TWI783593B - Intelligent production line equipment precise preventive maintenance and energy consumption visual monitoring system and method - Google Patents

Abstract

The present invention discloses a smart production line equipment precise preventive maintenance and energy consumption visualization monitoring system and method thereof, which includes an equipment monitoring module, an energy consumption monitoring module, an equipment health diagnosis unit and a monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes a routine maintenance control database and an equipment diagnosis module. The equipment diagnosis module searches for the schedule control data of machine parts that are about to expire to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, power consumption history information and working power consumption information in a visual way, so that by establishing a smart machinery industry network, the health, decline, failure and other conditions of equipment can be monitored in real time to reduce downtime Failure time and major losses, as well as energy visualization monitoring and cumulative power consumption, instantaneous voltage and other power consumption history tracking for power consumption, as energy consumption simulation and prediction-peak off-peak suggestions.

Description

Intelligent production line equipment precise preventive maintenance and energy consumption visual monitoring system and method

The present invention relates to a precise preventive maintenance and energy consumption visualization monitoring system and method for intelligent production line equipment, especially a system that can reduce downtime by establishing an industrial network of intelligent machinery to control equipment health, decline, and failure in real time It is an intelligent production line equipment control technology that can monitor power consumption visually and track the history of power consumption such as cumulative power consumption and instantaneous voltage.

By the way, the maintenance of general machine equipment (such as metal processing tools; or other machine processing equipment, etc.) is mostly realized by manpower or computer control. The maintenance schedule of machine equipment and the replacement of required machine parts The schedule is recorded in the work log or the computer management database; in other words, the staff must constantly monitor the work log or computer management database, so as to achieve the purpose of machine equipment maintenance and machine parts replacement. Although this conventional technology can achieve the functions of basic maintenance and machine parts replacement; however, when the key machine parts (such as cutting tools) of the machine equipment are in a state of exhaustion, it is really difficult to control in terms of manpower control ; That is, failures are about to occur but are not discovered, resulting in a decline in production quality and yield. When the equipment is shut down and fails, production scheduling impacts and production capacity declines will occur during maintenance, resulting in serious losses.

In order to solve the above-mentioned deficiencies, industry players in related technical fields have developed a patent as shown in Invention No. I663510 "Equipment Maintenance Prediction System and Its Operation Method". the patent It includes a processor, a factor decision module, a prediction module and a maintenance early warning module, the processor is electrically connected to the factor decision module, the prediction module and the maintenance early warning module, and the processor uses The factor decision module selects one of multiple parameter types as a decision parameter type according to a key parameter type, and the decision parameter type is the most relevant to the key parameter type; the processor makes the prediction module according to the decision parameter A predictive model is generated from the partial plurality of historical sensing values of the type and a maintenance alert condition is formulated based on the partial plurality of historical sensing values of the key parameter type. Although the patent enables the maintenance warning module to monitor and warn according to the maintenance warning conditions to achieve regular maintenance and predictive warning functions; however, the patent does not have a big data function for visual monitoring of energy consumption, so that it is impossible to monitor electricity consumption. Visual monitoring of energy - cumulative power consumption, instantaneous voltage and other power consumption history tracking and other management, so that it is impossible to make energy consumption simulation and prediction system - peak off-peak, power contract capacity and power cost calculation energy consumption, etc. It is suggested that, therefore, this patent is indeed not perfect in terms of functional enhancement, and thus there is a need for improvement.

Furthermore, the current major tool processing manufacturers in China mainly use power capture systems to capture the total power consumption data of processing machines. Obviously, there is indeed no energy-saving solution that can effectively evaluate the optimal processing conditions for existing production line equipment. Not only that, at present, the major domestic tool processing manufacturers will not be able to accurately define the content of the electricity contract due to the complex factors in the estimation of the entire plant's electricity consumption, resulting in situations where the demand cannot be met or misestimated. Therefore, how to develop a technology that can establish a big data cloud database to realize the predictability of production intelligent production line equipment maintenance, track energy usage visualization, and energy consumption simulation prediction has become an urgent challenge and solution for industry players in related technical fields. technical issues.

The reason is that, based on the urgent needs of related industries, the inventor has finally developed a set of the present invention which is different from the above-mentioned conventional technology and the previously disclosed patents through continuous efforts in research and development.

The first purpose of the present invention is to provide a precise preventive maintenance and energy consumption visualization monitoring system and method for intelligent production line equipment, mainly through the establishment of intelligent machinery industry networking, and real-time control of equipment health, decline, Faults and other conditions, reduce downtime and major losses, increase stand-alone production capacity, avoid defective product output, and further conduct energy visualization monitoring of electricity consumption-accumulated electricity consumption, instantaneous voltage and other power consumption history tracking management, to Make suggestions on energy consumption simulation and forecasting system - off-peak peak, electricity contract capacity and electricity cost calculation energy consumption, etc. The technical means to achieve the aforementioned first objective include equipment monitoring module, energy consumption monitoring module, equipment health diagnosis unit and monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes a routine maintenance control database and an equipment diagnosis module. The equipment diagnosis module searches for the schedule control data of machine parts that are about to expire to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, electricity consumption history information and working electricity consumption information in a visual way.

The second object of the present invention is to provide a precise preventive maintenance and energy consumption visual monitoring system and method for smart production line equipment capable of outputting diagnostic prediction information as a basis for modulating the diagnostic information. The technical means to achieve the aforementioned second objective include equipment monitoring module, energy consumption monitoring module, equipment health diagnosis unit and monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes routine maintenance control database and equipment diagnosis Module, the equipment diagnosis module searches for the schedule control data of machine parts that are about to expire, so as to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, electricity consumption history information and working electricity consumption information in a visual way. Wherein, the equipment health diagnosis unit further includes a diagnosis prediction module and a data database, the diagnosis prediction module calculates a diagnosis prediction message after obtaining the at least one monitoring signal, and stores the diagnosis prediction module in the data base In the database, the diagnosis prediction information is to predict the monitoring signal obtained by the at least one equipment monitoring module from detecting the at least one working machine in the future, so as to serve as a basis for adjusting the diagnosis information.

The third object of the present invention is to provide a precise preventive maintenance and energy consumption visual monitoring system and method for intelligent production line equipment equipped with simulated and predicted electricity demand forecast information. The technical means to achieve the aforementioned third objective include equipment monitoring module, energy consumption monitoring module, equipment health diagnosis unit and monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes a routine maintenance control database and an equipment diagnosis module. The equipment diagnosis module searches for the schedule control data of machine parts that are about to expire to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, electricity consumption history information and working electricity consumption information in a visual way. Wherein, the energy consumption monitoring module further includes an energy consumption simulation prediction module, which obtains the electricity consumption history information and the working electricity consumption information and simulates and predicts an electricity demand prediction information.

The fourth object of the present invention is to provide a precise preventive maintenance and energy consumption visual monitoring system for intelligent production line equipment with the real-scene visual display and monitoring functions of processing machines. The system and its method are mainly based on the construction of real scene visualization data of the processing machine and machine parts to make it easier to control and monitor the processing machine and machine parts, and the installation position of the equipment is displayed with the current status of the diagram. When the administrator clicks on the equipment, relevant detailed information can be provided immediately, making it easy and clear to monitor the status. The technical means to achieve the aforementioned fourth objective include equipment monitoring module, energy consumption monitoring module, equipment health diagnosis unit and monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes a routine maintenance control database and an equipment diagnosis module. The equipment diagnosis module searches for the schedule control data of machine parts that are about to expire to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, electricity consumption history information and working electricity consumption information in a visual way. Wherein, the routine maintenance control database further includes a plurality of environmental real image photos, a plurality of overall photos and a plurality of machine part photos extracted from the environment where the at least one working machine is located, and each machine part photo is correspondingly set with a The time schedule control data; one display screen display of the at least one monitoring device includes a real image display interface for displaying the real image photo of the environment, the overall photo and the machine part photo and a text corresponding to the time schedule control data Data display interface; when at least one of the machine parts needs to be replaced, maintained or repaired, the equipment diagnosis module will output a series of real image photos of the environment corresponding to the at least one machine part that needs to be replaced, maintained or repaired, The overall photo, the machine part photo and the corresponding time schedule control data are then visually displayed by the real image display interface and the text data display interface of the at least one monitoring device.

The fifth object of the present invention is to provide a continuous machine dynamic image that can display the real-time operation status of the processing machine when the information of recession or fault diagnosis is issued, so that the machine can be displayed at the first time A smart production line equipment precise preventive maintenance and energy consumption visual monitoring system and method based on preliminary fault judgment. The technical means to achieve the aforementioned fifth objective includes equipment monitoring module, energy consumption monitoring module, equipment health diagnosis unit and monitoring device. The data processing module collects and processes the monitoring signal of the equipment monitoring module as monitoring information. The energy consumption monitoring module monitors the power consumption of the working machine and the processing control parameters, and outputs the power consumption history information and the working power consumption information as the basis for modifying the processing control parameters. The equipment health diagnosis unit includes a routine maintenance control database and an equipment diagnosis module. The equipment diagnosis module searches for the schedule control data of machine parts that are about to expire to input maintenance information. The equipment diagnosis module receives monitoring information and obtains diagnosis information through calculation and analysis. The monitoring device displays maintenance information, diagnosis information, electricity consumption history information and working electricity consumption information in a visual way. Wherein, at least one image capture device is provided near the position of the at least one working machine, which is used to capture the operation status of the at least one working machine and image it as a continuous dynamic image of the machine. The at least one monitoring device has a built-in There is a monitoring program (APP), when the diagnostic information is decline or failure, the monitoring program (APP) displays the diagnosis information of decline or failure on one of its display screens and is used to input and display the dynamic image of the machine When the input interface is activated, the display screen displays the real-time dynamic image of the at least one working machine.

1: Working machine

1a: Controller

10: Equipment monitoring module

11:Device sensing module

110: sensor

111: Data acquisition module

12: Data processing module

20: Energy consumption monitoring module

21: Energy consumption simulation prediction module

22: Energy consumption database

30:Equipment health diagnosis unit

31: Routine maintenance control database

32:Equipment diagnosis module

33: Prediction module

34: Data database

40: Monitoring device

41: display screen

410: Real image display interface

411: Text data display interface

412: Floor plan display interface

42: Image acquisition module of workpiece to be processed

43: Quantity input module

44:Processing engineering input module

50:Network communication system

FIG. 1 is a schematic diagram of the implementation of the overall architecture of the present invention.

FIG. 2 is a schematic diagram of the implementation of the functional block connection of the specific architecture of the present invention.

Fig. 3 is a schematic diagram of the application and implementation of the energy consumption monitoring module of the present invention.

FIG. 4 is a schematic diagram of another implementation of the energy consumption monitoring module of the present invention.

Fig. 5 is a schematic diagram of the implementation of the real image display interface of the present invention to display the real image photo of the whole machine.

FIG. 6 is a schematic diagram showing another real image photo of a machine on the real image display interface of the present invention.

FIG. 7 is a schematic diagram showing another real image photo of a machine on the real image display interface of the present invention.

FIG. 8 is a schematic diagram of the implementation of the plan view display interface of the present invention for displaying plan view data.

In order to allow your review committee to further understand the overall technical characteristics of the present invention and the technical means to achieve the purpose of the present invention, specific embodiments and accompanying drawings are hereby described in detail:

Please refer to Fig. 1, 3 and Fig. 4, in order to achieve the first specific embodiment of the first object of the present invention, it includes an equipment monitoring module 10, an energy consumption monitoring module 20, and an equipment health diagnosis unit 30 And technical features such as a monitoring device 40. The equipment monitoring module 10 includes a plurality of equipment sensing modules 11 and a data processing module 12. The plurality of equipment sensing modules 11 are used to monitor the operating status of each working machine 1 arranged in a factory area to generate monitoring signals. The data processing module 12 is used for collecting monitoring signals and converting them into monitoring information. Each equipment sensing module 11 includes a sensor 110. The sensor 110 includes a working machine image capture module, a noise sensing module and a vibration sensing module. The working machine image capture The module is used to capture the machine dynamic image of the working machine 1 to generate a real-time machine dynamic image signal and capture the image of the working machine 1 at a predetermined time to generate a real-time machine image signal, the noise The sensing module is used to sense the noise generated by the working machine 1 to generate an instant noise signal, and the vibration sensing module is used to sense the vibration state generated by the working machine 1 to generate an instant vibration signal , the plurality of monitoring signals includes the real-time machine dynamic image signal, the real-time noise signal and the real-time vibration signal. The equipment sensing module 11 converts the real-time machine dynamic image signal and the real-time machine image signal, the real-time noise signal and the real-time vibration signal into real-time machine dynamic image and real-time machine image, real-time noise information and real-time vibration Information, the plurality of monitoring information includes the real-time machine dynamic image and real-time machine image, the real-time noise information and the real-time vibration information. The equipment monitoring module 10 further establishes each working machine, the image of the machine parts corresponding to the working machine, and the image data of the machine parts installed on the working machine library, the identification information database of each working machine and each machine part, and the address information and factory floor plan database of each working machine located in the factory area and each machine part located in the corresponding working machine The address information of the station and the image database of the working machine.

As shown in Figures 1, 3 and 4, the energy consumption monitoring module 20 is used to monitor the power consumption of the working machine 1 and the processing control parameters (such as processing formula or displacement control program, etc.; but not This is the limit) to complete the processing time and power consumption to output the power consumption history information and work power consumption information of the working machine 1 in multiple working periods, and to use the power consumption history information and work power consumption information The information is used as the basis for modifying the processing control parameters. The electricity usage history information includes electricity usage time period and electricity usage time. The equipment health diagnosis unit 30 includes a regular maintenance control database 31 with schedule control data for multiple machine parts corresponding to the working machine 1, an abnormal maintenance control database, and an equipment diagnosis module 32. The equipment diagnosis module The group 32 automatically searches the routine maintenance control database 31 for at least one machine part schedule control data that is about to expire at each interval, so as to output the maintenance information of the machine parts that need to be replaced, maintained or repaired. On the other hand, the equipment diagnosis module 32 receives the multiple monitoring information including the real-time machine dynamic image, the real-time noise information and the real-time vibration information output by the equipment monitoring module 10, and according to the real-time machine dynamic Compare the image with the real-time machine image, the real-time noise information and the real-time vibration information with the reference machine image feature parameters, reference noise parameters and reference vibration parameters in the abnormal maintenance control database to find the corresponding abnormal machine parts , to output the abnormal maintenance information of the machine parts to be maintained, and the corresponding diagnostic information representing normality, decline and failure can be obtained through calculation analysis. The energy consumption monitoring module 20 establishes a reference machine image feature parameter database of each workpiece to be processed, and establishes the electricity consumption history information and the work cost corresponding to each processing project of each workpiece to be processed. Electricity information database; it is used for estimating the required total electricity consumption for utilization according to the quantity of the work to be processed, the required processing engineering, the electricity consumption time and the electricity consumption. Energy consumption monitoring module 20 more Establish a graphical display module, which is used to display the electricity consumption history information and the work electricity consumption information of each processing project of each workpiece to be processed as a graph for users to easily and clearly Understand the power demand status of each workpiece to be processed and its processing engineering. The energy consumption monitoring module 20 further establishes an off-peak electricity evaluation modeling group. The off-peak electricity evaluation modeling group allows users to input the models of all workpieces to be processed, the quantity of workpieces to be processed, and the corresponding required processing projects. And compared with the preset off-peak power consumption time period, the processing time suggestion information of each workpiece to be processed is generated for the user's reference.

As shown in Figures 1, 3 and 4, the monitoring device 40 displays maintenance information, diagnostic information, power consumption history information and working power consumption information in a visual manner, which is used to receive the maintenance information and maintenance information of the machine parts. The abnormal maintenance message of the machine part is triggered to display the machine part to be maintained and repaired, and to display the image of the machine part to be maintained and repaired, and the machine part is installed on the working machine and the plane image of the factory area where the working machine is located in the factory area. The monitoring device 40 includes a piece to be processed image capture module 42, a quantity input module 43 and a processing engineering input module 44, the piece to be processed image capture module 42 is used to capture the image of the piece to be processed in real time Generate real-time image information of workpieces to be processed, the quantity input module 43 is used for inputting a quantity value of the workpieces to be processed, and the processing project input module 44 is used for inputting a processing project; the monitoring device 40 will instantly process the image information of the workpieces in The image feature parameter database of the reference machine is compared to the workpiece to be processed, and the required power consumption time and power consumption are estimated for use according to the input quantity value and the processing project.

Specifically, as shown in Figure 1, the equipment monitoring module 11 includes at least one sensor 110 and at least one data acquisition module 111; the at least one sensor 110 is used to monitor the operating status of each working machine 1 and generate sensing data; the at least one data acquisition module 111 is used to monitor the control information of the controller 1a (PLC) of each working machine 1; the data processing module 12 is used to collect each sensing data and The control message is processed and converted into the monitoring information mentioned above.

Please refer to Figures 1 to 4, in order to achieve the second specific embodiment of the second object of the present invention, in addition to the overall technical content of the aforementioned first specific embodiment, the device health diagnosis unit 30 further includes A prediction module 33 and a data database 34 . The prediction module 33 calculates a diagnostic prediction message after obtaining each monitoring signal, and stores the diagnostic prediction message in the data database 34. The diagnostic prediction message is the monitoring obtained by the future detection of the working machine 1 by the equipment monitoring module 11. The signal is used as the basis for modulating the fault diagnosis message. Specifically, the forecasting module 33 above can be a technique using gray forecasting method, moving average method, linear regression method or one-time exponential smoothing method.

Please refer to the embodiment shown in FIGS. 1-2 , the equipment monitoring module 10, the energy consumption monitoring module 20 (such as a cloud server), the equipment health diagnosis unit 30 (such as a cloud server) and a plurality of monitoring devices 40 ( Such as a computer or a smart phone) are connected to each other through a network communication system 50, so that the equipment monitoring module 10 can send each monitoring information and the energy consumption monitoring module 20 can send the electricity consumption history information and the working electricity consumption information to the remote end Upload to the equipment health diagnosis unit 30, and enable the remote monitoring device 40 to download maintenance information, diagnosis information, power consumption history information and working power consumption information.

As mentioned above, the equipment health diagnosis unit 30 further includes a data database 34, the data database 34 is used to record multiple maintenance messages, multiple diagnostic messages, equipment monitoring modules 10 and energy consumption monitoring modules generated in each time period. Multiple monitoring information, multiple power consumption history messages and multiple working power consumption messages uploaded by group 20 in each time period.

Please refer to Figures 1 to 4, in order to achieve the third specific embodiment of the third object of the present invention, this embodiment includes the overall technical content of the first specific embodiment above, the energy consumption monitoring module 20 is more It includes an energy consumption simulation and forecasting module 21. The energy consumption simulation and forecasting module 21 simulates and predicts an electricity demand forecasting message after obtaining the electricity consumption history information and the working electricity consumption information. Wherein, the energy consumption monitoring module 20 further includes an energy consumption database 22, and the energy consumption database 22 contains There is a peak-off-peak electricity price data and an order scheduling data, and the energy consumption simulation prediction module 21 makes a power consumption planning suggestion message according to the peak-off-peak electricity price data and order scheduling data, as shown in FIG. 4 Show.

Please refer to Figures 1-7, in order to achieve the fourth specific embodiment of the fourth object of the present invention, in addition to including the overall technical content of the first specific embodiment, the routine maintenance control database 31 is more Including the establishment of multiple environmental real image photos, multiple overall photos and multiple machine part photos extracted from the environment where the working machine 1 is located. Each machine part photo is correspondingly set with a schedule control data. The display screen 41 display of the monitoring device 40 includes a real image display interface 410 for displaying environmental real image photos, overall photos and machine parts photos and a text data display interface 411 for displaying corresponding time schedule control data; when at least one of the machine When a machine part needs to be replaced, maintained or repaired, the equipment diagnosis module will output a series of environmental real image photos, overall photos (that is, the overall photo of the working machine), machine parts The photo (that is, the partial photo of the working machine) and the corresponding schedule control data are then visually displayed by the real image display interface 410 and the text data display interface 411 of the monitoring device 40 .

Based on the above, the routine maintenance control database 31 further includes the establishment and storage of the plan data of the monitored location of at least one working machine 1. When at least one machine part needs to be replaced, maintained or repaired, the equipment diagnosis module The group 32 outputs the plan data corresponding to the parts of the machine that need to be replaced, maintained or repaired, and displays it on the display screen 41 on the plan view display interface 412 of the monitoring device 40, as shown in FIG. 8 .

Please refer to Figs. 1 to 7, in order to achieve the fifth specific embodiment of the fifth object of the present invention, in addition to the overall technical content of the aforementioned first specific embodiment, the present embodiment is provided near the position of each working machine. There is at least one image capture device, which is used to capture the operating status of each working machine and image it as a continuous dynamic image of the machine. Each monitoring device has a built-in monitoring program (APP), when the broken message is decline or failure, the monitoring program (APP) then displays the diagnosis information of decline or failure on one of the display screens 41 and the input for displaying the dynamic image of the machine for input interface, when the input interface is activated, the display screen 41 then displays the real-time machine dynamic images of each working machine.

Specifically, the power consumption history information is selected from one or a combination of cumulative power consumption, instantaneous voltage, processing power consumption of each single section, idle power consumption, processing power consumption, and air-cutting power consumption, as shown in Figure 3 . The construction of the equipment monitoring module 10 and the equipment health diagnosis unit 30 of the present invention is mainly considered to be able to grasp the exhaustion status of metal processing machinery or cutting tools or machine equipment, and to establish an equipment maintenance data management system, through data management The library can timely remind the operator when to perform equipment maintenance, such as replacing tools, to avoid poor quality of the produced workpieces due to equipment metal fatigue or tool breakage. Therefore, the present invention can build a set of predictability functions for machine equipment maintenance of the intelligent production line equipment system. In the case of equipment and machine health pre-diagnosis, the machine equipment is about to fail but has not been found, resulting in a decline in production quality and yield. When the shutdown fails, production scheduling impacts, production capacity decline, etc. are caused during the maintenance period. The loss is huge, and the production equipment is easily damaged. For key machine parts, develop health diagnosis database and calculation analysis technology. Real-time control of equipment health, decline, failure and other conditions, reduce downtime/major losses, increase single-machine production capacity (full-line production capacity), and avoid defective product output.

As for the construction of the energy consumption monitoring module 20, it is mainly considered to be applied to some industries of hand tools such as the forging process. The forging process is a high-energy-consuming industry, especially in the summer when electricity consumption is tight, and it is often concerned by the power company. It is hoped that it will replace energy-saving equipment in the factory or make proper planning for peak and off-peak power consumption. Therefore, the control of energy consumption is very important. The planning energy visualization system can allow managers to understand and do a good job of avoiding peak power consumption and reducing energy use costs. economic benefits. Establish a big data cloud database to track energy usage visualization, energy consumption simulation prediction, production history traceability, etc. establish After the establishment of the smart machinery industrial machine networking, it will further improve the electricity consumption. Energy visualization monitoring - cumulative power consumption, instantaneous voltage and other power consumption history tracking, and energy consumption simulation and prediction system - peak and off-peak recommendations and power contract capacity and power cost calculation energy consumption. For example, the forging industry is traditionally a high-energy-consuming industry, and energy costs usually account for about 20% of variable costs. With the continuous rise of energy prices in the international market, the proportion of energy costs of enterprises will continue to rise; energy conservation work will directly affect the competitiveness of enterprises. Usually, most forgings, especially die forgings, must undergo heat treatment to meet the processing performance or performance requirements of forgings. The energy consumption of the heat treatment process accounts for about 30% to 35% of the entire energy consumption of forgings. It is important to reduce heat treatment consumption. content. After the hot forging process is completed, the forging still has a residual heat of about 1000 ° C, which provides an available space for subsequent heat treatment. Post-forging heat treatment can not only greatly reduce the energy consumption of heat treatment, but also shorten the production cycle, improve production efficiency, and reduce equipment investment. It is an important energy-saving practice.

Therefore, after the detailed description of the above specific embodiments, the present invention really has the following characteristics:

1. The present invention can indeed control equipment health, decline, failure and other conditions in real time by establishing a smart machinery industry network with big data cloud computing technology, reduce downtime and major losses, increase stand-alone production capacity, avoid defective product output, and It can further carry out energy visual monitoring of electricity consumption-accumulated electricity consumption, instantaneous voltage and other electricity consumption history tracking and other management to make energy consumption simulation and prediction system-peak off-peak, electricity contract capacity and electricity cost accounting energy Suggestions on power consumption, etc.

2. The present invention does have the function of outputting diagnostic prediction information as a basis for modulating the diagnostic information.

3. The present invention does have functions such as simulating and predicting electricity demand forecast information.

4. The present invention can capture the power consumption of the processing machine in each working period and the single-section processing formula generated by the processing process, and establish the power consumption history of each working period.

5. The present invention can integrate the power consumption signals of the production line machines to analyze the power consumption during the product processing period, and can predict the total power consumption of the whole factory through forecasting power demand and order scheduling, so as to dynamically predict power consumption The content of the contract effectively meets the electricity demand.

6. The present invention has the real-scene visual display and monitoring functions of the processing machine, mainly through the construction of the real-scene visualization data of the processing machine and machine parts, making it easier to control and monitor the processing machine and machine parts, and The installation location of the equipment is displayed with the current status of the diagram. When the manager clicks on the equipment, the relevant detailed information can be provided immediately, so that the status monitoring is simple and clear.

7. The present invention can display the continuous machine dynamic images of the real-time operation status of the processing machine when the information of recession or fault diagnosis is released, so as to make the basis for the preliminary judgment of the fault at the first time.

The above is only a more feasible embodiment of the present invention, and is not intended to limit the patent scope of the present invention. All equivalent implementations of other changes based on the content, features and spirit of the following claims are cited. All should be included in the patent scope of the present invention. The structural features of the invention specifically defined in the claims are not found in similar items, and are practical and progressive, and have met the requirements of an invention patent. I file an application in accordance with the law. I would like to ask the Jun Bureau to approve the patent in accordance with the law to maintain this invention. The legitimate rights and interests of the applicant.

1: Working machine

1a: Controller

10: Equipment monitoring module

11:Equipment monitoring module

110: sensor

111: Data acquisition module

12: Data processing module

20: Energy consumption monitoring module

30:Equipment health diagnosis unit

40: Monitoring device

41: display screen

42: Image acquisition module of workpiece to be processed

43: Quantity input module

44:Processing engineering input module

50:Network communication system

Claims (6)

A precise preventive maintenance and energy consumption visual monitoring system for intelligent production line equipment, which includes: An equipment monitoring module, which includes a plurality of equipment sensing modules and a data processing module; the plurality of equipment sensing modules are respectively used to sense the operating status of a plurality of working machines installed in a factory area to generate a plurality of monitoring signals, The data processing module is used to collect the multiple monitoring signals and process them into multiple monitoring information; each equipment sensing module includes a working machine image capture module, a noise sensing module and a vibration sensing module set, the working machine image capture module is used to capture the machine dynamic image of the working machine to generate a real-time machine dynamic image signal and a real-time machine image signal, and the noise sensing module is used to sense Measuring the noise generated by the working machine to generate a real-time noise signal, the vibration sensing module is used to sense the vibration state generated by the working machine to generate a real-time vibration signal, the plurality of monitoring signals includes the real-time machine dynamics The image signal and the real-time machine image signal, the real-time noise signal and the real-time vibration signal; the device sensing module combines the real-time machine motion image signal and the real-time machine image signal, the real-time noise signal and the real-time vibration signal Converted into real-time machine dynamic images and real-time machine images, real-time noise information and real-time vibration information, the plurality of monitoring information includes the real-time machine dynamic images and real-time machine images, the real-time noise information and the real-time vibration information; the device The monitoring module also establishes each working machine, the image of the machine parts corresponding to the working machine, and the image database of the machine parts installed on the working machine. Each working machine and each machine part The identification information database, and the address information of each working machine in the factory area and the factory floor plan database, and the address information and image database of the working machine where each machine part is located in the corresponding working machine ; An energy consumption monitoring module, which is used to monitor a set of processing control parameters for each processing project of each workpiece to be processed by each working machine and the time and power consumption required to complete the processing, so as to output the The power consumption history information and work power consumption information of each processing project for each workpiece to be processed by the operating machine. The power consumption history information includes the power consumption period and power consumption time; it establishes the benchmark for each workpiece to be processed The image feature parameter database of the machine, and the electricity consumption history information and the work electricity consumption information database corresponding to each processing project of each workpiece to be processed are established; it is used to base on the quantity of the work to be processed , the required processing engineering, power consumption time and power consumption to estimate the total power consumption required for utilization; An equipment health diagnosis unit, which includes a regular maintenance control database for machine parts of each working machine, an abnormal maintenance control database, and an equipment diagnosis module. Automatically search the routine maintenance control database for the time schedule control data of the machine parts that are about to expire, so as to output the maintenance information of the machine parts to be maintained; the equipment diagnosis module receives information from the equipment sensing module Output the multiple monitoring information including the real-time machine dynamic image and the real-time machine image, the real-time noise information and the real-time vibration information, and based on the real-time machine dynamic image, the real-time noise information and the real-time vibration information and the Compare the reference machine image feature parameters, reference noise parameters, and reference vibration parameters in the abnormal maintenance control database to the corresponding abnormal machine parts, so as to output the abnormal maintenance information of the machine parts to be repaired; and A monitoring device, which is used to be triggered by the maintenance message of the machine part and the abnormal maintenance message of the machine part, to display the machine part to be maintained and repaired, and to display the machine part to be maintained and repaired The image of the machine part, the image of the machine part installed on the working machine, and the plant plane image of the working machine located in the factory area; it includes an image capture module for workpieces to be processed, a quantity input module Set and a processing project input module, the image capture module of the workpiece to be processed is used to capture the image of the workpiece to be processed in real time to generate real-time image information of the workpiece to be processed, the quantity input module is used to input a quantity of the workpiece to be processed value, the processing project input module is used to input a processing project; the The monitoring device compares the image information of the workpiece to be processed in real time with the image feature parameter database of the reference machine to obtain the workpiece to be processed, and estimates the required power consumption time and power consumption according to the input quantity value and the processing project for use; wherein, the equipment health diagnosis unit further includes a prediction module and a data database, and the prediction module calculates a diagnosis prediction message after obtaining the at least one monitoring signal, and stores the diagnosis prediction module in In the data database, the diagnosis prediction information is to predict the monitoring signal obtained by the at least one equipment monitoring module from detecting the at least one working machine in the future, as a basis for modulating the fault diagnosis information; the power consumption history information is Selected from one or a combination of cumulative power consumption, instantaneous voltage, processing power consumption of each single section, idle power consumption, processing power consumption, and air-cutting power consumption; the routine maintenance control database also includes information extracted from the A plurality of environmental real image photos, a plurality of overall photos and a plurality of machine part photos of the environment where at least one working machine is located, and each of the machine part photos is correspondingly set with a time schedule control data; the prediction module is selected from the gray prediction method, moving average method, linear regression method and exponential smoothing method; one of the display screen display of the at least one monitoring device includes a real image display interface for displaying the real image photo of the environment, the overall photo and the machine part photo and a text data display interface corresponding to the time schedule control data; when at least one of the machine parts needs to be replaced, maintained or repaired, the equipment diagnosis module will output a series of the at least one part that needs to be replaced, maintained or repaired The real image photo of the environment, the overall photo, the photo of the machine part, and the corresponding time schedule control data corresponding to a machine part are visually displayed by the real image display interface and the text data display interface of the at least one monitoring device , the routine maintenance control database further includes establishing and storing the plan data of the monitored location of the at least one working machine. When at least one of the machine parts needs to be replaced, maintained or repaired, the equipment diagnosis module outputs the required The plan data of the at least one machine part to be replaced, maintained or repaired is displayed on the display screen on the plan view display interface of the at least one monitoring device. The precise preventive maintenance and energy consumption visualization monitoring system for intelligent production line equipment as described in claim 1, wherein the equipment monitoring module, the energy consumption monitoring module, the equipment health diagnosis unit and the at least one monitoring device are connected through A network communication system is connected with each other to enable the equipment monitoring module to upload at least one monitoring information and the energy consumption monitoring module to remotely upload the electricity consumption history information and the working electricity consumption information to the equipment health diagnosis unit, and enable the at least one monitoring device to remotely download the maintenance information, the diagnosis information, the electricity consumption history information and the working electricity consumption information. As stated in claim 2, the accurate preventive maintenance and energy consumption visualization monitoring system for smart production line equipment, wherein, the equipment health diagnosis unit further includes a data database, which is used to record the multiple Maintenance information, the plurality of diagnostic messages, the plurality of monitoring information uploaded by the equipment monitoring module and the energy consumption monitoring module at each time period, the plurality of electricity consumption history messages, and the plurality of work electricity consumption information. As described in claim 1, the accurate preventive maintenance and energy consumption visualization monitoring system for smart production line equipment, wherein the energy consumption monitoring module further includes an energy consumption simulation prediction module, which obtains the energy consumption simulation and prediction module After the electricity history information and the work electricity consumption information are simulated and predicted to generate an electricity demand forecast message; the energy consumption monitoring module further includes an energy consumption database, and the energy consumption database has a peak-off-peak electricity price data and An order scheduling data, the energy consumption simulation prediction module makes a power consumption planning suggestion message according to the peak-off-peak electricity price data and the order scheduling data. The accurate preventive maintenance and energy consumption visualization monitoring system for intelligent production line equipment as described in claim 1, wherein at least one image capture device is installed near the position of the at least one work machine to capture the at least one work The operating status of the machine is imaged as a continuous dynamic image of the machine. A monitoring program (APP) is built in the at least one monitoring device. A display screen displays the diagnostic message of degradation or failure and an input interface for inputting and displaying the dynamic image of the machine. When the input interface is activated, the display screen is Displaying the real-time dynamic image of the at least one working machine. A precise preventive maintenance and energy consumption visualization monitoring method for intelligent production line equipment, which includes: providing multiple equipment monitoring modules, an energy consumption monitoring module, an equipment health diagnosis unit, and a monitoring device; the equipment monitoring module includes a An equipment sensing module and a data processing module; the plurality of equipment sensing modules are respectively used to sense the operating status of a plurality of working machines installed in a factory area to generate a plurality of monitoring signals, and the data processing module is used to collect the Multiple monitoring signals are processed and converted into multiple monitoring information; each equipment monitoring module includes a working machine image capture module, a noise sensing module and a vibration sensing module; the equipment monitoring module is built with each A working machine, an image of machine parts corresponding to the working machine and an image database of the machine parts installed on the working machine, an identification information database of each working machine and each machine part, And the address information of each working machine located in the factory area and the factory floor plan database and the address information of the working machine and the image database of the working machine corresponding to each machine part; the energy consumption monitoring module Establish a reference machine image feature parameter database for each workpiece to be processed, and establish a database of the electricity consumption history information and the power consumption information database corresponding to each processing project of each workpiece to be processed; The equipment health diagnosis unit includes a regular maintenance control database, an abnormal maintenance control database, and an equipment diagnosis module for the machine parts of each working machine; the monitoring device includes an image capture module for workpieces to be processed , a quantity input module and a processing project input module, the image capture module of the workpiece to be processed is used to capture the image of the workpiece to be processed in real time to generate real-time image information of the workpiece to be processed, the quantity input module is used to input the image of the workpiece to be processed A quantity value of a workpiece, the processing project input module is used to input a processing project; the energy consumption monitoring module establishes a graphical display module and an off-peak power consumption evaluation modeling group; the image capture of the working machine The acquisition module captures the machine dynamic image of the working machine to generate a Real-time machine dynamic image signal and real-time machine image signal, using the noise sensing module to sense the noise generated by the working machine to generate a real-time noise signal, using the vibration sensing module to sense the noise generated by the working machine The vibration state generates a real-time vibration signal, so that the multiple monitoring signals include the real-time machine dynamic image signal and the real-time machine video signal, the real-time noise signal and the real-time vibration signal; the real-time The machine dynamic image signal and the real-time machine image signal, the real-time noise signal and the real-time vibration signal are converted into real-time machine dynamic image, real-time noise information and real-time vibration information, so that the plurality of monitoring information includes the real-time machine dynamic image With the real-time machine image, the real-time noise information and the real-time vibration information; use the energy consumption monitoring module to monitor a set of processing control parameters of each working machine for each processing project of each workpiece to be processed to complete the processing The required time and power consumption to output the power consumption history information and working power consumption information of each work machine for each processing project of each workpiece to be processed. The power consumption history information includes power consumption time period and power consumption Time; use the energy consumption monitoring module to estimate the total power consumption required for utilization based on the quantity of work to be processed, the required processing engineering, power consumption time and power consumption; display in this graph The module displays the electricity consumption history information and the work electricity consumption information of each processing project of each workpiece to be processed as a graph; the energy consumption monitoring module is used for the user to input the model of all workpieces to be processed, the workpieces to be processed The quantity and the corresponding processing engineering required are compared with a preset off-peak power consumption time period, and the processing time suggestion information of each workpiece to be processed is generated for user reference; the equipment diagnosis module is used for each Automatically search the schedule control data of the machine parts that are about to expire in the regular maintenance control database at intervals, so as to output the maintenance information of the machine parts to be maintained; use the equipment diagnosis module to receive information from the equipment monitoring module group output includes the instant machine The multiple monitoring information of the dynamic image of the machine and the real-time machine image, the real-time noise information and the real-time vibration information, and based on the real-time machine dynamic image and the real-time machine image, the real-time noise information and the real-time vibration information and The reference machine image feature parameters, reference noise parameters and reference vibration parameters in the abnormal maintenance control database are compared to the corresponding abnormal machine parts, so as to output the abnormal maintenance information of the machine parts to be repaired; and The monitoring device is triggered by the maintenance message of the machine part and the abnormal maintenance message of the machine part to display the machine part to be maintained and repaired, and to display the status of the machine part to be maintained and repaired Image, the image of the machine parts installed on the working machine and the plane image of the working machine located in the factory area; and use the monitoring device to upload the image information of the real-time workpiece to be processed to the image characteristic parameter data of the reference machine Kubi takes out the parts to be processed, and estimates the required power consumption time and power consumption for utilization according to the input quantity value and the processing project; wherein, the equipment health diagnosis unit further includes a prediction module and A data database, the prediction module calculates a diagnostic prediction message after obtaining the at least one monitoring signal, and stores the diagnostic prediction module in the data database, the diagnostic prediction information is to predict the at least one equipment monitoring model Group the monitoring signal obtained by detecting the at least one working machine in the future as the basis for adjusting the diagnostic message of the fault; the power consumption history information is selected from the cumulative power consumption, instantaneous voltage, processing power consumption of each single section, One or a combination of idle power consumption, processing power consumption, and air-cutting power consumption; the routine maintenance control database further includes multiple environmental real-image photos, multiple overall photos, and multiple The photo of the machine part, each of the photo of the machine part is correspondingly set with the schedule control data; the prediction module is selected from one of the gray prediction method, moving average method, linear regression method and one-time exponential smoothing method; the A display screen display of at least one monitoring device includes a real image for displaying the real image photo of the environment, the overall photo and the photo of the machine parts A display interface and a text data display interface corresponding to the time schedule control data; when at least one of the parts of the machine needs to be replaced, maintained or repaired, the equipment diagnostic module outputs a series of information related to the need for replacement, maintenance or repair The real image photo of the environment, the overall photo, the photo of the machine part and the corresponding time schedule control data corresponding to the at least one machine part are visualized by the real image display interface and the text data display interface of the at least one monitoring device According to the display, the routine maintenance control database further includes the establishment and storage of the floor plan data of the monitored location of the at least one working machine. When at least one of the machine parts needs to be replaced, maintained or repaired, the equipment diagnosis module will Output the floor plan data corresponding to the at least one machine part that needs to be replaced, maintained or repaired, and display it on the display screen on the floor plan display interface of the at least one monitoring device.

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