CN113189912B - On-line monitoring and controlling system for workshop equipment energy - Google Patents
On-line monitoring and controlling system for workshop equipment energy Download PDFInfo
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- CN113189912B CN113189912B CN202110513906.3A CN202110513906A CN113189912B CN 113189912 B CN113189912 B CN 113189912B CN 202110513906 A CN202110513906 A CN 202110513906A CN 113189912 B CN113189912 B CN 113189912B
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 16
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 46
- 238000004891 communication Methods 0.000 claims abstract description 40
- 239000003345 natural gas Substances 0.000 claims abstract description 23
- 239000000498 cooling water Substances 0.000 claims abstract description 14
- 238000012423 maintenance Methods 0.000 claims description 32
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- 238000010438 heat treatment Methods 0.000 description 3
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0428—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
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Abstract
The invention discloses an on-line monitoring and controlling system for energy of workshop equipment, wherein each machine to be monitored in a workshop is provided with a PLC (programmable logic controller) to collect a start signal of the equipment, an EMU4-HD (electro-magnetic resonance Unit) electric energy module to collect real-time electric energy data of the machine, a pulse module A to collect cooling water consumption data of the machine, or a pulse module B to collect natural gas consumption data of the machine; then, each machine is respectively connected with a CC-Link communication module as a communication slave station, and the CC-Link communication module is connected to a server; and then the main pipe computer is connected to the server, and the start and stop of each machine are controlled in a feedback mode. The invention can monitor the energy signals of each machine, such as electric energy, cooling water, steam, natural gas and the like, and can adopt a feedback control mode with fewer control circuits.
Description
Technical Field
The invention relates to an energy-saving technology in the electromechanical industry.
Background
The modern industry has continuously improved requirements for enterprise production management, not only monitoring and controlling the state of production sites, but also combining the site information and management information, and establishing a set of fully integrated, open and comprehensive automatic information platform to form comprehensive treatment on information such as business decision, management, planning, scheduling, process optimization, fault diagnosis, site control and the like.
At present, only data acquisition and drawing are carried out on energy consumption of factory energy consumption equipment in China, and high-throughput analysis operation on the data is not carried out. Even the appointed server only aims at the data acquisition function in a certain aspect, the specific upper computer programming and debugging are needed, and the wide application cannot be realized.
Authorized bulletin number: the chinese patent CN101329370B is for an electrical quantity measuring device of an energy transmission line, operatively connected to a cable of a power line or an installation thereof, formed by a device for monitoring a voltage signal and a device for monitoring a current signal. The device for monitoring the voltage signal has a through capacitance (TV) in the form of a metal ring, which is arranged coaxially with the cable and can be connected to a capacitive voltage divider. The device for monitoring a current signal has at least one current sensor with a coil (TA) which is susceptible to current flow through the coil due to inductive effects. The coil is obtained on at least one printed circuit board having a central opening, which is formed by an electrical connection between radial deposits provided on both sides of the printed circuit board and radial deposits arranged on both sides. The patent does not provide the function of the reverse control device.
Authorized bulletin number: the patent CN101446382B describes a special gas supply and distribution device, which relates to the field of high purity gas delivery. The special gas supply and distribution equipment consists of a gas source supply device (1), valves (21-24), pressure sensors (31, 32), a front filter (41), a rear filter (42), an overflow detector (5), a test port (6), a pneumatic angle valve (7), a vacuum generator (8), a gas cylinder (9) and an dead valve (10). The invention adopts the way of transmitting digital quantity signals to the PLC through an RJ45 network line, but the control measures are not adopted when the signals are abnormal.
Disclosure of Invention
The invention aims to:
the workshop equipment energy on-line monitoring and controlling system can detect the electric energy consumption of the machine, the cooling water consumption and the natural gas consumption of the machine and can feed back and control the running state of the machine.
The technical scheme is as follows:
the invention relates to an on-line monitoring and controlling system for workshop equipment energy, which comprises the following hardware architecture: each machine to be monitored in the workshop is provided with a PLC (programmable logic controller) for collecting a start signal of equipment, and an EMU4-HD electric energy module (the EMU4-HD electric energy module can set collection precision and frequency according to the total power value of the equipment) for collecting real-time electric energy data (such as KWH) of the machine; if the use requirement of cooling water (or other refrigerants) is met, the pulse module A is provided for collecting the data of the machine cooling water consumption (such as through a flow test), and if the use requirement of steam (or other heating mediums) is met, the pulse module A is provided for collecting the steam consumption (such as through a steam pressure test); if natural gas (or other gaseous fuel) usage requires, pulse module B is provided to collect machine natural gas usage (e.g., via natural gas volume) data.
And then, a CC-Link communication module (the module can design that the bottom layer uses the combination of CC-Link Field and the upper layer CC-Link control protocol from the aspect of communication architecture, so that the number of monitoring devices can be greatly expanded, the stability of data transmission of each device is ensured) is adopted as an open Field bus device, each machine is respectively connected, and the open Field bus device is used as a communication slave station of one, two, three or four data of each machine.
And then the CC-Link communication module is connected to a server (such as Mitsubishi ecoloweb server III can be selected, and the server is provided with a MODBUS communication interface, and can be used as a communication master station for equipment which is not Mitsubishi products but has a common communication protocol, such as an electric energy instrument, a flow display instrument and the like). Thus, the communication secondary station not only can collect data such as a start signal, electric energy, water (or steam), natural gas and the like of each machine, but also can realize functions such as data processing and display by the communication primary station (server).
The CC-Link communication module preferably adopts a QJ61BT11N module with an expansion function, not only receives the communication protocol of the Mitsubishi energy metering product, but also gives consideration to metering data of other standard communication protocols CC-Link or modbus, has strong expansibility, and is suitable for connection communication of serial-parallel machines with complex structures. Such as communication functions with remote equipment stations, communication functions with local machines, system reliability improvement functions, and easy-to-output functions.
The server is internally provided with control software, standard data parameters of each machine can be input and set, new collected data are recorded and summarized, analysis and comparison are carried out on the data, a produced data graph or a histogram is formed, and the server is connected into an Ethernet network of a factory or a workshop by using a network cable. The factory or workshop manager obtains the data through the webpage login server and obtains the working condition of each machine in each period. The power consumption or other data in the period is found to be obviously increased or reduced, the reason can be analyzed, different operations are adopted to carry out improved control, and even automatic adjustment control is not needed to be realized manually.
In terms of control software setting, the setting of ecoweb serviceIII main server software MES3-255C-CN is mainly researched, according to summarized data, result icons of each month, each day, each hour and even each minute can be selected, a produced data graph and a histogram are provided, data abnormal points and data values which should be stable are pre-judged by comparison, a production manager is helped to find out the problem of non-standardization of production operation, a waste source of energy sources is timely found, such as non-optimization of equipment process parameter setting, overlong material waiting time, overhigh temperature setting and the like, unnecessary excessive processing is omitted, the operation of different operators is caused, the preparation time of a platform is too long, the unnecessary waiting time is too long, and the production efficiency is improved and the water, electricity and gas are saved by the graph.
The specific technical process of the application is as follows:
(1) And designing a complete flow of on-line intelligent monitoring and analysis control of the energy of workshop equipment.
(2) And constructing a hardware architecture system. Each device to be monitored is provided with an EMU4-HD electric energy module and a pulse module, and a CC-Link communication module is extended to be used as a communication slave station. A server module is adopted as a communication master station.
(3) The communication master station sets the number of communication slave stations, sets parameters such as power standard consumption data and pulse standard consumption data for each machine of each communication slave station, and sets acquisition frequency and storage time in the communication master station software.
(4) Setting the address and data acquisition throughput of a server, connecting the server to a factory Ethernet by using a network cable, logging in a web interface of the server by a factory or workshop manager through a manager computer, selecting various setting parameters in a visual picture of the server, and checking equipment data, such as an energy chart or a trend chart.
(5) And feedback controlling the open state of each machine.
The master station firstly collects values at a certain frequency through the server, automatically calculates and predicts the data of the electric energy value, the water energy, the natural gas quantity and the like consumed in the process of the equipment machine in the time period, and compares the data with the standard data of the equipment in the time period when the equipment works normally. Once the abnormal high energy consumption value occurs in the corresponding time period or under the same working condition of starting, the server feeds back the output I/O signal to control the starting state of each machine and can be connected with the alarm device at the same time.
Two common feedback control modes of the machine connection structure (other connection structures can be decomposed into two types of connection structures and then reference is made to the execution):
I. feedback control mode of the tandem machine:
machine 1 and machine 2 are connected in series (referred to as a process series), and communication slave station Q collects each consumption data of machine 1 and machine 2, respectively, and transmits each consumption data to server S; the server S is connected to the Ethernet E, and the host computer, the employee computer and the output equipment are respectively connected to the Ethernet E.
The host computer sends a request to the server S through the feedback of the host PLC, the server S sends an instruction to the PLC of the machine 1, and the PLC of the machine 1 controls the start and stop of the machine 1; the server S issues instructions to the PLC of the machine 2, the PLC of the machine 2 controlling the start and stop of the machine 2.
If the sum of the electric energy, the water quantity or the air quantity consumed by each machine does not have large fluctuation, each machine is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 1 of the previous working procedure is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, and the data of the machine 1 has fluctuation 1, the machine 1 is stopped for maintenance, and the machine 2 in the subsequent process is also stopped and maintenance is not needed.
And II, feedback control mode of parallel machine:
machine 2 and machine 3 are connected in parallel (refer to parallel working procedures), and communication slave station Q collects each consumption data of machine 2 and machine 3 respectively and transmits the consumption data to server S; the server S is connected to the Ethernet E, and the host computer, the employee computer and the output equipment are respectively connected to the Ethernet E.
The host computer sends a request to the server S through the feedback of the host PLC, the server S sends an instruction to the PLC of the machine 2, and the PLC of the machine 2 controls the start and stop of the machine 2; the server S issues instructions to the PLC of the machine 3, the PLC of the machine 3 controlling the start and stop of the machine 3.
If the sum of the electric energy, the water quantity or the air quantity consumed by each machine does not have large fluctuation, each machine is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 3 is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 3 has fluctuation 3, and the difference value between the sum and the fluctuation 3 does not have fluctuation, the machine 3 is stopped for maintenance, and the machine 2 is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 has fluctuation, the machine 2 is stopped for maintenance and the machine 3 is stopped for maintenance;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 3 has fluctuation 3, and the difference value between the sum and the fluctuation 3 has fluctuation, the machine 3 is shut down for maintenance and the machine 2 is shut down for maintenance.
Two feedback control modes of abnormal machine data (cooling water and natural gas):
as the cooling water is used for cooling, the water consumption is more, the cooling effect is good, the water consumption is less, the water flow is insufficient, the temperature is easily raised, and the danger is generated.
So that when the water consumption data of a certain machine is large, emergency stop is not needed (overhaul is carried out after the whole production line is stopped, so that water resource waste is prevented); the consumption of cooling water is less, and the emergency shutdown maintenance is necessary.
Because natural gas is used by combustion, less consumption means that the heating amount is small, the system is safe from the temperature rising angle, more consumption means that the heating amount is large, and the system is unsafe from the temperature rising angle.
So that the natural gas consumption data of a certain machine is smaller without emergency stop (overhauling after the whole production line is stopped, and preventing defective products from occurring due to insufficient heat); emergency shut down for maintenance is necessary if the fuel consumption of a machine is high.
The beneficial effects are that:
the invention can respectively monitor each machine independent of each other, energy signals such as electric energy, cooling water, steam, natural gas and the like can be respectively collected, and the feedback control can adopt an intelligent control mode with fewer control circuits and more accurate control.
The production efficiency of the equipment in stable operation can be known through the management of the original units, and the production efficiency of the same equipment/production line in different time periods or between different equipment/production lines can be compared and analyzed.
The project can realize the function of network energy meter reading, and more importantly, the project has the function of analyzing loopholes in production management, solves the problem of energy meter reading work in a production workshop, and saves time and labor. The factory can predict the trend of the total consumption value in the future; the equipment department can also pre-judge the fault precursor of the equipment in early stage through the abnormal power consumption data value of the equipment, and timely make maintenance and maintenance measures. All energy sources such as electric power, steam, natural gas, water and the like are spirally upgraded and improved, and the method is an important development direction of 4.0 of energy conservation and intelligent factories in the future.
Drawings
FIG. 1 is a schematic diagram of the connection and control circuitry of a tandem machine of the present invention;
fig. 2 is a schematic diagram of a parallel machine connection and control circuit according to the present invention.
In the figure, 1-machine 1PLC; 2-machine 1; 3-machine 3; 4-machine 3PLC; 5-master PLC;6, a main computer; 7-an output device; 8-staff computers; 9-Ethernet; 10-a server; 11-CC-Link module (or QJ61BT11N module); 12-machine 2; 13-machine 2PLC.
Detailed Description
Embodiment one:
the plant energy on-line monitoring and control system of fig. 1, machine 1 and machine 2 are connected in series.
The adopted hardware architecture comprises: each machine to be monitored in the workshop is provided with a PLC (programmable logic controller) for acquiring a start signal of equipment, and an EMU4-HD electric energy module for acquiring real-time electric energy data of the machine; or a pulse module A is provided for collecting the consumption data of the machine cooling water, or a pulse module B is provided for collecting the consumption data of the natural gas of the machine; then, a CC-Link communication module is adopted to be respectively connected with each machine to be used as a communication slave station of one, two, three or four data of each machine; then connecting the CC-Link communication module to a server as a communication master station; control software is built in the server, standard data parameters of each machine can be input and set, new collected data are recorded and summarized, and analysis and comparison are carried out on the data to form a produced data graph or bar graph; the server is connected to the factory Ethernet, the factory or workshop manager logs in the server through the host computer, sets parameters, checks data and feeds back and controls the start state of each machine.
If the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 1 of the previous working procedure is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, and the data of the machine 1 has fluctuation 1, the machine 1 is stopped for maintenance, and the machine 2 in the subsequent process is also stopped and maintenance is not needed.
Embodiment two:
the machine 2 is connected with the machine 3 in parallel as shown in the figure as a 2 workshop equipment energy on-line monitoring and control system.
The adopted hardware architecture comprises: each machine to be monitored in the workshop is provided with a PLC (programmable logic controller) for acquiring a start signal of equipment, and an EMU4-HD electric energy module for acquiring real-time electric energy data of the machine; or a pulse module A is provided for collecting the consumption data of the machine cooling water, or a pulse module B is provided for collecting the consumption data of the natural gas of the machine; then, the QJ61BT11N module is used for respectively connecting each machine as a communication slave station of one, two, three or four data of each machine; then connecting the QJ61BT11N module to a server as a communication master station; control software is built in the server, standard data parameters of each machine can be input and set, new collected data are recorded and summarized, and analysis and comparison are carried out on the data to form a produced data graph or bar graph; the server is connected to the factory Ethernet, the factory or workshop manager logs in the server through the host computer, sets parameters, checks data and feeds back and controls the start state of each machine.
If the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 3 is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 has fluctuation, the machine 2 is shut down for maintenance and the machine 3 is shut down for maintenance.
Claims (3)
1. An on-line monitoring and control system for workshop equipment energy, which adopts a hardware architecture comprising: each machine to be monitored in the workshop is provided with a PLC (programmable logic controller) for acquiring a start signal of equipment, and the machine to be monitored is provided with a machine 1 and a machine 2 which are connected in series;
an EMU4-HD electric energy module is equipped to collect real-time electric energy data of the machine; the pulse module A is provided for collecting the consumption data of the machine cooling water, and the pulse module B is provided for collecting the consumption data of the natural gas of the machine; then, a CC-Link communication module is adopted to be respectively connected with each machine and used as a communication slave station of the electric energy value, the water consumption and the natural gas consumption data of each machine; then connecting the CC-Link communication module to a server as a communication master station; control software is built in the server, standard data parameters of each machine can be input and set, new collected data are recorded and summarized, and analysis and comparison are carried out on the data to form a produced data graph or bar graph; the server is connected to a factory Ethernet, a factory or workshop supervisor logs in the server through a supervisor computer, parameters are set, data are checked, and the starting state of each machine is controlled in a feedback mode;
the communication master station sets the number of communication slave stations, sets acquisition frequency and storage time in the communication master station software, checks and predicts the consumed electric energy value, water consumption and natural gas consumption data of each machine to be monitored in the time period flow of the equipment, and compares the consumed electric energy value, water consumption and natural gas consumption data with standard data of the machine in the time period when the machine works normally; once an abnormally high energy consumption value occurs, the server feeds back an output I/O signal to control the starting state of each machine; the method is characterized in that:
the following feedback mode is adopted:
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine does not have large fluctuation, each machine is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 1 of the previous working procedure is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation and the data of the machine 1 has fluctuation 1, the machine 1 is stopped for maintenance, the machine 2 in the subsequent procedure is stopped and maintenance is not needed;
in the machine 1 and the machine 2, when the water consumption data of a certain machine is large, the machine is not stopped in an emergency, and the cooling water consumption is reduced for maintenance in an emergency stop; the machine does not need emergency stop when the natural gas consumption data of a certain machine is small, and the machine is in emergency stop maintenance when the natural gas consumption is large.
2. The plant energy on-line monitoring and control system of claim 1, wherein:
there is also a machine 3 connected in parallel with the machine 2; the following feedback approach is used:
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 does not have fluctuation, the machine 2 is stopped for maintenance, and the machine 3 is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 3 has fluctuation 3, and the difference value between the sum and the fluctuation 3 does not have fluctuation, the machine 3 is stopped for maintenance, and the machine 2 is not stopped;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 2 has fluctuation 2, and the difference value between the sum and the fluctuation 2 has fluctuation, the machine 2 is stopped for maintenance and the machine 3 is stopped for maintenance;
if the sum of the electric energy, the water quantity or the air quantity consumed by each machine has large fluctuation, the data of the machine 3 has fluctuation 3, and the difference value between the sum and the fluctuation 3 has fluctuation, the machine 3 is shut down for maintenance and the machine 2 is shut down for maintenance;
when the water consumption data of a certain machine is large, the machine is not stopped in an emergency, and the cooling water consumption is less in emergency stop maintenance; the machine does not need emergency stop when the natural gas consumption data of a certain machine is small, and the machine is in emergency stop maintenance when the natural gas consumption is large.
3. The plant energy on-line monitoring and control system according to claim 1 or 2, characterized in that: the pulse module A has the function of collecting the steam consumption.
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