period setting unit 44.

[0077] The target device identification unit 43 identifies the following based on the power consumption P1 and PA of the first pump 33 and the power consumption PA of the extractor 11, when both conditions (specifically, conditions A1 to A3) are met: that the target of cleaning by the cleaning device 30 at this time is the extractor 11; and that the operating period T1 of the first pump 33 during the cleaning of the extractor 11 is identified. This operating period T1 is stored in the storage unit 41.

[0078] On the other hand, the target device identification unit 43 identifies the following based on the power consumption P1 of the first pump 33 and the power consumption PB of the mixing device 14 when the conditions (specifically, conditions B1 to B4) are met. That is, it identifies that the object to be cleaned by the cleaning device 30 at this time is the mixing device 14. It also identifies the operating period T2 of the first pump 33 during the cleaning of the mixing device 14 in this instance. This operating period T2 is stored in the storage unit 41.

[0079] On the other hand, the target device identification unit 43 identifies the following based on the power consumption P2 of the second pump 35 when the trend of power consumption P2 of the second pump 35 satisfies the above conditions (specifically, conditions C1 and C2). That is, it identifies that the targets of cleaning by the cleaning device 30 at this time are the sterilization device 15, the sterile tank 16, and the filling device 17. It also identifies the operating period T3 of the second pump 35 in this cleaning process. This operating period T3 is stored in the storage unit 41.

[0080] The unit period setting unit 44 defines the "unit period," which is the calculation period used when calculating the amount of energy consumed in conjunction with the operation of the process equipment to be cleaned, as identified by the target equipment identification unit 43.

[0081] If the cleaning target identified by the target device identification unit 43 is the extractor 11, the unit period setting unit 44 reads the operating period T1 of the first pump 33 in the cleaning of the extractor 11 from the storage unit 41 and sets the unit period based on the operating period T1 as follows: That is, the period from the end of the operating period T1 in the cleaning process immediately before the operation of the extractor 11 to the end of the operating period T1 of the first pump 33 in the cleaning process immediately after the operation of the extractor 11 is set as the unit period TA. In this embodiment, this unit period TA is used as the calculation period when calculating the amount of energy consumed in conjunction with the operation of the extractor 11.

[0082] On the other hand, when the cleaning target identified by the target device identification unit 43 is the mixing device 14, the unit period setting unit 44 reads the operating period T2 of the first pump 33 in the cleaning of the mixing device 14 from the storage unit 41 and sets the unit period based on the operating period T2 as follows: That is, the period from the end of the operating period T2 of the first pump 33 in the cleaning process immediately before the operation of the mixing device 14 to the end of the operating period T2 in the cleaning process immediately after the operation of the mixing device 14 is set as the unit period TB. In this embodiment, this unit period TB is used as the calculation period when calculating the amount of energy consumed in conjunction with the operation of the mixing device 14.

[0083] On the other hand, if the cleaning targets identified by the target device identification unit 43 are the sterilization device 15, the sterile tank 16, and the filling device 17, the unit period setting unit 44 determines the unit period as follows based on the operating period T3 of the second pump 35 during cleaning. That is, it reads the operating period T3 from the storage unit 41. Then, it determines the unit period TC as the period from the end of the operating period T3 in the cleaning process immediately before operation of the sterilization device 15, the sterile tank 16, and the filling device 17 to the end of the operating period T3 in the cleaning process immediately after operation. In this embodiment, this unit period TC is used as the calculation period when calculating the amount of energy consumed in conjunction with the operation of the sterilization device 15, the sterile tank 16, and the filling device 17.

[0084] (Process detection unit, pump detection unit) The energy efficiency evaluation support system of this embodiment is equipped with the current sensors 50 to 59 described below. Specifically, the apparatus of this embodiment is equipped with a current sensor 50 for detecting the current consumption of the extractor 11, a current sensor 51 for detecting the current consumption of the centrifuge 12, and a current sensor 52 for detecting the current consumption of the mixing device 14. The system of this embodiment is also equipped with a current sensor 53 for detecting the current consumption of the sterilization device 15, a current sensor 54 for detecting the current consumption of the filling device 17, and a current sensor 55 for detecting the current consumption of the labeling device 18. Furthermore, the system of this embodiment is equipped with a current sensor 56 for detecting the current consumption of the packaging device 19 and a current sensor 57 for detecting the current consumption of the boxing device 20. In addition, the system of this embodiment is also equipped with a current sensor 58 for detecting the current consumption of the first pump 33 and a current sensor 59 for detecting the current consumption of the second pump 35.

[0085] Current sensors 50 to 59 are all attached to the manufacturing equipment 10 after it has been installed in the factory. The output signals of each current sensor 50 to 59 are taken up by the computer 40. The computer 40 calculates the power consumption of the equipment corresponding to these current sensors 50 to 59 based on the output signals of these current sensors 50 to 59, and uses that power consumption for various calculations. In this embodiment, the current sensor 58 provided on the first pump 33 corresponds to a pump detection unit that detects an index value of the power consumption of the washing pump. Also in this embodiment, the current sensor 50 provided on the extractor 11 and the current sensor 51 provided on the mixing device 14 correspond to a process detection unit that separately detects index values ​​of the power consumption of multiple types of process equipment.

[0086] The energy efficiency evaluation support system of this embodiment includes the steam flow meters 60 and 61 described below. A steam flow meter 60 is provided in the first boiler piping 62 connecting the boiler 21 and the sterilization device 15 to detect the amount of steam supplied to the sterilization device 15. A steam flow meter 61 is provided in the second boiler piping 63 connecting the boiler 21 and the sterile tank 16 to detect the amount of steam supplied to the sterile tank 16. The output signals from the steam flow meters 60 and 61 are received by the computer 40. The computer 40 uses the amount of steam detected by the steam flow meters 60 and 61 for various calculation processes, such as the calculation of energy intensity.

[0087] The energy efficiency evaluation support system of this embodiment has an optical sensor 70 for detecting and counting beverage products sent from the filling device 17 to the labeling device 18. The output signal of the optical sensor 70 is received by the computer 40. Based on the output signal of the optical sensor 70, the computer 40 determines the execution period T4 during which the filling of beverage containers by the filling device 17 is being performed. The computer 40 determines that the filling of beverages by the filling device 17 is being performed when the passage of beverage products is detected by the optical sensor 70. The computer 40 also determines that the filling of beverages by the filling device 17 is not being performed when the passage of beverage products is not detected by the optical sensor 70. The computer 40 also determines the number of beverage containers filled with beverages during the execution period T4 based on the output signal of the optical sensor 70. In this embodiment, the optical sensor 70 corresponds to the production quantity detection unit.

[0088] (Procedure for calculating energy intensity) The following is a detailed explanation of the procedure for calculating the energy intensity required for the manufacture of beverage products.

[0089] In the energy efficiency evaluation support system of this embodiment, the energy intensity is calculated by dividing the sum of the energy consumption amounts A, B, C, D, and E described below by the number of beverage products manufactured N ([A+B+C+D+E] / N).

[0090] (Energy Consumption A) The total amount of energy consumed in the operation of the extractor 11 and the centrifuge 12 during the extraction process. (Energy Consumption B) The total amount of energy consumed in conjunction with the operation of the blending apparatus 14 during the blending process.

[0091] (Energy Consumption C) The total amount of energy consumed in the operation of the sterilization device 15, sterile tank 16, and filling device 17 during the filling process. (Energy Consumption D) The total amount of energy consumed in the operation of the labeling device 18, packaging device 19, and boxing device 20 during the finishing process.

[0092] (Energy Consumption E) The total amount of energy consumed in connection with the operation of the cleaning device 30, which is performed in the cleaning process immediately after the operation of the process equipment in the extraction process, the cleaning process immediately after the operation of the process equipment in the blending process, and the cleaning process immediately after the operation of the process equipment in the filling process.

[0093] (Procedure for calculating energy consumption A) The method for calculating energy consumption A will be explained below. In this embodiment, the target device identification unit 43 of the computer 40 identifies the extractor 11 as the target of cleaning by the cleaning device 30 when all of the following conditions A1, A2, and A3 are met.

[0094] (Condition A1) The average value of the power consumption of the extractor 11 over a predetermined period of time (for example, several minutes) is equal to or greater than the predetermined value AA1. The predetermined value AA1 is set to be greater than the power consumption AA2 of the extractor 11 during normal operation for extracting the extract (AA1 > AA2).

[0095] (Condition A2) The average value of the power consumption of the first pump 33 over a predetermined period of time (e.g., several minutes) is equal to or greater than the predetermined value AA3. (Condition A3) From a state where both conditions A1 and A2 are met, the average value of the power consumption of the first pump 33 over a predetermined period of time (e.g., several minutes) becomes less than or equal to a predetermined value AA4 (e.g., approximately 0kW).

[0096] In this embodiment, the inventors have determined, through verification of the operating data of the manufacturing apparatus 10, the characteristic power consumption trends of the first pump 33 and the power consumption trends of the extractor 11 that appear when the extractor 11 is being cleaned by the cleaning apparatus 30. The inventors have also predetermined conditions (conditions A1 to A3) that allow them to identify when these characteristic power consumption trends of the first pump 33 and the extractor 11 have occurred, and these conditions A1 to A3 are stored in the storage unit 41. As a result, when all of conditions A1, A2, and A3 are met, it is possible to accurately identify that the object being cleaned by the cleaning apparatus 30 is the extractor 11.

[0097] In the manufacturing apparatus 10 of this embodiment, when the extractor 11 is cleaned by the cleaning apparatus 30, in addition to the operation of the first pump 33 of the cleaning apparatus 30, the extractor 11 also operates. Taking this into consideration, in this embodiment, conditions A1 to A3 are defined, which are parameters of the power consumption of the first pump 33 and the power consumption of the extractor 11.

[0098] If it is determined that the object to be cleaned is the extractor 11, the unit period setting unit 44 of the computer 40 determines the "unit period TA," which is the calculation period used when calculating the amount of energy consumed A, based on the operating period T1 stored in the storage unit 41.

[0099] In the extraction process, prior to the extraction of the extractant by the extractor 11, the extractor 11 is cleaned by the cleaning device 30. In this embodiment, the completion timing of this cleaning of the extractor 11 is set to the start timing of the unit period TA. Also in the extraction process, after the extraction of the extractant by the extractor 11 is completed, the extractor 11 is cleaned by the cleaning device 30 in preparation for the next extraction process. In this embodiment, the completion timing of this cleaning of the extractor 11 is set to the end timing of the unit period TA. Therefore, the unit period TA is defined as the period from the end timing of the operating period T1 of the first pump 33 in the cleaning process immediately before the operation of the extractor 11 to the end timing of the operating period T1 in the cleaning process immediately after the operation of the extractor 11.

[0100] In this embodiment, the manufacturing apparatus 10 enters a standby state between the completion of cleaning of the extractor 11 by the cleaning device 30 and the start of extraction of the extractant by the extractor 11. Since the extractor 11 consumes energy such as electricity even in the standby state, it is necessary to consider this standby energy of the extractor 11 when calculating the amount of energy consumed A. In this embodiment, the unit period TA is defined in a way that includes this standby period.

[0101] In this embodiment, the amounts of various energies consumed during a unit period TA are accumulated, and this accumulated value is calculated as "Energy Consumption A". Examples of various energies include the power consumption of the extractor 11, the power consumption of the centrifugal separator 12, the amount of steam used (more specifically, the amount of gas consumed by the boiler 21 to supply the same amount of steam), and the amount of water used.

[0102] In this embodiment, the computer 40 can automatically perform the processes of detecting various calculation parameters using sensors provided in various parts of the manufacturing apparatus 10, and calculating the amount of energy consumed A based on these calculation parameters. Alternatively, various calculation parameters obtained separately can be input to the computer 40 through the operation of an input device, and the calculation of the amount of energy consumed A based on these calculation parameters can be performed through calculation processing by the computer 40. According to this embodiment, since the unit period TA is determined in the manner described above, it becomes possible to perform the calculation of the amount of energy consumed A using this unit period TA as the calculation target period.

[0103] (Procedure for calculating energy consumption amount B) Next, we will explain how to calculate the amount of energy consumed B. In this embodiment, the target device identification unit 43 of the computer 40 identifies the mixing device 14 as the target of cleaning by the cleaning device 30 when all of the following conditions B1, B2, B3, and B4 are met.

[0104] (Condition B1) The first pump 33 is in operation, and the power consumption of the mixing device 14 has remained at or above a predetermined value BB1 ​​for a predetermined period of time or longer. The predetermined value BB1 ​​is set to be greater than the power consumption BB2 of the mixing device 14 during normal operation for mixing (BB1 > BB2).

[0105] (Condition B2) From the state in which Condition B1 is met, the power consumption of the mixing device 14 temporarily decreases to a predetermined value BB3 or less. (Condition B3) Immediately after Condition B2 is met, the first pump 33 is in operation and the power consumption of the mixing device 14 is equal to or greater than a predetermined value BB1 ​​for a predetermined period of time (e.g., 10 minutes or more).

[0106] (Condition B4) The state in which the first pump 33 stopped after the state in which condition B3 was met. In this embodiment, the inventor has determined in advance the characteristic power consumption trends of the first pump 33 and the power consumption trends of the mixing device 14 that appear when the mixing device 14 is being cleaned by the cleaning device 30, through verification of the operating performance data of the manufacturing device 10. The inventor has then predetermined conditions (conditions B1 to B4) that allow for the identification of the occurrence of these characteristic power consumption trends of the first pump 33 and the mixing device 14, and these conditions B1 to B4 are stored in the storage unit 41. As a result, when all of conditions B1, B2, B3, and B4 are met, it is possible to accurately identify that the object to be cleaned by the cleaning device 30 is the mixing device 14.

[0107] In the manufacturing apparatus 10 of this embodiment, when the mixing apparatus 14 is cleaned by the cleaning apparatus 30, in addition to the operation of the first pump 33 of the cleaning apparatus 30, the mixing apparatus 14 also operates. Taking this into consideration, in this embodiment, conditions B1 to B4 are defined, with the power consumption of the first pump 33 and the power consumption of the mixing apparatus 14 as parameters.

[0108] If it is determined that the item to be cleaned is the mixing device 14, the unit period setting unit 44 of the computer 40 determines the "unit period TB," which is the calculation period used to calculate the amount of energy consumed B, based on the operating period T2 stored in the memory unit 41.

[0109] In the blending process, prior to blending by the blending device 14, the blending device 14 is cleaned by the cleaning device 30. In this embodiment, the completion timing of this cleaning of the blending device 14 is set to the start timing of the unit period TB. Also, in the blending process, after blending by the blending device 14 is completed, the blending device 14 is cleaned by the cleaning device 30 in preparation for the next blending process. In this embodiment, the completion timing of this cleaning of the blending device 14 is set to the end timing of the unit period TB. Therefore, the unit period TB is defined as the period from the end timing of the operating period T2 of the first pump 33 in the cleaning process immediately before operation of the blending device 14 to the end timing of the operating period T2 in the cleaning process immediately after operation of the blending device 14.

[0110] In this embodiment, the manufacturing apparatus 10 enters a standby state between the completion of cleaning of the mixing apparatus 14 by the cleaning apparatus 30 and the start of mixing of the compounding liquid by the mixing apparatus 14. Since the mixing apparatus 14 consumes energy such as electricity even in the standby state, it is necessary to consider this standby energy of the mixing apparatus 14 when calculating the amount of energy consumed B. In this embodiment, the unit period TB is defined to include this standby period.

[0111] In this embodiment, the amounts of various types of energy consumed during a unit period TB are accumulated, and this accumulated value is calculated as "Energy Consumption B". Examples of various types of energy include the power consumption of the mixing device 14 and the amount of water used.

[0112] In this embodiment, the computer 40 can automatically perform the processes of detecting various calculation parameters using sensors provided in various parts of the manufacturing apparatus 10, and calculating the amount of energy consumed B based on these calculation parameters. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then perform the calculation of the amount of energy consumed B based on these calculation parameters through calculation processing by the computer 40. According to this embodiment, since the unit period TB is determined in the manner described above, it becomes possible to perform the calculation of the amount of energy consumed B with this unit period TB as the calculation target period.

[0113] (Procedure for calculating energy consumption C) Next, we will explain how to calculate the amount of energy consumed C. In this embodiment, the target device identification unit 43 of the computer 40 identifies that the targets to be cleaned by the cleaning device 30 are the sterilization device 15, the sterile tank 16, and the filling device 17 when both of the following conditions C1 and C2 are met.

[0114] (Condition C1) The power consumption of the sterilization device 15 is below a predetermined value. That is, the operation of the sterilization device 15 is stopped. (Condition C2) The power consumption of the second pump 35 has stopped operating from a state where it was above a predetermined value.

[0115] In this embodiment, the inventors have determined in advance the characteristic power consumption trends of the second pump 35 and the power consumption trends of the sterilization device 15 that appear when the cleaning device 30 cleans the sterilization device 15, the sterile tank 16, and the filling device 17, through verification of operational data. The inventors have then predetermined conditions (conditions C1 and C2) that allow them to identify when these characteristic power consumption trends of the second pump 35 and the sterilization device 15 have occurred, and these conditions C1 and C2 are stored in the storage unit 41. As a result, when both conditions C1 and C2 are met, it is possible to accurately identify that the cleaning targets of the cleaning device 30 are the sterilization device 15, the sterile tank 16, and the filling device 17.

[0116] Once the cleaning target has been identified in this manner, the unit period setting unit 44 of the computer 40 determines the "unit period TC," which is the calculation period used to calculate the amount of energy consumed C, based on the operating period T3 stored in the memory unit 41.

[0117] In the filling process, prior to the filling of beverage containers by the filling device 17, the sterilization device 15, the sterile tank 16, and the filling device 17 are cleaned by the cleaning device 30. In this embodiment, the completion timing of this cleaning is set to the start timing of the unit period TC. Also in the filling process, after the filling by the filling device 17 is completed, the sterilization device 15, the sterile tank 16, and the filling device 17 are cleaned by the cleaning device 30 in preparation for the next filling process. In this embodiment, the completion timing of this cleaning is set to the end timing of the unit period TC. Therefore, the unit period TC is defined as the period from the end timing of the operating period T3 of the second pump 35 in the cleaning process immediately before the operation of the filling device 17 to the end timing of the operating period T3 in the cleaning process immediately after the operation of the filling device 17.

[0118] In this embodiment, the manufacturing apparatus 10 enters a standby state between the completion of cleaning of the sterilization apparatus 15, sterile tank 16, and filling apparatus 17 by the cleaning apparatus 30 and the start of filling by the filling apparatus 17. Since the sterilization apparatus 15, sterile tank 16, and filling apparatus 17 consume energy even in the standby state, it is necessary to consider this standby energy when calculating the amount of energy consumed C. In this embodiment, the unit period TC is defined to include this standby period.

[0119] In this embodiment, the amounts of various types of energy consumed during a unit period TC are accumulated, and this accumulated value is calculated as "Energy Consumption C". Examples of various types of energy include the power consumption and steam usage of the sterilization device 15, the power consumption and steam usage of the sterile tank 16, and the power consumption of the filling device 17.

[0120] In this embodiment, the computer 40 can automatically perform the processes of detecting various calculation parameters using sensors provided in various parts of the manufacturing apparatus 10, and calculating the amount of energy consumed C based on these calculation parameters. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then perform the calculation of the amount of energy consumed C based on these calculation parameters through calculation processing by the computer 40. According to this embodiment, since the unit period TC is determined in the manner described above, it becomes possible to perform the calculation of the amount of energy consumed C for this unit period TC as the calculation target period.

[0121] (Procedure for calculating energy consumption D) Next, we will explain how to calculate the amount of energy consumed D. In this embodiment, the amounts of various types of energy (such as power consumption) consumed by the labeling device 18, packaging device 19, and boxing device 20 during a unit period TC are accumulated, and this accumulated value is calculated as "energy consumption amount D".

[0122] In this embodiment, the computer 40 can automatically perform the processes of detecting various calculation parameters using sensors provided in various parts of the manufacturing apparatus 10, and calculating the amount of energy consumed D based on these calculation parameters. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then perform the calculation of the amount of energy consumed D based on these calculation parameters through calculation processing by the computer 40. According to this embodiment, since the unit period TC is determined in the manner described above, it is possible to perform the calculation of the amount of energy consumed D using this unit period TC as the calculation target period.

[0123] (Procedure for calculating energy consumption E) Next, we will explain how the amount of energy consumed E is calculated. First, the total amount of various energy consumed in the operation of the washing device 30 during a series of processes, including the extraction process, the blending process, and the filling process, specifically from the start of unit period TA to the end of unit period TC, is calculated. This total amount is then calculated as the energy consumed E. Examples of these various energy sources include the power consumption of the first pump 33, the power consumption of the second pump 35, and the amount of washing solution used.

[0124] In this embodiment, the computer 40 can automatically perform the processes of detecting various calculation parameters using sensors provided in various parts of the manufacturing apparatus 10, and calculating the amount of energy consumed E based on these calculation parameters. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then perform the calculation of the amount of energy consumed E based on these calculation parameters through calculation processing by the computer 40. According to this embodiment, since the unit periods TA, TB, and TC are determined in the manner described above, it becomes possible to perform the calculation of the amount of energy consumed E based on the unit periods TA, TB, and TC.

[0125] (Procedure for calculating energy intensity) Next, we will explain how energy intensity is calculated. In the energy efficiency evaluation support system of this embodiment, the number of beverage products (production quantity N) produced in a series of processes (extraction process, blending process, filling process, and finishing process) is detected by the optical sensor 70. Then, in the system of this embodiment, the energy intensity is calculated by dividing the sum of energy consumption A, energy consumption B, energy consumption C, energy consumption D, and energy consumption E by the production quantity N ([A+B+C+D+E] / N).

[0126] In this embodiment, the process of calculating the energy intensity in this manner can be automatically performed by the computer 40. Alternatively, the energy intensity can also be calculated manually using the separately calculated energy consumption amounts A to E and the number of units produced N detected by the optical sensor 70.

[0127] (Evaluation of energy efficiency) The energy efficiency evaluation support system of this embodiment has multiple evaluation periods defined for evaluating the energy efficiency of the manufacturing equipment 10 for a series of manufacturing processes that produce a predetermined number of beverage products. For each evaluation period, it is determined whether there is any waste in energy consumption during that evaluation period.

[0128] (Time length detection unit, determination unit) The computer 40 is capable of executing a determination program that determines whether energy consumption is wasted during each evaluation period. The computer 40 has a time length detection unit 45 and a determination unit 46 as functional units.

[0129] The time length detection unit 45 individually detects the time length of multiple evaluation target periods as actual time lengths and stores them in the storage unit 41. In this embodiment, each evaluation target period is defined by the start and end timings of the operation periods T1, T2, and T3, the start and stop timings of the operation of each process equipment, and the start and end timings of the beverage filling execution period T4 by the filling device 17. The time length detection unit 45 detects these timings based on the detection signals of the current sensors 50 to 59 and the optical sensor 70, and detects the time length of each evaluation target period based on these timings.

[0130] The determination unit 46 compares a reference value with a detected value (actual time length) for the length of the evaluation period, and determines whether energy waste occurred during the evaluation period based on the comparison result.

[0131] The memory unit 41 stores a reference value for the duration of each evaluation period. In this embodiment, the reference values ​​for the duration of multiple evaluation periods are determined in advance through verification of the operating performance data of the manufacturing apparatus 10 by the inventor. In this embodiment, the memory unit 41 corresponds to the reference memory unit.

[0132] In this embodiment, the length of the evaluation period (L, L-1 to L-7), described later, that allows for an appropriate reduction in energy consumption during that period is predetermined from the operating performance data of the manufacturing apparatus 10. The memory unit 41 stores a value determined based on this length as a reference value (JL, JL-1 to JL-7) for the evaluation period (L, L-1 to L-7).

[0133] Furthermore, the memory unit 41 pre-stores the number N of beverage products manufactured in a series of manufacturing processes, the types of beverage products manufactured in a series of manufacturing processes, and the relationship RF between these numbers N and types and the reference value JF for the length of the evaluation period F.

[0134] When the determination unit 46 performs a determination of whether energy consumption waste has occurred for the evaluation target period F, as described later, it calculates a reference value JF for the evaluation target period F from the above-mentioned relationship RF based on the number N and type of beverage products manufactured. This calculated reference value JF is then used for comparison with the actual time length. In this embodiment, the types of beverage products manufactured in a series of manufacturing processes are input to the computer 40 through the operation of the input device of the computer 40 and are also stored in the storage unit 41. The types of beverage products stored in the storage unit 41 are used to calculate the reference value JF. In this embodiment, the above-mentioned relationship RF stored in the storage unit 41 includes a first relationship between the number N of products manufactured in a series of manufacturing processes and a reference value corresponding to that number N, and a second relationship between the types of products manufactured in a series of manufacturing processes and a reference value corresponding to that type.

[0135] Furthermore, the memory unit 41 pre-stores a relationship RS between the stopping mode for terminating (stopping) the operation of the manufacturing apparatus 10 for manufacturing beverage products and the standard value (JS, JS-1 to JS-4) for the length of the evaluation period (S, S-1 to S-4) corresponding to that stopping mode. The stopping modes include weekend stopping, which is stopping before the weekend; holiday stopping, which is stopping before a long holiday; normal stopping, which is stopping when manufacturing the same type of beverage product is being carried out continuously; and switching stopping, which occurs when switching the type of beverage product being manufactured during the stop.

[0136] When the determination unit 46 determines whether energy consumption is wasted during the evaluation period (S, S-1 to S-4) described later, it calculates reference values ​​(JS, JS-1 to JS-4) for the evaluation period (S, S-1 to S-4) from the relationship RS described above based on the stopping pattern. These calculated reference values ​​(JS, JS-1 to JS-4) are then used for comparison with the actual time length. Since the content of the cleaning process by the cleaning device 30 differs depending on the stopping pattern of the manufacturing device 10, the time required to execute the cleaning process also differs. In this embodiment, reference values ​​(JS, JS-1 to JS-4) for the time length of the evaluation period (S, S-1 to S-4) are calculated in accordance with the stopping pattern of the manufacturing device 10.

[0137] In this embodiment, the production plan for beverage products by the manufacturing apparatus 10 is input into the computer 40 through the operation of the computer's input device and is also stored in the storage unit 41. When calculating the reference values ​​(JS, JS-1 to JS-4), the production plan stored in the storage unit 41 is used to determine whether the stop mode is a normal stop or a switchover stop.

[0138] In this embodiment, when calculating the reference values ​​(JS, JS-1 to JS-4), the detection signal from the optical sensor 70 is used to determine whether the stop mode is a weekend stop or a pre-holiday stop. Specifically, if the optical sensor 70 does not detect the passage of a beverage product for a first predetermined time (e.g., 24 hours) or longer, it is determined to be a "weekend stop". Also, if the optical sensor 70 does not detect the passage of a beverage product for a second predetermined time (e.g., 60 hours) or longer than the first predetermined time, it is determined to be a "pre-holiday stop".

[0139] (Multiple evaluation periods and criteria for evaluation) The following provides a detailed explanation of how multiple evaluation periods are defined and how the determinations are executed within each evaluation period.

[0140] As shown in Figure 3, each evaluation period is defined by the start and end timings of the operating periods T1, T2, and T3, the start and stop timings of each process equipment, and the start and end timings of the beverage filling execution period T4 by the filling equipment 17.

[0141] In this embodiment, the start timing for each process device is determined when the current consumption detected by the current sensor corresponding to the process device increases to a predetermined level L1 or higher while the cleaning device 30 is not in operation. The predetermined level L1 is predetermined for each process device, based on a power consumption value that allows it to be determined that the process device is in operation. The stop timing for each process device is determined when the current consumption detected by the current sensor corresponding to the process device decreases to a value below a predetermined level L2 while the cleaning device 30 is not in operation. The predetermined level L2 is predetermined for each process device, based on a power consumption value that allows it to be determined that the process device is in a stopped state.

[0142] In this embodiment, if the execution period of a series of manufacturing processes for producing a predetermined number of beverage products is defined as the "manufacturing period TM," then, as shown in the following relationship, the "manufacturing period TM" is divided into three periods: the "startup period TL," the "filling period TF," and the "shutdown period TS."

[0143] (Manufacturing period TM) = (Start-up period TL) + (Filling period TF) + (Stopping period TS) (Evaluation period L) In this embodiment, the startup period TL is defined as the evaluation period L.

[0144] The startup period TL is the period from the start of operation of the manufacturing equipment 10 for the production of beverage products until the start of beverage filling by the filling equipment 17. Specifically, the evaluation period L is defined as the period starting from the end of the operation period T1 of the first pump 33 during the cleaning of the extractor 11, and ending from the start of the execution period T4 of beverage filling into beverage containers by the filling equipment 17.

[0145] The judgment process for the evaluation period L is performed as follows: The determination unit 46 reads the actual time length KL of the start-up period TL detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL for the evaluation target period L that is pre-stored in the storage unit 41. In this embodiment, the reference value JL is set to 1.2 times the standard time length of the evaluation target period L obtained from the operating performance data. The standard time length is the time length of the evaluation target period that is suitable for reducing energy consumption. As the standard time length, the time length of the evaluation target period when the energy intensity in that period is appropriately small can be adopted, or the shortest time length within the range that can be achieved in a series of manufacturing processes from the values ​​(time lengths) included in the operating performance data can be adopted. Alternatively, as the standard time length, the time length of the evaluation target period when the energy intensity was good can be adopted, or the shortest time length (or a time length close to it) in the operating performance data can be adopted.

[0146] Subsequently, the determination unit 46 determines whether the actual time length KL is greater than or equal to the reference value JL. If it is determined that the actual time length KL is less than or equal to the reference value JL, it is determined that the actual time length KL is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual time length KL is greater than the reference value JL, it is determined that the actual time length KL has exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the evaluation period L, i.e., the start-up period TL, has become longer, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption during the start-up period TL.

[0147] (Evaluation period F) In this embodiment, the filling period TF is defined as the evaluation period F. The filling period TF is the period during which the filling device 17 is used to fill beverages. Specifically, the evaluation period F is defined as the execution period T4 during which the filling device 17 is used to fill beverage containers with beverages.

[0148] The judgment process for the evaluation period F is performed as follows: The determination unit 46 reads the actual time length KF of the filling period TF, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JF for the evaluation period F from the relationship RF, which is pre-stored in the storage unit 41, based on the number N and type of beverage products manufactured. In this embodiment, the reference value JF is calculated by multiplying the standard time length of the evaluation period F obtained from the operational performance data by 1.2.

[0149] Subsequently, the determination unit 46 determines whether the actual time length KF is greater than or equal to the reference value JF. If it is determined that the actual time length KF is less than or equal to the reference value JF, it is determined that the actual time length KF is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual time length KF is greater than the reference value JF, it is determined that the actual time length KF has exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the evaluation period F, i.e., the filling period TF, has become longer, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption during the filling period TF.

[0150] (Evaluation period S) In this embodiment, the downtime TS is defined as the evaluation period S. The shutdown period TS is the period from when the filling of beverages by the filling device 17 is completed until the operation of the manufacturing device 10 for manufacturing beverage products is completed. Specifically, the evaluation period L is defined as a period that starts at the end of the execution period T4 described above and ends at the end of the operation period T3 of the second pump 35 during the cleaning of the sterilization device 15, sterile tank 16, and filling device 17.

[0151] The judgment process for the evaluation period S is performed as follows: The determination unit 46 reads the actual time length KS of the stop period TS, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JS for the evaluation target period S from the relationship RS, which is stored in advance in the storage unit 41, based on the stop pattern of the manufacturing equipment 10 (weekend stop, pre-holiday stop, switchover stop, or normal stop). In this embodiment, the reference value JS is calculated by multiplying the standard time length of the evaluation target period S obtained from the operating performance data by 1.2.

[0152] Subsequently, the determination unit 46 determines whether the actual time length KS is greater than or equal to the reference value JS. If it is determined that the actual time length KS is less than or equal to the reference value JS, it is determined that the actual time length KS is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual time length KS is greater than the reference value JS, it is determined that the actual time length KS has exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the evaluation period S, i.e., the stop period TS, has become longer, and based on this determination, it is possible to determine that there is a possibility of wasted energy consumption during the filling period TF. Furthermore, according to this embodiment, it is also possible to determine that the completion of cleaning may have been delayed due to the increased time required for cleaning the sterilization device 15, the sterile tank 16, and the filling device 17.

[0153] (Evaluation period L-1) In this embodiment, the evaluation period L-1 is defined as the period from the completion of cleaning the extractor 11 until the start of operation of the extractor 11. Specifically, the evaluation period L-1 is defined as a period that starts at the end of the operation period T1 of the first pump 33 during the cleaning of the extractor 11 and ends at the start of operation of the extractor 11.

[0154] The judgment process for the evaluation period L-1 is performed as follows. The determination unit 46 reads the actual time length KL-1 of the evaluation target period L-1, which has been detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-1 for the same evaluation target period L-1, which has been pre-stored in the storage unit 41. In this embodiment, the reference value JL-1 is set to be 1.2 times the standard time length of the evaluation target period L-1 obtained from the operating performance data.

[0155] Subsequently, the determination unit 46 determines whether the actual time length KL-1 is greater than or equal to the reference value JL-1. If it is determined that the actual time length KL-1 is less than or equal to the reference value JL-1, the actual time length KL-1 is considered to be within the acceptable range, and a normal judgment is made.

[0156] On the other hand, if the actual time length KL-1 is judged to be greater than the standard value JL-1, an abnormality is determined, as the actual time length KL-1 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of operation of the extractor 11 after the cleaning of the extractor 11 was delayed for some reason, and that the amount of energy consumed during the evaluation period L-1 may have increased accordingly.

[0157] Thus, according to this embodiment, it is possible to determine that the evaluation period L-1 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-1.

[0158] (Evaluation period L-2) In this embodiment, the evaluation period L-2 is defined as the period from the completion of cleaning of the extractor 11 until the start of operation of the centrifuge 12. Specifically, the evaluation period L-2 is defined as a period that starts at the end of the operation period T1 and ends at the start of operation of the centrifuge 12.

[0159] The judgment process for the evaluation period L-2 is performed as follows. The determination unit 46 reads the actual time length KL-2 of the evaluation period L-2 detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-2 for the same evaluation period L-2 that is pre-stored in the storage unit 41. In this embodiment, the reference value JL-2 is calculated by multiplying the standard time length of the evaluation period L-2 obtained from the operating performance data by 1.2.

[0160] Subsequently, the determination unit 46 determines whether the actual time length KL-2 is greater than or equal to the reference value JL-2. If it is determined that the actual time length KL-2 is less than or equal to the reference value JL-2, the actual time length KL-2 is considered to be within the acceptable range, and a normal judgment is made.

[0161] On the other hand, if the actual time length KL-2 is judged to be greater than the standard value JL-2, an abnormality is determined, as the actual time length KL-2 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of operation of the centrifuge 12 after the cleaning of the extractor 11 was delayed for some reason, and that the amount of energy consumed during the evaluation period L-2 may have increased accordingly.

[0162] Thus, according to this embodiment, it is possible to determine that the evaluation period L-2 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-2.

[0163] (Evaluation period L-3) In this embodiment, the evaluation period L-3 is defined as the period from the completion of cleaning the mixing device 14 until the start of operation of the mixing device 14. Specifically, the evaluation period L-3 is defined as a period that starts at the end of the operation period T2 of the first pump 33 during the cleaning of the mixing device 14 and ends at the start of operation of the mixing device 14.

[0164] The judgment process for the evaluation period L-3 is performed as follows. The determination unit 46 reads the actual time length KL-3 of the evaluation period L-3 detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-3 for the same evaluation period L-3 that is pre-stored in the storage unit 41. In this embodiment, the reference value JL-3 is set to 1.2 times the standard time length of the evaluation period L-3 obtained from the operating performance data.

[0165] Subsequently, the determination unit 46 determines whether the actual time length KL-3 is greater than or equal to the reference value JL-3. If it is determined that the actual time length KL-3 is less than or equal to the reference value JL-3, the actual time length KL-3 is considered to be within the acceptable range, and a normal judgment is made.

[0166] On the other hand, if the actual time length KL-3 is judged to be greater than the standard value JL-3, an abnormality is determined, as the actual time length KL-3 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of operation of the mixing device 14 was delayed after the cleaning of the mixing device 14 was completed due to some cause, and that the amount of energy consumed during the evaluation period L-3 may have increased accordingly.

[0167] Thus, according to this embodiment, it is possible to determine that the evaluation period L-3 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-3.

[0168] (Evaluation period L-4) In this embodiment, the evaluation period L-4 is defined as the period from the completion of cleaning of the sterilization device 15, sterile tank 16, and filling device 17 until the start of operation of the sterilization device 15. Specifically, the evaluation period L-4 is defined as a period that starts at the end of the operation period T3 of the second pump 35 during cleaning of the sterilization device 15, sterile tank 16, and filling device 17, and ends at the start of operation of the sterilization device 15.

[0169] The judgment process for the evaluation period L-4 is performed as follows. The determination unit 46 reads the actual time length KL-4 of the evaluation period L-4 detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-4 for the same evaluation period L-4 that is pre-stored in the storage unit 41. In this embodiment, the reference value JL-4 is set to 1.2 times the standard time length of the evaluation period L-4 obtained from the operating performance data.

[0170] Subsequently, the determination unit 46 determines whether the actual time length KL-4 is greater than or equal to the reference value JL-4. If it is determined that the actual time length KL-4 is less than or equal to the reference value JL-4, the actual time length KL-4 is considered to be within the acceptable range, and a normal judgment is made.

[0171] On the other hand, if the actual time length KL-4 is judged to be longer than the standard value JL-4, an abnormality is determined, as the actual time length KL-4 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of operation of the sterilization device 15 after the completion of cleaning was delayed for some reason, and that the amount of energy consumed during the evaluation period L-4 may have increased accordingly.

[0172] Thus, according to this embodiment, it is possible to determine that the evaluation period L-4 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-4.

[0173] (Evaluation period L-5) In this embodiment, the evaluation period L-5 is defined as the period from the completion of cleaning of the sterilization device 15, sterile tank 16, and filling device 17 until the start of filling beverage containers with beverages by the filling device 17. Specifically, the starting point of the evaluation period L-5 is defined as the end of the operating period T3 of the second pump 35 during the cleaning of the sterilization device 15, sterile tank 16, and filling device 17. The ending point of the evaluation period L-5 is defined as the start of the execution period T4, when the filling of beverage containers with beverages by the filling device 17 is performed.

[0174] The judgment process for the evaluation period L-5 is performed as follows. The determination unit 46 reads the actual time length KL-5 of the evaluation target period L-5, which has been detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-5 for the same evaluation target period L-5, which has been pre-stored in the storage unit 41. In this embodiment, the reference value JL-5 is set to 1.2 times the standard time length of the evaluation target period L-5 obtained from the operating performance data.

[0175] Subsequently, the determination unit 46 determines whether the actual time length KL-5 is greater than or equal to the reference value JL-5. If it is determined that the actual time length KL-5 is less than or equal to the reference value JL-5, the actual time length KL-5 is considered to be within the acceptable range, and a normal judgment is made.

[0176] On the other hand, if the actual time length KL-5 is judged to be greater than the standard value JL-5, an abnormality is determined, as the actual time length KL-5 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of beverage filling into beverage containers by the filling device 17 after the completion of washing was delayed for some reason, and that the amount of energy consumed during the evaluation period L-5 may have increased accordingly.

[0177] Thus, according to this embodiment, it is possible to determine that the evaluation period L-5 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-5.

[0178] (Evaluation period L-6) In this embodiment, the evaluation period L-6 is defined as the period from the completion of cleaning of the sterilization device 15, sterile tank 16, and filling device 17 until the start of operation of the filling device 17. Specifically, the evaluation period L-6 is defined as a period that starts at the end of the operating period T3 of the second pump 35 during the cleaning of the sterilization device 15, sterile tank 16, and filling device 17, and ends at the start of operation of the filling device 17.

[0179] The judgment process for the evaluation period L-6 is performed as follows. The determination unit 46 reads the actual time length KL-6 of the evaluation target period L-6, which has been detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-6 for the same evaluation target period L-6, which has been pre-stored in the storage unit 41. In this embodiment, the reference value JL-6 is set to 1.2 times the standard time length of the evaluation target period L-6 obtained from the operating performance data.

[0180] Subsequently, the determination unit 46 determines whether the actual time length KL-6 is greater than or equal to the reference value JL-6. If it is determined that the actual time length KL-6 is less than or equal to the reference value JL-6, the actual time length KL-6 is considered to be within the acceptable range, and a normal judgment is made.

[0181] On the other hand, if the actual time length KL-6 is judged to be longer than the standard value JL-6, an abnormality is determined, as the actual time length KL-6 has exceeded the acceptable range. In this case, it is understood that, specifically, the start of operation of the filling device 17 after the completion of cleaning was delayed for some reason, and that the amount of energy consumed during the evaluation period L-6 may have increased accordingly.

[0182] Thus, according to this embodiment, it is possible to determine that the evaluation period L-6 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-6.

[0183] (Evaluation period L-7) In this embodiment, the evaluation period L-7 is defined as the period from when the filling device 17 starts operating until when the filling device 17 starts filling beverage containers with beverages. Specifically, the evaluation period L-7 is defined as a period that starts at the timing when the filling device 17 starts operating and ends at the timing when the execution period T4 starts.

[0184] The judgment process for evaluation period L-7 is performed as follows. The determination unit 46 reads the actual time length KL-7 of the evaluation target period L-7, which has been detected by the time length detection unit 45 and stored in the storage unit 41, and also reads the reference value JL-7 for the same evaluation target period L-7, which has been pre-stored in the storage unit 41. In this embodiment, the reference value JL-7 is set to be 1.2 times the standard time length of the evaluation target period L-7 obtained from the operating performance data.

[0185] Subsequently, the determination unit 46 determines whether the actual time length KL-7 is greater than or equal to the reference value JL-7. If it is determined that the actual time length KL-7 is less than or equal to the reference value JL-7, the actual time length KL-7 is considered to be within the acceptable range, and a normal judgment is made.

[0186] On the other hand, if the actual time length KL-7 is judged to be longer than the standard value JL-7, an abnormality is determined, as the actual time length KL-7 is longer than the acceptable range. In this case, it is understood that, specifically, the start of beverage filling by the filling device 17 was delayed after the start of operation of the filling device 17 due to some cause, and that the amount of energy consumed during the evaluation period L-7 may have increased accordingly.

[0187] Thus, according to this embodiment, it is possible to determine that the evaluation period L-7 has become longer, and based on that determination, it is possible to conclude that there is a possibility of wasted energy consumption during the evaluation period L-7.

[0188] (Evaluation period S-1) In this embodiment, the evaluation period S-1 is defined as the period from the time when the cleaning of the extractor 11 for the next series of manufacturing processes is completed to the time when the beverage filling by the filling device 17 in the current series of manufacturing processes is completed.

[0189] Specifically, the starting point of the evaluation period S-1 is defined as the end of the operating period T1 of the first pump 33 during the cleaning of the extractor 11 for the next series of manufacturing processes. The ending point of the evaluation period S-1 is defined as the end of the execution period T4 of the beverage filling into beverage containers by the filling device 17 in the current series of manufacturing processes.

[0190] The judgment process for evaluation period S-1 is performed as follows: The determination unit 46 reads the actual time length KS-1 of the evaluation period S-1, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JS-1 for the evaluation period S-1 from the relationship RS, which is stored in the storage unit 41 in advance, based on the stopping pattern of the manufacturing equipment 10 (weekend stop, pre-holiday stop, switchover stop, or normal stop). In this embodiment, the reference value JS-1 is calculated as 1.2 times the standard time length of the evaluation period S-1 obtained from the operating performance data.

[0191] Subsequently, the determination unit 46 determines whether the actual time length KS-1 is smaller than the reference value JS-1. If it is determined that the actual time length KS-1 is equal to or greater than the reference value JS-1, the actual time length KS-1 is considered to be within the acceptable range, and a normal judgment is made.

[0192] On the other hand, if the actual time length KS-1 is judged to be smaller than the standard value JS-1, an abnormality is determined, as the actual time length KS-1 has become shorter than the acceptable range. In this case, it can be seen that, specifically, the cleaning process for the extractor 11 for the next beverage product was delayed due to some reason, such as the time required for cleaning the extractor 11. This delay in the completion of cleaning the extractor 11 causes a delay in the completion of cleaning the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product, based on the completion of beverage filling by the filling device 17 for the current beverage product. From this, it can be seen that in this case, the delay in the completion of cleaning the extractor 11 for the next beverage product caused the delay in the completion of cleaning the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product. Furthermore, it can be seen that the amount of energy consumed during the period from the completion of beverage filling by the filling device 17 to the completion of cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17 (evaluation period S) may have increased by the amount of time it took to complete the cleaning.

[0193] Thus, according to this embodiment, it is determined that the evaluation period S-1 has been shortened. Based on this determination, it can be concluded that there is a possibility that energy consumption during the evaluation period S has been wasted due to the lengthening of the evaluation period S.

[0194] (Evaluation period S-2) In this embodiment, the evaluation period S-2 is defined as the period from the time when the cleaning of the mixing device 14 for the next series of manufacturing processes is completed to the time when the beverage filling by the filling device 17 in the current series of manufacturing processes is completed.

[0195] Specifically, the evaluation period S-2 is defined as a period that begins at the end of the operation period T2 in the next series of manufacturing processes and ends at the end of the execution period T4 in the current series of manufacturing processes.

[0196] The judgment process for evaluation period S-2 is performed as follows: The determination unit 46 reads the actual time length KS-2 of the evaluation period S-2, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JS-2 for the evaluation period S-2 from the relationship RS, which is pre-stored in the storage unit 41, based on the stopping pattern of the manufacturing apparatus 10. In this embodiment, the reference value JS-2 is calculated by multiplying the standard time length of the evaluation period S-2 obtained from the operating performance data by 1.2.

[0197] Subsequently, the determination unit 46 determines whether the actual time length KS-2 is smaller than the reference value JS-2. If it is determined that the actual time length KS-2 is equal to or greater than the reference value JS-2, the actual time length KS-2 is considered to be within the acceptable range, and a normal judgment is made.

[0198] On the other hand, if the actual time length KS-2 is judged to be smaller than the standard value JS-2, an abnormality is determined, as the actual time length KS-2 has become shorter than the acceptable range. In this case, it can be seen that, specifically, the cleaning process for the mixing device 14 for the next beverage product was delayed due to some reason, such as the time required for cleaning the mixing device 14. This delay in the completion of cleaning the mixing device 14 causes a delay in the completion of cleaning the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product, based on the completion of beverage filling by the filling device 17 for the current beverage product. From this, it can be seen that in this case, the delay in the completion of cleaning the mixing device 14 for the next beverage product was the cause of the delay in the completion of cleaning the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product. Furthermore, it can be seen that the amount of energy consumed during the period from the completion of beverage filling by the filling device 17 to the completion of cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17 (evaluation period S) may have increased by the amount of time it took to complete the cleaning.

[0199] Thus, according to this embodiment, it is determined that the evaluation period S-2 has been shortened. Based on this determination, it can be concluded that there is a possibility that energy consumption during the evaluation period S has been wasted due to the lengthening of the evaluation period S.

[0200] (Evaluation period S-3) In this embodiment, the evaluation period S-3 is defined as the period from the time when the cleaning of the extractor 11 is completed to the time when the cleaning of the mixing device 14 is completed.

[0201] Specifically, the evaluation period S-3 is defined as a period that begins at the end of the above-mentioned operating period T1 and ends at the end of the above-mentioned operating period T2. The evaluation process for the evaluation period S-3 is performed as follows:

[0202] The determination unit 46 reads the actual time length KS-3 of the evaluation period S-3, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JS-3 for the evaluation period S-3 from the relationship RS, which is stored in the storage unit 41 in advance, based on the stopping pattern of the manufacturing apparatus 10. In this embodiment, the reference value JS-3 is calculated by multiplying the standard time length of the evaluation period S-3 obtained from the operating performance data by 1.2.

[0203] Subsequently, the determination unit 46 determines whether the actual time length KS-3 is greater than or equal to the reference value JS-3. If it is determined that the actual time length KS-3 is less than or equal to the reference value JS-3, the actual time length KS-3 is considered to be within the acceptable range, and a normal judgment is made.

[0204] On the other hand, if the actual time length KS-3 is judged to be greater than the standard value JS-3, an abnormality is determined, as the actual time length KS-3 has exceeded the acceptable range. In this case, it can be determined that, for some reason, the cleaning of the mixing device 14 was delayed after the cleaning of the extractor 11. This delay in the cleaning of the mixing device 14 causes a delay in the cleaning of the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product, based on the completion of beverage filling by the filling device 17 for the current beverage product. From this, it can be seen that in this case, the delay in the cleaning of the mixing device 14 for the next beverage product caused a delay in the cleaning of the sterilization device 15, sterile tank 16, and filling device 17 for the next beverage product. Furthermore, it can be seen that the amount of energy consumed during the period from the completion of beverage filling by the filling device 17 to the completion of cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17 (evaluation period S) may have increased by the amount of time it took to complete the cleaning.

[0205] Thus, according to this embodiment, it is determined that the evaluation period S-3 has become longer. Based on this determination, it can be concluded that there is a possibility that energy consumption is being wasted during the evaluation period S due to the lengthening of the evaluation period S.

[0206] (Evaluation period S-4) In this embodiment, the evaluation period S-4 is defined as the period from the time when the mixing device 14 is finished cleaning to the time when the sterilization device 15, sterile tank 16, and filling device 17 are finished cleaning.

[0207] Specifically, the evaluation period S-4 is defined as a period that begins at the end of the above-mentioned operating period T2 and ends at the end of the above-mentioned operating period T3. The judgment process for evaluation period S-4 is performed as follows:

[0208] The determination unit 46 reads the actual time length KS-4 of the evaluation target period S-4, which has been detected by the time length detection unit 45 and stored in the storage unit 41. The determination unit 46 also calculates a reference value JS-4 for the evaluation target period S-4 from the relationship RS, which is pre-stored in the storage unit 41, based on the stopping pattern of the manufacturing apparatus 10. In this embodiment, the reference value JS-4 is calculated by multiplying the standard time length of the evaluation target period S-4, which has been determined from the operating performance data, by 1.2.

[0209] Subsequently, the determination unit 46 determines whether the actual time length KS-4 is greater than or equal to the reference value JS-4. If it is determined that the actual time length KS-4 is less than or equal to the reference value JS-4, the actual time length KS-4 is considered to be within the acceptable range, and a normal judgment is made.

[0210] On the other hand, if the actual time length KS-4 is judged to be greater than the standard value JS-4, an abnormality is determined, as the actual time length KS-4 is longer than the acceptable range. In this case, it can be determined that, for some reason, the completion of cleaning of the sterilization device 15, sterile tank 16, and filling device 17 was delayed after the completion of cleaning of the mixing device 14. It can also be determined that the amount of energy consumed during the period from the completion of beverage filling by the filling device 17 to the completion of cleaning of the sterilization device 15, sterile tank 16, and filling device 17 (evaluation period S) may have increased accordingly.

[0211] Thus, according to this embodiment, it is determined that the evaluation period S-4 has become longer. Based on this determination, it can be concluded that there is a possibility that energy consumption is being wasted during the evaluation period S due to the lengthening of the evaluation period S.

[0212] In the energy efficiency evaluation support system of this embodiment, the judgment results for each evaluation period are displayed on the display device of the computer 40. By checking the judgment results displayed on the display device, the user can recognize if there is any waste in energy consumption during any of the evaluation periods. Then, by analyzing the energy consumption patterns during the evaluation periods recognized in this way, it is possible to reduce the energy intensity per unit of consumption.

[0213] (Effects and Benefits) According to this embodiment, the following effects and advantages can be obtained. (1) Multiple evaluation periods are defined for a series of manufacturing processes that produce a predetermined number of beverage products. The time length detection unit 45 individually detects the time length of each of the multiple evaluation periods as the actual time length. The storage unit 41 stores reference values ​​for the time lengths of the multiple evaluation periods in advance. The determination unit 46 determines whether energy waste has occurred during the evaluation period based on the result of comparing the actual time length corresponding to the same evaluation period with the reference value.

[0214] There is an appropriate length for the manufacturing process of the manufacturing apparatus 10 in order to minimize energy consumption in the production of beverage products. Therefore, if the manufacturing process time in the manufacturing apparatus 10 is long, it can be said that there is a possibility of wasted energy consumption in the manufacturing apparatus 10.

[0215] In this embodiment, the actual time length, which is a detected value for the duration of such manufacturing processes (specifically, each evaluation period), is compared with a pre-stored reference value for the duration of the same evaluation period. Based on this comparison, it can be determined that the evaluation period has become longer, and based on this determination, it can be judged that there is a possibility of wasted energy consumption in each of the multiple evaluation periods. Thus, according to this embodiment, it is possible to determine the occurrence of wasted energy consumption in the manufacturing of beverage products.

[0216] (2) The manufacturing apparatus 10 manufactures multiple beverage products through a series of manufacturing processes. The memory unit 41 stores a first relationship between the number of beverage products manufactured N in the series of manufacturing processes and a reference value JF for the evaluation period F corresponding to the number of beverage products manufactured N. The determination unit 46 calculates the reference value JF from the first relationship based on the number of beverage products manufactured N and uses the reference value JF as a comparison target with the actual time length KF of the evaluation period F.

[0217] As the number of beverage products N produced in a series of manufacturing processes increases, the duration of those processes also increases. Consequently, the duration of the filling period TF (evaluation period F) and the reference value JF for that duration also change accordingly. According to this embodiment, the reference value JF for the duration of the evaluation period F can be determined according to the number of products N produced. Therefore, based on this reference value JF, it is possible to accurately determine the amount of energy waste generated in the production of beverage products in accordance with the number of beverage products N produced.

[0218] (3) The manufacturing apparatus 10 is used in sequence to produce multiple types of beverage products. The memory unit 41 stores a second relationship between the types of beverage products produced in a series of manufacturing processes and a reference value JF for the evaluation period F corresponding to those types. The determination unit 46 calculates the reference value JF from the second relationship based on the types of beverage products produced in a series of manufacturing processes, and uses this reference value JF as a comparison target with the actual time length KF of the evaluation period F.

[0219] When the type of beverage product manufactured in a series of manufacturing processes differs, the duration of those processes also differs. Consequently, the duration of the filling period TF (evaluation period F) and the reference value JF for that duration also change accordingly. According to this embodiment, the reference value JF for the duration of the evaluation period F can be determined according to the type of beverage product. Therefore, based on this reference value JF, it is possible to accurately determine the amount of energy waste in the manufacturing of beverage products, tailored to the type of beverage product.

[0220] (4) If the determination unit 46 determines that the actual time length is greater than the reference value, it can determine that the actual time length has exceeded the allowable range and make an abnormal determination. (5) Multiple evaluation periods include a start-up period TL, a filling period TF, and a shutdown period TS. A series of manufacturing processes for producing a predetermined number of beverage products can be divided into a start-up period TL for starting up the manufacturing equipment 10, a filling period TF for filling beverage containers with beverage to produce beverage products, and a shutdown period TS for stopping the manufacturing equipment 10 after the beverage products have been produced. According to this embodiment, it is possible to determine the occurrence of energy waste in each of these start-up period TL, filling period TF, and shutdown period TS.

[0221] (6) The manufacturing apparatus 10 is provided with a current sensor 58 for detecting the power consumption of the first pump 33. The storage unit 41 of the computer 40 stores in advance conditions for identifying the process equipment (extractor 11 or mixing device 14) to be cleaned when the cleaning apparatus 30 is in operation. When the power consumption of the first pump 33 changes and satisfies the above conditions, the target equipment identification unit 43 identifies the process equipment (extractor 11 or mixing device 14) to be cleaned by the cleaning apparatus 30 and the operating period of the first pump 33 for cleaning the process equipment, based on the power consumption. In this embodiment, a number of evaluation periods are determined based on the process equipment to be cleaned identified by the target equipment identification unit 43 and the operating period of the first pump 33 for cleaning the process equipment.

[0222] In the manufacturing apparatus 10, the cleaning apparatus 30 is driven by a shared first pump 33 for cleaning the extractor 11 and the mixing apparatus 14. However, if the process equipment being cleaned (extractor 11 or mixing apparatus 14) is different, the cleaning method of the process equipment will be different, and therefore the driving method of the first pump 33 will also be different.

[0223] In this embodiment, the characteristic movements of the first pump 33 during the operation of the cleaning device 30 are known in advance for each of the extractor 11 and the mixing device 14. The conditions under which these characteristic movements of the first pump 33 can be identified are stored in the storage unit 41 as conditions for identifying the process equipment to be cleaned. Therefore, according to this embodiment, the characteristic movements of the first pump 33 can be captured based on the above conditions, and the process equipment to be cleaned by the cleaning device 30 can be identified. Moreover, the operating period of the first pump 33 for cleaning the process equipment to be cleaned can also be identified from the changes in the power consumption of the first pump 33.

[0224] In a manufacturing apparatus 10 having a cleaning device 30, the evaluation period for determining energy consumption is determined by the period during which the process equipment is operated and the periods T1 to T3 during which the cleaning device 30 is operated for cleaning the process equipment before or after use. According to this embodiment, the target equipment identification unit 43 can identify the operating period T1 of the first pump 33 for cleaning the extractor 11 and the operating period T2 of the first pump 33 for cleaning the mixing device 14. Therefore, these operating periods T1 and T2 can be used as parameters for setting multiple evaluation periods.

[0225] (7) If the power consumption trends of the first pump 33 and the power consumption trends of the extractor 11 satisfy conditions A1 to A3, then based on these power consumption levels, it is determined that the extractor 11 is a process device to be cleaned and that the operating period T1 of the first pump 33 for cleaning the extractor 11 is determined. If the power consumption trends of the first pump 33 and the power consumption trends of the mixing device 14 satisfy conditions B1 to B4, then based on these power consumption levels, it is determined that the mixing device 14 is a process device to be cleaned and that the operating period T2 of the first pump 33 for cleaning the mixing device 14 is determined.

[0226] Both the extractor 11 and the compounding device 14 are process devices that operate themselves (either the extractor 11 or the compounding device 14) when the washing device 30 is operated for cleaning. According to this embodiment, in addition to using the power consumption of the first pump 33, the power consumption of the extractor 11 can be used as a parameter defining conditions A1 to A3 for identifying that the process equipment to be cleaned is the extractor 11. This allows for fine-tuning of conditions A1 to A3, enabling accurate identification of the process equipment to be cleaned as the extractor 11 and the operating period T1 of the first pump 33 for cleaning the extractor 11. Furthermore, in addition to using the power consumption of the first pump 33, the power consumption of the mixing device 14 can be used as a parameter defining conditions B1 to B4 for identifying that the process equipment to be cleaned as the mixing device 14. This allows for fine-tuning of conditions B1 to B4, enabling accurate identification of the process equipment to be cleaned as the mixing device 14 and the operating period T2 of the first pump 33 for cleaning the mixing device 14.

[0227] (8) The energy efficiency evaluation support system of this embodiment was applied to a manufacturing apparatus 10 for manufacturing beverage products. The manufacturing apparatus 10 for manufacturing beverage products has a sealed structure through which raw materials pass, making it difficult to grasp the operating status of each process device. According to this embodiment, in such a manufacturing apparatus 10, the process devices to be cleaned by the cleaning device 30 and the operating period of the first pump 33 for cleaning the said process devices can be accurately identified.

[0228] (9) The energy efficiency evaluation support system of this embodiment is equipped with current sensors 50 to 59 in each process apparatus for detecting the current consumption of the process apparatus. Multiple evaluation periods are determined based on the changes in current consumption detected by the current sensors 50 to 59. According to this embodiment, by adding current sensors 50 to 59, the evaluation period can be precisely defined according to the actual operating conditions of each process apparatus.

[0229] (modified version) The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0230] As shown in Figure 4, the standard value storage unit 47 of the computer 80 may be configured to store standard values ​​for the duration of multiple evaluation periods in advance. Any predetermined value can be used as the standard value. Alternatively, the standard value could be the duration of an evaluation period when the energy intensity is reasonably low, or the shortest duration achievable within a series of manufacturing processes from the values ​​(durations) included in the operational performance data. In addition, the standard value could be the duration of an evaluation period when the energy intensity was good, or the shortest duration (or the closest duration) in the operational performance data.

[0231] Furthermore, the notification unit 48 of the computer 80 may be configured to notify the user of the evaluation period (hereinafter referred to as the standard period) determined by the above standard value during the manufacturing of beverage products by the manufacturing apparatus 10, by displaying it on the display device of the computer 80.

[0232] With this configuration, the user can understand the standard period, which is a typical period for the evaluation period, based on the information notified by the notification unit 48 during the production of beverage products by the manufacturing equipment 10. This allows the user to understand the difference between the standard period and the actual evaluation period, and to control the operation of multiple types of process equipment and the washing equipment 30 while checking the standard period. With the above configuration, it is possible to support the efficient operation of the manufacturing equipment 10 by the user in this way.

[0233] Furthermore, the following configuration can be used to inform the user of the above standard period. Based on the above standard period, the operating period of each process device and the cleaning device 30 are determined, and an operating schedule is created for these process devices and the cleaning device 30, and this operating schedule is displayed on the display device of the computer 80. The standard period is displayed on the display device of the computer 80 as a timer display, such as a countdown display. The standard period is output by voice using the speaker of the computer 80.

[0234] Furthermore, if the operation is delayed or completed ahead of schedule, the operation schedule may be reviewed and modified accordingly. In addition, timer displays such as countdown displays may be reviewed and modified in accordance with such revisions to the operation schedule.

[0235] The method for setting the reference value for the duration of each evaluation period, and the method for executing the judgment process based on the reference value, can be arbitrarily changed. For example, the standard duration of the evaluation period can be set as the reference value. In this case, the judgment process can be executed such that an abnormality is determined when the difference between the actual duration of the evaluation period and the reference value exceeds a predetermined level.

[0236] An abnormality may be determined if the actual time length of the evaluation period L, L-1 to L-7, F, S, S-3, S-4 is shorter than the standard time length of the same evaluation period by a predetermined level or more (for example, a level equivalent to 20% of the standard time length).

[0237] In the manufacturing apparatus 10, if the time length of the manufacturing process becomes too short, it may result in wasted energy consumption, such as the manufacturing apparatus 10 not being able to prepare in time. With the above configuration, it is possible to determine if the actual time length of the evaluation period L, L-1 to L-7, F, S, S-3, S-4 has become shorter than the acceptable range, and based on this determination, an abnormality can be judged.

[0238] In the above configuration, for example, a time shorter than the standard duration of the evaluation period determined from the operational performance data can be set as the reference value. In this case, the judgment process can be executed such that an abnormality is determined when the actual duration of the evaluation period is judged to be less than the reference value. Alternatively, the standard duration of the evaluation period can also be set as the reference value. In this case, the judgment process can be executed such that an abnormality is determined when the difference between the actual duration of the evaluation period and the reference value exceeds a predetermined level.

[0239] In a manufacturing apparatus 10 that produces only one type of beverage product, when determining whether energy consumption is wasted, the standard value JF for the evaluation period F may be calculated based on the number of beverage products produced N, without using the type of beverage product. In this configuration, the storage unit 41 only needs to pre-store the relationship between the number of beverage products produced N in a series of manufacturing processes and the standard value JF for the length of the evaluation period F corresponding to the number of products produced N.

[0240] In a manufacturing apparatus 10 of the type that produces the same number of beverage products in a series of manufacturing processes, when determining energy consumption, the standard value JF for the evaluation period F may be calculated based on the type of beverage product, without using the number of beverage products N produced. In this configuration, the storage unit 41 only needs to pre-store the relationship between the types of beverage products produced in a series of manufacturing processes and the standard value JF for the length of the evaluation period F corresponding to those types.

[0241] Instead of using the stopping pattern of the manufacturing equipment 10 as the calculation parameter for the reference value (JS,JS-1~JS-4) of the evaluation period (S,S-1~S-4), the content of the cleaning process performed by the cleaning device 30 may be used. In this case, the relationship between the content of the cleaning process performed by the cleaning device 30 when the manufacturing equipment 10 is stopped and the reference value of the length of the evaluation period (S,S-1~S-4) corresponding to that content should be stored in the storage unit 41 in advance. The content of the cleaning process performed by the cleaning device 30 can be determined based on the production plan stored in the storage unit 41. With this configuration, the reference value (JS,JS-1~JS-4) for the length of the evaluation period (S,S-1~S-4) can be calculated in a manner that corresponds to the content of the cleaning process performed by the cleaning device 30, which differs depending on the stopping pattern of the manufacturing equipment 10.

[0242] In a manufacturing apparatus 10 that produces the same number of identical beverage products in a series of manufacturing processes, when determining whether energy consumption is wasted, a predetermined reference value JF stored in the memory unit 41 may be used.

[0243] The optical sensor 70 can be positioned to detect beverage products sent from the labeling device 18 to the packaging device 19, or to detect beverage products sent from the packaging device 19 to the boxing device 20. With this configuration, the computer 40 can determine the execution period T4 during which the filling device 17 fills beverage containers with beverages, based on the output signal of the optical sensor 70, and can detect the number of beverage containers filled with beverages (production quantity N) during the execution period T4.

[0244] Instead of the optical sensor 70, a proximity sensor or an image processing device may be provided. The proximity sensor or image processing device can also be used to detect when a beverage product has passed from the filling device 17 to the labeling device 18.

[0245] • As current sensors 50-59, it is not limited to using sensors that are added to the manufacturing equipment 10 after it has been installed in the factory; sensors that are originally installed in the manufacturing equipment 10 can also be used.

[0246] As parameters for defining the conditions for identifying the process equipment to be cleaned, it is not limited to using the power consumption of the first pump 33 or the power consumption of the process equipment; it is also possible to use the current consumption of the first pump 33 or the current consumption of the process equipment.

[0247] - If it is possible to detect an indicator value of the power consumption of the process equipment and the first pump 33 and second pump 35, then instead of the current sensors 50-59, a power sensor that detects the power consumption itself or a voltage sensor that detects the voltage as an indicator value of power consumption can be provided.

[0248] Instead of calculating the amount of energy consumed A using the unit period TA as the calculation period, or in conjunction with this, a value (amount of energy consumed Aa) may be calculated by integrating the amounts of various energies consumed in conjunction with the operation of the extractor 11 during the unit period TA. Alternatively, a value (amount of energy consumed Ab) may be calculated by integrating the amounts of various energies consumed in conjunction with the operation of the centrifuge 12 during the unit period TA. With this configuration, it is possible to perform a detailed analysis of the amount of energy consumed for each process device, such as scrutinizing the amount of energy consumed Aa for the efficient operation of the extractor 11, or scrutinizing the amount of energy consumed Ab for the efficient operation of the blending device 14.

[0249] Instead of calculating the amount of energy consumed C using the unit period TC as the calculation period, or in conjunction with this, the amount of energy consumed Ca (energy consumed) may be calculated by integrating the amounts of various energies consumed in conjunction with the operation of the sterilization device 15 during the unit period TC. Alternatively, the amount of energy consumed Cb (energy consumed) may be calculated by integrating the amounts of various energies consumed in conjunction with the operation of the sterile tank 16 during the unit period TC. Furthermore, the amount of energy consumed Cc (energy consumed) may be calculated by integrating the amounts of various energies consumed in conjunction with the operation of the filling device 17 during the unit period TC. With the above configuration, it is possible to perform a detailed analysis of the amount of energy consumed for each process device, such as scrutinizing the amount of energy consumed Ca for the efficient operation of the sterilization device 15, or scrutinizing the amount of energy consumed Cb for the efficient operation of the sterile tank 16.

[0250] Instead of calculating the amount of energy consumed D using the unit period TD as the calculation period, or in conjunction with this, a value obtained by integrating the amounts of various energy consumed in conjunction with the operation of the labeling device 18 during the unit period TD (amount of energy consumed Da) may be calculated. Alternatively, a value obtained by integrating the amounts of various energy consumed in conjunction with the operation of the packaging device 19 during the unit period TD (amount of energy consumed Db) may be calculated. Furthermore, a value obtained by integrating the amounts of various energy consumed in conjunction with the operation of the boxing device 20 during the unit period TD (amount of energy consumed Dc) may be calculated. With the above configuration, it is possible to perform a detailed examination of the amount of energy consumed for each process device, such as examining the amount of energy consumed Da for the efficient operation of the labeling device 18, or examining the amount of energy consumed Db for the efficient operation of the packaging device 19. In addition, the energy intensity for the labeling device 18 may be calculated based on the amount of energy consumed Da, or the energy intensity for the packaging device 19 may be calculated based on the amount of energy consumed Db. It is also possible to calculate the energy intensity for the boxing device 20 based on the amount of energy consumed Dc.

[0251] The energy efficiency evaluation support system according to the above embodiment can also be applied to manufacturing equipment that performs "cleaning of the extractor 11," "cleaning of the mixing device 14," and "cleaning of the sterilization device 15, sterile tank 16, and filling device 17" through the drive of the same cleaning pump. Furthermore, the energy efficiency evaluation support system according to the above embodiment can also be applied to manufacturing equipment that performs "cleaning of the extractor 11," and "cleaning of the sterilization device 15, sterile tank 16, and filling device 17" through the drive of the same cleaning pump. In any configuration, by defining conditions for identifying the process equipment to be cleaned for each process equipment, it is possible to capture the characteristic movements of the power consumption of the cleaning pump and the power consumption of the process equipment based on these conditions and identify the process equipment to be cleaned by the cleaning device 30.

[0252] The energy efficiency evaluation support system according to the above embodiment is applicable to any manufacturing apparatus having multiple types of process equipment through which liquid raw materials pass, and a cleaning apparatus that cleans the inside of these process equipment using a cleaning solution driven by the same cleaning pump. With this configuration, by defining conditions for identifying the process equipment to be cleaned for each process equipment, it is possible to capture the characteristic movements of the power consumption of the cleaning pump and the power consumption of the process equipment based on these conditions, and identify the process equipment to be cleaned by the cleaning apparatus. Examples of such manufacturing apparatus include those that manufacture beverage products other than tea, such as juice, coffee, and milk, as well as those that manufacture food products such as mayonnaise, and those that manufacture pharmaceuticals. Other examples include those that manufacture cosmetics, toiletries, and soap.

[0253] The conditions for identifying the process equipment to be cleaned during the operation of the cleaning device 30 can be arbitrarily changed. The above conditions can be defined as follows: The characteristic power consumption trends of the first pump 33 and the power consumption trends of the process equipment that appear when the cleaning device 30 is used to clean the process equipment are determined in advance. Then, conditions that allow for the identification of the occurrence of such characteristic power consumption trends of the first pump 33 and the power consumption trends of the process equipment are defined and stored in the storage unit 41.

[0254] - When specifying the conditions for identifying the process equipment to be cleaned during operation of the cleaning device 30, the conditions may be defined without using the power consumption trends of the process equipment. In this case, the above conditions may be defined as follows: The power consumption trends of the first pump 33 that characteristically appear when the cleaning device 30 is used to clean the process equipment are determined in advance. Then, conditions that allow for the identification of the occurrence of such characteristic power consumption trends of the first pump 33 are defined and stored in the storage unit 41.

[0255] The unit periods TA and TB may be defined as the period from the start timing of the operating periods T1 and T2 of the first pump 33 in the cleaning process immediately before operation of the process equipment to the start timing of the operating periods T1 and T2 of the cleaning process immediately after operation of the same process equipment. Alternatively, the unit period TC may be defined as the period from the start timing of the operating period T3 of the second pump 35 in the cleaning process immediately before operation of the process equipment (sterilization device 15, sterile tank 16, filling device 17) to the start timing of the operating period T3 of the cleaning process immediately after operation.

[0256] In the above configuration, for example, the unit period TA can be defined as follows: The operating period T1 of the first pump 33 in the cleaning of the extractor 11 is read from the storage unit 41. Then, the period from the start timing of the operating period T1 in the cleaning process immediately before the operation of the extractor 11 to the start timing of the operating period T1 in the cleaning process immediately after the operation of the extractor 11 is defined as the unit period TA. Furthermore, the unit period TB can be defined as follows: The operating period T2 of the first pump 33 in the cleaning of the mixing device 14 is read from the storage unit 41. Then, the period from the start timing of the operating period T2 in the cleaning process immediately before the operation of the mixing device 14 to the start timing of the operating period T2 in the cleaning process immediately after the operation of the mixing device 14 is defined as the unit period TB.

[0257] The energy efficiency evaluation support system according to the above embodiment can be applied to manufacturing equipment that uses multiple types of process equipment to produce products, even if it does not have process equipment through which liquid raw materials pass or cleaning equipment for cleaning the inside of the process equipment. With the same configuration, multiple evaluation periods can be defined for a series of manufacturing processes, and by comparing the actual time length corresponding to the same evaluation period with a reference value, it is possible to determine the occurrence of wasted energy consumption during the evaluation period. Examples of such manufacturing equipment include casting equipment for producing castings, paint drying equipment for producing painted products, and extrusion molding equipment for producing resin molded products.

[0258] (Second Embodiment) The following describes a second embodiment of the energy efficiency evaluation support system. First, the manufacturing apparatus to which the energy efficiency evaluation support system of this embodiment is applied will be described. The manufacturing apparatus of this embodiment is for manufacturing metal pipe materials as manufactured products. Specifically, by using the manufacturing apparatus in sequence, multiple types of metal pipe materials of different sizes are manufactured.

[0259] As shown in FIG. 5, the manufacturing apparatus 100 of the present embodiment includes a pedestal 111, a feeder 110, a shot blast 120, and a puller 130. In the present embodiment, the feeder 110, the shot blast 120, and the puller 130 correspond to a plurality of types of process apparatuses.

[0260] A coiled pipe as a material, so-called pipe-in-coil 101, is placed on the pedestal 111. (Feeder) The feeder 110 is a setting device for sending the pipe 102 constituting the pipe-in-coil 101 to a downstream process apparatus (specifically, the puller 130) when the pipe-in-coil 101 is newly placed on the pedestal 111. The feeder 110 has an electric motor (hereinafter, a feed motor 112). In the present embodiment, by operating the feed motor 112 with the pipe-in-coil 101 placed on the pedestal 111, the pipe 102 constituting the pipe-in-coil 101 is sent to the downstream process apparatus.

[0261] (Shot blast) The shot blast 120 is a process apparatus for removing rust on the surface of the pipe 102. In the present embodiment, the pipe 102 passes through the inside of the shot blast 120. The shot blast 120 sprays an abrasive onto the surface of the pipe 102 passing through the inside. Thereby, the rust on the surface of the pipe 102 is removed.

[0262] The shot blast 120 has a plurality (four in the present embodiment) of electric motors (hereinafter, blast motors 121). By operating the blast motors 121, the abrasive is jetted and sprayed toward the pipe 102. In the present embodiment, as the operating state of the shot blast 120, it is possible to select either a standby state in which the blast motors 121 are operated without spraying the abrasive or a functional state in which the blast motors 121 are operated while spraying the abrasive. The load of the blast motors 121 becomes large in the functional state of spraying the abrasive, while it becomes relatively small in the standby state of not spraying the abrasive.

[0263] (Pulling machine) The drawing machine 130 is a process device that performs a so-called drawing process, in which the pipe 102 is passed through a hole in a die 133 and drawn out to form a metal pipe material of a desired shape. The drawing machine 130 has a drawing section 131 and a straightening section 132.

[0264] The drawing section 131 includes a die 133 for drawing, an electric motor (hereinafter referred to as the drawing motor 134), and a control device 135. The drawing motor 134 is used as the power source for the section that pulls the pipe 102 and continuously feeds it downstream. The control device 135 controls the operation of the drawing motor 134.

[0265] In this embodiment, the pipe 102 that has passed through the shot blast 120 is guided to the mold 133 of the extraction section 131. The pipe 102 is then passed through the mold 133 and continuously pulled downstream by the operation of the extraction motor 134, thereby being extracted from the mold 133. This adjusts the inner and outer diameters of the pipe 102, forming a metal pipe of the desired shape.

[0266] The straightening unit 132 is a process device for straightening the pipe 102 after the drawing process. The straightening unit 132 is composed of, for example, a roll straightening machine. The straightening unit 132 has a straightening roller 136, an electric motor (hereinafter referred to as the straightening motor 137), and a control device 138. The straightening motor 137 is used as a power source to operate the straightening unit 132. The control device 138 controls the operation of the straightening motor 137.

[0267] In this embodiment, when manufacturing metal tubing using the manufacturing apparatus 100, the pipe 102, after passing through the drawing section 131, is guided to the straightening section 132. At this time, the straightening section 132 and the straightening motor 137 are in operation. As the pipe 102 passes through the inside of the operating straightening section 132, the pipe 102 is straightened into a straight shape.

[0268] The feeder 110, shot blaster 120, and drawing machine 130 are each equipped with an operation panel. During the manufacturing of metal pipes by the manufacturing apparatus 100, the operation of the corresponding process equipment is controlled by the operator through the operation of each operation panel. In this embodiment, the manufacturing apparatus 100 manufactures metal pipes using the feeder 110, shot blaster 120, and drawing machine 130. The metal pipes manufactured by the manufacturing apparatus 100 are cut to predetermined lengths by the subsequent processing equipment 103.

[0269] (Management system) The manufacturing apparatus 100 has a management system 140. The management system 140 has a storage unit 141 and an input unit 142. The storage unit 141 is configured with a hard disk drive or a solid-state drive, etc. The input unit 142 is configured with a keyboard or mouse. In this embodiment, various information related to the manufacturing of metal pipes, such as production plans, is stored through the user's operation of the input unit 142. Specifically, the storage unit 141 stores various information related to the manufacturing of metal pipes for each series of manufacturing processes (hereinafter referred to as a manufacturing cycle) in which identical types of metal pipes are continuously manufactured from a single pipe-in-coil 101. The various information stored includes the time of completion of manufacturing, the type of steel ordered, the shape of the metal pipe (length, cross-sectional shape, size), and the total weight of the metal pipes actually manufactured.

[0270] The manufacturing cycle will be explained below. As shown in Figure 5, in the manufacturing cycle, the pipe-in-coil 101 is first placed on the base 111. The pipe-in-coil 101 is selected to have a steel type and shape that matches the metal pipe material to be manufactured in this manufacturing cycle.

[0271] Subsequently, the tip of the pipe-in-coil 101 (more specifically, the pipe 102) placed on the base 111 is pulled out and fed into the feeder 110. As a result, the pipe 102 is subsequently fed towards the shot blaster 120 through the operation of the feeder 110.

[0272] Subsequently, the tip of the pipe 102 passes through the inside of the shot blast 120 and then reaches the extraction section 131 of the extraction machine 130. When the tip of the pipe 102 reaches the extraction section 131, the operation of the feeder 110 is stopped. This completes the production preparation.

[0273] Thereafter, the pipe 102 is pulled downstream by the extraction unit 131 (driven by the extraction motor 134). When the pipe 102 is moved by the extraction unit 131 in this way, the operation state of the shot blast 120 is switched to a function state in which abrasive material is sprayed. In this embodiment, during the period from the start of the manufacturing cycle until the pipe 102 is moved by the extraction unit 131, the shot blast 120 operates in a standby state without spraying abrasive material.

[0274] At this point, as the pipe 102 is pulled by the extraction unit 131, the load on the extraction motor 134 gradually increases, and the power consumption of the extraction unit 131 gradually increases. Subsequently, as the extraction process by the mold 133 becomes stable, the load on the extraction motor 134 becomes approximately constant, and the power consumption of the extraction unit 131 becomes approximately constant.

[0275] After passing through the drawing section 131, the pipe 102 then passes through the straightening section 132. This straightening section 132 straightens the pipe 102 into a straight shape. When a predetermined amount of metal tubing material has been produced, the drawing machine 130 stops operating. At this time, the operating state of the shot blast 120 is switched as follows: If the production of metal tubing material by the manufacturing device 100 continues thereafter, the operating state of the shot blast 120 is switched to standby mode in preparation for the next production cycle. On the other hand, if the production of metal tubing material by the manufacturing device 100 is completed, the operation of the shot blast 120 stops.

[0276] In each manufacturing cycle, the processes of shot blasting 120, drawing 131, and straightening 132 are basically performed at the same time, although the areas being processed on the pipe 102 are different.

[0277] (Energy efficiency evaluation support system) The energy efficiency evaluation support system of this embodiment includes a computer 150. The computer 150 includes a display device 151 that displays information for the user, and input devices (not shown) that are operated by the user. The computer 150 could be a personal computer such as a desktop, notebook, or tablet, or a portable computer such as a smartphone.

[0278] The computer 150 is capable of running support programs to assist in calculating the energy intensity of metal pipes manufactured by the manufacturing equipment 100, as well as evaluation programs to evaluate the energy efficiency of the manufacturing equipment 100.

[0279] (Storage part) The computer 150 is equipped with a storage unit 152 for storing various data. The storage unit 152 stores support programs, evaluation programs, and various calculation results from the computer 150. The storage unit 152 also stores conditions for defining the first evaluation period T10 for evaluating the energy efficiency of the manufacturing equipment 100. The storage unit 152 also stores conditions for defining the second evaluation period T20 for evaluating the energy efficiency of the manufacturing equipment 100, and so on.

[0280] The energy efficiency evaluation support system of this embodiment includes current sensors 160 to 166 described below. That is, the system of this embodiment includes a current sensor 160 for detecting the current consumption of the feeder 110, a current sensor 161 for detecting the current consumption of the shot blast 120, and a current sensor 162 for detecting the current consumption of the extractor 130. In addition, the system of this embodiment also includes current sensors 163 to 166 for detecting the current consumption of each device constituting the extractor 130. Specifically, the system of this embodiment includes a current sensor 163 for detecting the current consumption of the extraction unit 131 and a current sensor 164 for detecting the current consumption of the correction unit 132. Further, the system of this embodiment includes a current sensor 165 for detecting the current consumption of the extraction motor 134 and a current sensor 166 for detecting the current consumption of the correction motor 137.

[0281] All of the current sensors 160 to 166 are attached to the manufacturing apparatus 100 installed in the factory in a manner of being added later. The output signals of the current sensors 160 to 166 are captured by the computer 150. The computer 150 calculates the power consumption of the devices corresponding to the current sensors 160 to 166 based on the output signals of these current sensors 160 to 166, and uses the power consumption for various calculations. In this embodiment, the current sensors 160 to 166 correspond to a process detection unit that separately detects index values of the power consumption of a plurality of types of process devices.

[0282] In this embodiment, a first evaluation target period T10 for evaluating the energy efficiency of the manufacturing apparatus 100 is defined. The computer 150 is capable of executing a determination program for determining the occurrence of wasteful energy consumption during the first evaluation target period T10. The computer 150 has, as functional units, a time length detection unit 153 and a time length determination unit 154.

[0283] (Time length detection unit) The time length detection unit 153 detects the time length of the first evaluation target period T10 as the actual time length RA and stores it in the storage unit 152.

[0284] First, the time-length detection unit 153 determines the operating state of the feeder 110 based on the changes in the detection signal of the current sensor 160, and the operating pattern of the extraction machine 130 based on the changes in the detection signal of the current sensor 162. Then, based on the relationship between the operating state of the feeder 110 and the operating pattern of the extraction machine 130 that it has determined, it determines the first evaluation period T10.

[0285] As shown in Figure 6, in this embodiment, the starting point TA1 of the first evaluation period T10 is defined as the timing at which the manufacturing of metal pipes begins in the manufacturing cycle. Specifically, the starting point TA1 of the first evaluation period T10 is defined as the timing that satisfies all of the following conditions S-1 to S-3. (Condition S-1) The feeder 110 is running. Specifically, the power consumption of the feeder 110 has increased from a state of being less than or equal to a predetermined value SS1 (for example, approximately 0kW) to a state of being greater than or equal to a predetermined value SS2 (for example, 1kW). (Condition S-2) The operation of the extraction machine 130 is stopped in conjunction with the start of the feed machine 110. Specifically, before the start of the feed machine 110, the power consumption of the extraction machine 130 is reduced from the value in the stable operating state of the extraction machine 130 (e.g., several tens of kW) to a predetermined value SS3 (e.g., approximately 0 kW) or less. (Condition S-3) The power consumption of the extraction machine 130 is at a predetermined value SS3 (for example, approximately 0kW) or less.

[0286] Furthermore, the endpoint TA2 of the first evaluation period T10 is defined as the timing when the power consumption of the drawing machine 130 becomes approximately constant at a value suitable for the production of metal pipes in this manufacturing cycle. Specifically, the timing that satisfies the following (condition E-1) is defined as the endpoint TA2 of the first evaluation period T10. (Condition E-1) The power consumption of the extraction machine 130 increases to the value of the extraction machine 130 in its stable operating state (for example, several tens of kW) upon the start of operation of the extraction machine 130, and then becomes approximately constant at the same value.

[0287] In this manner, the time length detection unit 153 determines the start point TA1 and end point TA2 based on the transition of the detection signals from the current sensors 160 and 162, and defines the first evaluation period T10 using these start point TA1 and end point TA2. The time length detection unit 153 then detects the length of this first evaluation period T10 as the actual time length RA.

[0288] (Time length determination unit) The time length determination unit 154 compares the first reference value JA and the detected value (actual time length RA) for the time length of the first evaluation period T10, and determines whether energy waste occurred during the first evaluation period T10 based on the comparison result.

[0289] The memory unit 152 has a first reference value JA for the duration of the first evaluation period T10 stored in it. In this embodiment, the first reference value JA is determined in advance by the inventor through verification of the operating performance data of the manufacturing apparatus 100. In this embodiment, the memory unit 152 corresponds to the duration reference memory unit.

[0290] In this embodiment, the length of the first evaluation period T10 that allows for an appropriate reduction in energy consumption during the first evaluation period T10 is predetermined from the operating performance data of the manufacturing apparatus 100. The memory unit 152 stores a value determined based on this length as the first reference value JA for the first evaluation period T10. Specifically, the memory unit 152 pre-stores the relationship REA between the amount of metal pipe material manufactured in the manufacturing cycle VL (specifically, the total weight of the metal pipe material), the type of metal pipe material TY, and the first reference value JA corresponding to the amount of material manufactured VL and type TY. This relationship REA is stored in the memory unit 152, for example, as a calculation map.

[0291] When the time length determination unit 154 performs a determination of whether energy consumption waste occurs for the first evaluation period T10, it calculates a first reference value JA from the above relationship REA based on the amount VL and type TY of metal pipe material produced. This calculated first reference value JA is then used for comparison with the actual time length RA.

[0292] In this embodiment, the amount VL, type TY, and manufacturing period (start time and end time) of metal pipes manufactured in a manufacturing cycle are input to the management system 140 through operations such as the input unit 142, and are also stored in the storage unit 141 of the management system 140. The amount VL and type TY of metal pipes stored in the storage unit 141 are used to calculate the first reference value JA. Specifically, the storage unit 141 stores information including the amount VL, type TY, and manufacturing period of metal pipes manufactured in a manufacturing cycle for each manufacturing cycle. In this embodiment, based on the first evaluation target period T10, the amount VL and type TY of metal pipes to be manufactured in the first evaluation target period T10 are identified from the above information stored in the storage unit 141. Then, the identified amount VL and type TY are used to calculate the first reference value JA.

[0293] In this embodiment, the above-mentioned relationship REA includes a third relationship between the amount of products manufactured in a series of manufacturing processes and a first reference value corresponding to that amount, and a fourth relationship between the type of products manufactured in a series of manufacturing processes and a first reference value corresponding to that type.

[0294] (Determination of waste occurrence during the first evaluation period T10) The process for determining the occurrence of energy waste during the first evaluation period T10 is performed by computer 150 as follows.

[0295] The time length determination unit 154 reads the actual time length RA of the first evaluation target period T10, which has been detected by the time length detection unit 153 and stored in the storage unit 152, and also reads the first reference value JA for the first evaluation target period T10, which has been previously stored in the storage unit 152.

[0296] In this embodiment, the first reference value JA is defined as 1.2 times the standard duration of the first evaluation period T10 obtained from the operational performance data. The standard duration is the duration of the first evaluation period T10 that is suitable for reducing energy consumption. As the standard duration, one can adopt the duration of the first evaluation period T10 when the energy intensity is appropriately low, or the shortest duration within the feasible range from the values ​​(durations) included in the operational performance data. Alternatively, one can adopt the duration of the first evaluation period T10 when the energy intensity was good, or the shortest duration (or the closest duration) in the operational performance data.

[0297] Subsequently, the time length determination unit 154 determines whether the actual time length RA is greater than or equal to the first reference value JA. If it is determined that the actual time length RA is less than or equal to the first reference value JA, it is determined that the actual time length RA is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual time length RA is greater than the first reference value JA, it is determined that the actual time length RA has exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the first evaluation period T10 has become longer, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption during the first evaluation period T10.

[0298] In this embodiment, the first evaluation period T10 is the period from the start of the manufacturing cycle until the shot blaster 120 starts operating in a functional state, that is, the period during which the shot blaster 120 operates in a standby state (hereinafter referred to as the idle operation period). If an abnormality is determined in the evaluation of the first evaluation period T10, it is determined that there is a possibility that some kind of trouble occurred during the idle operation period of the shot blaster 120.

[0299] In this embodiment, the actual time length RA for each manufacturing cycle is stored in the storage unit 152 of the computer 150, along with the judgment result (normal judgment or abnormal judgment) for the first evaluation period T10. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the first evaluation period T10 is an abnormal judgment, the color (text color or background color) of the field displaying the actual time length RA is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the first evaluation period T10 is a normal judgment, the color (text color or background color) of the field displaying the actual time length RA is set to a less conspicuous color (for example, white).

[0300] In this embodiment, a second evaluation period T20 is defined for evaluating the energy efficiency of the manufacturing apparatus 100. The computer 150 is capable of executing a determination program that determines whether energy waste occurs during the second evaluation period T20 based on the operating rate of the drawing machine 130. The computer 150 has an operating rate calculation unit 155 and an operating rate determination unit 156 as functional units.

[0301] (Operating rate calculation unit) The operating rate calculation unit 155 calculates the operating rate of the extraction machine 130 during the second evaluation period T20 and stores it in the storage unit 152.

[0302] First, the operating rate calculation unit 155 grasps the operating state of the feeder 110 based on the changes in the detection signal of the current sensor 160, and grasps the operating pattern of the extraction machine 130 based on the changes in the detection signal of the current sensor 162. Then, it determines the second evaluation period T20 from the relationship between the grasped operating state of the feeder 110 and the operating pattern of the extraction machine 130. Finally, it detects the time length (actual time length RB) of the second evaluation period T20 and stores it in the storage unit 152.

[0303] In this embodiment, the second evaluation period T20 is defined as the period during which identical metal piping is continuously manufactured from a single pipe-in-coil (one manufacturing cycle). Therefore, the starting point TB1 of the second evaluation period T20 is defined as the timing at which the current manufacturing cycle begins. Specifically, the timing at which all of the above conditions (S-1) to (S-3) are satisfied is defined as the starting point TB1 of the second evaluation period T20. Furthermore, the ending point TB2 of the second evaluation period T20 is defined as the timing at which the next manufacturing cycle begins. Specifically, the timing at which all of the above conditions (S-1) to (S-3) are satisfied in the next manufacturing cycle is defined as the ending point TB2 of the second evaluation period T20.

[0304] In this manner, the operating rate calculation unit 155 determines the start point TB1 and end point TB2 based on the transition of detection signals from the current sensors 160 and 162, and defines the second evaluation period T20 using these start point TB1 and end point TB2. The operating rate calculation unit 155 then detects the length of this second evaluation period T20 as the actual time length RB.

[0305] Furthermore, the operating rate calculation unit 155 determines the operating period T30 of the extraction machine 130 based on the relationship between the operating state of the feeder 110 and the operating mode of the extraction machine 130, which is determined based on the changes in the detection signals of the current sensors 160 and 162. It then detects the duration (actual duration RW) of the operating period T30 of the extraction machine 130 and stores it in the storage unit 152.

[0306] In this embodiment, the starting point TC1 of the operating period T30 of the drawing machine 130 is determined to be the timing at which the power consumption of the drawing machine 130 becomes approximately constant at a value suitable for the production of metal pipes in this manufacturing cycle. Specifically, the timing that satisfies the above (condition E-1) is determined to be the starting point TC1.

[0307] In this embodiment, the endpoint TC2 of the second evaluation period T20 is defined as the endpoint TB2 of the second evaluation period T20. Specifically, the timing in the next manufacturing cycle when all of the above conditions S-1 to S-3 are met is defined as the endpoint TC2 of the operation period T30 of the extraction machine 130.

[0308] In this manner, the operating rate calculation unit 155 determines the start point TC1 and end point TC2 based on the transition of detection signals from the current sensors 160 and 162, and defines the operating period T30 of the extraction machine 130 based on these start point TC1 and end point TC2. The operating rate calculation unit 155 then detects the length of this operating period T30 of the extraction machine 130 as the actual time length RW.

[0309] As shown in Figure 7, the utilization rate calculation unit 155 calculates the utilization rate (actual utilization rate W) of the extraction machine 130 in the manufacturing cycle by dividing the actual time length RW of the extraction machine 130's operating period T30 by the actual time length RB of the second evaluation period T20 (RW / RB). This actual utilization rate W is stored in the storage unit 152 of the computer 150.

[0310] (Operating rate determination unit) The operating rate determination unit 156 compares the reference value JW for the operating rate of the extraction machine 130 with the detected value (actual operating rate W), and determines the occurrence of energy waste during the second evaluation period T20 based on the comparison result.

[0311] The memory unit 152 has a reference value JW for the actual operating rate W of the extraction machine 130 stored in advance. In this embodiment, the reference value JW is determined in advance through verification of the operating performance data of the manufacturing apparatus 100 by the inventor.

[0312] In this embodiment, the operating rate of the drawing machine 130 is predetermined from the operating performance data of the manufacturing apparatus 100, which enables the amount of energy consumed during the second evaluation period T20 to be appropriately reduced. The memory unit 152 stores a value determined based on this operating rate as a reference value JW for the operating rate of the drawing machine 130. Specifically, the memory unit 152 pre-stores the relationship REW between the amount of metal pipe material manufactured in the manufacturing cycle VL, the type of metal pipe material TY, and the reference value JW corresponding to the amount of material manufactured VL and type TY. This relationship REW is stored in the memory unit 152, for example, as a calculation map.

[0313] When the operating rate determination unit 156 determines whether energy consumption waste has occurred for the second evaluation period T20, it calculates a reference value JW from the above-mentioned relationship REW based on the amount VL and type TY of the metal pipe material to be manufactured. This calculated reference value JW is then used for comparison with the actual operating rate W. In this embodiment, the amount VL and type TY of the metal pipe material to be manufactured stored in the storage unit 141 of the management system 140 are used to calculate the reference value JW. Specifically, based on the second evaluation period T20, the amount VL and type TY of the metal pipe material to be manufactured during the second evaluation period T20 are identified from the information stored in the storage unit 141. These identified amounts VL and type TY are then used to calculate the reference value JW.

[0314] (Determination based on the actual operating rate W of the extraction machine 130) The process of determining the occurrence of energy waste during the second evaluation period T20 based on the actual operating rate W of the extraction machine 130 is performed by the computer 150 as follows.

[0315] The operating rate determination unit 156 reads the actual operating rate W of the extraction machine 130, which has been detected by the operating rate calculation unit 155 and stored in the storage unit 152, and also reads a reference value JW for the operating rate of the extraction machine 130, which has been pre-stored in the storage unit 152.

[0316] In this embodiment, the reference value JW is defined as 0.8 times the standard value of the operating rate of the extraction machine 130 obtained from the operational performance data. The standard value is the operating rate of the extraction machine 130 that is suitable for reducing energy consumption. As the standard value, the operating rate of the extraction machine 130 when the energy intensity is moderately low during the second evaluation period T20 can be adopted, or the highest operating rate within the feasible range among the values ​​(operating rates) included in the operational performance data can be adopted. Alternatively, as the standard value, the operating rate of the extraction machine 130 when the energy intensity was good can be adopted, or the highest operating rate (or an operating rate close to it) in the operational performance data can be adopted.

[0317] Subsequently, the operating rate determination unit 156 determines whether the actual operating rate W is less than or equal to the reference value JW. If it is determined that the actual operating rate W is equal to or greater than the reference value JW, it is determined that the actual operating rate W is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual operating rate W is less than the reference value JW, it is determined that the actual operating rate W is lower than the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the operating rate of the extraction machine 130 is low, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption during the second evaluation period T20.

[0318] In this embodiment, the second evaluation period T20 corresponds to one manufacturing cycle. If an abnormality is detected during the evaluation of the second evaluation period T20 (specifically, the operating rate of the drawing machine 130), it is determined that there is a possibility that some kind of trouble occurred during one manufacturing cycle.

[0319] In this embodiment, the actual operating rate W of the extraction machine 130 is stored in the storage unit 152 of the computer 150, along with the judgment result (normal or abnormal) regarding the operating rate of the extraction machine 130. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the operating rate of the extraction machine 130 is abnormal, the color (text color or background color) of the field displaying the actual operating rate W is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the operating rate of the extraction machine 130 is normal, the color (text color or background color) of the field displaying the actual operating rate W is set to a less conspicuous color (for example, white).

[0320] The computer 150 is capable of executing a determination program that determines the occurrence of energy waste in the second evaluation period T20 based on the energy consumption per unit of operation of the process equipment. The computer 150 has a unit consumption calculation unit 157 and a unit consumption determination unit 158 ​​as functional units.

[0321] (Unit Cost Calculation Unit) The unit intensity calculation unit 157 calculates the energy intensity for the second evaluation period T20 by accumulating the power consumption of the process equipment during the second evaluation period T20 and dividing the accumulated value by the production volume VL during the second evaluation period T20.

[0322] First, the unit consumption calculation unit 157 calculates the following energy consumption amounts AX, BX, CX, DX, EX, FX, and GX. (Energy Consumption AX) The cumulative power consumption of the feeder 110 during the second evaluation period T20.

[0323] (Energy Consumption BX) The cumulative power consumption of the shot blast 120 during the second evaluation period T20. (Energy Consumption CX) The cumulative power consumption of the extraction machine 130 during the second evaluation period T20.

[0324] (Energy Consumption DX) The cumulative value of power consumption by the extraction section 131 during the second evaluation period T20. (Energy Consumption EX) The cumulative power consumption of the extraction motor 134 during the second evaluation period T20.

[0325] (Energy Consumption FX) The cumulative power consumption by the straightening unit 132 during the second evaluation period T20. (Energy Consumption GX) The cumulative power consumption of the straightening motor 137 during the second evaluation period T20.

[0326] Then, as shown in Figure 8, the unit consumption calculation unit 157 calculates the energy intensity for the equipment described in (B-1) to (B-6) below, based on the above-mentioned energy consumption amounts AX to GX and the amount of metal pipe material manufactured VL stored in the management system 140. The calculation method of the energy intensity for each piece of equipment will be explained in detail below.

[0327] (B-1) Multiple types of process equipment (feeder 110, shot blaster 120, and drawing machine 130). The unit consumption calculation unit 157 calculates the energy consumption unit (hereinafter referred to as the actual unit consumption RB1) for multiple types of process equipment by dividing the sum of the energy consumption amounts AX, BX, and CX by the production amount VL ([AX+BX+CX] / VL).

[0328] (B-2) Extraction machine 130. The unit intensity calculation unit 157 calculates the energy intensity of the drawing machine 130 (hereinafter referred to as the actual unit intensity RB2) by dividing the energy consumption amount CX by the production amount VL (CX / VL).

[0329] (B-3) Pulling section 131. The unit intensity calculation unit 157 calculates the energy intensity of the extraction unit 131 (hereinafter referred to as the actual unit intensity RB3) by dividing the energy consumption amount DX by the production amount VL (DX / VL).

[0330] (B-4) Extraction motor 134. The unit consumption calculation unit 157 calculates the energy consumption amount EX divided by the production amount VL (EX / VL) as the energy unit consumption of the extraction motor 134 (hereinafter referred to as the actual unit consumption RB4).

[0331] (B-5) Correction Department 132. The unit intensity calculation unit 157 calculates the energy intensity (hereinafter referred to as the actual unit intensity RB5) of the correction unit 132 by dividing the amount of energy consumed FX by the amount of production VL (FX / VL).

[0332] (B-6) Correction motor 137. The unit consumption calculation unit 157 calculates the energy consumption amount GX divided by the production amount VL (GX / VL) as the energy unit consumption of the straightening motor 137 (hereinafter referred to as the actual unit consumption RB6).

[0333] (Unit cost determination unit) The unit intensity determination unit 158 ​​compares the second reference values ​​(JB1 to JB6) and the calculated values ​​(actual unit intensity RB1 to RB6) for the energy intensity of each of the above devices. Based on the comparison results, the unit intensity determination unit 158 ​​determines whether any energy waste occurred during the second evaluation period T20.

[0334] The memory unit 152 stores in advance second reference values ​​(JB1 to JB6) for energy intensity for each of the above-mentioned devices. In this embodiment, the second reference values ​​(JB1 to JB6) are determined in advance through verification of the operating performance data of the manufacturing apparatus 100 by the inventor. In this embodiment, the memory unit 152 corresponds to the unit intensity reference memory unit.

[0335] In this embodiment, the energy intensity of each device that can moderately reduce the energy consumption of each device during the second evaluation period T20 is predetermined from the operating performance data of the manufacturing equipment 100. The memory unit 152 stores values ​​determined based on these energy intensity as second reference values ​​(JB1 to JB6) for the actual unit (RB1 to RB6).

[0336] In this embodiment, the second reference values ​​(JB1 to JB6) are defined as values ​​obtained by multiplying the standard values ​​of the energy intensity (values ​​corresponding to the actual energy intensity RB1 to RB6) of each device, which are obtained from the operational performance data, by 1.2. The standard value is the energy intensity at which energy consumption is moderately low. As the standard value, the energy intensity at which the energy intensity is moderately low during the second evaluation period T20 can be adopted. Alternatively, as the standard value, the smallest value within the range achievable in a series of manufacturing processes from the values ​​(energy intensity) included in the operational performance data can be adopted. In addition, as the standard value, the energy intensity at which the energy intensity was good during the second evaluation period T20 can be adopted, or the minimum value of the energy intensity in the operational performance data, or a value close to it, can be adopted.

[0337] Furthermore, the memory unit 152 pre-stores the relationship REB between the type TY of metal pipe material manufactured in the manufacturing cycle and the corresponding second reference values ​​(JB1 to JB6) for that type TY. This relationship REB is stored in the memory unit 152, for example, as a calculation map.

[0338] When the unit consumption determination unit 158 ​​performs a determination of whether energy waste has occurred in the second evaluation period T20, it calculates second reference values ​​(JB1 to JB6) from the above-mentioned relationship REB based on the type TY of the metal pipe material. The unit consumption determination unit 158 ​​then uses these calculated second reference values ​​(JB1 to JB6) for comparison with the actual unit consumption (RB1 to RB6). In this embodiment, the type TY of the metal pipe material stored in the storage unit 152 of the management system 140 described above is used to calculate the second reference values ​​(JB1 to JB6). Specifically, based on the second evaluation period T20, the production quantity VL and type TY of the metal pipe material to be manufactured in the second evaluation period T20 are identified from the information stored in the storage unit 141. The identified production quantity VL and type TY are then used to calculate the second reference values ​​(JB1 to JB6).

[0339] In this embodiment, the relationship REB stored in the storage unit 152 of the computer 150 corresponds to a fifth relationship with the type of product manufactured in a series of manufacturing processes and a second reference value that corresponds to the same type.

[0340] (Determination based on actual unit costs RB1~RB6) In the system of this embodiment, the computer 150 performs the following process to determine the occurrence of energy waste in the second evaluation period T20 based on the actual unit consumption (RB1 to RB6).

[0341] In this process, first, the actual unit values ​​(RB1~RB6) detected by the unit value calculation unit 157 and stored in the storage unit 152 are read. Then, based on the type of metal pipe material TY, a second reference value (JB1~JB6) is calculated from the above-mentioned relationship REB.

[0342] Subsequently, it is determined whether the actual energy consumption (RB1~RB6) is greater than the second reference value (JB1~JB6). If it is determined that the actual energy consumption (RB1~RB6) is less than or equal to the second reference value (JB1~JB6), the energy consumption is deemed to be within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual energy consumption (RB1~RB6) is greater than the second reference value (JB1~JB6), the energy consumption is deemed to have exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the energy consumption in the second evaluation period T20 is large, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the same second evaluation period T20.

[0343] In this embodiment, this determination process is performed for each of the devices described in (B-1) to (B-6) above. The execution method of the determination process in each device will be described in detail below.

[0344] (B-1) Multiple types of process equipment. In the judgment process for multiple types of process equipment, it is determined whether the actual unit cost RB1 is greater than the second reference value JB1. If it is determined that the actual unit cost RB1 is less than or equal to the second reference value JB1, it is determined that the energy unit costs of the multiple types of process equipment are within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual unit cost RB1 is greater than the second reference value JB1, it is determined that the energy unit costs of the multiple types of process equipment have exceeded the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the energy unit costs of the multiple types of process equipment are high, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption somewhere in the multiple types of process equipment.

[0345] In this embodiment, the actual unit cost RB1 is stored in the storage unit 152 of the computer 150 along with the judgment results (normal judgment or abnormal judgment) for multiple types of process equipment. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for multiple types of process equipment is an abnormal judgment, the color (text color or background color) of the field for displaying the actual unit cost RB1 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for multiple types of process equipment is a normal judgment, the color (text color or background color) of the field for displaying the actual unit cost RB1 is set to a less conspicuous color (for example, white).

[0346] (B-2) Extraction machine 130. In the judgment process for the drawing machine 130, it is determined whether the actual unit cost RB2 is greater than the second reference value JB2. If it is determined that the actual unit cost RB2 is less than or equal to the second reference value JB2, the energy unit cost of the drawing machine 130 is considered to be within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual unit cost RB2 is greater than the second reference value JB2, the energy unit cost of the drawing machine 130 is considered to be greater than the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the energy unit cost of the drawing machine 130 is high, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the operation of the drawing machine 130.

[0347] In this embodiment, the actual unit consumption RB2 is stored in the storage unit 152 of the computer 150 along with the judgment result (normal or abnormal) for the energy consumption of the drawing machine 130. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the energy consumption of the drawing machine 130 is abnormal, the color (text color or background color) of the field displaying the actual unit consumption RB2 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the energy consumption of the drawing machine 130 is normal, the color (text color or background color) of the field displaying the actual unit consumption RB2 is set to a less conspicuous color (for example, white).

[0348] (B-3) Pulling section 131. In the determination process for the extraction unit 131, it is determined whether the actual unit consumption RB3 is greater than the second reference value JB3. If it is determined that the actual unit consumption RB3 is less than or equal to the second reference value JB3, it is determined that the energy unit consumption of the extraction unit 131 is within the acceptable range, and a normal determination is made. On the other hand, if it is determined that the actual unit consumption RB3 is greater than the second reference value JB3, it is determined that the energy unit consumption of the extraction unit 131 has exceeded the acceptable range, and an abnormal determination is made. Thus, according to this embodiment, it is possible to determine that the energy unit consumption of the extraction unit 131 is large, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the operation of the extraction unit 131.

[0349] In this embodiment, the actual unit consumption RB3 is stored in the storage unit 152 of the computer 150 along with the judgment result (normal or abnormal) for the energy consumption of the extraction unit 131. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the energy consumption of the extraction unit 131 is abnormal, the color (text color or background color) of the field displaying the actual unit consumption RB3 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result for the energy consumption of the extraction unit 131 is normal, the color (text color or background color) of the field displaying the actual unit consumption RB3 is set to a less conspicuous color (for example, white).

[0350] (B-4) Extraction motor 134. In the determination process for the extraction motor 134, it is determined whether the actual energy consumption RB4 is greater than the second reference value JB4. If it is determined that the actual energy consumption RB4 is less than or equal to the second reference value JB4, the energy consumption of the extraction motor 134 (actual energy consumption RB4) is within the acceptable range, and a normal determination is made. On the other hand, if it is determined that the actual energy consumption RB4 is greater than the second reference value JB4, the energy consumption of the extraction motor 134 is greater than the acceptable range, and an abnormal determination is made. Thus, according to this embodiment, it is possible to determine that the energy consumption of the extraction motor 134 is large, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the operation of the extraction motor 134.

[0351] In this embodiment, the actual unit consumption RB4 is stored in the storage unit 152 of the computer 150 along with the judgment result (normal or abnormal) regarding the energy consumption of the extraction motor 134. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result regarding the energy consumption of the extraction motor 134 is abnormal, the color (text color or background color) of the field displaying the actual unit consumption RB4 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result regarding the energy consumption of the extraction motor 134 is normal, the color (text color or background color) of the field displaying the actual unit consumption RB4 is set to a less conspicuous color (for example, white).

[0352] (B-5) Correction Department 132. In the judgment process for the straightening unit 132, it is determined whether the actual unit value RB5 is greater than the second reference value JB5. If it is determined that the actual unit value RB5 is less than or equal to the second reference value JB5, the energy unit value (actual unit value RB5) of the straightening unit 132 is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual unit value RB5 is greater than the second reference value JB5, the energy unit value of the straightening unit 132 is greater than the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the energy unit value of the straightening unit 132 is large, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the operation of the straightening unit 132.

[0353] In this embodiment, the actual unit consumption RB5 is stored in the storage unit 152 of the computer 150 along with the judgment result (normal or abnormal) of the energy unit consumption of the straightening unit 132. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result of the energy unit consumption of the straightening unit 132 is abnormal, the color (text color or background color) of the field for displaying the actual unit consumption RB5 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result of the energy unit consumption of the straightening unit 132 is normal, the color (text color or background color) of the field for displaying the actual unit consumption RB5 is set to a less conspicuous color (for example, white).

[0354] (B-6) Correction motor 137. In the judgment process for the straightening motor 137, it is determined whether the actual energy consumption RB6 is greater than the second reference value JB6. If it is determined that the actual energy consumption RB6 is less than or equal to the second reference value JB6, the energy consumption of the straightening motor 137 (actual energy consumption RB6) is within the acceptable range, and a normal judgment is made. On the other hand, if it is determined that the actual energy consumption RB6 is greater than the second reference value JB6, the energy consumption of the straightening motor 137 is greater than the acceptable range, and an abnormal judgment is made. Thus, according to this embodiment, it is possible to determine that the energy consumption of the straightening motor 137 is large, and based on that determination, it is possible to determine that there is a possibility of wasted energy consumption in the operation of the straightening motor 137.

[0355] In this embodiment, the actual unit consumption RB6 is stored in the storage unit 152 of the computer 150 along with the judgment result (normal or abnormal) regarding the energy consumption of the straightening motor 137. When various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result regarding the energy consumption of the straightening motor 137 is abnormal, the color (text color or background color) of the field displaying the actual unit consumption RB6 is set to a conspicuous color (for example, red). On the other hand, when various information related to manufacturing in each manufacturing cycle is displayed on the display device 151, if the judgment result regarding the energy consumption of the straightening motor 137 is normal, the color (text color or background color) of the field displaying the actual unit consumption RB6 is set to a less conspicuous color (for example, white).

[0356] (Effects and Benefits) According to this embodiment, the following effects and advantages can be obtained. (10) A first evaluation period T10 is defined for a series of manufacturing processes for producing metal pipes. The time length detection unit 153 detects the length of the first evaluation period T10 as the actual time length RA. The storage unit 152 has a first reference value JA for the length of the first evaluation period T10 stored in advance. The time length determination unit 154 determines whether there is any wasted energy consumption in the first evaluation period T10 based on the result of comparing the actual time length RA with the first reference value JA.

[0357] Normally, there is an appropriate time length for the manufacturing process in the manufacturing apparatus 100 to minimize energy consumption in the production of metal pipes. Therefore, if the time length of the manufacturing process in the manufacturing apparatus 100 is long, it can be said that there is a possibility of wasted energy consumption in the manufacturing apparatus 100. In this embodiment, the actual time length RA, which is a detected value for the time length of the first evaluation period T10, is compared with a first reference value JA for the same time length of the first evaluation period T10 that is stored in advance. From the comparison result, it can be determined that the first evaluation period T10 is long, and based on this determination, it can be decided that there is a possibility of wasted energy consumption in the first evaluation period T10. Thus, according to this embodiment, it is possible to determine whether there is wasted energy consumption in the production of metal pipes.

[0358] (11) The memory unit 152 stores a relationship REA that includes a third relationship between the amount of metal pipe material to be manufactured in a series of manufacturing processes VL and a first reference value JA corresponding to that amount VL. The time length determination unit 154 calculates the first reference value JA from the relationship REA based on the amount of metal pipe material to be manufactured VL, and uses the first reference value JA as a comparison target with the actual time length RA.

[0359] As the amount of metal pipe material produced in a series of manufacturing processes increases, the duration of those processes also increases. In response to these changes in the duration of the manufacturing processes, the duration of the first evaluation period T10 and the first reference value JA for that duration also change. According to this embodiment, the first reference value JA can be determined according to the above-mentioned production amount VL. Therefore, based on this first reference value JA, it is possible to accurately determine the amount of energy waste related to the production of metal pipe material in accordance with the production amount VL of the metal pipe material.

[0360] (12) The manufacturing apparatus 100 is used in sequence to manufacture multiple types of metal pipes. The memory unit 152 stores a relationship REA that includes a fourth relationship between the type TY of the metal pipe manufactured in a series of manufacturing processes and a first reference value JA that corresponds to that type TY. The time length determination unit 154 calculates the first reference value JA from the relationship REA based on the type TY of the metal pipe manufactured in a series of manufacturing processes, and uses this first reference value JA as a comparison target with the actual time length RA.

[0361] If the type TY of metal pipe material manufactured in a series of manufacturing processes differs, the duration of those processes will also differ. In response to these changes in the duration of the manufacturing processes, the duration of the first evaluation period T10 and the first reference value JA for that duration will also change. According to this embodiment, the first reference value JA can be determined according to the type TY of metal pipe material. Therefore, based on this first reference value JA, it is possible to accurately determine the amount of waste in energy consumption related to the manufacturing of metal pipe material in a manner that corresponds to the type TY of metal pipe material.

[0362] (13) If the actual time length RA of the first evaluation period T10 is greater than the first reference value JA, an abnormality can be determined, as the actual time length RA has exceeded the acceptable range.

[0363] (14) The feeder 110 and the extractor 130 are equipped with current sensors 160 and 162 for detecting current consumption. The first evaluation period T10 is determined based on the changes in current consumption detected by the current sensors 160 and 162. According to this embodiment, by adding the current sensors 160 and 162, the first evaluation period T10 can be accurately defined according to the actual operating mode of the feeder 110 and the extractor 130.

[0364] (15) A second evaluation period T20 is defined for a series of manufacturing processes for producing metal pipes. The unit cost calculation unit 157 defines the second evaluation period T20 based on the changes in current consumption detected by current sensors 160 and 162. The unit cost calculation unit 157 calculates the energy cost for manufacturing metal pipes based on the energy consumption of the manufacturing equipment 100 (specifically, each component of the manufacturing equipment 100) and the amount of metal pipes produced by the manufacturing equipment 100, VL, during the second evaluation period T20.

[0365] In the manufacturing apparatus 100, metal pipes are produced through the operation of multiple types of process equipment in a series of manufacturing processes. Therefore, according to this embodiment, it is possible to identify the operating state of the manufacturing apparatus 100 based on the operating state of each process equipment, specifically, the relationship between the power consumption of each process equipment. Based on the identified operating state of the manufacturing apparatus 100, a second evaluation period T20, which is a specific period in the series of manufacturing processes for producing metal pipes, can be determined. By determining the second evaluation period T20 in this way, the energy intensity required for the production of metal pipes during the second evaluation period T20 can be calculated based on the energy consumption of each piece of equipment and the amount of metal pipes produced VL during the second evaluation period T20. This energy intensity then allows for the evaluation of the energy efficiency of the manufacturing apparatus 100.

[0366] (16) The manufacturing apparatus 100 has a management system 140. The storage unit 141 of the management system 140 stores information including the amount VL, type TY, and manufacturing period of the metal pipe material manufactured in the manufacturing cycle for each manufacturing cycle. According to this embodiment, based on the first evaluation target period T10, the type TY and amount VL of the metal pipe material to be manufactured in the first evaluation target period T10 can be identified from the above information stored in the management system 140. Then, using the type TY and amount VL, it is possible to determine whether waste has occurred in terms of energy consumption related to the manufacturing of the metal pipe material.

[0367] (17) The memory unit 152 has in advance stored second reference values ​​(JB1 to JB6) for the energy intensity during the second evaluation period T20. The unit intensity calculation unit 157 calculates the actual unit intensity (RB1 to RB6) during the second evaluation period T20. The unit intensity determination unit 158 ​​determines that there is waste in energy consumption during the second evaluation period T20 if the actual unit intensity (RB1 to RB6) is greater than the second reference values ​​(JB1 to JB6).

[0368] According to this embodiment, by comparing the actual unit values ​​(RB1 to RB6) with the second reference values ​​(JB1 to JB6), it is possible to determine that the energy unit values ​​in the second evaluation period T20 have increased. Based on this determination, it is possible to conclude that there is a possibility of wasted energy consumption in the second evaluation period T20. Thus, according to this embodiment, it is possible to determine the occurrence of wasted energy consumption in the manufacturing of metal pipes based on the energy unit values ​​in the second evaluation period T20.

[0369] (18) The manufacturing apparatus 100 has a management system 140. The management system 140 stores information including the type TY of the metal pipe material and the production quantity VL. The storage unit 152 stores the relationship REB between the type TY of the metal pipe material manufactured in a series of manufacturing processes and the corresponding second reference values ​​(JB1 to JB6). The unit cost calculation unit 157 calculates the actual unit costs RB1 to RB6 based on the production quantity VL stored in the management system 140. The unit cost determination unit 158 ​​calculates the second reference values ​​(JB1 to JB6) from the relationship REB based on the type TY stored in the management system 140, and uses these second reference values ​​(JB1 to JB6) as a comparison target with the actual unit costs (RB1 to RB6). According to this embodiment, by using the type TY of the metal pipe material and the production quantity VL stored in the management system 140, it is possible to calculate the energy unit cost for manufacturing the metal pipe material and to determine whether waste occurs in the energy consumption for manufacturing the metal pipe material.

[0370] (19) According to this embodiment, based on the second evaluation period T20, the type TY and production quantity VL of metal pipes to be manufactured during the second evaluation period T20 can be identified from the information stored in the management system 140. Then, using these types TY and production quantity VL, the energy intensity required for the manufacture of metal pipes can be calculated, and the waste of energy consumption required for the manufacture of metal pipes can be determined.

[0371] (Example of change) Furthermore, the second embodiment described above can be implemented with the following modifications. The second embodiment described above and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0372] The computer 150 may store a standard value (standard value) for the length of the first evaluation period T10 in its memory unit 152. In this configuration, the memory unit 152 corresponds to the standard value memory unit. Any predetermined value can be adopted as the standard value. Alternatively, the standard value could be the length of the first evaluation period T10 when the energy intensity in that period is reasonably low, or the shortest feasible length among the values ​​(lengths) included in the operating performance data. In addition, the standard value could be the length of the first evaluation period T10 when the energy intensity was good, or the shortest length (or a length close to it) in the operating performance data. Furthermore, during the manufacturing of metal pipes by the manufacturing apparatus 100, the first evaluation period T10 (hereinafter referred to as the standard period) determined by the above standard value may be displayed on the display device 151 of the computer 150 to inform the user. In this configuration, the display device 151 corresponds to the notification unit.

[0373] With this configuration, the user can understand the standard period, which is the typical duration for the first evaluation period T10, based on the information displayed (notified) on the display device 151 during the manufacturing of metal pipes by the manufacturing equipment 100. This allows the user to understand the difference between the standard period and the actual first evaluation period T10, and to control the operation of multiple types of process equipment while confirming the standard period. With the above configuration, it is possible to support the efficient operation of the manufacturing equipment 100 by the user in this way. As a configuration for notifying the user of the standard period, a configuration in which the standard period is output by voice using the speaker of the computer 150 may be adopted.

[0374] The method of setting the first reference value JA for the duration of the first evaluation period T10, and the method of executing the judgment process based on the first reference value JA, can be arbitrarily changed. For example, the standard duration of the first evaluation period T10 can be set as the first reference value JA. In this case, the judgment process can be executed such that an abnormality is determined when the difference between the actual duration of the first evaluation period T10 and the first reference value JA exceeds a predetermined level.

[0375] The method for setting the reference value JW for the operating rate of the extraction machine 130, and the method for executing the judgment process based on the reference value JW, can be arbitrarily changed. For example, the reference value JW can be set to a standard value for the operating rate of the extraction machine 130. In this case, the judgment process can be executed such that an abnormality is determined when the difference between the actual operating rate W of the extraction machine 130 and the reference value JW exceeds a predetermined level.

[0376] The method of setting the second reference values ​​(JB1~JB6) for the energy intensity of each device during the second evaluation period T20, and the method of executing the judgment process based on the second reference values ​​(JB1~JB6), can be arbitrarily changed. For example, the standard energy intensity of each device during the second evaluation period T20 can be set as the second reference values ​​(JB1~JB6). In this case, the judgment process can be executed such that an abnormality is determined when the difference between the actual energy intensity (RB1~RB6) and the second reference values ​​(JB1~JB6) exceeds a predetermined level.

[0377] In a manufacturing apparatus 100 that produces only metal pipes of the same type (same steel grade and shape), the first reference value JA may be calculated based on the amount of metal pipes produced VL without using the type of metal pipe TY. In this configuration, the storage unit 152 should pre-store the relationship between the amount of metal pipes produced VL in the manufacturing cycle and the first reference value JA corresponding to that amount VL.

[0378] In a manufacturing apparatus 100 that produces only one type of metal pipe material, the reference value JW may be calculated based on the amount of metal pipe material produced VL, without specifying the type of metal pipe material TY. In this configuration, the storage unit 152 should pre-store the relationship between the amount of metal pipe material produced VL in the manufacturing cycle and the reference value JW corresponding to that amount VL.

[0379] In a manufacturing apparatus 100 that produces only one type of metal pipe material, a certain value corresponding to the type TY of metal pipe material produced by the manufacturing apparatus 100 can be predetermined as a second reference value (JB1 to JB6).

[0380] In a manufacturing apparatus 100 that produces the same amount of metal pipe material in each manufacturing cycle, the first reference value JA may be calculated based on the type of metal pipe material TY, without using the amount of metal pipe material produced VL. In this configuration, the storage unit 152 should pre-store the relationship between the type of metal pipe material TY produced in the manufacturing cycle and the first reference value JA corresponding to that type of metal pipe material TY.

[0381] In a manufacturing apparatus 100 that produces the same amount of metal pipe material in each manufacturing cycle, the reference value JW may be calculated based on the type of metal pipe material TY, without using the amount of metal pipe material produced VL. In this configuration, the storage unit 152 should pre-store the relationship between the type of metal pipe material TY produced in the manufacturing cycle and the reference value JW corresponding to that type of metal pipe material TY.

[0382] In a manufacturing apparatus 100 that produces the same quantity of the same type of metal pipe material in each manufacturing cycle, a predetermined fixed value stored in the memory unit 152 may be used as the first reference value JA and the reference value JW.

[0383] The manufacturing apparatus 100 may be equipped with a product detection unit for detecting the type TY and production quantity VL of the metal pipe material produced by the manufacturing apparatus 100. For example, an image processing device can be used as the product detection unit. By analyzing an image of the pipe 102 captured by the image processing device, the type TY and production quantity VL of the metal pipe material produced by the manufacturing apparatus 100 can be detected.

[0384] In the above configuration, instead of the type TY and production quantity VL stored in the management system 140, the type TY and production quantity VL detected by the product detection unit can be used to perform various processes for determining the occurrence of waste in energy consumption. Examples of these processes include calculating the first reference value JA, the reference value JW, and the second reference values ​​(JB1 to JB6), and calculating the energy intensity of each device during the second evaluation period T20.

[0385] The type TY of metal pipe material to be manufactured in the manufacturing cycle may be identified based on the current consumption of the process equipment detected by the current sensor. In this case, the power consumption of the process equipment (specifically, the drawing machine 130) differs depending on the type TY of metal pipe material to be manufactured in the manufacturing equipment 100. With the above configuration, the type TY of metal pipe material to be manufactured by the manufacturing equipment 100 can be identified by capturing the difference in power consumption of the drawing machine 130. Then, based on the identified type TY of metal pipe material, various processes can be executed to determine whether any energy waste has occurred.

[0386] For example, the type of metal pipe material TY to be manufactured in the manufacturing cycle can be identified based on the current consumption of the drawing machine 130 detected by the current sensor 160. The process of identifying the type of metal pipe material TY can be performed by the computer 150 as follows. When the drawing process by the drawing machine 130 is performed in a stable state, the power consumption of the drawing machine 130 becomes approximately constant at a value suitable for the manufacture of metal pipe material. The computer 150 first detects the power consumption P of the drawing machine 130 when it becomes approximately constant at a value suitable for the manufacture of metal pipe material. The storage unit 152 has in advance stored the relationship between the power consumption P and the type of metal pipe material TY. Based on the power consumption P detected at this time, the computer 150 identifies the type of metal pipe material TY from the above relationship. In this configuration, the computer 150 corresponds to the type identification unit.

[0387] The process of calculating the energy intensity of the devices that make up the manufacturing apparatus 100, and the process of making a determination based on the actual unit intensity (RB1~RB6), may be performed only for some (1 to 5) of the devices described in (B-1) to (B-6).

[0388] The following processes can be omitted: one or two of the processes for determining waste occurrence during the first evaluation period T10, the process for determining based on the actual operating rate W of the extraction machine 130, and the process for determining based on the actual unit costs RB1 to RB6.

[0389] The VL of the metal tubing to be manufactured is not limited to the total weight of the metal tubing, but can also be the number of metal tubing pieces manufactured after being cut to a predetermined length by the post-processing device 103, or the amount of metal tubing processed (for example, the length of the metal tubing pieces processed).

[0390] • Current sensors 160-166 are not limited to those that are added to the manufacturing equipment 100 after it has been installed in the factory; sensors that are originally installed in the manufacturing equipment 100 can also be used.

[0391] If it is possible to detect an indicator value of the power consumption of the process equipment, then instead of current sensors 160-166, a power sensor that detects the power consumption itself, or a voltage sensor that detects the voltage as an indicator value of power consumption can be provided.

[0392] The energy efficiency evaluation support system according to the above embodiment can also be applied to a manufacturing apparatus having a drawing machine that produces metal rods (or metal wires) of a desired shape through drawing. [Explanation of Symbols]

[0393] 10 Manufacturing equipment 11 Extractor 14 Mixing device 15 Sterilizer 16 sterile tanks 17 Filling equipment 30 Washing device 33 Pump No. 1 40,80 Computers 41 Storage section 43 Target device identification section 45-hour length detection unit 46 Judgment section 47 Standard value storage unit 48 Hochi Department 50-59 Current Sensor 100 Manufacturing equipment 110 feeder 120 Shot Blast 121 Blast motor 130 Extraction Machine 131 Extraction section 132 Orthodontics Department 134 Extraction Motor 137 Correction motor 140 Management Systems 141 Storage section 150 Computers 151 Display equipment 152 Storage section 153 Time Length Detection Unit 154 Time Length Determination Unit 155 Operating Rate Calculation Unit 156 Operating Rate Determination Unit 157 Unit Cost Calculation Unit 158 Unit Cost Determination Unit 160~166 Current Sensor

Claims

1. This applies to manufacturing equipment that uses multiple types of process equipment to produce products. For a series of manufacturing processes that produce the aforementioned product, multiple evaluation periods are defined for evaluating the energy efficiency of the manufacturing equipment. A time length detection unit that individually detects the time lengths of multiple evaluation target periods as actual time lengths, A reference storage unit that pre-stores reference values ​​for the duration of the multiple evaluation periods, A determination unit that determines the occurrence of energy waste during the evaluation period based on the result of comparing the actual time length corresponding to the same evaluation period with the reference value, The system includes a process detection unit that detects the power consumption index values ​​of each of the aforementioned multiple types of process equipment, Based on the changes in the index value detected by the process detection unit, the plurality of evaluation periods are determined. The determination unit is an energy efficiency evaluation support system that determines that waste has occurred when the actual time length is greater than the reference value.

2. The manufacturing apparatus manufactures multiple products through the series of manufacturing processes described above. The reference storage unit stores a first relationship between the number of products manufactured in the series of manufacturing processes and the reference value corresponding to that number. The energy efficiency evaluation support system includes a production quantity detection unit that detects the number of products manufactured in the series of manufacturing processes, The determination unit calculates the reference value from the first relationship based on the number of units manufactured detected by the number of units manufactured, and uses the calculated reference value as a comparison target with the actual time length. The energy efficiency evaluation support system according to claim 1.

3. The manufacturing apparatus manufactures multiple types of the aforementioned products, The reference storage unit stores a second relationship between the type of product manufactured in the series of manufacturing processes and the reference value corresponding to that type. The determination unit calculates the reference value from the second relationship based on the type of product manufactured in the series of manufacturing processes, and uses the calculated reference value as a comparison target with the actual time length. The energy efficiency evaluation support system according to claim 1.

4. The manufactured product is a beverage product in a beverage container, The aforementioned multiple types of process equipment include a filling device for filling beverage containers with beverages. The aforementioned multiple evaluation periods are, The start-up period is the period from when the operation of the manufacturing apparatus for manufacturing the beverage product is started until the filling of the beverage by the filling apparatus is started, A filling period is the period during which the filling of the beverage by the filling device is performed, This includes a downtime which is the period from when the filling of the beverage by the filling device is completed until the operation of the manufacturing device for manufacturing the beverage product is completed. The energy efficiency evaluation support system according to claim 1.

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