CN117575575A - Intelligent manufacturing-oriented production data dynamic analysis system - Google Patents
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Abstract
The invention discloses a production data dynamic analysis system for intelligent manufacturing, relates to the technical field of production data dynamic analysis, and solves the technical problems that production strategies of a production line are not adjusted in time, production overdue phenomenon is easy to occur, production efficiency is low, and production cost is increased; the invention counts the abnormal times of the index in the processing period through the data processing module, analyzes the proportion of the index in the processing period, and further judges whether the equipment has abnormality; if the abnormality exists, the comprehensive judging module further analyzes the fault evaluation value of the equipment, if the fault evaluation value is larger than a preset threshold value, the equipment needs to be maintained, and the maintenance time and the produced output are counted; based on maintenance time, produced output and production line production information, reasonably adjusting production speed or starting a standby production line to produce simultaneously; the flexibility and the accuracy of the production plan are improved, and the production efficiency of the production line is ensured.
Description
Technical Field
The invention belongs to the field of dynamic analysis of production data, and particularly relates to an intelligent manufacturing-oriented dynamic analysis system of production data.
Background
With the rapid development of manufacturing industry, smart manufacturing has become a major trend in manufacturing industry; the intelligent manufacturing is a novel manufacturing mode integrating the technologies of automation, informatization, internet of things and the like, and aims to improve the production efficiency, reduce the cost and improve the product quality.
In intelligent manufacturing, production data is an important basis for realizing optimization decision and fine management, however, traditional analysis of the production data of intelligent manufacturing is only aimed at equipment indexes on a production line, the acquired equipment indexes are compared with a threshold value, whether equipment is faulty or not is judged, and future production states are predicted, but the production strategy of the production line is not adjusted in time, so that overdue production is easy to occur, the production efficiency is low, and the production cost is increased.
Therefore, the invention provides an intelligent manufacturing-oriented production data dynamic analysis system.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems existing in the prior art; therefore, the invention provides an intelligent manufacturing-oriented production data dynamic analysis system which is used for solving the technical problems that the production strategy of a production line is not adjusted in time, the production overdue phenomenon is easy to occur, the production efficiency is low, and the production cost is increased.
To achieve the above object, a first aspect of the present invention provides an intelligent manufacturing-oriented production data dynamic analysis system, which includes a data processing module, and a sensor and a comprehensive decision module connected with the data processing module; the sensor comprises a temperature sensor, a current sensor and a voltage sensor;
and a data processing module: acquiring equipment indexes on a production line through a sensor, and judging whether the indexes in a processing period exceed a corresponding threshold range; if not, marking as normal value; if yes, marking as numerical value abnormality, analyzing the abnormal index, generating a feedback result and sending the feedback result to the comprehensive judgment module; wherein, the equipment index comprises temperature, current and voltage; the feedback result comprises abnormal equipment indexes in the processing period or normal equipment indexes in the processing period;
and a comprehensive judging module: when the index of the equipment in the processing period is abnormal, analyzing a fault evaluation value of the equipment in the processing period, and judging whether the fault evaluation value is larger than a preset threshold value or not; if not, the production line runs normally; if yes, stopping the production line, maintaining the equipment, and counting the produced yield S0 and the equipment maintenance time Timax; adjusting the production speed according to the produced yield S0, the maintenance time Timax and the production line production information, and ensuring that the production line completes the target yield in the production period; wherein i represents a device number, i=0, 1,2, …, N, and N is a positive integer; the production line production information comprises the normal production speed of the production line, the production speed threshold value is marked as V, the target yield of the production line in the production period is marked as S.
Preferably, the analyzing the index of abnormality includes:
counting the abnormal times of each index in the processing period, analyzing the proportion of the indexes in the processing period to obtain the abnormal proportion of the indexes, and judging whether the abnormal proportion of the indexes is larger than a preset proportion threshold value or not; if yes, the device index in the processing period is abnormal; if not, the equipment index in the processing period is normal.
Preferably, the analyzing the fault evaluation value of the device in the processing period includes:
calculating the mean value of each index of the equipment in the processing period, namely Eij, and calculating the failure evaluation value Qi of the equipment in the processing period through a formula Qi=alpha×E0j+beta×E1j+gamma×E2j; where j is a device index number, j=0 represents temperature, j=1 represents current, and j=2 represents voltage; Σ represents the sum of j; alpha, beta and gamma are weight coefficients, and the values are all larger than 0.
According to the method, whether the equipment index acquired in the processing period exceeds the corresponding threshold range is judged, the abnormal times of the index are counted, and the abnormal proportion is analyzed; if the abnormal proportion is greater than a preset proportion threshold value, analyzing and processing a fault evaluation value of the intra-week equipment; the invention detects and identifies equipment faults in time, ensures normal operation of the equipment, thereby avoiding the problems of production interruption or product quality reduction and the like, optimizing maintenance strategies according to the actual operation conditions of the equipment, and improving the reliability and the service life of the equipment.
Preferably, the adjusting the production speed according to the produced output S0, the maintenance time Timax, and the production line production information includes:
calculating to obtain the production speed V1 required for producing the residual yield by the formula V1= (S-S0)/((S-S0)/V0-Timax); judging whether the production speed V1 exceeds a production speed threshold V or not; if not, the production speed is adjusted to V1; if yes, the production speed is adjusted to a production speed threshold V, and the standby production line is started to simultaneously carry out production.
It should be noted that Timax is the longest time required for equipment maintenance; namely, a plurality of equipment faults occur simultaneously in a processing period, and maintenance is required, wherein the maintenance time is Timax; such as: and (3) maintaining the equipment A for 2h and maintaining the equipment B for 6h, wherein Timax=6h.
Preferably, the adjusting the production speed to V1 includes:
when the production speed is adjusted to V1, acquiring the produced output of the production line at a monitoring time node P of the remaining production period, and marking the produced output as SP; calculating to obtain the time y0 required for completing the residual yield through a formula y0= (S-SP)/V1, and judging whether the residual time y1 of the production period is exceeded or not; if yes, starting the standby production line to simultaneously produce; if not, the standby production line is not started; wherein, the production cycle residual time y1= (S-S0)/V0-Timax-P; monitoring time node p= (1/m) × ((S-S0)/V0-Timax), m being a positive integer greater than 0.
When equipment fails, the maintenance time Timax of the failed equipment is recorded, and the production speed V1 required for producing the residual yield is estimated based on the current produced yield S0 and production line production information; when the production speed V1 does not exceed the production speed threshold V, the equipment speed is adjusted to V1; if the number exceeds the preset number, the production line is adjusted to V, and a standby production line is started to simultaneously produce; when the equipment speed is V1, acquiring the produced yield SP of the production line at the monitoring node P, calculating the time required for completing the residual target yield, and analyzing whether the standby production line needs to be started for simultaneous production; by monitoring the production condition of the production line and adjusting the production strategy in time, the production line can complete production tasks in the production period, thereby avoiding overdue production and increasing additional production cost.
Preferably, when the time y0 required for completing the remaining target yield exceeds the remaining time y1 of the production cycle, the standby line is started to perform the production simultaneously, including:
and calculating to obtain the production speed V3 of the standby production line through a formula V3= (S-SP)/y 0-V1.
Preferably, the method for adjusting the production speed to the equipment operation threshold V and starting the standby production line to simultaneously produce comprises the following steps:
the production speed V2 of the standby production line is calculated by the formula V2= (S-S0)/((S-S0)/V0-Timax) -V.
It should be noted that there are several spare lines on the production line, and a certain number of spare lines are started to perform production according to the purpose that the production line completes the target yield in the production cycle.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the invention, the equipment indexes are collected through the sensor, the equipment indexes are analyzed, the running state of the equipment is estimated by integrating the changes of the indexes, the problems are found in time, the maintenance is carried out, the unplanned downtime is reduced, and the production efficiency is improved; meanwhile, according to the production condition of the production line, the production speed of the production line is reasonably regulated or the standby production line is started to simultaneously produce; the production line achieves the target yield in the production period, and the phenomenon of overdue production is avoided;
2. the sensor acquires equipment indexes, the data processing module compares the equipment indexes in the processing period with corresponding threshold ranges, and counts the abnormal times of the indexes in the processing period; analyzing the proportion of the abnormal times to the processing period, and further judging whether the equipment has abnormality or not; if the abnormality exists, the comprehensive judging module analyzes the fault evaluation value of the equipment in the processing period, if the fault evaluation value is larger than a preset threshold value, the equipment needs to be maintained, and the maintenance time and the produced output are counted; based on maintenance time, produced output and production line production information, reasonably adjusting production speed or starting a standby production line to produce simultaneously; according to the invention, the comprehensive judging module is used for analyzing the fault evaluation value of the equipment in the processing period, so that whether the equipment needs to be maintained or not and whether the standby production line needs to be started for simultaneous production can be accurately judged, the flexibility and the accuracy of a production plan are improved, the production efficiency of the production line is ensured, and the production line achieves the target yield in the production period.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a system block diagram of the present invention;
FIG. 2 is a flow chart of a method of equipment failure analysis according to the present invention;
FIG. 3 is a flow chart of a method for adjusting production efficiency according to the present invention.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-2, an embodiment of a first aspect of the present invention provides an intelligent manufacturing-oriented dynamic analysis system for production data, which includes a data processing module, and a sensor and a comprehensive decision module connected with the data processing module; the sensor comprises a temperature sensor, a current sensor and a voltage sensor;
the data processing module acquires equipment indexes on the production line through a sensor and judges whether the indexes in the processing period exceed the corresponding threshold range; if not, marking as normal value; if yes, marking as numerical value abnormality, counting the abnormality times of each index, analyzing the proportion of the abnormality times to the processing period to obtain index abnormality proportion, and judging whether the index abnormality proportion is larger than a preset proportion threshold; if yes, the exception of the equipment in the processing period is indicated; if not, the equipment in the processing period is normal;
when the equipment in the processing period has abnormality, calculating to obtain a fault evaluation value Qi of the equipment in the processing period through a formula Qi=alpha×E0j+beta×E1j+gamma×E2j; judging whether the fault evaluation value Qi is larger than a preset threshold value or not; if not, the production line runs normally; if yes, the production line stops running, equipment is maintained, and the produced yield S0 and the equipment maintenance time Timax are counted.
Example 1: two production devices are respectively marked as device 1 and device 2 on each production line of a certain factory; acquiring equipment indexes by using a sensor to obtain equipment indexes in a processing period, wherein the equipment indexes 1 are obtained in a certain processing period: temperature index (25, 22, 24, 35, 38, 35); current indicator (320, 345, 351, 454, 628, 650) a; voltage indicators (388, 397, 452, 463, 481, 505) V; equipment 2 index: temperature index (26, 30, 32, 30, 35, 36); current indicators (456, 466, 567, 665, 636, 687) a; voltage indicator (310, 325, 420, 455, 510, 484) V; wherein, assume each index threshold range of the device 1: the temperature index threshold range is [22,25] DEG C, the current threshold range is [350,650] A, and the voltage threshold range is [300, 620] V; each index threshold range of the apparatus 2: the temperature index threshold range is [22,28] DEG C, the current threshold range is [340,550] A, and the voltage threshold range is [300, 500] V; correction coefficient α=0.01; α=20%, β=40%, γ=40%;
device 1: the abnormal proportion of the temperature index is 50%, the abnormal proportion of the current index is 33%, and the abnormal proportion of the voltage index is 0%;
device 2: the abnormal proportion of the temperature index is 83%, the abnormal proportion of the current index is 67%, and the abnormal proportion of the voltage index is 17%;
first case: assume that the preset ratio threshold is set to 50%
The abnormal proportion of the temperature index of the equipment 1 exceeds the proportion threshold;
calculating to obtain a temperature average value: e10 =29.83 ℃, current mean: e11 =458A, voltage mean: e12 = 447.67V; fault assessment value q1=20% ×29.83+40% ×458+40% × 447.67 ≡ 368.23 for apparatus 1;
the abnormal proportion of the temperature index and the current index of the equipment 2 exceeds a proportion threshold;
calculating to obtain a temperature average value: e20 =31.5 ℃, current mean: e21 = 579.5a, voltage mean: e22 = 417.33V; fault assessment value q2=20% ×31.5+40% ×579.5+40% × 417.33 ≡ 404.03 for device 2;
second case: assume that the preset ratio threshold is set to 60%
The abnormal proportion of the temperature index of the apparatus 1 does not exceed the proportion threshold value, so that the failure evaluation value of the apparatus 1 does not need to be analyzed;
the abnormal ratio of the temperature index and the current index of the apparatus 2 exceeds the ratio threshold, so that the failure evaluation value q2≡ 404.03 of the apparatus 2 is analyzed.
Referring to fig. 3, a production speed V1 required for producing the remaining yield is calculated by the formula v1= (S-S0)/((S-S0)/V0-Timax) based on the produced yield S0, the maintenance time Timax, and the line production information;
if the production speed V1 does not exceed the production speed threshold V, adjusting the production speed to V1, and acquiring the produced yield SP of the production line at a monitoring node P of the remaining production period; calculating to obtain the time y0 required for completing the residual target yield through a formula y0= (S-SP)/V1;
if y0 is not greater than the remaining time y1 of the production cycle, starting the standby production line and simultaneously producing; the production speed V3 of the standby line is calculated by the formula v3= (S-SP)/y 0-V1.
If y0 is greater than the remaining time of the production cycle, not starting the standby production line;
wherein y1= (S-S0)/V0-Timax-P; monitoring time node p= (1/m) × ((S-S0)/V0-Timax), m being a positive integer greater than 0.
Example 2: taking the first case in example 1 as an example, assuming that the produced yield is s0=4000 pieces, the normal production speed v0=400 pieces/h of the apparatus, the production speed threshold v=550 pieces/h, and the yield s=1 ten thousand pieces of the production line in the production cycle;
from example 1, it is known that the failure evaluation value q1= 368.23 of the apparatus 1; fault assessment value q2= 404.03 for device 2; the production conditions of the production line are analyzed under the assumption that the following two conditions exist;
case a: if the fault evaluation value of the equipment 2 exceeds a preset threshold value, maintenance is needed, and at the moment, the production line stops producing, and the maintenance time is assumed to be 3 hours; calculating the production speed V1 = (10000-4000)/((10000-4000)/400-3) =500 pieces/h required for producing the residual yield;
case B: if the failure evaluation values of the equipment 1 and the equipment 2 exceed the preset threshold, the equipment 1 and the equipment 2 are maintained simultaneously, the production line stops producing, and if the equipment 1 is maintained for 2 hours and the equipment 2 is maintained for 5 hours, the total required maintenance time is 5 hours; calculating the production speed V1 = (10000-4000)/((10000-4000)/400-5) = 600 pieces/h required for producing the residual yield;
as can be seen from the calculation result, if the production speed V1 required in the case a does not exceed the production speed threshold V, the production speed of the production line is adjusted to V1; assuming that the monitoring time node P is 2/3 of the remaining production cycle, the produced yield sp=5000; calculating to obtain the time y0= (10000-5000)/500=10h required for completing the residual target yield; and the remaining time y1= ((10000-4000)/400-3)/3=4h; if the residual time is insufficient, starting a standby production line to simultaneously produce; production speed v3= (10000-5000)/4-500=750 pieces/h of the spare production line.
If the production speed V1 exceeds the production speed threshold V, adjusting the production speed to the production speed threshold V, and starting a standby production line to simultaneously produce; at this time, the production speed of the standby line equipment is calculated by the formula v2= (S-S0)/((S-S0)/V0-Timax) -V.
Example 3: taking the case B of the example 2 as an example, if the production speed V1 required for producing the residual yield exceeds the production speed threshold V, starting a standby production line to simultaneously produce; the production speed v2=6000/(6000/400-5) -550=50 pieces/h of the spare production line is calculated.
The starting quantity of the standby production lines is determined according to actual conditions.
The partial data in the formula is obtained by removing dimension and taking the numerical value for calculation, and the formula is obtained by simulating a large amount of acquired data through software and is closest to the real situation; the preset parameters and the preset threshold values in the formula are set by those skilled in the art according to actual conditions or are obtained through mass data simulation.
The above embodiments are only for illustrating the technical method of the present invention and not for limiting the same, and it should be understood by those skilled in the art that the technical method of the present invention may be modified or substituted without departing from the spirit and scope of the technical method of the present invention.
Claims (7)
1. The intelligent manufacturing-oriented production data dynamic analysis system is characterized by comprising a data processing module, and a sensor and a comprehensive judging module which are connected with the data processing module; the sensor comprises a temperature sensor, a current sensor and a voltage sensor;
and a data processing module: acquiring equipment indexes on a production line through a sensor, and judging whether the indexes in a processing period exceed a corresponding threshold range; if not, marking as normal value; if yes, marking as numerical value abnormality, analyzing the abnormal index, generating a feedback result and sending the feedback result to the comprehensive judgment module; wherein, the equipment index comprises temperature, current and voltage; the feedback result comprises abnormal equipment indexes in the processing period or normal equipment indexes in the processing period;
and a comprehensive judging module: when the index of the equipment in the processing period is abnormal, analyzing a fault evaluation value of the equipment in the processing period, and judging whether the fault evaluation value is larger than a preset threshold value or not; if not, the production line runs normally; if yes, stopping the production line, maintaining the equipment, and counting the produced yield S0 and the equipment maintenance time Timax; adjusting the production speed according to the produced yield S0, the maintenance time Timax and the production line production information; wherein i represents a device number, i=0, 1,2, …, N, and N is a positive integer; the production line production information comprises the normal production speed of the production line, the production speed threshold value is marked as V, the target yield of the production line in the production period is marked as S.
2. The intelligent manufacturing oriented production data dynamic analysis system of claim 1, wherein the analysis of the indicators of anomalies comprises:
counting the abnormal times of each index in the processing period, analyzing the proportion of the indexes in the processing period to obtain the abnormal proportion of the indexes, and judging whether the abnormal proportion of the indexes is larger than a preset proportion threshold value or not; if yes, the device index in the processing period is abnormal; if not, the equipment index in the processing period is normal.
3. The intelligent manufacturing oriented production data dynamic analysis system of claim 1, wherein the analyzing the fault assessment value of the device in the processing cycle comprises:
calculating the mean value of each index of the equipment in the processing period, namely Eij, and calculating the failure evaluation value Qi of the equipment in the processing period through a formula Qi=alpha×E0j+beta×E1j+gamma×E2j; where j is a device index number, j=0 represents temperature, j=1 represents current, and j=2 represents voltage; Σ represents the sum of j; alpha, beta and gamma are weight coefficients, and the values are all larger than 0.
4. The intelligent manufacturing oriented production data dynamic analysis system of claim 1, wherein said adjusting the production speed based on the produced production S0, the maintenance time Timax, and the line production information comprises:
calculating to obtain the production speed V1 required for producing the residual yield by the formula V1= (S-S0)/((S-S0)/V0-Timax); judging whether the production speed V1 exceeds a production speed threshold V or not; if not, the production speed is adjusted to V1; if yes, the production speed is adjusted to a production speed threshold V, and the standby production line is started to simultaneously carry out production.
5. The intelligent manufacturing oriented production data dynamic analysis system of claim 4, wherein said adjusting the production speed to V1 comprises:
when the production speed is adjusted to V1, acquiring the produced output of the production line at a monitoring time node P of the remaining production period, and marking the produced output as SP; calculating to obtain the time y0 required for completing the residual yield through a formula y0= (S-SP)/V1, and judging whether the residual time y1 of the production period is exceeded or not; if yes, starting the standby production line to simultaneously produce; if not, the standby production line is not started; wherein, the production cycle residual time y1= (S-S0)/V0-Timax-P; monitoring time node p= (1/m) × ((S-S0)/V0-Timax), m being a positive integer greater than 0.
6. The intelligent manufacturing oriented production data dynamic analysis system of claim 5, wherein when the time y0 required to complete the remaining target yield exceeds the remaining time y1 of the production cycle, the standby line starts to simultaneously perform production, comprising:
and calculating to obtain the production speed V3 of the standby production line through a formula V3= (S-SP)/y 0-V1.
7. The intelligent manufacturing-oriented production data dynamic analysis system according to claim 4, wherein the adjusting the production speed to the equipment operation threshold V and starting the standby production line to perform production simultaneously comprises:
the production speed V2 of the standby production line is calculated by the formula V2= (S-S0)/((S-S0)/V0-Timax) -V.
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