JP5312475B2 - Method for analyzing energy consumption of mechanical device and mechanical device - Google Patents

Abstract

A method for analysing the power consumption in machines, wherein one method step involves a multiplicity of data items being recorded which are characteristic of a plurality of sub-procedures in an operating procedure and also a multiplicity of data items being recorded which are characteristic of a power consumption for the machine. Another step involves the data items for the sub-procedures of the machine and the data items which are characteristic of the power consumption of the machine being stored in a memory device (10). Finally, the power consumption is ascertained from the data items recorded in a memory device (10) and the power consumption is displayed, the power consumption for at least two sub-procedures being able to be shown separately.

Description

  The present invention relates to a method for analyzing energy consumption of a mechanical device, and the mechanical device. Recently, there has been an increasing demand for systems to reduce the energy consumption of machinery. In the prior art, it has long been known to provide an ammeter that detects the energy consumption of the entire system. However, these current measuring devices can only output a certain amount of consumption value, with a fine consumption of the true flow for each step, work tool, or time such as main work time or sub work time. It had the disadvantage that the quantity could not be output.

  Therefore, the problem underlying the present invention is to be able to accurately analyze the energy consumption of a mechanical device. This problem is solved by a method for analyzing the energy consumption of a mechanical device having the characteristics of claim 1 of the present invention and the mechanical device having the characteristics of claim 11 of the present invention. Advantageous embodiments and implementations are described in the dependent claims.

In the energy consumption analysis method for a mechanical device according to the present invention, first, a plurality of data representing each partial function of one work function of the mechanical device is recorded, and then a plurality of data representing the energy consumption amount of the mechanical device. Then, a plurality of data representing each partial function and a plurality of data representing the energy consumption amount are stored in the memory device, and the energy consumption amount is obtained from the data stored in the memory device and displayed. The Here, the energy consumption for at least two partial functions is displayed separately.

  According to the method of the invention, the energy consumption of the mechanical device is displayed in detail. That is, not only the total energy consumption of the mechanical device but also the energy consumption for each partial process and the energy consumption for each work unit can be displayed in detail. Displaying each part in this way requires a particularly energy-intensive process or drive. This makes it possible to introduce measures for reducing the energy consumption of the corresponding process or of the corresponding drive.

FIG. 3 is a block diagram of the method of the present invention. It is a graph of the 1st variation of the energy consumption of a mechanical device. It is a graph of the 2nd variation of the energy consumption of a mechanical apparatus. It is a graph of the 3rd variation of the energy consumption of a mechanical apparatus.

Advantageously, a plurality of data or quantities representing the energy consumption of the mechanical device are measured by the sensor device. In the present invention, the energy consumption in the mechanical device can be detected in a specific manner related to the mechanical function, and can be displayed graphically. For this reason, energy consumption can be reduced manually or automatically. Such energy record analysis methods are not known in the automation field. In other words, it is known to record individual signals such as engine flow rate during signal analysis, but in order to output energy characteristic values, individual signals such as engine flow rate are specifically evaluated in relation to the function. It is not known to do. For this reason, fine analysis cannot be performed in the prior art, but according to the present invention, analysis related to functions , processes and work tools, or analysis related to main work time, sub work time and other time can be performed. It is.

  In an advantageous embodiment, a plurality of data representing energy consumption and the reference data are compared. For example, measurement data such as engine flow rate is compared with the target flow rate, and high energy consumption is inferred. In addition to directly measuring energy consumption, it is also possible to detect parameters such as engine torque and engine flow that have a significant effect on energy consumption, and to infer energy consumption using these parameters. The energy consumption amount is obtained from these parameters by using a mathematical method, and the obtained energy consumption amount is graphically displayed to the user. In addition to electrical parameters, mechanical parameters can also be measured to determine energy consumption.

The two partial functions are for example two different process steps in one process. It can also be configured such that the two partial functions represent two different work tools or two different drives, from which the energy consumption of the mechanical device can be inferred. In another advantageous embodiment, a representative value for comparison between a plurality of data representing energy consumption and the reference data is output. In this way, it is possible to display to the user whether or not the measured energy consumption corresponds to the predicted value or whether or not the value exceeds the predicted value, for example.

  For example, individual machine parts, mechanical mechanisms (hydraulic system means, pneumatic system means, cooling means), shafts (individual shafts, rail shafts, auxiliary shafts), spindles, etc., programmed work processes, processing processes , Process steps, work tools, operating strategies, NC sets, main work time, sub work time, work tool time, work tool change time, etc., can be displayed in particular graphical form.

  In another advantageous embodiment, a work order is output based on the result of the comparison. This automatically analyzes the data measured and stored in the memory device and outputs suggestions to the user on how to save energy. The user can also optimize the consumption by himself.

  In another advantageous embodiment, the mechanical device is controlled in consideration of a plurality of data representing energy consumption. To be precise, the individual partial processes can be optimized on the basis of the determined data. Therefore, it can be confirmed that, for example, the energy consumption of a certain cooling pump is high during the control. Moreover, the power consumption of the cooling pump can be reduced without impairing the process executed by the mechanical device. Thus, the energy consumption can be reduced by accurately analyzing the energy consumption and subsequently introducing specific measures. The parameters to be measured are, for example, engine flow rate, engine stress, engine torque, engine speed, and the like.

Advantageously, each partial function is a temporal part of one work function . In this case, the entire work function is temporally divided into a plurality of process steps, and the energy consumption is analyzed for each work function .

Alternatively, each partial function may represent a respective work tool of the mechanical device. This means, for example, that the energy consumption is strictly analyzed for each of the plurality of drive units of the mechanical device, and which unit of the single mechanical device is intensively consuming energy is identified. It is also possible to determine the energy consumption over a predetermined time. At this time, the analysis of energy consumption may be performed with or without being related to the program flow. Furthermore, the energy consumption over a predetermined working distance, in particular the energy consumption over the working distance of a given work tool element, can also be monitored in relation to or not related to the program flow. As described above, the energy consumption varies from work tool to work tool or from time to time. For example, it varies depending on the main work time, the sub work time, the work tool exchange time, the member exchange time, the use time, and the like. It is also possible to monitor each energy consumption separately for each control channel.

  By storing the above-described data, the recorded data can be accurately analyzed later. It is also possible to perform optimization by comparing the energy consumption between the recordings. Further, it is possible to distinguish the energy consumption for each work sequence, each processing cycle, each partial cycle, and each hierarchy.

  The energy consumption is displayed by various graphs such as a bar code graph or a pie graph.

  Furthermore, analysis using the Internet can be performed. For example, a user of a mechanical device can store a plurality of data representing energy consumption at a predetermined position and access a database via the Internet for evaluation of the data. Here, the data is formed from, for example, a data sheet.

In another advantageous embodiment, a plurality of data representing each partial function and a plurality of data representing energy consumption are repeatedly recorded and stored.

  For example, energy data can be recorded, stored, and processed periodically, for example, weekly, over a predetermined period of time. In this way, for example, by outputting a trend graph, condition monitoring for early identification of component damage can be performed.

  For example, if three measurements and recordings are made and energy-related data of individual parts is collected, the corresponding mechanical device is switched on during the first measurement but no movement occurs, and the second In the measurement, the mechanical device moves without a member to be processed (that is, idles), and in the third measurement, the mechanical device moves to process the member.

  Of these measurements, the energy value required for the work process of the mechanical device can be inferred by subtracting the energy determined in the second measurement from the energy determined in the third measurement. Of these measurements, the energy required for the motion of the mechanical device can be inferred by subtracting the energy determined in the first measurement from the energy determined in the second measurement.

  Furthermore, the status of each part or each step can be inferred by periodically measuring.

The invention also relates to a mechanical device. The mechanical device of the present invention includes at least one sensor unit that transmits at least one value representing the energy consumption amount of the mechanical device, a plurality of data representing each partial function of one work function of the mechanical device, and the A first output device that outputs a value representing the energy consumption of the mechanical device, a memory device that stores a plurality of data representing the energy consumption value and each partial function, and a different energy consumption from each partial function A corresponding processor device and a second output device for separately displaying the energy consumption of at least two partial functions . The second output device is in particular a display device such as a display or a monitor.

Therefore, according to the mechanical apparatus of this invention, the energy consumption for every partial function can be displayed. Here, the partial function may be an operation for each component such as various driving units, or may be a temporal portion or a spatial portion of the operation of one or a plurality of components.

  The sensor device is a flow rate measuring device that measures a predetermined engine flow rate of the drive unit. Advantageously, a plurality of such flow measuring devices are provided. In particular, one unique sensor unit is provided for each drive unit (drive element) of the mechanical device.

By making each data representing energy consumption correspond to each partial function , as described above, the energy consumption of the mechanical device can be easily analyzed.

  In another advantageous embodiment, the mechanical device has an input device for inputting another data describing the mechanical device to the memory device. Here, for example, the input device is a PC capable of inputting data formed from a data sheet such as a target flow rate and a target torque. If these data are used supplementarily, analysis of energy consumption becomes easy. It is also possible to perform estimation using these data as supplementary information.

  Further advantageously, the machine device has a plurality of drive units and has an output device for individually outputting a plurality of data representing the energy consumption of each drive unit. In this way, the energy consumption of the mechanical device can be strictly analyzed for each of the various drive units.

  In another advantageous embodiment, the mechanical device has a control device for controlling itself, and the control device outputs characteristic data used to control the mechanical device to a memory device. In this case, for example, SPS control for controlling the mechanical device is performed. The feature data used for controlling the mechanical device is not only output to the mechanical device for control but also output to the memory device. Such SPS data is also taken into account when evaluating the energy consumption of the machine, which allows a rigorous analysis of the energy consumption.

  Other features, advantages and embodiments of the present invention will be described with reference to the illustrated examples.

  FIG. 1 shows a block diagram of the method of the present invention. Here, an actual mechanical device 1 having a plurality of drive units is used. In addition, at least one, preferably a plurality of sensor devices 2 are provided, which record data or measured quantities representing energy consumption.

  An output device 4 is also provided for outputting engine characteristic data such as engine flow rate, engine speed, and engine torque to the receiving device. In general, drive bus data is output via the output device 4. On the contrary, a plurality of data, in particular, different data for each drive unit can be transferred from the input unit 6 to the actual mechanical device 1 or the drive unit 4 inside thereof.

  Further, an output device 5 is provided for outputting the characteristic quantities of the sensor device 2, for example, measured characteristic quantities such as a position sensor, a temperature sensor, and a pressure sensor.

  Sensor data is received by the input unit 7. The data transmitted to the input units 6 and 7 is sent to the memory device or data collection device 10 and stored therein. For this reason, the memory device 10 also stores data representing the energy consumption of the mechanical device. In addition, data directly representing the motion sequence of the engine, such as data on the engine driving time and work tool exchange time, is also stored.

  In this way, in the memory device 10, for example, data representing each energy consumption amount is associated with and stored in a plurality of steps obtained by dividing one process in terms of time. The mechanical device of the present invention is also provided with a control device 16 that performs control for operating the actual mechanical device in the normal mode. In this case, SPS control is particularly performed. Data used for actual control of the mechanical device 1 is also stored in the memory device 10. In this way, data specific to control can be assigned.

  In addition, a first input device 18 such as a PC for inputting data representing the machine device 1 as a data sheet is also provided. Furthermore, a second input device 22 is also provided here for sending internal NC data, for example data describing the relevant work tool, to the memory device 10. Therefore, as a whole, an actual control system 20 for the machine device 1 is formed.

  In the illustrated block 25, processing of data stored in the memory device 10 is performed. More specifically, the data stored in the memory device 10 is analyzed using mathematical auxiliary means, and a measure of energy consumption is output. At this time, the energy consumption for each part of the actual mechanical device can be output separately. Therefore, the energy consumption amount for each drive unit such as a pump drive mechanism can be output. In addition, the energy consumption can be output in relation to the generated pressure. For this purpose, a data processing unit 12 is provided.

  The energy consumption of the mechanical device 1 is displayed graphically by the display device 14.

For example, the formula _Pist (t) = _Uist (t) · _Iist (t)
Instantaneous power actual value _{P ist} (t) is outputted in accordance with.

にしたがって、エネルギ値も出力される。 Correspondingly, the formula

Accordingly, the energy value is also output.

Instead of the actual voltage value _Uist (t) or the actual current value _Iist (t), another parameter proportional to these may be used for the approximate calculation. For example, the target voltage value U _soll , the voltage average value U _Mittelwelt , or the voltage value U _Datenblatt extracted from the data sheet can be used. Correspondingly, the target current value _Isol , the current average value I _Mittelwelt , the current value taken from the data sheet or the current curve I _Datenblatt, etc. can also be used. In particular, if this is done, the energy consumption of the SPS-controlled drive, such as a hydraulic drive mechanism or electrical actuator, can be determined very simply.

Precisely, the actual voltage value U _ist (t), which is a measured quantity, and the actual current value I _ist (t), which is a calculated approximate quantity, can be used to calculate power.

In place of electric power, the expression P _Mech (t) = _Fist (t) · _νist (t) + _Mist (t) · _ωist (t)
The mechanical output can also be detected as follows.

  FIG. 2 shows a first embodiment of the display of energy consumption. Here, the energy consumption is shown in various time formats, i.e. times divided according to main work time I, sub work time II, work tool change time III. Each bar in the graph represents an individual drive A-E of the machine. In this way, it is evaluated that the drive units A and D require a large amount of power during the main work time. Such measures to reduce power are also attempted within the scope of analysis. The power P is shown on the y-axis of the graph.

  FIG. 3 shows a second embodiment of the display of energy consumption. Here, the energy consumption in the set process is shown for various work tools F to K. In addition, each bar can be divided according to the work step of the work tool, so that a finer display can be performed. For this purpose, work tools can be called up in the display for further analysis.

FIG. 4 shows a third embodiment of the display of energy consumption. Here, a curve 30 shows a time characteristic E (t) of energy consumption and a time characteristic P (t) of power consumption in a predetermined component, for example, an electric drive mechanism. In FIG. 4, not only the time characteristics but also the consumption for each partial function of the work function or for each instruction line of the program is shown as a lower partial diagram. In this way, it is possible to analyze which step or program instruction the energy is particularly concentrated on. To be precise, NC flow analysis is possible and individual sets can be monitored separately from the point of view of energy consumption.

  In particular, by using data from the control device, it is possible to confirm an energy efficient process and know how to save energy. For example, when looking at the individual parts of a mechanical device, suppose that the coolant pump is found to account for a very large component of the total energy consumption. At the same time, it is detected that the coolant pressure maintained by the coolant pump is significantly higher than the pressure required for normal operation of the machinery. In this case, the driving state of the coolant pump can be corrected to reduce the energy consumption in the entire mechanical device.

  All features shown in the specification, claims and drawings of the present application may be the subject of the present invention alone or in any combination as long as they are novel with respect to the prior art.

  DESCRIPTION OF SYMBOLS 1 Mechanical apparatus, 2 Sensor apparatus, 4,5 Output apparatus, 6,7 Input part, 10 Memory apparatus or data collection apparatus, 12 Data processing unit, 14 Display apparatus, 16 Control apparatus, 18 1st input apparatus, 20 Control System, 22 second input device, 25 blocks, 30 curves, I main work time, II sub work time, III work tool change time, A, B, C, D, E power or energy consumption in the drive, F, G, H, I, K Power or energy consumption in machinery, P Power

Claims (15)

Recording a plurality of data representing each partial function of one work function of a mechanical device, each partial function being a different process step in one process;
Recording a plurality of data representing energy consumption of the mechanical device;
Storing a plurality of data representing each partial function of one work function of the mechanical device and a plurality of data representing an energy consumption amount of the mechanical device in a memory device;
Determining the energy consumption as a function of time from data stored in the memory device;
An energy consumption analysis of a mechanical device, characterized in that the energy consumption for the determined at least two partial functions is displayed for each individual process step and further for each instruction line of the program Method.   The method for analyzing energy consumption of a mechanical device according to claim 1, wherein a plurality of data representing the energy consumption of the mechanical device are compared with reference data.   The method for analyzing energy consumption of a mechanical device according to claim 2, wherein a representative value for comparison between the plurality of data representing the energy consumption of the mechanical device and the reference data is output.   The analysis method of the energy consumption of the mechanical device of Claim 2 or 3 which outputs a work instruction | indication based on the said comparison performed.   The method for analyzing energy consumption of a mechanical device according to any one of claims 1 to 4, wherein the mechanical device is controlled in consideration of a plurality of data representing energy consumption of the mechanical device.   6. The method for analyzing energy consumption of a mechanical device according to claim 1, wherein each partial function is a temporal part of the one work function.   6. The method for analyzing energy consumption of a mechanical device according to claim 1, wherein each partial function is a spatial part of one work function.   6. The method for analyzing energy consumption of a mechanical device according to claim 1, wherein each partial function is a sequence unique to various work tools of the mechanical device.   9. The method for analyzing energy consumption of a mechanical device according to claim 2, wherein a plurality of data of various work functions are compared.   The method for analyzing energy consumption of a mechanical device according to any one of claims 1 to 9, wherein the energy consumption is analyzed using the Internet.   11. The apparatus according to claim 1, wherein a plurality of data representing each partial function of one work function of the mechanical device and a plurality of data representing energy consumption of the mechanical device are repeatedly recorded and stored. A method for analyzing the energy consumption of the machine device according to the item. At least one sensor unit (2) for outputting at least one value representing the energy consumption of the mechanical device (1);
A first output device (4, 5) for outputting a plurality of data representing each partial function of one work function of the mechanical device and a value of energy consumption of the mechanical device;
A memory device (10) for storing each value of energy consumption of the mechanical device and a plurality of data or values representing each partial function of one work function of the mechanical device;
A processor device (12) that associates each partial function with a different energy consumption;
A second output device (14) for separately displaying the energy consumption of at least two partial functions,
Wherein each part feature, Ri different process steps der in one process,
In the memory device (10), data or values representing the energy consumption are stored in association with each process step as a function of time,
The determined energy consumption of at least two partial functions is displayed for each individual process step and also for each instruction line of the program by means of the second output device (14). A mechanical device (1) characterized by the above.   The mechanical device (1) according to claim 12, wherein the mechanical device (1) comprises an input device (18) for inputting data describing the mechanical device (1) to the memory device (10).   The said mechanical device (1) has a some drive part, The some data showing the energy consumption of each drive part is output separately by the said 2nd output device (14). Or the mechanical apparatus (1) of 13.   The mechanical device has a control device (16) for controlling itself, and the control device (16) sends a plurality of data for controlling the mechanical device to the memory device (10). 15. A machine (1) according to any one of claims 12 to 14.

Images