Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It will be understood that the terms "comprises" and/or "comprising," when used in this specification and the appended claims, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
It is also to be understood that the terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the specification of the present invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It should be further understood that the term "and/or" as used in this specification and the appended claims refers to any and all possible combinations of one or more of the associated listed items and includes such combinations.
Referring to fig. 1, fig. 1 is a schematic flow chart of a process data and management coordination method according to an embodiment of the present invention, which specifically includes: steps S101 to S106.
S101, establishing a process time domain relation and a corresponding process time domain relation graph according to actual service requirements;
s102, defining at least one process path according to the sequence of the processes based on the process time sequence relation and the process time domain relation graph, defining the length of the process path according to the process path, and setting corresponding process sequence numbers for the processes according to the process path;
s103, creating process metadata corresponding to each process based on the process time sequence relation and the process sequence number;
s104, acquiring parameter data corresponding to each procedure, and establishing a corresponding minimum energy consumption operation parameter table for each procedure through the parameter data;
s105, determining at least one starting process according to the process sequence number, taking the starting process as a first target process, and setting reasonable operation parameters for the first target process according to a parameter setting process;
wherein, the parameter setting process comprises: acquiring the output rate corresponding to the first target process; when the output rates of all the first target processes are larger than 0, calculating the reasonable output rate of each first target process according to the process metadata; setting reasonable operation parameters for the first target process by combining the minimum energy consumption operation parameter table and the reasonable output rate;
and S106, based on the parameter setting process, sequentially setting corresponding reasonable operation parameters for subsequent processes of the beginning process according to the process sequence number, and starting each process according to the reasonable operation parameters.
In this embodiment, a corresponding process time-domain relationship and a process time-domain relationship graph are first established according to a service requirement in an actual scene, so that at least one process path corresponding to an actual service can be obtained in the process time-domain relationship graph, and meanwhile, the length of each process path is determined to select a longest process path, and a process sequence number is set for each process according to the longest process path. And then establishing corresponding process metadata for each process according to the process sequence number, and acquiring and establishing a minimum energy consumption operation parameter table for each process according to the parameter data of each process. And then, setting a flow according to the parameters, and setting reasonable operation parameters for each process by combining the process metadata and the minimum energy consumption operation parameter table, so that each process starts to operate according to the reasonable operation parameters.
In the embodiment, lean management is taken as a target, process metadata of a production line and equipment operation parameter experimental data of processes are imported, and reasonable output rate and reasonable operation parameters are set for each process based on the data, so that real-time cooperation of the processes is achieved, the maximization of factory benefits is realized, and the optimal operation state is achieved. And when the process capacity of the production line is ensured, the equipment operation parameter configuration of each process is automatically adjusted according to the reasonable operation parameters, so that the real-time cooperation of each process can be effectively completed, the resource waste is reduced, and the energy consumption is reduced.
In one embodiment, as shown in fig. 2, the step S102 includes: steps S201 to S204.
S201, selecting a procedure without a pre-procedure as a starting procedure of a procedure path, and then sequencing all the procedures according to the sequence of the procedures until a finishing procedure without a post-procedure is reached;
s202, counting the number of processes contained in each process path, and taking the counting result as the length of the process path;
s203, selecting the longest process path in the length of each process path;
and S204, setting the process sequence number of the initial process to be 1, and adding 1 to other processes in sequence based on the longest process path.
In this embodiment, when defining a process path, a process without a preceding process is determined as a starting process, and a process without a subsequent process is determined as an ending process according to the sequence of the processes, so that the process order between the starting process and the ending process can be used as the process path. For each process path, the number of processes included therein is the process length thereof, and the process path including the largest number of processes is the longest process path.
When the process sequence number is set, the process sequence number is set for each process on the longest process path in sequence by a positive integer starting with 1 according to the longest process path. Of course, if there are a plurality of longest process paths, one may be arbitrarily selected.
As illustrated in connection with fig. 4, taking a beverage production line as an example, the longest process path in the beverage production line is first determined: the process comprises the steps of bottle body process, filling process, cap screwing process, labeling process, packaging process and transportation process, and the process path length is 6. Then setting corresponding process sequence numbers: 1,2,3,4,5,6.
In an embodiment, the step S102 further includes:
judging whether a second target process without a process sequence number exists;
if a second target process without a process sequence number exists, acquiring a target process path containing the second target process, and setting the target process path by subtracting 1 in sequence in a reverse order from the ending process;
judging whether a target initial process with a process sequence number not being 1 exists;
if a target initial process with a process sequence number not being 1 exists, the process sequence number of the target initial process is revised to be 1.
When the process sequence number is set in the longest process route, since there may be some processes that are not included in the longest process route, the process sequence number is not set to the processes that are not included in the longest process route. In this embodiment, the processes without the process sequence numbers are used as the second target processes, and the target process path including the second target process is found in the process timing relationship diagram. Meanwhile, since the ending process in the longest process path is usually the ending process in the whole production line, and the target process path includes the ending process, the present embodiment sequentially decrements 1 the process sequence numbers of the respective processes on the target process path from the ending process according to the reverse method, so that the process sequence number of the second target process can be obtained.
After setting the process sequence numbers of all the processes, checking the process sequence numbers of all the processes, namely checking whether an initial process (namely the target initial process) with the process sequence number not being 1 exists, and if the target initial process exists, modifying the process sequence number of the target initial process to be 1 to indicate that the process sequence number is the initial process in a certain process path.
As illustrated in connection with fig. 5, also taking the beverage production line as an example, first a process without a process sequence number is found in the beverage production line: a beverage process and a bottle cap process. And then searching a process path comprising the beverage process and the bottle cap process, wherein the process path comprising the beverage process and the bottle cap process are respectively searched because one process path comprising the beverage process and the bottle cap process does not exist.
Wherein, the process route comprising the beverage process is as follows: the beverage processing method comprises the steps of beverage processing, filling processing, capping processing, labeling processing, packaging processing and transporting processing, wherein the sequence number of the transporting processing is 6, so that the sequence number of the beverage processing is determined to be 1 according to the principle that 1 is subtracted from the reverse sequence.
The process route comprising the bottle cap process is as follows: the bottle cap process, the cap screwing process, the labeling process, the packaging process and the transportation process, wherein the process sequence number of the transportation process is 6, so that the process sequence number of the bottle cap process is determined to be 2 according to the principle that 1 is subtracted in sequence in the reverse order.
In the process of checking the sequence number of the working procedure, the bottle cap working procedure is found to have no preorder working procedure, namely the initial working procedure of the working procedure path, and the working procedure sequence number of the bottle cap working procedure is 2, so the working procedure sequence number is revised to be 1.
In one embodiment, the process metadata includes a process ID, a process code, a process description, a process sequence number, a pre-sequence code and quantity, and a post-sequence code.
In this embodiment, the process metadata is created through the process time domain relationship and the process sequence number, and may include ID, process code, process description, process sequence number, previous code and number, subsequent code, and the like, where the process metadata style is shown in table 1:
TABLE 1
In table 1, "ID" represents a unique identification of the piece of metadata; "description of process" means a brief description of the corresponding process; "process code" means a unique number for the corresponding process; the 'process sequence number' indicates that the corresponding process is in the next process on the whole production line; "preamble process code/quantity" means the number of all preamble processes of the corresponding process and the quantity of workpieces provided by each preamble process, null means that there is no preamble process, i.e. it is the first process of the production line and there is no preamble; the "subsequent process code" indicates the number of the next process of the corresponding process, null indicates that no subsequent process exists, i.e. the process is the last process of the production line; the "subsequent process sequence number" indicates a process sequence number of a next process of the process, and Null indicates that there is no subsequent process, that is, the process is the last process of the production line.
Taking a beverage production line as an example, process metadata is created by the process sequence relationship and the process sequence number, as shown in table 2:
TABLE 2
In one embodiment, as shown in fig. 3, the step S104 includes: steps S301 to S305.
S301, acquiring historical data corresponding to each parameter data for any process, and calculating an average value of each parameter data;
s302, obtaining a theoretical minimum output rate and a theoretical maximum output rate of the working procedure, and equally dividing the interval of the theoretical minimum output rate and the theoretical maximum output rate into n parts to obtain n +1 theoretical output rates;
s303, setting the output rate of the working procedure according to the n +1 theoretical output rates;
s304, for each output rate, establishing an operation parameter table containing parameter data, setting each parameter by combining the average value of each parameter data, operating the process under the condition of changing one parameter each time, and recording energy consumption data of the process after operating for a preset time interval;
s305, selecting the parameter data corresponding to the minimum energy consumption data as the lowest energy consumption operation parameter of the corresponding process, and creating the lowest energy consumption operation parameter table according to the lowest energy consumption operation parameter data.
In this embodiment, the acquired parameter data may include: production rate, fluid flow rate, percussion pressure, frequency, pressure, etc. And carrying out arithmetic mean on the historical data of each parameter data to obtain a mean value. And then recording the lowest energy consumption operation parameters of each process in an experimental mode.
The method comprises the following steps: for any process, the interval between the theoretical minimum output rate and the theoretical maximum output rate of the process is equally divided into n parts, namely n +1 output rates are obtained. The output rates of the process are adjusted to be set to the n +1 output rates described above, respectively. And designing an operation parameter table under each output rate, setting each parameter based on the average value of each parameter data, only changing one parameter each time, starting the process according to the operation parameter table, operating at preset time intervals, and recording the energy consumption data of the process.
For example, the interval between the theoretical minimum output rate and the theoretical maximum output rate of the process is equally divided into 10 parts, i.e. 11 output rates are obtained, each parameter is set according to the average value of the data of each parameter, i.e. plus or minus 2%, the process is operated for 1 day, and the final energy consumption data is obtained by recording, as shown in table 3, wherein
The average value of the "
parameter 1" is represented,
the average value of the "
parameter 2" is indicated,
mean value for "
parameter 3":
TABLE 3
And comparing the 'energy consumption' in the table 3, finding the operating parameter corresponding to the minimum value, and taking the operating parameter as the lowest energy consumption operating parameter setting value of the corresponding process at the corresponding output rate. And calculating 11 groups of minimum energy consumption operation parameter setting values of the process by the method to obtain a corresponding minimum energy consumption operation parameter table. Such as
Shown in Table 4:
process number
|
Rate of production
| Parameter | 1
|
Parameter 2
|
Parameter 3
|
……
|
ZJF002
|
v 1 |
T 1 |
t 1 |
T 1 '
|
……
|
ZJF002
|
v 2 |
T 2 |
t 2 |
T' 2 |
……
|
……
|
……
|
……
|
……
|
……
|
……
|
ZJF002
|
v 11 |
T 11 |
t 11 |
T' 11 |
…… |
TABLE 4
And switching the working procedures, and finally obtaining the lowest energy consumption operation parameter set values of all the working procedures so as to create the lowest energy consumption operation parameter table for each working procedure.
In an embodiment, when the output rates of all the first target processes are greater than 0, calculating a reasonable output rate of each first target process according to the process metadata includes:
all preorder processes of the first target process and real-time output rates corresponding to all preorder processes are obtained through the process metadata and are marked as v 1 ,v 2 ,……,v m ;
Determining a reasonable output rate v for said first target process step according to i :
v i =min(v 1 ,v 2 ,……,v m )。
In this embodiment, according to the created process metadata, the "number/number of the preorder processes" of the first target process is read, that is, the preorder processes of the first target process are obtained, and then the output rate corresponding to the preorder processes is obtained through the real-time monitoring data, so that the reasonable output rate of the first target process is calculated. It should be noted that, in this embodiment, the first process is used as a reference, and the cooperation of the subsequent processes is realized, so that for the process with the process sequence number of 1, the calculation of the reasonable output rate is not needed. Of course, for the subsequent processes of the beginning process, all corresponding preamble processes are obtained, and the real-time output rate of the corresponding preamble processes is obtained through the real-time monitoring data, so that the reasonable output rate of the beginning process is calculated. It is understood that the first target process described in this embodiment is not referred to as the first process (i.e., the initial process), i.e., the initial process is not referred to as the initial process, but rather as the first process to calculate the reasonable output rate, since the first process does not need to calculate the reasonable output rate.
In addition, considering that the preceding process provides a workpiece for the subsequent process, and therefore the output rate of the subsequent process is restricted by the output rate of the preceding process, the embodiment sets the reasonable output rate of the ith process to be "slowest" in the preceding process.
In one embodiment, the setting of reasonable operation parameters for the first target process by combining the minimum energy consumption operation parameter table and the reasonable output rate includes:
setting output rate as an abscissa and various parameter data as an ordinate based on the minimum energy consumption operation parameter table, and solving a spline function for each parameter data by adopting cubic spline interpolation;
and setting the reasonable operation parameters of the first target process by spline functions corresponding to the parameter data and combining the reasonable output rate.
In this embodiment, according to the minimum energy consumption operation parameter table, the output rate is used as an abscissa, each parameter data is used as an ordinate, and a cubic spline interpolation method is adopted to obtain a spline function of each parameter data, so as to calculate a reasonable operation parameter setting value of a corresponding process at a reasonable output rate through the spline function. And then, setting the equipment according to the reasonable operation parameter set value, and starting a corresponding process.
For example, taking a beverage production line as an example, reasonable operation parameters are set for the ZJF004 filling procedure, and a minimum energy consumption operation parameter table of the ZJF004 filling procedure is created first, as shown in table 5:
process number
|
Rate of production
|
Pressure intensity
|
ZJF004
|
v 1 |
P 1 |
ZJF004
|
v 2 |
P 2 |
……
|
……
|
……
|
ZJF004
|
v 11 |
P 11 |
TABLE 5
Taking the output rate as an abscissa, respectively taking the data of each parameter as an ordinate, and solving a spline function by adopting a cubic spline interpolation method, wherein v is 1 To v 11 The number of the sub-intervals is 11, the sub-intervals are 10, interpolation is carried out according to the pressure parameter, and a function equation in each sub-interval is obtained:
p i (v)=a i +b i (v-v i )+c i (v-v i ) 2 +d i (v-v i ) 3
wherein v is i <v<v i+1 I =1,2,3, \ 8230;, 10. Thereby determining a reasonable operating parameter for the "pressure" parameter.
Fig. 6 is a schematic block diagram of a process data and management cooperation apparatus 600 according to an embodiment of the present invention, where the apparatus 600 includes:
a time domain relation establishing unit 601, configured to establish a process time domain relation and a corresponding process time domain relation graph according to actual service requirements;
a path defining unit 602, configured to define at least one process path according to a sequence before and after each process based on the process time-series relationship and the process time-domain relationship diagram, define a process path length according to the process path, and set a corresponding process sequence number for each process according to the process path;
a metadata creating unit 603 configured to create process metadata corresponding to each process based on the process timing relationship and the process sequence number;
a parameter table creating unit 604, configured to obtain parameter data corresponding to each process, and create a corresponding minimum energy consumption operation parameter table for each process according to the parameter data;
a parameter setting unit 605, configured to determine at least one starting process according to the process sequence number, use the starting process as a first target process, and set reasonable operation parameters for the first target process according to a parameter setting flow;
wherein, the parameter setting process comprises: acquiring the output rate corresponding to the first target process; when the output rates of all the first target processes are larger than 0, calculating the reasonable output rate of each first target process according to the process metadata; setting reasonable operation parameters for the first target process by combining the minimum energy consumption operation parameter table and the reasonable output rate;
and the process starting unit 606 is configured to set corresponding reasonable operation parameters in sequence for subsequent processes of the start-up process according to the process sequence number based on the parameter setting process, and start each process according to the reasonable operation parameters.
In one embodiment, as shown in fig. 7, the path definition unit 602 includes:
a procedure selecting unit 701, configured to select a procedure without a preceding procedure as a starting procedure of a procedure path, and then sort the procedures according to a sequence of the procedures until an ending procedure without a subsequent procedure is reached;
a number counting unit 702 configured to count the number of processes included in each of the process paths, and use the counted result as a process path length;
a path selection unit 703 for selecting the longest process path among the process path lengths;
a sequence number setting unit 704 configured to set the process sequence number of the initial process to 1, and sequentially add 1 to the other processes based on the longest process path.
In an embodiment, the path definition unit 602 further includes:
a first judgment unit configured to judge whether there is a target process for which a process sequence number is not set;
a reverse order setting unit, configured to, if there is a target process for which a process order number is not set, acquire a target process path including the target process, and set, starting from the end process, by subtracting 1 in order on the target process path;
a second judgment unit configured to judge whether or not there is a target start process whose process sequence number is not 1;
and a revision unit for revising the process sequence number of the target initial process to 1 if the target initial process with the process sequence number not being 1 exists.
In one embodiment, the process metadata includes a process ID, a process code, a process description, a process sequence number, a pre-sequence code and quantity, and a post-sequence code.
In one embodiment, as shown in fig. 8, the parameter table creating unit 604 includes:
an average value calculation unit 801 configured to acquire history data corresponding to each parameter data for any process, and calculate an average value of each parameter data;
an interval equally dividing unit 802, configured to obtain a theoretical minimum output rate and a theoretical maximum output rate of a process, and equally divide the interval between the theoretical minimum output rate and the theoretical maximum output rate into n parts, so as to obtain n +1 theoretical output rates;
a rate setting unit 803, configured to set output rates of the processes according to the n +1 theoretical output rates, respectively;
the data recording unit 804 is used for establishing an operation parameter table containing parameter data for each output rate, then setting each parameter by combining the average value of each parameter data, operating the working procedure under the condition of changing one parameter each time, and recording the energy consumption data of the working procedure after operating a preset time interval;
the parameter selecting unit 805 is configured to select parameter data corresponding to the minimum energy consumption data as a minimum energy consumption operation parameter of the corresponding process, and create the minimum energy consumption operation parameter table according to the minimum energy consumption operation parameter.
In an embodiment, the parameter setting process includes:
a rate marking unit, configured to obtain all preamble procedures of the first target procedure and real-time output rates corresponding to the preamble procedures through the procedure metadata, and mark the real-time output rates as v in sequence 1 ,v 2 ,……,v m ;
A rate determination unit for determining a reasonable output rate v of the first target process according to the following formula i :
v i =min(v 1 ,v 2 ,……,v m )。
In an embodiment, the parameter setting process further includes:
the function solving unit is used for setting a spline function by taking the output rate as an abscissa and each parameter data as an ordinate based on the minimum energy consumption operation parameter table and solving each parameter data by adopting cubic spline interpolation;
and the combination unit is used for setting the reasonable operation parameters of the first target process by the spline function corresponding to each parameter data and combining the reasonable output rate.
Since the embodiments of the apparatus portion and the method portion correspond to each other, please refer to the description of the embodiments of the method portion for the embodiments of the apparatus portion, which is not repeated here.
Embodiments of the present invention also provide a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed, the steps provided by the above embodiments can be implemented. The storage medium may include: various media capable of storing program codes, such as a usb disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk, or an optical disk.
The embodiment of the present invention further provides a computer device, which may include a memory and a processor, where the memory stores a computer program, and the processor may implement the steps provided in the above embodiment when calling the computer program in the memory. Of course, the computer device may also include various network interfaces, power supplies, and the like.
The embodiments are described in a progressive mode in the specification, the emphasis of each embodiment is on the difference from the other embodiments, and the same and similar parts among the embodiments can be referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description. It should be noted that, for those skilled in the art, it is possible to make several improvements and modifications to the present application without departing from the principle of the present application, and such improvements and modifications also fall within the scope of the claims of the present application.
It is further noted that, in the present specification, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrases "comprising a," "8230," "8230," or "comprising" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.