Industrial equipment operation support system

Abstract

An industrial equipment operation support system (1) comprises: a plurality of environmental sensors (5) arranged on industrial equipment (2); a plurality of controllers (61) equipped on the industrial equipment (2); and a plurality of information processing devices (6) that are configured to acquire and accumulate environmental information detected by the environmental sensors (5) and work information generated by the controllers (61) and that have a hierarchical structure for transmitting the environmental information and the work information from a downstream side to an upstream side. The plurality of information processing devices (6) have: an information processing engine (31) that executes predetermined information processing on the acquired environmental information and work information in one or more hierarchies; an information accumulation platform (37) that accumulates the environmental information and work information which has been subjected to the predetermined information processing; a useful information generation engine (32) that generates useful information contributing to equipment operation using the environmental information and work information accumulated in the information accumulation platform (37); and a UI provision engine (33) that provides a user interface for displaying the useful information generated by the useful information generation engine (32) on a user terminal (40).

Description

Industrial equipment operation support system

[0001] This application claims priority to Japanese Patent Application No. 2024-127695, filed on August 2, 2024, the contents of which are incorporated herein by reference. The technology disclosed in this specification relates to an industrial facility operation support system.

[0002] 2. Description of the Related Art In the technical field related to industrial facilities, a maintenance management method such as that disclosed in Patent Document 1 is known.

[0003] Japanese Patent Application Laid-Open No. 2002-298270

[0004] When operating industrial facilities, for example, a certain level of proficiency is required of users (equipment operators), and there is a demand for technology that can support the operation of industrial facilities so that the industrial facilities can be operated smoothly.

[0005] The technology disclosed in this specification aims to support the operation of industrial facilities.

[0006] This specification provides an industrial equipment operation support system. The industrial equipment operation support system includes multiple environmental sensors installed in the industrial equipment, multiple controllers equipped in the industrial equipment, and multiple information processing devices configured to acquire and store environmental information detected by the environmental sensors and operation information generated by the controllers, and having a hierarchical structure for transmitting the environmental information and operation information from downstream to upstream. The multiple information processing devices include, at one or more hierarchical levels, an information processing engine that performs predetermined information processing on the acquired environmental information and operation information, an information accumulation platform that accumulates the environmental information and operation information that has undergone the predetermined information processing, a useful information generation engine that generates useful information contributing to equipment operation using the environmental information and operation information accumulated in the information accumulation platform, and a UI provision engine that provides a user interface for displaying the useful information generated by the useful information generation engine on a user terminal.

[0007] The technology disclosed in this specification supports the operation of industrial facilities.

[0008] FIG. 1 is a diagram schematically illustrating an industrial equipment operations support system according to an embodiment. FIG. 2 is a diagram schematically illustrating industrial machinery and demand equipment according to an embodiment. FIG. 3 is a hardware configuration diagram illustrating an information processing device according to an embodiment. FIG. 4 is a diagram for explaining an information processing device according to an embodiment. FIG. 5 is a functional block diagram illustrating an information processing device according to an embodiment. FIG. 6 is a diagram for explaining useful information according to an embodiment. FIG. 7 is a diagram for explaining user-suggested information according to an embodiment. FIG. 8 is a diagram for explaining recommended information according to an embodiment. FIG. 9 is a diagram for explaining processing of a performance value prediction engine according to an embodiment. FIG. 10 is a diagram illustrating an example of a portal page of the industrial equipment operations support system according to an embodiment. FIG. 11 is a diagram illustrating an example of a maintenance and maintenance page according to an embodiment. FIG. 12 is a diagram illustrating an example of an energy management page according to an embodiment. FIG. 13 is a diagram illustrating an example of a quality control page according to an embodiment. FIG. 14 is a diagram illustrating an example of a steam equipment group page according to an embodiment.

[0009] [1] Industrial equipment operation support system Fig. 1 is a diagram schematically illustrating an industrial equipment operation support system 1 according to an embodiment. The industrial equipment operation support system 1 acquires and accumulates environmental information and operation information of the industrial equipment 2 to support the operation of the industrial equipment 2. The industrial equipment operation support system 1 generates useful information that contributes to equipment operation using the environmental information and operation information of the industrial equipment 2. The industrial equipment operation support system 1 supports the operation of the industrial equipment 2 by providing useful information that contributes to equipment operation to a user of the industrial equipment 2.

[0010] A user of industrial equipment 2 refers to a person who owns or leases industrial equipment 2. A maintenance business operator for industrial equipment 2 provides a comprehensive equipment operation support service to the user through the industrial equipment operation support system 1 based on a contract concluded with the user of industrial equipment 2. The comprehensive equipment operation support service aims to create an environment in which the user can concentrate on their core business (main business related to the production of goods and the provision of services) and further maximize the performance of equipment operation by having the maintenance business operator take on various construction tasks for equipment maintenance and operate the equipment on their behalf.

[0011] The comprehensive facility operation support service may include, for example, the following services: (1) Provision of hardware and software for connecting the industrial facility 2 and maintenance providers via information and communication technology (ICT). (2) Provision of a user interface (UI) for connecting users and maintenance providers via ICT. (3) Provision of content for visualizing operational performance information (operational performance by maintenance providers) of the industrial facility 2. (4) Provision of content for visualizing condition information (current status and history) of the industrial facility 2. (5) Provision of before-maintenance (condition-based maintenance and time-based maintenance) and after-maintenance for the industrial facility 2. (6) Provision of notifications regarding the daily management of the industrial facility 2. (7) Professional proposals regarding smart operation (labor reduction and autonomy) and added value improvement (low carbonization and SDGs) of the industrial facility 2.

[0012] Equipment refers to machinery installed in buildings such as factories or in vehicles, ships, etc. Equipment is a general term for machines, instruments, and appliances. Industrial equipment 2 refers to machinery and appliances used to produce goods or provide services. Industrial equipment 2 includes utility conversion machinery and appliances that convert primary utilities into secondary utilities that can be used by demand equipment 8, a utility distribution network that delivers the secondary utilities, and demand-end machinery and appliances that use the primary utilities or secondary utilities. Demand equipment 8 consisting of demand-end machinery and appliances is one aspect of industrial equipment 2.

[0013] Utilities refer to energy sources or fluids required for industrial activities. Examples of primary utilities input to utility conversion machines include fuel (gas, oil), electricity, and raw water. Examples of secondary utilities output from industrial equipment 2 include heat transfer media (steam, thermal oil, hot water, cold water), compressed air, electricity, and treated water.

[0014] The demand facility 8 uses the secondary utilities output from the industrial facility 2. The demand facility 8 uses the heat medium as a heat source for various production processes or air conditioning. The demand facility 8 uses compressed air as a power source for pneumatic equipment or pneumatic tools. The demand facility 8 uses electricity as a power source for electrically powered equipment, electrically powered tools, or lighting. The demand facility 8 uses treated water as process water for food, cosmetics, pharmaceuticals, or semiconductor manufacturing.

[0015] Examples of utility conversion machinery and equipment include thermal equipment, air compressors, generators, and water treatment equipment. Examples of thermal equipment include combustion-type steam boilers, electric heater steam boilers, heat recovery steam boilers, combustion-type heat medium boilers, combustion-type hot water boilers, electric heater hot water boilers, heat recovery hot water boilers, electric heat pumps, electric chillers, electric heat pump chillers, and flash steam generators. Examples of air compressors include electric air compressors, heat recovery electric air compressors, and steam-driven air compressors. Examples of generators include mono-generation generators and co-generation generators. Examples of water treatment equipment include reverse osmosis membrane devices, water softeners, deoxygenators, and various filtration devices.

[0016] FIG. 2 is a diagram schematically illustrating an industrial facility 2 and a demand facility 8 according to an embodiment. The industrial facility 2 converts a primary utility into a secondary utility that can be used by the demand facility 8. The primary utility is supplied to the industrial facility 2 via a supply path 21. The secondary utility sent from the industrial facility 2 is delivered to the demand facility 8 via a transport path 22. The secondary utility that has passed through the demand facility 8 is discharged via a discharge path 23. The transport path 22 may be formed as a transport piping network. In addition, auxiliary facilities for medium storage (such as a steam header, a hot water tank, and a cold water tank) may be provided along the transport path 22.

[0017] The industrial equipment 2 may also include medical machinery and equipment used in a series of processes from receiving items to be cleaned and sterilized to discharging them, laundry machinery and equipment used in a series of processes from collecting items to shipping them, food and beverage manufacturing machinery and equipment used in a series of processes from receiving raw materials to preserving the products, vehicles that transport cargo unmanned between multiple points set up within a business premises, navigation machinery and equipment mounted on ships such as cargo ships, etc.

[0018] Examples of medical equipment and instruments include washer and sterilizer. Examples of washer include vacuum boiling washer and ultrasonic washer. Examples of sterilizer include steam sterilizer and gas sterilizer. Medical equipment and instruments are installed in the central supply room of a medical institution.

[0019] Examples of laundry machines and appliances include washing machines, dryers, and finishing machines. Examples of washing machines include continuous washing machines, cold water washing machines, and dry cleaning machines. Examples of dryers include gas dryers and steam dryers. Examples of finishing machines include gas roll ironers and steam roll ironers. Laundry machines and appliances are installed in laundry factories.

[0020] Examples of machinery and equipment for producing food and beverages include thawing machines, cooking machines, cooling machines, and sterilizers. Examples of thawing machines include vacuum steam thawing machines, microwave thawing machines, high-frequency thawing machines, and running water thawing machines. Examples of cooking machines include steam kneaders, steam kettles, and saturated steam cookers. Examples of cooling machines include vacuum coolers, cold water coolers, and cold air coolers. Examples of sterilizers include retort sterilizers and pasteurizers. Machinery and equipment for producing food and beverages are installed in food factories and beverage factories.

[0021] Examples of autonomously driven automated guided vehicles include cart-type vehicles, forklift-type vehicles, and tow-type vehicles. Automated guided vehicles are used in various manufacturing plants.

[0022] Examples of navigational machinery and equipment include main engines (single-fuel / dual-fuel diesel engines), turbochargers (auxiliary engines), exhaust gas economizers (steam generators), shaft generators, steam turbine generators, binary generators, freshwater generators, BOG combustion boilers, and exhaust gas scrubbing equipment. Examples of cargo handling machinery and equipment include diesel generators, cranes, derricks, ballast water pumps, and ballast water treatment systems.

[0023] Returning to FIG. 1 , a business establishment 3 refers to an individual location where the production of goods or the provision of services is carried out as a business. The industrial facility 2 is installed in the business establishment 3. A factory 4 is set up in the business establishment 3 where goods are produced, etc. Examples of the factory 4 include a food factory, a beverage factory, a metal product factory, a plastic product factory, a textile factory, and a laundry factory. The industrial facility 2 is installed in the factory 4.

[0024] It should be noted that the establishment 3 that provides the service does not necessarily have to have a factory 4. The business conducted at the establishment 3 may include public health services. Examples of public health services include hospitals, clinics, and health centers. The establishment 3 may also include a food service center. The industrial equipment 2 may be installed on a ship used for maritime transportation services instead of the establishment 3.

[0025] In the example shown in FIG. 1 , there are three business establishments 3 operated by a certain business operator. The business establishments 3 include a first business establishment 3A, a second business establishment 3B, and a third business establishment 3C. A factory 4 is set up in the second business establishment 3B. The factory 4 set up in the second business establishment 3B includes a first factory 4A and a second factory 4B. Note that a factory 4 may be set up in one or both of the first business establishment 3A and the third business establishment 3C.

[0026] The industrial equipment 2 is installed in each of the first factory 4A and the second factory 4B. The data collection terminal 7 is installed in each of the first factory 4A and the second factory 4B. The data collection terminal 7 is a general term for devices in the business establishment 3 that are used for data collection.

[0027] The industrial equipment operation support system 1 comprises a plurality of environmental sensors 5 arranged in the industrial equipment 2, a plurality of controllers 61 equipped in the industrial equipment 2, and a plurality of information processing devices 6 configured to acquire and store environmental information detected by the environmental sensors 5 and operation information generated by the controllers 61.

[0028] The environmental sensors 5 detect environmental information of the industrial equipment 2. The environmental information of the industrial equipment 2 refers to the environmental state or conditions of the space in which the industrial equipment 2 operates. The environmental information of the industrial equipment 2 includes environmental information of the business establishment 3 (factory 4) in which the industrial equipment 2 is installed. The environmental information includes physical parameters of the main body of the industrial equipment 2 and its surroundings. Data detected by some of the environmental sensors 5 is used for the operation or control of the industrial equipment 2. Examples of the environmental sensors 5 include a temperature sensor, a humidity sensor, a pressure sensor, a water level sensor, a flow rate sensor, an electrical conductivity sensor (EC sensor), a power sensor, a distance sensor, an image sensor, and a force sensor.

[0029] The environmental sensor 5 is connected to the controller 61 of the industrial equipment 2 and the controller 61 of the data collection terminal 7 .

[0030] 2, the environmental sensor 5 is provided on the supply route 21 (on the primary utility side). The environmental sensor 5 is provided on the transport route 22 (on the secondary utility side). The environmental sensor 5 may be disposed closer to the industrial facility 2 or closer to the demand facility 8 on the transport route 22. The environmental sensor 5 may also be disposed on the discharge route 23 (downstream of the demand facility 8).

[0031] In an embodiment, the environmental information of the industrial facility 2 detected by the environmental sensor 5 includes input energy information and output energy information of the industrial facility 2. The input energy information includes the input amount of a primary utility. The output energy information includes the output amount of a secondary utility. The environmental information includes actual quality level information of a medium or article produced in the industrial facility 2.

[0032] The controller 61 has the function of controlling the operation of the industrial equipment 2 and controlling data collection. The controller 61 is mainly used to control the operation of machinery and equipment (heat equipment, water treatment equipment, water quality measurement equipment, etc.). The controller 61 is connected to environmental sensors 5 attached to the machinery and equipment. The controller 61 may also be configured as part of a data collection terminal 7 specialized in collecting information from environmental sensors 5 not attached to the machinery and equipment (environmental sensors that are retrofitted to machinery and equipment or retrofitted to a piping network, etc.).

[0033] The controller 61 is incorporated into the industrial equipment 2 and the data collection terminal 7. Examples of the controller 61 incorporated into the industrial equipment 2 include a microcomputer 61A (microcomputer) and a programmable logic controller 61B (PLC). In the embodiment, the industrial equipment 2 includes a first industrial equipment 2A in which the microcomputer 61A is disposed, and a second industrial equipment 2B in which the programmable logic controller 61B is disposed. An example of the controller 61 incorporated into the data collection terminal 7 is the microcomputer 61A.

[0034] The controller 61 of the industrial equipment 2 uses the environmental information collected from the environmental sensors 5 to control the operation of the industrial equipment 2 and records it for operational management. The controller 61 of the industrial equipment 2 may receive environmental information collected by a controller 61 incorporated in another industrial equipment 2 or the data collection terminal 7 and use the information to control the operation of its own equipment.

[0035] The controller 61 of the data collection terminal 7 is connected to each of the plurality of environmental sensors 5 scattered throughout the establishment 3. The controller 61 of the data collection terminal 7 is connected to the plurality of environmental sensors 5 of different types.

[0036] The controller 61 generates operation information of the industrial equipment 2. The controller 61 may generate the operation information of the industrial equipment 2 based on detection data of the environmental sensor 5. In the embodiment, the operation information of the industrial equipment 2 generated by the controller 61 includes the operation time of the industrial equipment 2 and whether or not there is an abnormality in the industrial equipment 2. The operation information includes actual operation time information linked to the normal state of the industrial equipment 2 and non-operation time information linked to the abnormal state. The operation information includes whether the condition of the industrial equipment 2 is good or bad. The operation information includes an abnormality notification signal that is transmitted by the controller 61 when a malfunction event occurs in the industrial equipment 2.

[0037] The condition of the industrial equipment 2 is detected by the environmental sensor 5. For example, when the condition of the industrial equipment 2 deteriorates, the detected value of the environmental sensor 5 is often a numerical value that deviates from the detected value of the environmental sensor 5 when the condition of the industrial equipment 2 is normal. Therefore, for example, multiple thresholds are set according to the deviation level of the detected value of the environmental sensor 5 from the normal value, and the controller 61 is configured to detect that there is a sign of an abnormality when the deviation level reaches a lower first threshold, and that an abnormality has occurred when the deviation level reaches a higher second threshold.

[0038] If the industrial equipment 2 is a steam boiler, the operation information relating to the condition includes scale adhesion information based on the water pipe temperature, feedwater pump performance information based on water level control inside the boiler, etc. If the industrial equipment 2 is a heat pump or chiller, the operation information relating to the condition includes refrigerant leak detection information, differential pressure information of the condenser and evaporator, etc. If the industrial equipment 2 is an air compressor, the operation information relating to the condition includes lubricant deterioration detection information, differential pressure information of filters, etc. If the industrial equipment 2 is an RO membrane device, the operation information relating to the condition includes permeation flux information of the membrane element, water quality information of the permeate, etc.

[0039] [2] Information Processing Device The industrial facility operation support system 1 has a plurality of information processing devices 6. The information processing devices 6 include a controller 61, an edge computer 62, a gateway 63, a guest computer 64, and a host computer 65.

[0040] 3 is a hardware configuration diagram showing an information processing device 6 according to an embodiment. The information processing device 6 includes a computer 10. Each of a controller 61, an edge computer 62, a gateway 63, a guest computer 64, and a host computer 65 includes a computer 10. The computer 10 includes a processor 11, a storage device 12, a communication interface 13, and an input / output interface 14. The information processing device 6 also includes a power supply device (not shown).

[0041] The processor 11 includes a CPU (Central Processing Unit). The processor 11 may also include a GPU (Graphics Processing Unit). The storage device 12 includes a recording medium that records computer programs and data in a manner that allows the processor 11 to read them. The storage device 12 includes on-board system memory such as RAM (Random Access Memory) or ROM (Read Only Memory), large-capacity flash memory such as an SD card or USB memory, and large-capacity storage such as an HDD (Hard Disk Drive) or SSD (Solid State Drive).

[0042] The communication interface 13 communicates via a communication network. Examples of communication networks include a local area network (LAN), a wide area network (WAN), and a commercial network such as the Internet. The local area network may be a wired LAN or a wireless LAN. The wide area network may include a mobile line or a satellite communication line. The computer 10 transmits data to an external computer via the communication network. The computer 10 receives data from an external computer via the communication network. The computer 10 is connected to an external device via the input / output interface 14.

[0043] The storage device 12 stores various software programs (engines and applications, which will be described later). The processor 11 reads the software programs from the storage device 12, loads them into the system memory, and executes processing in accordance with the software programs. In other words, the processor 11 can be considered to have multiple functional units, such as engines. The functions of the engines and the like of the processor 11 are realized by the software programs. The software programs may be distributed to the computer 10 via a communication network.

[0044] A software program that realizes a specific function on a computer is called an engine, and the functional unit of an engine is called a module. An engine may be installed on a computer as a single software package with all functions, but it is preferable that each functional unit of the engine is installed on a computer as a separate software module. If the functional unit of the engine is modularized, it becomes easier to update when functional modifications are made. Note that a software program prepared to allow an end user (mainly a customer who uses equipment) to perform a specific task on a computer is called an application, and can be distinguished from an engine in terms of purpose.

[0045] The environmental sensors 5 are connected to the input / output interface 14 of the controller 61. A plurality of environmental sensors 5 are connected to one controller 61. The controller 61 collects environmental information in real time from the environmental sensors 5. The communication interface 13 of the controller 61 transmits the real-time environmental information and real-time operation information to the edge computer 62 via a communication network (LAN).

[0046] The edge computer 62 is installed in the factory 4. One or more edge computers 62 are installed in each factory 4. The communication interface 13 of the edge computer 62 communicates with each of the multiple controllers 61 belonging to the factory 4 in which the edge computer 62 is located, via a communication network (LAN). The edge computer 62 receives environmental information and operation information from the controllers 61 via the communication network.

[0047] To be able to store a sufficient amount of information, the edge computer 62 has an on-board memory of around 5 GB as the storage device 12. The edge computer 62 may have an AI engine (neural network processing unit: NPU) to execute the learning phase and inference phase in machine learning.

[0048] The gateway 63 constitutes a connection node between the local area network and the Internet, and has performance and specifications equivalent to those of the edge computer 62. The gateway 63 is installed at the business establishment 3. One or more gateways 63 are installed at one business establishment 3. The communication interface 13 of the gateway 63 communicates with each of the multiple edge computers 62 belonging to the business establishment 3 where the gateway 63 is located, via a communication network (LAN). The gateway 63 receives environmental information and operation information from the edge computer 62 via the communication network. Note that if the factory 4 located at the business establishment 3 is a single building, the edge computer 62 and gateway 63 may be integrated into a single computer.

[0049] The guest computer 64 is located outside the business establishment 3. The guest computer 64 is installed, for example, at a regional base of a service provider that undertakes tasks such as status monitoring and maintenance inspection of the industrial equipment 2 installed at the business establishment 3. One guest computer 64 is installed at each management base. The guest computer 64 includes a local server. The communication interface 13 of the guest computer 64 communicates with a gateway 63 belonging to the business establishment 3 via a communication network (Internet). The guest computer 64 receives environmental information and operation information from the gateway 63 via the communication network. If a guest computer 64 is not installed, the gateway 63 and a host computer 65, which will be described later, will be connected via a communication network.

[0050] The host computer 65 is located outside the business establishment 3. The host computer 65 is installed, for example, at the headquarters of a service provider. The host computer 65 includes a cloud server. The communication interface 13 of the host computer 65 communicates with each of the multiple guest computers 64 via a communication network (the Internet). The host computer 65 receives environmental information and operation information from the guest computers 64 via the communication network.

[0051] [3] Hierarchical Structure FIG. 4 is a diagram illustrating an information processing device 6 according to an embodiment. The multiple information processing devices 6 have a hierarchical structure in which environmental information detected by the environmental sensor 5 and operation information generated by the controller 61 are transmitted from downstream to upstream. Of the multiple information processing devices 6, the controller 61 to which the environmental sensor 5 is connected is the most downstream (lower layer, lower) information processing device 6, the edge computer 62 is the downstream information processing device 6 next to the controller 61, the gateway 63 is the downstream information processing device 6 next to the edge computer 62, the guest computer 64 is the downstream information processing device 6 next to the gateway 63, and the host computer 65 is the most upstream (upper layer, upper) information processing device 6.

[0052] The information processing devices 6 are connected to each other via a communication network. A local area network is used as the communication network inside the building or ship, and a commercial wide area network such as the Internet or a mobile phone line is used as the communication network outside the building or ship. Satellite communication is used for communication between the ship and land.

[0053] Environmental information is detected by the environmental sensors 5. The controller 61, which is a lower-level information processing device in the hierarchical structure, acquires real-time environmental information from the environmental sensors 5. The real-time environmental information detected by the environmental sensors 5 and collected by the controller 61 is transmitted from the controller 61 to the edge computer 62 via the communication network. Real-time operation information generated by the controller 61 is also transmitted from the controller 61 to the edge computer 62 via the communication network. The environmental information and operation information transmitted to the edge computer 62 are transmitted from the edge computer 62 to the gateway 63 via the communication network. The environmental information and operation information transmitted to the gateway 63 are transmitted from the gateway 63 to the guest computer 64 via the communication network. The environmental information and operation information transmitted to the guest computer 64 are transmitted from the guest computer 64 to the host computer 65 via the communication network.

[0054] The controller 61 is a lower information processing device in the hierarchical structure. The edge computer 62, the gateway 63, and the guest computer 64 are intermediate information processing devices in the hierarchical structure. The host computer 65 is a higher information processing device in the hierarchical structure.

[0055] The lower information processing device functions as an IoT device to which an environmental sensor 5 is connected. The lower information processing device can transmit various environmental information and operation information to the intermediate information processing device. The intermediate information processing device functions as a relay between the lower information processing device and the upper information processing device. The intermediate information processing device can receive various environmental information and operation information from the lower information processing device and transmit the various environmental information and operation information to the upper information processing device. The upper information processing device can receive various environmental information and operation information from the intermediate information processing device. The upper information processing device has an information accumulation platform. The information accumulation platform is, for example, an open IoT operating system based on cloud computing, and is capable of systematically accumulating information aggregates, etc., as described below. Note that some or all of the functions realized by the information accumulation platform may be incorporated into the intermediate information processing device.

[0056] [4] Information Processing Device Figure 5 is a functional block diagram showing an information processing device 6 according to an embodiment. As shown in Figure 2, the information processing device 6 includes a computer 10 having a processor 11. The information processing device 6 includes an information processing engine 31, a useful information generation engine 32, a UI provision engine 33, a performance value prediction engine 34, a maintenance plan engine 35, a treatment content extraction engine 36, an information accumulation platform 37, and a database 38. Note that the database 38 may be a group of databases that handle a wide variety of information, or may be a component of the information accumulation platform 37.

[0057] A user terminal 40 is connected to the information processing device 6. Examples of the user terminal 40 include a personal computer, a tablet terminal, and a smartphone. The user terminal 40 includes a display device such as a liquid crystal display or an organic EL display.

[0058] The multiple information processing devices 6 (61, 62, 63, 64, 65) have, at one or more hierarchical levels, an information processing engine 31, a useful information generation engine 32, a UI providing engine 33, a performance value prediction engine 34, a maintenance plan engine 35, a treatment content extraction engine 36, an information accumulation platform 37, and a database 38. That is, each of the information processing engine 31, the useful information generation engine 32, the UI providing engine 33, the performance value prediction engine 34, the maintenance plan engine 35, the treatment content extraction engine 36, the information accumulation platform 37, and the database 38 can be a functional unit at one or more hierarchical levels of the multiple information processing devices 6 (61, 62, 63, 64, 65).

[0059] It is preferable that the information processing engine 31 be a functional part of the edge computer 62 or gateway 63, and it is preferable that the useful information generation engine 32, UI provision engine 33, performance value prediction engine 34, maintenance planning engine 35, treatment content extraction engine 36, information accumulation platform 37, and database 38 be functional parts of the host computer 65.

[0060] <4-1> Information Processing Engine The information processing engine 31 executes predetermined information processing on the acquired environmental information and operation information. The information processing executed by the information processing engine 31 includes batch processing that adjusts the time-series environmental information and operation information to the required time granularity. The information processing executed by the information processing engine 31 includes grouping processing that integrates multiple different types of environmental information and operation information into an information aggregate linked to a hierarchical level of industrial activity.

[0061] (4-1-1) Generation Processing of Real-Time Environmental Information and Real-Time Operation Information The generation processing of real-time environmental information and real-time operation information is performed by the information processing engine 31 of the lower-level information processing device. Note that the generation processing of real-time environmental information and real-time operation information may be performed by the information processing engine 31 of the intermediate information processing device or the information processing engine 31 of the higher-level information processing device.

[0062] The information processing engine 31 acquires and stores real-time environmental information at predetermined sampling intervals from the environmental sensor 5. The information processing engine 31 has an A / D conversion function that converts analog signals from the environmental sensor 5 into digital signals, a function that replaces A / D values ​​with measurement sample values, a function that selects and rejects measurement sample values, a function that calculates a moving average of measurement sample values, a function that measures the period or frequency of pulse signals, and the like, and uses these functions to calculate final measurement values ​​in real time.

[0063] If the environmental sensor 5 is a temperature sensor, pressure sensor, or water level sensor, the information processing engine 31 reads the analog signal of the environmental sensor 5 at a predetermined sampling interval (approximately 10 to 25 ms), quantizes it, and converts it into a digital signal to calculate an A / D value. The information processing engine 31 processes the most recent N sampling results at each sampling timing, and determines the average of the A / D values ​​for M (= N - 4) samples, excluding the first and second largest values ​​and the first and second smallest values, as the final A / D value. The information processing engine 31 references a judgment table or uses a calculation formula to generate temperature, pressure, or water level as real-time environmental information from the final A / D value. The information processing engine 31 also determines whether the environmental sensor 5 is normal or abnormal based on the final A / D value.

[0064] When the environmental sensor 5 is a flow sensor, the information processing engine 31 measures the pulse width, which is the interval between the falling edge and the next falling edge of a pulse signal obtained by converting a sine wave signal into a square wave signal. The pulse width is counted as one unit of the count clock period. The information processing engine 31 updates the pulse width at predetermined sampling intervals (approximately 100 ms) and calculates a sample value of the instantaneous flow rate by dividing a pulse constant (L / P: liters per pulse) by the pulse width. The information processing engine 31 processes the most recent N sampling results at each sampling timing and generates the latest instantaneous flow rate as real-time environmental information from the average of M (= N - 2) samples excluding the maximum and minimum values. The information processing engine 31 detects the number of times the falling edge of the pulse signal is detected every second as the pulse count (P / s). When the pulse count is updated, the information processing engine 31 adds the flow rate calculated by multiplying the pulse count by the pulse constant to the previous integrated flow rate to generate the latest integrated flow rate as real-time environmental information.

[0065] If the environmental sensor 5 is an EC sensor, the information processing engine 31 calculates a determined A / D value using the same process as for a temperature sensor, and calculates a calculated electrical conductivity value by applying a predetermined calculation formula depending on the range of the determined A / D value. Furthermore, the information processing engine 31 applies a correction coefficient for correcting for variations in individual sensors and temperature data measured by the temperature sensor to generate electrical conductivity converted at 25°C as real-time environmental information.

[0066] If the environmental sensor 5 is a power sensor (power monitor), the information processing engine 31 acquires sample values ​​of instantaneous power from the power sensor at a predetermined sampling period (approximately 80 to 100 ms), adds (sums) all sample values ​​for one period at each sampling interval Δt, and averages them over the period T to obtain real-time environmental information of instantaneous power [W]. The instantaneous power for each sampling period is accumulated to obtain real-time environmental information of accumulated power, and if one period is one second, the unit of the accumulated value is [W·s], and if this is multiplied by 3600, the unit becomes [W·h].

[0067] The information processing engine 31 acquires and stores real-time operation information from the controller 61 at predetermined sampling intervals. For example, the controller 61 transmits an operating signal when the industrial equipment 2 is operating normally, and transmits an abnormality stop signal when the industrial equipment 2 has stopped due to an abnormality. The information processing engine 31 measures the uptime (actual operating time information) of the industrial equipment 2 in real time using the operating signal received via the input / output interface 14. The information processing engine 31 also measures the downtime (non-operating time information) of the industrial equipment 2 in real time using the abnormality stop signal received via the input / output interface 14.

[0068] The time granularity of the real-time environmental information and real-time operation information depends on the sampling interval or recording interval and is generally quite fine (for example, the latest value is updated at intervals of 10 ms to 1 s). When multiple types of real-time environmental information are used to calculate other information (real-time values ​​such as boiler efficiency, differential pressure, and permeation flux) at the time of updating the real-time environmental information, the information processing engine 31 also treats the other information as real-time environmental information. The information processing engine 31 transmits the real-time environmental information together with an identification number (measurement item ID, device ID, location ID, etc.) and the update time to the upper information processing device 6.

[0069] (4-1-2) Batch Processing The real-time environmental information and real-time operation information are time-series data that are generated successively over time in the information processing engine 31. Batch processing refers to the process of adjusting the time-series real-time environmental information and real-time operation information to the required time granularity. Time granularity refers to an index that indicates the degree of time granularity, and can be selected from, for example, seconds, minutes, hours, and days. In the following explanation, the environmental information and operation information that have undergone batch processing may be referred to as "batch environmental information" and "batch operation information."

[0070] When batch processing is performed in the information processing engine 31 of the lower-level information processing device, the controller 61 includes a microcomputer 61A and a programmable logic controller 61B, so it is preferable to perform batch processing taking into account the difference in processing capabilities. For example, the microcomputer 61A, due to its high processing capabilities, can provide real-time environmental information and real-time operation information with finer time granularity than the programmable logic controller 61B. Therefore, it is preferable for the microcomputer 61A to perform batch processing in accordance with the programmable logic controller 61B, which has a coarser time granularity.

[0071] When batch processing is performed in the information processing engine 31 of the intermediate information processing device, the edge computer 62 acquires real-time environmental information from the controller 61 at predetermined intervals, accumulates it for a predetermined period, performs batch processing, and processes it into batch environmental information with adjusted time granularity. The intermediate information processing device continuously collects and integrates real-time environmental information, for example, at one-second intervals. If the real-time environmental information is temperature, pressure, instantaneous flow rate, or the like, the information processing engine 31 of the intermediate information processing device divides the integrated value of the real-time environmental information by the number of integrations to calculate an average value when the predetermined period is reached, and uses the calculated average value as the batch environmental information. If the real-time environmental information is an integrated flow rate or power consumption per unit time period, the information processing engine 31 of the intermediate information processing device uses the integrated value of the real-time environmental information as the batch environmental information. When processing the integrated real-time environmental information into batch environmental information, the information processing engine 31 of the intermediate information processing device also treats other information (such as COP or specific energy) calculated using multiple types of batch environmental information as batch environmental information.

[0072] Furthermore, when batch processing is performed in the information processing engine 31 of the upper information processing device instead of the intermediate information processing device, real-time environmental information transmitted from the information processing engine 31 of the lower information processing device to the information processing engine 31 of the intermediate information processing device is acquired at predetermined intervals, accumulated for a predetermined period, and batch-processed into batch environmental information with adjusted time granularity. The contents of the batch processing can be the same as those when performed in the information processing engine 31 of the intermediate information processing device.

[0073] Batch operation information is, for example, real-time operation information that has been subjected to threshold processing at a required time granularity. For example, the combustion stage of a steam boiler may be subjected to threshold processing at a predetermined interval, or the rotational load factor of an air compressor may be subjected to threshold processing at a predetermined interval.

[0074] The time granularity of the batch environmental information and batch operation information is preferably at a level that can be used to calculate or evaluate at least the operation performance value, energy performance value, quality performance value, and overall score value described below in the information utilization process associated with providing services to customers, and is selected from, for example, 0.5 hours, 1 hour, 2 hours, 6 hours, 12 hours, or 24 hours. Batch environmental information and batch operation information with this level of time granularity can also be used for optimization diagnostic simulations of industrial machinery or production equipment (such as reviewing control settings and control patterns and predicting the effects of equipment modifications). Note that the calculation or evaluation of energy performance values ​​may be accompanied by a calculation or evaluation of environmental impacts (such as carbon dioxide emissions and hazardous substance emissions).

[0075] (4-1-3) Grouping Processing Grouping processing refers to the process of integrating multiple different types of environmental information and operation information (real-time environmental information, batch environmental information, real-time operation information, batch operation information) into an information collection linked to the hierarchical level of industrial activity.

[0076] As shown in FIG. 4, the hierarchical levels of industrial activities include one or more of a machine unit level, a machine group level, a cell level, a line level, a building level, and a business establishment level.

[0077] The individual machine level is a level at which the operation performance value, energy performance value, quality performance value, and overall score value, which will be described later, are managed for each individual unit of industrial equipment 2 such as a steam boiler, heat pump, or air compressor.

[0078] The machine group level is a level at which the operation performance value, energy performance value, quality performance value, and overall score value are managed for multiple installations of industrial equipment 2 such as steam boilers, heat pumps, and air compressors.

[0079] The cell level is a level at which the operation performance value, energy performance value, quality performance value and overall score value of distributed industrial equipment 2 attached to one or more cells are managed at a site that employs a cell production method.

[0080] The line level is a level at which the operation performance value, energy performance value, quality performance value, and overall score value of distributed industrial equipment 2 attached to one or more lines (such as a container molding line or a beverage filling and sterilization line in a beverage manufacturing factory) at a site that adopts a line production system are managed.

[0081] The building level is a level at which the operation performance value, energy performance value, quality performance value and overall score value of the industrial equipment 2 are managed for each building unit (unit of the first factory 4A, unit of the second factory 4B) dispersed within the business premises 3.

[0082] The business establishment level is a level at which the operation performance value, energy performance value, quality performance value and overall score value of the industrial equipment 2 are managed for the entire business establishment 3 site (both the first factory 4A and the second factory 4B).

[0083] When grouping is performed in the information processing engine 31 of the upper information processing device (host computer 65), the information processing engine 31 of the upper information processing device selects and groups multiple pieces of batch environment information and batch operation information required for calculating or evaluating operation performance values, energy performance values, quality performance values, and overall scores from the diverse batch environment information and batch operation information generated by the edge computer 62. The information aggregate that has undergone this grouping process is accumulated in the information accumulation platform for a period required for history management (e.g., the past 12 months). The information aggregate may also be one that has been selected and grouped for multiple pieces of batch environment information and batch operation information required for demand management of utilities (hot water, steam, compressed air, treated water) of the demand equipment 8.

[0084] When grouping processing is performed in the information processing engine 31 of the intermediate information processing device (edge ​​computer 62), the information processing engine 31 of the edge computer 62 can perform the grouping processing while performing the above-mentioned batch processing. The content of the grouping processing can be the same as that performed in the information processing engine 31 of the higher-level information processing device.

[0085] The time granularity of each batch environment information and batch operation information that make up an information collection is basically the same, and each information collection is accompanied by information on the accumulation period of the real-time environment information that forms the basis of the batch environment information and the real-time operation information that forms the basis of the batch operation information.

[0086] An example of grouping processing will be described below. The information processing engine 31 of the host information processing device performs grouping processing of batch environment information for the purpose of performing heat recovery air compressor energy management, heat recovery air compressor demand management, heat pump energy management, heat pump demand management, steam boiler energy management, and steam boiler demand management. The batch environment information that has undergone grouping processing is accumulated in the information accumulation platform 37. The time granularity of the batch environment information that is the subject of grouping processing is, for example, in units of 30 minutes or 1 hour.

[0087] (4-1-3-1) Energy Management of Heat Recovery Air Compressors Heat recovery air compressors are equipped with a heat recovery heat exchanger that recovers the heat of compression contained in compressed air and lubricating oil to generate hot water from cooling water. The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to each sensor from a lower information processing device connected to a temperature sensor, a flow rate sensor, a power sensor, etc., and generates batch environmental information. The batch environmental information includes information such as the discharge air volume [m ３ / h], power consumption [kWh], average inlet water temperature [℃], average outlet hot water temperature [℃], and cumulative hot water volume [m ３ The host information processing device generates an information aggregate by grouping these multiple types of batch environment information. The information processing engine 31 of the host information processing device calculates the specific energy [kW / m] using the batch environment information integrated into the information aggregate. ３ ] and energy recovery rate [%] are calculated.

[0088] (4-1-3-2) Demand management of heat recovery air compressor The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to the sensors from the lower information processing device to which the flow rate sensor and the contact signal output device of the air supply valve are connected, and generates batch environmental information. The batch environmental information includes the discharge air volume [m ３ / h], air consumption [m ３ / h], and the cumulative open time [h] of the air supply valve. The information processing engine 31 of the host information processing device generates an information aggregate by grouping these multiple types of batch environment information. The information processing engine 31 of the host information processing device calculates the availability rate [%] of the demand equipment using the batch environment information integrated in the information aggregate. The information processing engine 31 of the host information processing device also diagnoses the presence or absence of leak loss in the air transport piping network by comparing the discharge air volume and consumed air volume integrated in the information aggregate. The air supply valve is provided at the end of the air transport piping and is opened when compressed air is used in the load equipment.

[0089] (4-1-3-3) Energy Management of Heat Pumps Machinery and appliances that are the subject of management include air-source heat pumps and water-source heat pumps. The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to each sensor from a lower information processing device connected to a temperature sensor, a flow rate sensor, and a power sensor, and generates batch environmental information. The batch environmental information includes the average inlet water temperature [°C], the average outlet hot water temperature [°C], the cumulative hot water volume [m ３ ], power consumption [kWh], and average heat source temperature [°C]. The information processing engine 31 of the host information processing device generates an information aggregate by grouping these multiple types of batch environment information. The information processing engine 31 of the host information processing device calculates the coefficient of performance (COP) and heat supply amount [W] using the batch environment information integrated into the information aggregate.

[0090] (4-1-3-4) Demand management of heat pumps When hot water generated by a heat pump is used in demand facilities, there are two modes: one in which hot water is sequentially supplied to the demand facilities, and one in which hot water is circulated to the demand facilities. In the former mode, the hot water itself is consumed and waste hot water is generated. In the latter mode, only the thermal energy of the hot water is consumed and the hot water after heat utilization is returned. The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to each sensor from a lower information processing device to which a temperature sensor, a flow rate sensor, etc. are connected, and generates batch environmental information. In the mode in which hot water is consumed in demand facilities, the batch environmental information includes the average supply temperature [°C], the average discharge temperature [°C], and the average hot water supply flow rate [m ３ / h], and in the case of hot water consumption in the demand facility, the average supply temperature [°C], the average return temperature [°C], and the average circulation flow rate [m ３ / h]. The information processing engine 31 of the host information processing device generates an information aggregate by grouping these multiple types of batch environment information. The information processing engine 31 of the host information processing device calculates the heat consumption [W] using the batch environment information integrated into the information aggregate.

[0091] (4-1-3-5) Energy Management of Steam Boiler The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to each sensor from a lower information processing device to which a temperature sensor, a pressure sensor, a flow rate sensor, etc. are connected, and generates batch environmental information. The batch environmental information includes the average header air supply pressure [MPa], the average feedwater temperature [°C], the cumulative steam supply amount [m ３ ], cumulative fuel consumption [m ３ ], average boiler efficiency [%], and average blowdown rate [%]. The boiler efficiency and blowdown rate are calculated based on multiple types of real-time environmental information. The information processing engine 31 of the host information processing device generates an information aggregate by grouping these multiple types of batch environmental information. The information processing engine 31 of the host information processing device calculates the heat supply amount [W] and energy efficiency [%] using the batch environmental information integrated into the information aggregate. Note that the heat gain of boiler feedwater due to drain recovery and heat pump heating and the heat loss due to concentrated blowdown not only affect fuel consumption but also change the apparent boiler efficiency, so the boiler efficiency and blowdown rate are integrated into the information aggregate as related batch environmental information.

[0092] (4-1-3-6) Steam boiler demand management The information processing engine 31 of the intermediate information processing device acquires real-time environmental information corresponding to each sensor from a lower information processing device to which a temperature sensor, a pressure sensor, a flow rate sensor, etc. are connected, and generates batch environmental information. The batch environmental information includes the average terminal supply steam pressure [MPa], the average terminal exhaust steam pressure [MPa], and the cumulative steam arrival amount [m ３ The information processing engine 31 of the host information processing device calculates the heat consumption amount [W] and the heat arrival amount [W] using the batch environment information integrated into the information aggregate. If the batch environment information relating to the heat supply amount, heat consumption amount, and heat delivery amount is integrated prior to calculating the heat supply amount, heat consumption amount, and heat delivery amount, the heat radiation loss can be evaluated by calculating the difference between the heat supply amount and the heat delivery amount.

[0093] <4-2> Information Storage Platform The information storage platform 37 stores various numerical values, images, and other information, and also provides a fundamental environment for running software (engines, applications) and hardware. The information storage platform 37 is configured to include, for example, an operating system and a database, and centrally manages a wide variety of big data, enabling smooth processing and utilization of information. The information storage platform 37 stores environmental information and operating information that have undergone specified information processing by the information processing engine 31, as well as various registration information registered via an input device.

[0094] <4-3> Useful Information Generation Engine The useful information generation engine 32 generates useful information that contributes to facility operation using the environmental information and operation information accumulated in the information accumulation platform 37. The useful information generation engine 32 has an operation performance value calculation module 321, an energy performance value calculation module 322, a quality performance value calculation module 323, an overall score value calculation module 324, a user-suggested information generation module 325, a status monitoring information generation module 326, a reminder information generation module 327, a recommendation information generation module 328, and an alarm information generation module 329.

[0095] 6 is a diagram illustrating useful information according to an embodiment. As shown in FIG. 6, the useful information includes an operation performance value, an energy performance value, a quality performance value, a total score value, user proposal information, status monitoring information, reminder information, recommendation information, and alarm information. The operation performance value, energy performance value, and quality performance value may also be referred to as equipment availability, energy efficiency, and quality achievement rate, respectively.

[0096] (4-3-1) Operation Performance Value Calculation Module The operation performance value calculation module 321 calculates an operation performance value. The operation performance value is an index value that indicates the operation performance of the industrial equipment 2. The higher the numerical value of the operation performance value, the lower the frequency of stoppages due to abnormalities, which indicates a positive impact (increased production efficiency, increased service provision efficiency) on the user's main business (production of goods, provision of services).

[0097] The operation information generated by the controller 61 includes actual operation time information linked to the normal state of the industrial equipment 2 and non-operation time information linked to the abnormal state of the industrial equipment 2. The operation performance value calculation module 321 calculates the operation performance value based on the actual operation time information and the non-operation time information.

[0098] The operation performance value is determined by the ratio of the actual operation time (uptime; the sum of operation time and standby time (time for output standby, start-up warm-up, etc.)) associated with the normal state of the industrial equipment 2 (machinery and equipment) to the non-operation time (downtime; the sum of abnormal shutdown time and recovery time) associated with the abnormal state during the operating hours of the factory 4. When multiple machines and equipment of the same type are installed, the operation performance value can be calculated for each machine or for the entire group. In the latter case, if even one machine is operating, the operation performance value is calculated assuming that it is in operation. The operation performance value is calculated based on the following formula (1). The denominator, the sum of actual operation time and non-operation time, is also called load time.

[0099] Operation performance value [%] = actual operation time / (actual operation time + non-operation time) × 100 ... (1)

[0100] A specific example of a method for calculating the operation performance value of the entire group will be described below. The operation performance value calculation module 321 can calculate the operation performance value of the entire group by simple calculation or advanced calculation.

[0101] For example, if three boilers belong to one group and the operating performance values ​​of each boiler are as shown in the following equations (2), (3), and (4), the operating performance value of the entire group can be calculated simply by using the following equation (5).

[0102] Operational performance value of boiler No. 1: 100% ... (2) Operational performance value of boiler No. 2: 90% ... (3) Operational performance value of boiler No. 3: 100% ... (4) Operational performance value of the entire group [%] = (100 + 90 + 100) ÷ (100 + 100 + 100) × 100 = 290 ÷ 300 × 100 = 97 ... (5)

[0103] When calculating the operation performance value of the entire group using advanced calculations, the operation performance value calculation module 321 uses the accumulated operation-related data to calculate a ratio using the sum of the actual operating time and non-operating time of each machine as the denominator and the sum of the actual operating time of each machine as the numerator.

[0104] (4-3-2) Energy Performance Value Calculation Module The energy performance value calculation module 322 calculates an energy performance value. The energy performance value is an index value that indicates the energy performance of the industrial equipment 2. The higher the energy performance value, the less energy is wasted, which indicates a positive impact (reduction in energy costs, reduction in carbon dioxide emissions) on the user's main business (production of goods, provision of services).

[0105] The environmental information detected by the environmental sensor 5 includes input energy information and output energy information in the industrial facility 2. The energy performance value calculation module 322 calculates an energy performance value based on the input energy information and the output energy information.

[0106] The input energy information includes the input amount of the primary utility. The output energy information includes the output amount of the secondary utility. As shown in FIG. 2 , the input amount of the primary utility is detected by an environmental sensor 5 arranged on the supply route 21. The output amount of the secondary utility is detected by an environmental sensor 5 arranged on the transportation route 22 closer to the industrial equipment 2. The energy performance value calculation module 322 calculates an energy performance value based on the input amount of the primary utility detected by the environmental sensor 5 arranged on the supply route 21 and the output amount of the secondary utility detected by the environmental sensor 5 arranged on the transportation route 22.

[0107] The energy performance value is an index showing the operational performance value of industrial equipment 2 (utility conversion machinery and equipment), and with some exceptions, is basically expressed as a ratio with the input amount of the primary utility as the denominator and the output amount of the secondary utility as the numerator. The energy performance value includes energy conversion efficiency [%], energy recovery efficiency [%], media generation efficiency [m ３ / J] and energy transport efficiency [%] are examples.

[0108] (4-3-2-1) Energy Conversion Efficiency Energy conversion efficiency is an index showing the operational performance of industrial equipment 2 used when supplying thermal energy or electrical energy to demand equipment 8. Energy conversion efficiency is the ratio expressed as a percentage, with the input energy of the primary utility as the denominator and the output energy of the secondary utility as the numerator. The higher the energy conversion efficiency, the greater the effect of suppressing running costs (fuel charges and electricity charges) and reducing carbon dioxide emissions.

[0109] (4-3-2-1-1) Thermal Equipment When the industrial facility 2 is a thermal equipment, the input energy [J] and output energy [J] are expressed by the following formulas: Input energy = lower heating value of fuel × fuel consumption + power consumption Output energy = outflow medium heat value - inflow medium heat value The lower heating value of fuel is a value determined by the type of fuel. Fuel consumption is measured using a flow rate sensor. Power consumption is measured using a power sensor.

[0110] The output energy of a steam boiler that generates steam as a secondary utility is expressed by the following formula: Output energy = (steam specific enthalpy - feedwater temperature x specific heat) x steam mass The specific enthalpy (total heat content) of saturated steam is determined by the pressure or temperature of the saturated steam, and can be found by referring to a saturated steam table. Saturated steam pressure is measured using a pressure sensor. Saturated steam temperature and feedwater temperature are measured using a temperature sensor. The mass of steam generated by the steam boiler per unit time is measured using, for example, a thermal flow sensor.

[0111] The output energy of a heat transfer boiler that circulates and heats heat transfer oil as a secondary utility is expressed by the following formula: Output energy = (oil outlet temperature - oil inlet temperature) x specific heat x density x volume The oil outlet temperature and oil inlet temperature are measured using temperature sensors. The volume of heat transfer oil circulating through the heat transfer boiler per unit time is measured using a flow rate sensor.

[0112] The output energy of a hot water boiler that generates hot water as a secondary utility is expressed by the following formula: Output energy = (outlet water temperature - inlet water temperature) x specific heat x density x volume The outlet water temperature and inlet water temperature are measured using temperature sensors. The volume of water passing through the hot water boiler per unit time is measured using a flow sensor.

[0113] The output energy of a heat pump that generates hot water as a secondary utility is expressed by the following formula: Output energy = (outlet water temperature - inlet water temperature) x specific heat x density x volume The outlet water temperature and inlet water temperature are measured using temperature sensors. The volume of water passing through the heat pump per unit time is measured using a flow sensor.

[0114] The output energy of a chiller that produces chilled water as a secondary utility is expressed by the following formula: Output energy = (inlet water temperature - outlet water temperature) x specific heat x density x volume The inlet water temperature and outlet water temperature are measured using temperature sensors. The volume of water passing through the chiller per unit time is measured using a flow rate sensor.

[0115] The output energy of a heat pump chiller, which simultaneously generates hot water and cold water as a secondary utility, is the same formula as that of a heat pump on the heating side and the same formula as that of a chiller on the cooling side.

[0116] The input energy required to operate the industrial equipment 2 varies depending on the type of industrial equipment 2. For example, combustion boilers require both fuel and electricity to operate, while heat pumps and chillers require only electricity. Power consumption includes auxiliary losses (power losses required to drive pumps, blowers, etc.). Raising the temperature of the inflow medium through preliminary water heating reduces the actual output energy, thereby reducing fuel and power consumption and improving efficiency. In a steam boiler, increasing the amount of concentrated boiler water blown down reduces the amount of steam produced, resulting in heat loss and reduced efficiency. In a heat pump, increasing the temperature of the heat source fluid (outdoor air, heat source water) increases the amount of heat absorbed by the evaporator, reducing the power consumption of the refrigerant compressor and improving efficiency. In a chiller, decreasing the temperature of the heat source fluid (outdoor air) increases the amount of heat released by the condenser, reducing the power consumption of the refrigerant compressor and improving efficiency.

[0117] (4-3-2-1-2) Electric Air Compressor If the industrial equipment 2 is an electric air compressor, the input energy [J] and output energy [J] are expressed by the following formulas: Input energy = power consumption Output energy = discharge pressure x discharge air volume Power consumption is measured using a power sensor. Discharge pressure is measured using a pressure sensor. The discharge air volume per unit time is measured using a flow rate sensor.

[0118] The power consumption includes not only motor power but also auxiliary losses (power losses required to drive cooling fans, ventilation fans, etc.).

[0119] (4-3-2-1-3) Heat recovery electric air compressor When the industrial equipment 2 is a heat recovery electric air compressor, the input energy [J] and output energy [J] are expressed by the following formulas: Input energy = power consumption Output energy = discharge pressure x discharge air volume + outflow medium heat volume - inflow medium heat volume Power consumption is measured using a power sensor. Discharge pressure is measured using a pressure sensor. Discharge air volume per unit time is measured using a flow sensor. In the output energy formula, the parts related to the discharge pressure and discharge air volume are the output energy of compressed air, and the parts related to the outflow medium heat volume and inflow medium heat volume are the output energy of hot water generated by heat recovery.

[0120] The output energy (portion related to the heat quantity of the outflowing medium and the heat quantity of the inflowing medium) of a heat recovery heat exchanger that generates hot water as a secondary utility is expressed by the following formula: Output energy = (outflowing water temperature - inflowing water temperature) x specific heat x density x volume The outflowing water temperature and inflowing water temperature are measured using temperature sensors. The volume of water passing through the heat recovery heat exchanger per unit time is measured using a flow rate sensor.

[0121] In electric air compressors, approximately 90% of the input energy is converted into heat of compression during the compression process, which is released into the atmosphere as waste heat. As a result, the energy conversion efficiency is very low. Therefore, by recovering the heat of compression and reusing it as hot water, a significant improvement in energy conversion efficiency (overall efficiency) can be expected.

[0122] (4-3-2-1-4) Mono-Generation Generator When the industrial equipment 2 is a mono-generation generator, the input energy [J] and output energy [J] are expressed by the following formulas. Note that examples of mono-generation generators include fuel cells and gas generators. Input energy = lower heating value of fuel × fuel consumption Output energy = net output electric energy The lower heating value of fuel is a value determined by the type of fuel. The fuel consumption is measured using a flow rate sensor. The net output electric energy is measured using a power sensor.

[0123] Once the generator is started, it operates autonomously, so the net output power is the generated power minus auxiliary losses (power losses required to drive fuel blowers, air blowers, etc.) and power conditioner losses (power losses associated with boosting and AC conversion).

[0124] (4-3-2-1-5) Cogeneration Generator When the industrial facility 2 is a cogeneration generator, the input energy [J] and output energy [J] are expressed by the following formulas. Note that examples of monogeneration generators include fuel cells and gas generators. Input energy = lower heating value of fuel × fuel consumption Output energy = net output power + outflow medium heat quantity - inflow medium heat quantity The lower heating value of fuel is a value determined by the type of fuel. Fuel consumption is measured using a flow sensor. Net output power quantity is measured using a power sensor. In the output energy formula, the part related to the net output power quantity is the output energy of electricity, and the parts related to the outflow medium heat quantity and inflow medium heat quantity are the output energy of hot water generated by heat recovery.

[0125] The output energy (portion related to the heat quantity of the outflowing medium and the heat quantity of the inflowing medium) of a heat recovery heat exchanger that generates hot water as a secondary utility is expressed by the following formula: Output energy = (outflowing water temperature - inflowing water temperature) x specific heat x density x volume The outflowing water temperature and inflowing water temperature are measured using temperature sensors. The volume of water passing through the heat recovery heat exchanger per unit time is measured using a flow rate sensor.

[0126] In mono-generation gas generators, 50-60% of the input energy is converted into combustion heat when the gas engine is running, and this is released into the atmosphere as waste heat. In addition, in solid oxide fuel cells, 35-50% of the input energy is converted into combustion heat when the power generation module is operating, and this is released into the atmosphere as waste heat. As a result, the energy conversion efficiency is relatively low. Therefore, by recovering the combustion heat and reusing it as hot water, a significant improvement in energy conversion efficiency (overall efficiency) can be expected.

[0127] (4-3-2-2) Energy Recovery Efficiency Energy recovery efficiency is an index showing the operational performance of industrial equipment 2 used when recovering thermal energy wasted in a factory 4 and supplying the thermal energy to demand equipment 8. Energy recovery efficiency is expressed as a percentage, where the input energy of the primary utility is the denominator and the output energy of the secondary utility is the numerator, and is usually a value exceeding 100%. The higher the energy recovery efficiency, the greater the energy saving effect and the effect of reducing carbon dioxide emissions. Note that energy recovery efficiency has the same meaning as the coefficient of performance (COP) in the refrigeration cycle.

[0128] (4-3-2-2-1) Thermal Equipment When the industrial facility 2 is a heat recovery type thermal equipment, the input energy [J] and output energy [J] are expressed by the following formulas: Input energy = power consumption Output energy = heat amount of outflowing medium - heat amount of inflowing medium Heat recovery type thermal equipment uses waste heat to generate secondary utilities, so the input energy consists only of auxiliary losses such as water supply pumps and motor-operated valves. Power consumption is measured using a power sensor.

[0129] The output energy of a heat recovery steam boiler that generates steam as a secondary utility is expressed by the following formula. Examples of heat recovery steam boilers include high-pressure steam boilers that use exhaust gas from gas engine generators or diesel engine generators as their heat source, and low-pressure steam boilers that use jacket waste hot water as their heat source. Output energy = (steam specific enthalpy - feedwater temperature x specific heat) x steam mass The specific enthalpy (total heat content) of saturated steam is determined by the pressure or temperature of the saturated steam and can be found by referring to a saturated steam table. Saturated steam pressure is measured using a pressure sensor. Saturated steam temperature and feedwater temperature are measured using a temperature sensor. The mass of steam generated by the steam boiler per unit time is measured using, for example, a thermal flow sensor.

[0130] The output energy of a heat recovery hot water boiler that generates hot water as a secondary utility is expressed by the following formula. Note that an example of a heat recovery hot water boiler is a hot water boiler that uses exhaust gas from a gas engine generator or a diesel engine generator as a heat source. Output energy = (outlet water temperature - inlet water temperature) x specific heat x density x volume The outlet water temperature and inlet water temperature are measured using a temperature sensor. The volume of water passing through the hot water boiler per unit time is measured using a flow sensor.

[0131] The output energy of a flash steam generator, which generates low-pressure steam as a secondary utility, is expressed by the following formula: Output energy = (steam specific enthalpy - drain temperature x specific heat) x steam mass The specific enthalpy (total heat content) of saturated steam is determined by the pressure or temperature of the saturated steam, and can be found by referring to a saturated steam table. Saturated steam pressure is measured using a pressure sensor. Saturated steam temperature and drain temperature are measured using a temperature sensor. The mass of steam generated by the flash steam generator per unit time is measured using a thermal flow sensor.

[0132] In a configuration where a flash steam generator is combined with a steam compressor to boost the pressure of the low-pressure steam generated by the flash steam generator, the motor power of the steam compressor is added to the input energy. Also, in the steam compressor, cooling water is sprayed onto the screw rotor, and this cooling water evaporates due to the heat of compression and friction, so the total steam mass increases and the output energy also increases.

[0133] (4-3-2-2-2) Steam-driven air compressor When the industrial equipment 2 is a heat recovery steam-driven air compressor, the input energy [J] and output energy [J] are expressed by the following formulas: Input energy = power consumption Output energy = discharge pressure x discharge air volume + outflow medium heat quantity - inflow medium heat quantity Power consumption is measured using a power sensor. Discharge pressure is measured using a pressure sensor. Discharge air volume per unit time is measured using a flow sensor. In the output energy formula, the parts related to the discharge pressure and discharge air volume are the output energy of compressed air, and the parts related to the outflow medium heat quantity and inflow medium heat quantity are the output energy of hot water generated by heat recovery.

[0134] The output energy (portion related to the heat quantity of the outflowing medium and the heat quantity of the inflowing medium) of a heat recovery heat exchanger that generates hot water as a secondary utility is expressed by the following formula: Output energy = (outflowing water temperature - inflowing water temperature) x specific heat x density x volume The outflowing water temperature and inflowing water temperature are measured using temperature sensors. The volume of water passing through the heat recovery heat exchanger per unit time is measured using a flow rate sensor.

[0135] A steam-driven air compressor uses steam, a secondary utility generated in a steam boiler, to rotate a steam motor, which is the prime mover, to drive the compressor itself. Therefore, the only input energy is auxiliary losses (power losses required to drive cooling fans, ventilation fans, etc.).

[0136] (4-3-2-3) Media generation efficiency Media generation efficiency is an index showing the operational performance of the industrial equipment 2, which is mainly used when consuming compressed air and treated water in the demand equipment 8. Media generation efficiency is expressed as the ratio of the input energy of the primary utility as the denominator to the output media amount of the secondary utility as the numerator, and is expressed in units of [m３ The higher the medium generation efficiency, the greater the effect of suppressing running costs (electricity charges) and reducing carbon dioxide emissions.

[0137] (4-3-2-3-1) Electric Air Compressor When the industrial equipment 2 is an electric air compressor, the input energy [J] and the output medium amount [m ３ ] is expressed by the following formula: Input energy = power consumption Output medium volume = discharged air volume Power consumption is measured using a power sensor. The discharged air volume per unit time is measured using a flow sensor.

[0138] The power consumption includes auxiliary losses (power losses required to drive cooling fans, ventilation fans, etc.). The medium generation efficiency indicates the medium generation capacity per unit of energy, and is expressed as the specific energy [kW / (m ３ / min)] with the numerator and denominator reversed. Note that as the outside air temperature increases, the density of the air decreases, requiring more energy for compression. Therefore, the generation efficiency may be temperature corrected (e.g., converted to 25°C).

[0139] In the case of a steam-driven air compressor, the compressor itself is driven by a steam motor, and since steam is a secondary utility, the input energy is limited to the auxiliary losses, and the generation efficiency exceeds that of an electrically powered type.

[0140] (4-3-2-3-2) When the water treatment equipment industrial facility 2 is an RO membrane device, which is a type of water treatment equipment, the input energy [J] and the output medium amount [m ３ ] is expressed by the following formula: Input energy = power consumption Output medium volume = permeate volume Power consumption is measured using a power sensor. The permeate volume per unit time is measured using a flow sensor.

[0141] The power consumption includes the driving power of the water supply pump, the pressure pump, etc. Note that as the raw water temperature decreases, the viscosity of the water decreases, so more energy is required to transport the water. Therefore, the medium production efficiency may be temperature-corrected (e.g., converted to 25°C).

[0142] (4-3-2-4) Energy Transport Efficiency Energy transport efficiency is an index that indicates the degree to which thermal energy loss is avoided during the transport process of secondary utilities, and affects, for example, the energy performance value of the entire equipment group. Energy transport efficiency is the delivery ratio (= delivered amount / transmitted amount) of the amount of thermal energy of secondary utilities (steam heat, hot water heat, etc.) sent from industrial equipment 2 to demand equipment 8, expressed as a percentage. Since the ideal energy transport efficiency, where there is no energy loss during transport, is 100%, the energy loss rate is calculated by subtracting the actual energy transport efficiency from this 100%. The amount of thermal energy transmitted and the amount of thermal energy delivered are detected using measurements from temperature sensors and flow rate sensors.

[0143] If the insulation in the steam or hot water transport path 22 (including tanks, etc.) deteriorates or peels off, heat loss occurs due to heat radiation, reducing energy transport efficiency. If a steam trap in the steam transport path 22 fails, causing drain retention or external steam leakage, heat loss occurs due to a drop in steam temperature or partial release, reducing energy transport efficiency. If the piping sealant in the compressed air transport path 22 deteriorates or the piping body is damaged, leakage loss occurs due to external leakage, reducing energy transport efficiency. Therefore, by managing energy transport efficiency, it becomes possible to determine the need for repairs to the transport path 22.

[0144] (4-3-2-5) Energy Performance Value of the Whole Group A specific example of a method for calculating the energy performance value of the whole group will now be described. The energy performance value calculation module 322 can calculate the energy performance value of the whole group by simple calculation or advanced calculation.

[0145] For example, if three boilers belong to one group and the energy performance values ​​of each boiler are as shown in the following equations (6), (7), and (8), the energy performance value of the entire group can be calculated simply by using the following equation (9).

[0146] Energy performance value of boiler No. 1: 95% ... (6) Energy performance value of boiler No. 2: 95% ... (7) Energy performance value of boiler No. 3: 92% ... (8) Energy performance value of the entire group [%] = (95 + 95 + 92) ÷ (100 + 100 + 100) × 100 = 282 ÷ 300 × 100 = 94 ... (9)

[0147] When calculating the energy performance value of the entire group using advanced calculations, the energy performance value calculation module 322 uses the accumulated energy-related data to calculate a ratio using the total input energy value of each unit as the denominator and the total output energy value of each unit as the numerator.

[0148] (4-3-3) Quality Performance Value Calculation Module The quality performance value calculation module 323 calculates a quality performance value. The quality performance value is an index value that indicates the quality performance of the industrial equipment 2. The higher the quality performance value, the better the quality, which indicates a positive impact on the user's main business (production of goods, provision of services) (continuity of business activities through the production of high-quality products, objects to be sterilized, and objects to be cleaned).

[0149] The environmental information detected by the environmental sensor 5 includes actual quality level information of the media or articles produced in the industrial facility 2. The quality performance value calculation module 323 calculates a quality performance value based on the actual quality level information and the user's required quality level information.

[0150] The media produced by industrial facility 2 are expected to include secondary utilities such as steam, hot water, cold water, compressed air, electricity, heating oil, and treated water. All media except treated water are energy media. Treated water can also be used as a cleaning medium, rinsing medium, or other process media in addition to being an energy medium. Actual quality level information (environmental information) of the media includes pressure, temperature, water quality, voltage, etc.

[0151] The products produced by the industrial facility 2 are expected to be processed items to be cleaned and sterilized, washed items to be washed, cooked food, prepared beverages, etc. Information on the actual quality level of the products is acquired as environmental information by constructing a system that automatically reads the color tone and scale of a judging tool such as an indicator using an image sensor (camera) and converts it into a numerical value.

[0152] (4-3-3-1) Steam (4-3-3-1-1) Steam supply pressure The specific enthalpy (total heat content) of saturated steam is determined by the pressure of saturated steam. To generate steam with the heat content (temperature) required by the demand facility, the supply pressure of the steam boiler must meet the required pressure. During the specified operating period of the steam boiler, the boiler operating time when the supply pressure is greater than or equal to the required pressure is defined as A, and the boiler operating time when the supply pressure is less than the required pressure is defined as B. The quality performance value [%] of the supply pressure is calculated as A / (A+B) x 100.

[0153] (4-3-3-1-2) Steam dryness This is the weight ratio of the gas phase to the liquid phase in steam, and the dryness fraction affects the total heat content of the steam. In other words, steam with a dryness fraction of 100% (wetness fraction of 0%) has only the latent heat of saturated steam at that pressure, and steam with a dryness fraction of 0% (wetness fraction of 100%) has only the sensible heat of saturated water at that pressure. As the dryness fraction decreases, the proportion of latent heat decreases, and the total heat content decreases. Dryness fraction can be measured with a throttling calorimeter or absorbance analyzer, and it can usually be thought of as "dryness fraction [%] = quality performance value [%]".

[0154] (4-3-3-1-3) Steam Purity: When live steam comes into direct contact with products during production processes such as cooking, sterilization, and drying, steam containing impurities is undesirable. Steam with no water treatment chemicals or concentrated boiler water contamination is considered to be of higher quality. Steam purity is determined by cooling wet or dry steam to condense it and measuring its electrical conductivity and pH. Distilled water has an electrical conductivity of 10 μS / cm or less (at 25°C) and a pH of approximately 7 (in the absence of dissolved carbon dioxide). These values ​​are used as the basis for determining the quality performance value. For example, for electrical conductivity, the quality performance value [%] can be calculated as [1 - (actual EC - reference EC) / actual EC] x 100. If the actual EC of steam condensate is 20 μS / cm, the quality performance value is 50%, and if the actual EC of steam condensate is 10 μS / cm, the quality performance value is 100%. Note that if the actual EC is less than 10 μS / cm, the quality performance value can be set to 100%.

[0155] (4-3-3-2) Hot or cold water supply temperatureThe same concept as for a steam boiler can be applied, and within the specified operating period of the heat pump, the heat pump operating time when the supply temperature is equal to or greater than the required temperature is defined as A, and the heat pump operating time when the supply temperature is less than the required temperature is defined as B, and the quality performance value [%] of the supply temperature is calculated as A / (A+B) x 100.In the case of a chiller, the chiller operating time when the supply temperature is less than or equal to the required temperature is defined as A, and the chiller operating time when the supply temperature is greater than the required temperature is defined as B, and the quality performance value [%] of the supply temperature is calculated as A / (A+B) x 100.

[0156] (4-3-3-3) Compressed air supply pressure This can be thought of in the same way as a steam boiler. Within the specified operating period of the air compressor, the operating time of the air compressor when the supply pressure is equal to or greater than the required pressure is defined as A, and the operating time of the air compressor when the supply pressure is less than the required pressure is defined as B. The quality performance value [%] of the supply pressure is calculated as A / (A+B) x 100.

[0157] (4-3-3-4) Quality of Treated Water Since the electrical conductivity of RO water is usually 5 μS / cm (25°C) or less, the quality performance value is calculated based on this value. For example, the quality performance value [%] is calculated as [1 - (actual EC - standard EC) / actual EC] x 100. In addition, the quality performance value is controlled by the turbidity of the treated water for filtration treatment (membrane filtration, sand filtration), and by the residual chlorine concentration of the treated water for activated carbon treatment.

[0158] (4-3-3-5) Electricity supply voltage The quality of electricity (AC) generated by a generator is evaluated by voltage and frequency. During the specified operating period of a generator such as a fuel cell, the operating time of the generator when the supply voltage is within a specified range above and below the required voltage is defined as A, and the operating time of the generator when the supply voltage is not within the specified range above and below the required voltage is defined as B. The quality performance value [%] of the supply voltage is calculated as A / (A+B) x 100.

[0159] (4-3-3-6) Sterilization and cleaning level of sterilized and cleaned items In the central supply room of a medical institution, a sterilization indicator is used as a tool to evaluate whether a sterilizer, which is a medical device, is operating normally and whether the items to be sterilized have been completely processed. A cleaning indicator is also used as a tool to evaluate whether a washer is operating normally and whether the items to be cleaned have been completely processed. For sterilizers and washers, the quality performance value is calculated based on the judgment level of the sterilization indicator or cleaning indicator (for example, a pass / fail judgment based on the gradual degree of color change). Quality performance value [%] = Number of passes / (Number of passes + Number of failures) x 100

[0160] (4-3-3-7) Quality Performance Value of the Whole Group A specific example of a method for calculating the quality performance value of the whole group will now be described. The quality performance value calculation module 323 can calculate the quality performance value of the whole group by simple calculation or advanced calculation.

[0161] For example, if three boilers belong to one group and the quality performance values ​​of each boiler are the values ​​shown in the following equations (10), (11), and (12), the quality performance value of the entire group can be calculated simply by the following equation (13): The quality performance value of a boiler indicates the quality performance value of the steam supply pressure.

[0162] Quality performance value of boiler No. 1: 95% ... (10) Quality performance value of boiler No. 2: 100% ... (11) Quality performance value of boiler No. 3: 100% ... (12) Quality performance value of the entire group [%] = (95 + 100 + 100) ÷ (100 + 100 + 100) × 100 = 295 ÷ 300 × 100 = 98 ... (13)

[0163] When calculating the quality performance value for the entire group using advanced calculations, the quality performance value calculation module 323 uses the accumulated historical data of steam supply pressure (time progression of pressure changes) to calculate a ratio using the sum of the operating times A + B of each unit as the denominator and the sum of the operating times A of each unit as the numerator.

[0164] (4-3-4) Overall Score Calculation Module The overall score calculation module 324 calculates an overall score by integrating two or more performance values ​​from the operation performance value, the energy performance value, and the quality performance value. The overall score is an index value that indicates the overall performance of the industrial equipment 2. The higher the overall score value, the higher the quality of the service provided by the maintenance company, indicating that it has a positive impact on the user's business activities (creating an environment where the user can concentrate on their core business).

[0165] For example, the percentages of the operation performance value, energy performance value, and quality performance value can each be converted to a score out of 100, and the three performance values ​​can be added together to arrive at a total score of up to 300. If a user places more importance on a particular performance value, they can adjust the scale (e.g., 100 x 1.5). For example, even if the energy performance value is poor, if the operation performance value and quality performance value are high enough, the production process can continue, so these two performance values ​​can be weighted more heavily.

[0166] A specific example of a method for calculating the total score will be described below. The total score calculation module 324 can calculate the total score using an additive formula or a multiplicative formula. As an example, if the operation performance value is 97, the energy performance value is 94, and the quality performance value is 98, the total score S1 calculated using the additive formula is expressed by the following formula (14), and the total score S2 calculated using the multiplicative formula is expressed by the following formula (15). Note that the maximum score for the total score S1 is 300, and the maximum score for the total score S2 is 1000.

[0167] S1=97+94+98=289...(14) S2=97×94×98÷1000=894...(15)

[0168] (4-3-5) User-Proposed Information Generation Module The user-proposed information generation module 325 generates user-proposed information, which is information related to value-added services that provide user benefits, based on each performance value and knowledge information and is used to propose to users. Knowledge information refers to information that contributes to maintaining or improving each of the above-mentioned performance values, such as the operation performance value, energy performance value, and quality performance value. The knowledge information is stored in the database 38. The user-proposed information generation module 325 generates user-proposed information based on each performance value and knowledge information stored in the database 38.

[0169] FIG. 7 is a diagram illustrating user proposal information according to an embodiment. As shown in FIG. 7 , the following are examples of user proposal information that improves energy performance values, i.e., brings about energy saving benefits: (1) If a downward trend in the energy conversion efficiency of steam equipment is observed, a change in the output condition value of the steam boiler is proposed. (2) If a downward trend in the energy conversion efficiency of refrigeration equipment is observed, a change in the output condition value of the heat pump or chiller is proposed. (3) If a downward trend in the energy conversion efficiency of air equipment is observed, a change in the output condition value of the air compressor is proposed. (4) If a downward trend in the energy transport efficiency of steam equipment is observed, a steam trap diagnosis of the steam piping network is proposed. (5) If a downward trend in the energy transport efficiency of refrigeration equipment is observed, a facility renovation based on heat radiation measurement is proposed. (6) If a downward trend in the energy transport efficiency of air equipment is observed, an air leak diagnosis of the compressed air transport piping network is proposed.

[0170] (4-3-6) Status Monitoring Information Generation Module The status monitoring information generation module 326 generates status monitoring information by superimposing marks that visually represent the condition of each constituent unit of the industrial equipment 2 on an equipment flow diagram read from the database 38. The operation information generated by the controller 61 includes the condition of the industrial equipment 2. The database 38 stores an equipment flow diagram that depicts the overall configuration or partial configuration of the industrial equipment 2. The status monitoring information generation module 326 generates status monitoring information based on the condition generated by the controller 61 and the equipment flow diagram stored in the database 38.

[0171] Semi-real-time information on the condition of the industrial equipment 2 is displayed graphically on a portal page displayed on the user terminal 40 (provision of visualization content). For example, OK / NG marks are superimposed on the constituent units of an equipment flow diagram. Constituent units of machinery and equipment may be represented not only by image diagrams but also by photographs.

[0172] (4-3-7) Reminder Information Generation Module The reminder information generation module 327 generates reminder information that notifies the planned timing of maintenance. The timing of maintenance is planned by the maintenance planning engine 35, which will be described later.

[0173] The reminder information may include the time of the before-maintenance visit (visit date and time) as well as the name, photo, and location name of the service technician in charge. The service technician in charge is a worker who can be dispatched by the maintenance company in charge of the maintenance work and the maintenance business partner who complements the maintenance work. The time of condition-based maintenance is set mainly by judging signs of abnormality from changes in environmental information. The time of time-based maintenance is set mainly based on operation information (for example, when the accumulated operating time since the previous inspection reaches a specified time).

[0174] (4-3-8) Recommendation Information Generation Module The recommendation information generation module 328 generates recommendation information that notifies the user of recommended measures to maintain the capacity of the industrial equipment 2 or avoid faults. The database 38 stores recommended measures to maintain the capacity of the industrial equipment 2 or avoid faults. The measure extraction engine 36 extracts measure contents associated with the feature quantities from the database 38 when the feature quantities included in the environmental information or operation information accumulated in the information accumulation platform 37 are predetermined numerical values. The recommendation information generation module 328 generates recommendation information that notifies the user of the measure contents extracted by the measure extraction engine 36, which will be described later.

[0175] FIG. 8 is a diagram illustrating recommendation information according to an embodiment. The recommendation information generation module 328 displays daily management-level actions that the user can take (mainly replenishment and replacement of consumables). Examples include replenishment of water treatment chemicals and reagents for water quality sensors, replenishment of water treatment material regeneration agents (granulated salt for regenerating cation exchange resin in water softeners), and replacement of filters (air filters, water filters). The determination of whether to issue recommendation information (notification determination) is performed based on operation information or environmental information. As shown in FIG. 8, the following are examples of feature quantities and recommendation information:

[0176] (1) If the chemical level (environmental information) in the water treatment chemical tank falls below the level threshold, it is recommended to replenish the water treatment chemical. (2) If the number of chemical discharges (operational information) since the last time the reagent cartridge for the water quality sensor reagent was replaced exceeds the discharge count threshold, it is recommended to replenish the water quality sensor reagent. (3) If the number of regenerations (operational information) since the last time the regeneration chemical was replaced exceeds the regeneration count threshold, or if the chemical concentration (environmental information) at the time of regeneration exceeds the concentration threshold, it is recommended to replenish the regeneration chemical. (4) If the cumulative operating time of the air compressor since the last air filter replacement (operational information) exceeds the time threshold, or if the pressure loss (environmental information) exceeds the loss threshold, it is recommended to replace the air filter. (5) If the cumulative water flow volume or cumulative water flow time (operational information) since the last water filter replacement exceeds the water flow threshold, or if the pressure loss (environmental information) exceeds the loss threshold, it is recommended to replace the water filter.

[0177] (4-3-9) Alarm Information Generation Module The alarm information generation module 329 generates alarm information indicating the occurrence status of a malfunction event based on the abnormality notification signal transmitted by the controller 61. The operation information generated by the controller 61 includes the abnormality notification signal transmitted by the controller 61 when a malfunction event occurs in the industrial equipment 2. The alarm information generation module 329 generates alarm information indicating the occurrence status of a malfunction event based on the abnormality notification signal transmitted by the controller 61.

[0178] The alarm information generation module 329 displays the occurrence status of a malfunction event based on an abnormality notification signal (such as an alarm code or an abnormality occurrence flag included in the communication message) sent by the machine / tool ​​controller 61. The communication message may be binary data or text data (such as email). In the case of a serious alarm that necessitates the shutdown of the machine / tool, recovery work is the job of a service technician, so the alarm information may include, for example, the expected date and time of the service technician's arrival. In the case of a minor alarm that can be handled by the user, a button for obtaining content that describes the procedure for resolution work is displayed. Content that can be called up using the content obtainment button includes manuals (document-based, video-based), instruction manuals, etc.

[0179] <4-4> UI Providing Engine The UI providing engine 33 provides a user interface (UI) for displaying the useful information generated by the useful information generating engine 32 on the user terminal 40 .

[0180] The user interface is a means of communication that allows users to connect with maintenance companies via ICT, and includes a user portal. The user portal includes a portal screen (UI screen) that is displayed on the user terminal 40. The portal screen includes multiple portlets. A portlet is a detachable user interface component that is placed on the portal screen.

[0181] The UI providing engine 33 provides a user portal (UI screen) as a user interface. The user portal includes a portal page with a screen configuration corresponding to the logged-in user and portlets that are incorporated into the portal page and operate to display useful information on the screen. By accessing the portal site created and distributed by the UI providing engine 33 from the user terminal 40, the user can view and obtain various useful information displayed on the portal page.

[0182] The type and level of useful information provided by the user portal is determined by the contents of the service contract concluded with the user. When a user accesses the portal site, a portal page with a screen configuration appropriate for the logged-in user is generated. The portal page is provided with multiple layout forms that can be customized according to, for example, the type of industry.

[0183] The UI providing engine 33 includes a portal page generating module 331 , a first tab group generating module 332 , a second tab group generating module 333 , and a portlet generating module 334 .

[0184] The portal page generation module 331 generates a portal page with a screen configuration corresponding to the logged-in user.

[0185] The first tab group generation module 332 generates a first tab group in a predetermined area of ​​the portal page for the user to select a management menu from among a plurality of management menus from which the user wishes to receive information.

[0186] The second tab group generation module 333 generates a second tab group in a predetermined area of ​​the portal page for the user to select a facility group from which the user wishes to receive information from among a plurality of facility groups.

[0187] The portlet generation module 334 generates a portlet that displays useful information in a predetermined area of ​​the portal page when a predetermined management menu is selected from the first tab group and a predetermined equipment group is selected from the second tab group. The portlet generation module 334 is prepared according to the amount of useful information to be provided (information related to operation performance values, energy performance values, quality performance values ​​and overall score values, equipment flow information, condition information, customer proposal information, reminder information, recommendation information, alarm information).

[0188] <4-5> Performance Value Prediction Engine The performance value prediction engine 34 inputs the environmental information and operation information accumulated in the information accumulation platform 37 into a mathematical model that simulates the operation of the industrial equipment 2, and outputs one or more virtual performance values ​​from the mathematical model, including the operation performance value, energy performance value, and quality performance value.

[0189] 9 is a diagram for explaining the processing of the performance value prediction engine 34 according to the embodiment. The performance value prediction engine 34 calculates virtual performance values, which are virtual performance values, using digital twin technology. The mathematical model is industrial equipment 2 in a virtual space that simulates the operation of the industrial equipment 2. The performance value prediction engine 34 inputs environmental information detected by the environmental sensors 5 and operation information generated by the controller 61 into the mathematical model, and causes the mathematical model to output one or more virtual performance values ​​from the operation performance value, energy performance value, and quality performance value.

[0190] The user-suggested information generation module 325 can generate user-suggested information based on the output virtual performance value and knowledge information from the mathematical model.

[0191] <4-6> Maintenance Planning Engine The maintenance planning engine 35 plans the timing of providing condition-based maintenance or time-based maintenance for the industrial equipment 2 based on the environmental information and operation information accumulated in the information accumulation platform 37. Maintenance includes before maintenance and after maintenance. Before maintenance refers to maintenance performed before an abnormality occurs in the industrial equipment 2. After maintenance refers to maintenance performed after an abnormality occurs in the industrial equipment 2. Before maintenance includes condition-based maintenance (CBM) and time-based maintenance (TBM). Condition-based maintenance is the most preferable maintenance method because it reduces unnecessary work compared to time-based maintenance.

[0192] <4-7> Treatment Content Extraction Engine When a feature contained in the environmental information or operation information stored in the information storage platform 37 is a predetermined numerical value, the treatment content extraction engine 36 extracts the treatment content (see FIG. 8) associated with the feature from the database 38.

[0193] <4-8> Database The database 38 accumulates knowledge information that contributes to maintaining or improving each of the performance values ​​of operation, energy, and quality. The database 38 stores an equipment flow diagram depicting the overall configuration or partial configuration of the industrial equipment 2. The database 38 determines the recommended measures to maintain the capacity of the industrial equipment 2 or to avoid failures. The database 38 may be prepared according to the number of modules that use the registered information.

[0194] [5] User Interface Fig. 10 is a diagram showing an example of a portal page 70 of the industrial equipment operation support system according to the embodiment. The portal page generation module 331 generates the portal page 70 and displays it on the display device of the user terminal 40. The portal page generation module 331 displays the portal page 70 with a screen configuration corresponding to the logged-in user on the user terminal 40.

[0195] The first tab group generation module 332 generates a first tab group 71 in the left region of the portal page 70. The first tab group 71 includes a plurality of management menus. The management menus include a main menu 71A, a maintenance and preservation menu 71B, a routine maintenance management menu 71C, an energy management menu 71D, a quality control menu 71E, an equipment list menu 71F, and a report menu 71G. The user can select a management menu from which to receive information from among the plurality of management menus.

[0196] The second tab group generation module 333 generates a second tab group 72 in the upper region of the portal page 70. The second tab group 72 includes a plurality of facility groups. The facility groups include an overall group 72A, a steam facility group 72B, a water treatment facility group 72C, a refrigeration facility group 72D, and an air facility group 72E. The user can select a facility group from which to receive information from among the plurality of facility groups.

[0197] FIG. 10 shows the portal page 70 when the main menu 71A is selected in the first tab group 71 and the overall group 72A is selected in the second tab group 72.

[0198] The portlet generated by the portlet generation module 334 operates to display, as useful information, an overall score value 73 obtained by integrating two or more performance values ​​from the operation performance value, the energy performance value, and the quality performance value on the portal page 70. In the example shown in Fig. 10, the overall score value 73 includes text data of "overall score value" and numeric data of "***".

[0199] The portlet generated by the portlet generation module 334 operates to display, as useful information, user-suggested information 74, which is information related to value-added services that provide user benefits and is used to propose to users, on the portal page 70. In the example shown in Fig. 10, the user-suggested information 74 includes a message such as "Notice: Suggestion for steam trap leak diagnosis."

[0200] The portlet generated by the portlet generation module 334 operates to display, as useful information, reminder information 75 notifying the timing of planned maintenance on the portal page 70. In the example shown in Fig. 10, the reminder information 75 includes messages such as "Regular inspection information: [□□××] will visit you to inspect △△ on XX / XX / XX at around XX hour." and "Maintenance information: [□□××] will visit you to perform maintenance on ◇◇ on XX / XX / XX at around XX hour."

[0201] The portlet generated by the portlet generation module 334 operates to display, as useful information, recommendation information 76 on the portal page 70, which notifies the user of recommended actions to maintain the capacity or avoid failures of the industrial equipment 2. In the example shown in Fig. 10, the recommendation information 76 includes messages such as "It is time to replenish chemicals" and "The filter of XX is clogged. Please replace the filter."

[0202] The portlet operates to display a content acquisition button 81 for calling up a content acquisition screen useful for working on the treatment content to the front of the portal page 70. The user can acquire the content by operating the content acquisition button 81. The content that can be called up by the content acquisition button 81 includes manuals (document-based and video-based) that describe the procedures for the treatment content, instruction manuals, etc.

[0203] The portlet operates to display an item arrangement button 82 for calling up an arrangement screen for items required for the work of the procedure to the front of the portal page 70. The user can order items by operating the item arrangement button 82. The items that can be arranged and ordered using the item arrangement button 82 are directly related to the procedure and are based on information (information related to the types, specifications, and quantities of various consumables) registered in advance for each user.

[0204] The portlet generated by the portlet generation module 334 operates to display, as useful information, alarm information 77 indicating the occurrence status of a malfunction event in the industrial equipment 2 on the portal page 70 based on the abnormality notification signal transmitted by the controller 61. In the example shown in Fig. 10, the alarm information 77 includes an alarm code and a message such as "F050-02 has occurred. Please replace XX" or "A001-01 has occurred. Stop the equipment and check XX."

[0205] The portlet operates to display a content acquisition button 83 for calling up a content acquisition screen useful for resolving the malfunction to the front of the portal page 70. The user can acquire the content by operating the content acquisition button 83. The content that can be called up by the content acquisition button 83 includes manuals (document-based and video-based) that describe procedures for resolving the malfunction, instruction manuals, etc.

[0206] The portlet generated by the portlet generation module 334 operates to display status monitoring information 78 as useful information on the portal page 70. The status monitoring information 78 includes display data in which marks 80 that visually represent the condition of each constituent unit of the industrial equipment 2 are superimposed on an equipment flow diagram 79 read from the database 38. The marks 80 include an OK mark 80A that indicates that the condition of the constituent unit of the industrial equipment 2 is good, and an NG mark 80B that indicates that the condition of the constituent unit of the industrial equipment 2 is not good.

[0207] As an example, if the industrial equipment 2 is a steam boiler equipment, its constituent units may include the boiler body, a water supply pipe for supplying boiler feedwater to the boiler body, a water softener for removing hardness components from the boiler feedwater, and a deoxygenator for removing dissolved oxygen from the boiler feedwater.

[0208] Fig. 11 is a diagram showing an example of a maintenance / maintenance page 701 according to the embodiment. When a maintenance / maintenance menu 71B is selected on the portal page 70 shown in Fig. 10, the portal page 70 shown in Fig. 10 transitions to a maintenance / maintenance page 701 shown in Fig. 11. The maintenance / maintenance page 701 is an example of a portal page.

[0209] The portlet generated by the portlet generation module 334 operates to display the operation performance value 84 as useful information on the maintenance page 701. In the example shown in Fig. 11, the operation performance value 84 includes text data of "operation performance value" and numeric data of "**%." Instead of the numeric data of the operation performance value 84, a graphical display such as an indicator bar may be used.

[0210] The portlet operates to display, as useful information, alarm information 85 indicating the occurrence status of a malfunction event in the industrial equipment 2 based on an abnormality notification signal sent by the controller 61 on the maintenance page 701 .

[0211] The portlet operates to display current status data 86 indicating the current status of the industrial facility 2 and comment data 87 regarding the current status of the industrial facility 2 on the maintenance page 701 .

[0212] Fig. 12 is a diagram showing an example of an energy management page 702 according to the embodiment. When an energy management menu 71D is selected on the portal page 70 shown in Fig. 10, the portal page 70 shown in Fig. 10 transitions to an energy management page 702 shown in Fig. 12. The energy management page 702 is an example of a portal page.

[0213] The portlet generated by the portlet generation module 334 operates to display the energy performance value 88 as useful information on the energy management page 702. In the example shown in Fig. 12, the energy performance value 88 includes text data of "energy performance value" and numerical data of "**%". A graphical display such as an indicator bar may be used instead of the numerical data of the energy performance value 88.

[0214] The portlet operates to display on the energy management page 702 a graph area 89 in which a trend graph relating to the energy usage of the industrial equipment 2 is displayed, user proposal information 90 relating to value-added services that provide user benefits and which is used to propose to the user, and the total energy usage 91 of the industrial equipment 2.

[0215] Fig. 13 is a diagram showing an example of a quality control page 703 according to the embodiment. When a quality control menu 71E is selected on the portal page 70 shown in Fig. 10, the portal page 70 shown in Fig. 10 transitions to a quality control page 703 shown in Fig. 13. The quality control page 703 is an example of a portal page.

[0216] The portlet generated by the portlet generation module 334 operates to display the quality performance value 92 as useful information on the quality management page 703. In the example shown in Fig. 13, the quality performance value 92 includes text data of "quality performance value" and numeric data of "**%." Instead of the numeric data of the quality performance value 92, a graphical display such as an indicator bar may be used.

[0217] The portlet operates to display first comment data 93 about the quality performance of the first item (wastewater pH) of the industrial equipment 2 and second comment data 94 about the quality performance of the second item (wastewater temperature) on the quality control page 703.

[0218] Fig. 14 is a diagram showing an example of a steam equipment group page 704 according to the embodiment. When the steam equipment group 72B is selected on the portal page 70 shown in Fig. 10, the portal page 70 shown in Fig. 10 transitions to a steam equipment group page 704 shown in Fig. 14. The steam equipment group page 704 is an example of a portal page.

[0219] In the portal page 70 shown in FIG. 10 , an equipment flow diagram 79 depicting the overall configuration of the industrial equipment 2 (e.g., the overall factory configuration) is displayed as the status monitoring information 78. When at least one equipment group in the second tab group 72 is selected, an equipment flow diagram 79 depicting an equipment group that is a partial configuration of the industrial equipment 2 is displayed as the status monitoring information 78. In the steam equipment group page 704 shown in FIG. 14 , an equipment flow diagram 79 depicting the steam equipment that is a partial configuration of the industrial equipment 2 is displayed as the status monitoring information 78. In addition, marks 80 visually representing the condition of each component unit of the industrial equipment 2 are displayed superimposed on the equipment flow diagram 79. The marks 80 include an OK mark 80A and an NG mark 80B.

[0220] Although not shown, when the water treatment equipment group 72C of the second tab group 72 is selected, an equipment flow diagram 79 depicting the water treatment equipment, which is a partial configuration of the industrial equipment 2, is displayed as the status monitoring information 78. When the refrigeration equipment group 72D is selected, an equipment flow diagram 79 depicting the refrigeration equipment (equipment mainly consisting of heat pumps and chillers), which is a partial configuration of the industrial equipment 2, is displayed as the status monitoring information 78. When the air equipment group 72E is selected, an equipment flow diagram 79 depicting the air equipment (equipment mainly consisting of air compressors), which is a partial configuration of the industrial equipment 2, is displayed as the status monitoring information 78.

[0221] [6] Effects As described above, in the embodiment, the industrial equipment operation support system 1 includes a plurality of environmental sensors 5 arranged in the industrial equipment 2, a plurality of controllers 61 equipped in the industrial equipment 2, and a plurality of information processing devices 6 configured to acquire and store environmental information detected by the environmental sensors 5 and operation information generated by the controllers 61, and having a hierarchical structure for transmitting the environmental information and operation information from downstream to upstream. The plurality of information processing devices 6 include, at one or more hierarchical levels, an information processing engine 31 that performs predetermined information processing on the acquired environmental information and operation information, an information storage platform 37 that stores the environmental information and operation information that has undergone the predetermined information processing, a useful information generation engine 32 that generates useful information contributing to equipment operation using the environmental information and operation information stored in the information storage platform 37, and a UI provision engine 33 that provides a user interface for displaying the useful information generated by the useful information generation engine 32 on a user terminal 40.

[0222] According to this configuration, a hierarchical structure is formed in which multiple information processing devices 6 transmit environmental information detected by the environmental sensors 5 and operation information generated by the controller 61 from downstream to upstream. In any one or more information processing devices 6 at the same level, predetermined information processing is performed on the acquired environmental information and operation information. Therefore, the load of required information processing for the collected environmental information and operation information can be distributed among the multiple information processing devices 6. In addition, useful information contributing to equipment operation is generated using the environmental information and operation information, and the useful information is displayed on the user terminal 40. Because the useful information is displayed on the user terminal 40, the operation of the industrial equipment 2 is supported and the user's workload is reduced.

[0223] In the embodiment, the information processing executed by the information processing engine 31 includes one or both of a batch process that adjusts time-series environmental information to a required time granularity and a grouping process that integrates multiple types of environmental information into an information aggregate linked to a hierarchical level of industrial activity. This configuration aligns the time granularity of related environmental information and integrates it into an information aggregate, thereby enabling highly accurate and fast calculation results using multiple pieces of environmental information. It also facilitates energy management.

[0224] In the embodiment, the UI providing engine 33 provides a user portal as a user interface. The user portal includes a portal page 70 having a screen configuration corresponding to a logged-in user, and a portlet that is incorporated into the portal page 70 and operates to display useful information on the screen. In this configuration, useful information corresponding to the logged-in user is provided to the user.

[0225] In the embodiment, the user portal includes a first tab group generation module 332 that generates a first tab group 71 in a predetermined area of ​​the portal page 70, allowing the user to select a management menu from a plurality of management menus for which the user wishes to receive information, a second tab group generation module 333 that generates a second tab group 72 in a predetermined area of ​​the portal page 70, allowing the user to select a facility group from a plurality of facility groups for which the user wishes to receive information, and a portlet generation module 334 that generates a portlet that displays useful information in a predetermined area of ​​the portal page 70 when a predetermined management menu is selected from the first tab group 71 and a predetermined facility group is selected from the second tab group 72. In this configuration, useful information is displayed on the user terminal 40 according to the management menu and facility group selected by the user.

[0226] In the embodiment, the operation information includes actual operation time information linked to a normal state of the industrial equipment 2 and non-operation time information linked to an abnormal state. The useful information generation engine 32 has an operation performance value calculation module 321 that calculates an operation performance value based on the actual operation time information and the non-operation time information. The portlet operates to display the operation performance value 84 as useful information. In this configuration, the operation performance value 84 is displayed on the user terminal 40, allowing the user to recognize the operation performance of the industrial equipment 2 from the operation performance value.

[0227] In the embodiment, the environmental information includes input energy information and output energy information of the industrial facility 2. The useful information generation engine 32 has an energy performance value calculation module 322 that calculates an energy performance value based on the input energy information and the output energy information. The portlet operates to display the energy performance value 88 as useful information. In this configuration, the energy performance value 88 is displayed on the user terminal 40, allowing the user to recognize the energy performance of the industrial facility 2 from the energy performance value.

[0228] In the embodiment, the environmental information includes actual quality level information of media or articles produced by the industrial facility 2. The useful information generation engine 32 has a quality performance value calculation module 323 that calculates a quality performance value based on the actual quality level information and user-requested quality level information. The portlet operates to display a quality performance value 92 as useful information. In this configuration, the quality performance value 92 is displayed on the user terminal 40, allowing the user to recognize the quality performance of the industrial facility 2 from the quality performance value.

[0229] In the embodiment, the operation information includes actual operation time information linked to a normal state of the industrial equipment 2 and non-operation time information linked to an abnormal state. The environmental information includes input energy information and output energy information for the industrial equipment 2, as well as actual quality level information for media or goods produced by the industrial equipment 2. The useful information generation engine 32 includes an operation performance value calculation module 321 that calculates an operation performance value based on the actual operation time information and non-operation time information, an energy performance value calculation module 322 that calculates an energy performance value based on the input energy information and the output energy information, a quality performance value calculation module 323 that calculates a quality performance value based on the actual quality level information and user-requested quality level information, and an overall score calculation module 324 that calculates an overall score value that integrates two or more performance values ​​from the operation performance value, the energy performance value, and the quality performance value. The portlet operates to display the overall score value 73 as useful information. In this configuration, the overall score value 73 is displayed on the user terminal 40, so that the user can recognize the overall performance of the industrial equipment 2 from the overall score value.

[0230] In the embodiment, the information processing device 6 has a database 38 that accumulates knowledge information that contributes to maintaining or improving each performance value, including the operation performance value, the energy performance value, and the quality performance value. The useful information generation engine 32 has a user-proposed information generation module 325 that generates user-proposed information, which is information related to value-added services that benefit the user based on each performance value and knowledge information and is used to propose to the user. The portlet operates to display user-proposed information 74 as useful information. In this configuration, the user-proposed information 74 is displayed on the user terminal 40, allowing the user to diagnose the industrial equipment 2, change the operating conditions of the industrial equipment 2, or repair the industrial equipment 2 in accordance with the user-proposed information so that the industrial equipment 2 operates properly.

[0231] In the embodiment, the information processing device 6 has a performance value prediction engine 34 that inputs environmental information and operation information accumulated in the information accumulation platform 37 into a mathematical model that simulates the operation of the industrial equipment 2 and outputs one or more virtual performance values ​​from the mathematical model, including an operation performance value, an energy performance value, and a quality performance value. The user-suggested information generation module 325 generates user-suggested information based on the virtual performance values ​​and knowledge information. In this configuration, the virtual performance values ​​are generated using digital twin technology, and user-suggested information is generated.

[0232] In the embodiment, the information processing device 6 has a database 38 that stores an equipment flow diagram 79 that depicts the overall or partial configuration of the industrial equipment 2. The operation information includes the condition of the industrial equipment 2. The useful information generation engine 32 has a status monitoring information generation module 326 that generates status monitoring information 78 by superimposing a mark 80 that visually represents the condition of each constituent unit of the industrial equipment 2 on the equipment flow diagram 79 read from the database 38. The portlet operates to display the status monitoring information 78 as useful information. In this configuration, the status monitoring information 78 is displayed on the user terminal 40, allowing the user to recognize the condition of each constituent unit of the industrial equipment 2.

[0233] In the embodiment, the information processing device 6 has a maintenance planning engine 35 that plans the timing of condition-based maintenance or time-based maintenance of the industrial equipment 2 based on the environmental information and operation information accumulated in the information accumulation platform 37. The useful information generation engine 32 includes a reminder information generation module 327 that generates reminder information that notifies the user of the planned timing of maintenance. The portlet operates to display reminder information 75 as useful information. In this configuration, the reminder information 75 is displayed on the user terminal 40, allowing the user to recognize the timing of maintenance.

[0234] In the embodiment, the information processing device 6 includes a database 38 that defines recommended measures for maintaining the capacity of the industrial equipment 2 or avoiding faults, and a measure extraction engine 36 that extracts measures associated with feature quantities from the database 38 when the feature quantities included in the environmental information or operation information stored in the information storage platform 37 are equal to predetermined numerical values. The useful information generation engine 32 includes a recommended information generation module 328 that generates recommended information that notifies the user of the extracted measures. The portlet operates to display the recommended information 76 as useful information. In this configuration, the recommended information 76 is displayed on the user terminal 40, allowing the user to take measures for maintaining the capacity of the industrial equipment 2 or avoiding faults.

[0235] In the embodiment, the portlet operates to display a content acquisition button 81 for calling up a content acquisition screen useful for the work of the treatment content to the front of the portal page 70. In this configuration, the user can easily acquire content useful for the work of the treatment content by operating the content acquisition button 81 displayed on the user terminal 40.

[0236] In this embodiment, the portlet operates to display an item arrangement button 82 for calling up an arrangement screen for items required for the work of the treatment content to the front of the portal page. In this configuration, the user can easily arrange for items required for the work of the treatment content by operating the item arrangement button 82 displayed on the user terminal 40.

[0237] In the embodiment, the operation information includes an abnormality notification signal transmitted by the controller 61 when a malfunction occurs in the industrial equipment 2. The useful information generation engine 32 has an alarm information generation module 329 that generates alarm information indicating the occurrence status of the malfunction based on the abnormality notification signal. The portlet operates to display alarm information 77 as useful information. In this configuration, the alarm information 77 is displayed on the user terminal 40, allowing the user to recognize that a malfunction has occurred in the industrial equipment 2.

[0238] In the embodiment, the portlet operates to display a content acquisition button 83 for calling up a screen for acquiring content useful for resolving the malfunction to the front of the portal page 70. In this configuration, the user can easily acquire content useful for resolving the malfunction by operating the content acquisition button 83 displayed on the user terminal 40.

[0239] [7] Other Embodiments In the above-described embodiment, the controller 61, which is a lower-level information processing device to which the environmental sensor 5 is connected, includes a microcomputer 61A and a programmable logic controller 61B. The lower-level information processing device to which the environmental sensor 5 is connected may also include a water quality measurement controller. The water quality measurement controller is a device that controls the measurement operation of a colorimetric water quality meter that uses a colorimetric reagent. The water quality measurement controller collects environmental information (water quality measurement values) in real time at preset measurement intervals. The water quality measurement controller is equipped with a light-emitting element and a light-receiving element for each measurement cell. After converting the analog signal from the light-receiving element to digital, the measurement value is determined by referring to a concentration determination table. The water quality measurement controller has a communication interface 13 and can transmit environmental information to an intermediate information processing device via a communication network. Environmental information may also be transmitted to specific industrial facilities (water treatment equipment) and used for operational control at the receiving end. Because the measurement interval varies depending on the water quality item, the time granularity of the environmental information (water quality measurement values) ranges from 0.5 to 24 hours.

[0240] [8] Contribution to the United Nations-led Sustainable Development Goals (SDGs) The industrial equipment operation support system according to the present disclosure can collect a wide range of environmental and operational information on industrial equipment and demand facilities, and can be used for operation management, energy management, quality control, etc. This can improve the energy efficiency and productivity of business establishments, including factories, and contribute to the realization of SDG 7, "Affordable and clean energy for all," of the Sustainable Development Goals (SDGs). Furthermore, improved energy efficiency can also reduce carbon dioxide emissions, which can contribute to the realization of SDG 13, "Take urgent action to combat climate change."

[0241] DESCRIPTION OF SYMBOLS 1...Industrial facility operation support system, 2...Industrial facility, 2A...First industrial facility, 2B...Second industrial facility, 3...Business establishment, 3A...First business establishment, 3B...Second business establishment, 3C...Third business establishment, 4...Factory, 4A...First factory, 4B...Second factory, 5...Environmental sensor, 6...Information processing device, 7...Data collection terminal, 8...Demand facility, 10...Computer, 11...Processor, 12...Storage device, 13...Communication interface, 14...Input / output interface, 21...Supply route, 22...Transportation route, 23...Discharge route, 31...Information processing engine, 32...Useful information generation engine, 33...UI provision engine gin, 34...performance value prediction engine, 35...maintenance planning engine, 36...treatment content extraction engine, 37...information accumulation platform, 38...database, 40...user terminal, 61...controller, 61A...microcomputer, 61B...programmable logic controller, 62...edge computer, 63...gateway, 64...guest computer, 65...host computer, 70...portal page, 71...first tab group, 71A...main menu, 71B...maintenance maintenance menu, 71C...daily maintenance management menu, 71D...energy Energy management menu, 71E...quality control menu, 71F...equipment list menu, 71G...report menu, 72...second tab group, 72A...overall group, 72B...steam equipment group, 72C...water treatment equipment group, 72D...refrigeration equipment group, 72E...air equipment group, 73...total score value, 74...user suggestion information, 75...reminder information, 76...recommendation information, 77...alarm information, 78...status monitoring information, 79...equipment flow diagram, 80...mark, 80A...OK mark, 80B...NG mark, 81...content acquisition button, 82...item arrangement button button, 83...content acquisition button, 84...operation performance value, 85...alarm information, 86...current status data, 87...comment data, 88...energy performance value, 89...graph area, 90...user proposed information, 91...total energy usage, 92...quality performance value, 93...first comment data, 94...second comment data, 321...operation performance value calculation module, 322...energy performance value calculation module, 323...quality performance value calculation module, 324...total score value calculation module, 325...user proposed information generation module, 326...status monitoring information generation module,327... reminder information generation module, 328... recommendation information generation module, 329... alarm information generation module, 331... portal page generation module, 332... first tab group generation module, 333... second tab group generation module, 334... portlet generation module, 701... maintenance page, 702... energy management page, 703... quality control page, 704... steam equipment group page.

Claims

1. An industrial equipment operation support system comprising: a plurality of environmental sensors arranged in industrial equipment; a plurality of controllers equipped on the industrial equipment; and a plurality of information processing devices configured to be able to acquire and store environmental information detected by the environmental sensors and operation information generated by the controllers, and having a hierarchical structure for transmitting the environmental information and the operation information from downstream to upstream, wherein the plurality of information processing devices have, at one or more hierarchical levels: an information processing engine that performs pre-defined information processing on the acquired environmental information and operation information; an information storage platform that stores the environmental information and the operation information that have undergone the pre-defined information processing; a useful information generation engine that generates useful information contributing to equipment operation using the environmental information and the operation information stored in the information storage platform; and a UI provision engine that provides a user interface for displaying the useful information generated by the useful information generation engine on a user terminal.

2. The industrial equipment operation support system of claim 1, wherein the information processing executed by the information processing engine includes one or both of a batch process that adjusts the time-series environmental information to a required time granularity, and a grouping process that integrates multiple different types of environmental information into an information collection linked to a hierarchical level of industrial activity.

3. The industrial equipment operation support system of claim 1, wherein the UI providing engine provides a user portal as a user interface, and the user portal comprises: a portal page with a screen configuration corresponding to a logged-in user; and a portlet that is incorporated into the portal page and operates to display the useful information on the screen.

4. The industrial equipment operation support system of claim 3, wherein the user portal is configured to include: a first tab group generation module that generates a first tab group in a designated area of ​​the portal page for the user to select a management menu from a plurality of management menus for which the user wishes to receive information; a second tab group generation module that generates a second tab group in a designated area of ​​the portal page for the user to select a facility group from a plurality of facility groups for which the user wishes to receive information; and a portlet generation module that generates the portlet that displays the useful information in the designated area of ​​the portal page when a designated management menu is selected from the first tab group and a designated facility group is selected from the second tab group.

5. The industrial equipment operation support system according to claim 3 or claim 4, wherein the operation information includes actual operation time information linked to a normal state of the industrial equipment and non-operation time information linked to an abnormal state, the useful information generation engine has an operation performance value calculation module that calculates an operation performance value based on the actual operation time information and the non-operation time information, and the portlet operates to display the operation performance value as the useful information.

6. The industrial equipment operation support system according to claim 3 or claim 4, wherein the environmental information includes input energy information and output energy information for the industrial equipment, the useful information generation engine has an energy performance value calculation module that calculates an energy performance value based on the input energy information and the output energy information, and the portlet operates to display the energy performance value as the useful information.

7. An industrial equipment operation support system as described in claim 3 or claim 4, wherein the environmental information includes actual quality level information of media or articles produced by the industrial equipment, the useful information generation engine has a quality performance value calculation module that calculates a quality performance value based on the actual quality level information and the user's required quality level information, and the portlet operates to display the quality performance value as the useful information.

8. The industrial equipment operation support system according to claim 3 or claim 4, wherein the operation information includes actual operation time information linked to a normal state of the industrial equipment and non-operation time information linked to an abnormal state, the environmental information includes input energy information and output energy information of the industrial equipment, and actual quality level information of media or goods produced by the industrial equipment, the useful information generation engine has: an operation performance value calculation module that calculates an operation performance value based on the actual operation time information and the non-operation time information, an energy performance value calculation module that calculates an energy performance value based on the input energy information and the output energy information, a quality performance value calculation module that calculates a quality performance value based on the actual quality level information and the user's required quality level information, and an overall score value calculation module that calculates an overall score value that integrates two or more performance values ​​from the operation performance value, the energy performance value, and the quality performance value, and the portlet operates to display the overall score value as the useful information.

9. The industrial equipment operation support system described in claim 8, wherein the information processing device has a database that accumulates knowledge information that contributes to maintaining or improving each of the operation performance values, the energy performance values, and the quality performance values; the useful information generation engine has a user-proposed information generation module that generates user-proposed information to be used in proposing to the user, the user-proposed information being information related to value-added services that bring benefits to the user based on each performance value and the knowledge information; and the portlet operates to display the user-proposed information as the useful information.

10. The industrial equipment operation support system described in claim 9, wherein the information processing device has a performance value prediction engine that inputs the environmental information and the operation information accumulated in the information accumulation platform into a mathematical model that simulates the operation of the industrial equipment and outputs a virtual performance value of one or more of the operation performance value, the energy performance value, and the quality performance value from the mathematical model, and the user-suggested information generation module generates the user-suggested information based on the virtual performance value and the knowledge information.

11. The industrial equipment operation support system described in claim 3 or claim 4, wherein the information processing device has a database storing an equipment flow diagram depicting the overall or partial configuration of the industrial equipment, the operation information includes the good or bad condition of the industrial equipment, the useful information generation engine has a status monitoring information generation module that generates status monitoring information by superimposing a mark that visually represents the good or bad condition of each component unit of the industrial equipment on the equipment flow diagram read from the database, and the portlet operates to display the status monitoring information as the useful information.

12. The industrial equipment operation support system described in claim 3 or claim 4, wherein the information processing device has a maintenance planning engine that plans the timing of condition-based maintenance or time-based maintenance of the industrial equipment based on the environmental information and operation information stored in the information storage platform, the useful information generation engine includes a reminder information generation module that generates reminder information that notifies the timing of the planned maintenance, and the portlet operates to display the reminder information as the useful information.

13. The industrial equipment operation support system according to claim 3 or claim 4, wherein the information processing device comprises: a database that defines recommended action contents for maintaining the capacity of the industrial equipment or avoiding faults; and a action content extraction engine that, when a feature contained in the environmental information or the operation information stored in the information storage platform is a predetermined numerical value, extracts action contents associated with the feature from the database; the useful information generation engine comprises a recommended information generation module that generates recommended information that notifies the extracted action contents; and the portlet operates to display the recommended information as the useful information.

14. The industrial equipment operation support system according to claim 13, wherein the portlet further operates to display a content acquisition button for calling up a content acquisition screen useful for the work of the procedure to the front of the portal page.

15. The industrial equipment operation support system according to claim 13, wherein the portlet further operates to display an item arrangement button for calling up an arrangement screen for items required for the work of the procedure content to the front of the portal page.

16. The industrial equipment operation support system according to claim 3 or claim 4, wherein the operation information includes an abnormality notification signal sent by the controller when a malfunction occurs in the industrial equipment, the useful information generation engine has an alarm information generation module that generates alarm information indicating the occurrence status of the malfunction based on the abnormality notification signal, and the portlet operates to display the alarm information as the useful information.

17. The industrial equipment operation support system according to claim 16, wherein the portlet further operates to display a content acquisition button for calling up a content acquisition screen useful for resolving the malfunction to the front of the portal page.

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