Energy monitoring device and control method therefor, and energy monitoring program

• US 8,942,934 B2
• Filed: 09/29/2011
• Issued: 01/27/2015
• Est. Priority Date: 04/10/2009
• Status: Active Grant

• Current Assignee: Omron Corporation
• Original Assignee: Omron Corporation
• Inventors: Yamamura, Kenji, Endo, Maki, Kitagawa, Shintaro, Tateishi, Taisuke, Saito, Hiroshi, Nakashima, Chisato
• Primary Examiner(s): Kundu, Sujoy
• Assistant Examiner(s): FORTICH, ALVARO E
• Application Number:
  US13/248,484
• Publication Number:
  US 20120084030A1
• Time in Patent Office: 1,216 Days
• Field of Search: 702/61
• US Class Current: 702/61
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/40938 Tool management
• CPC Class Codes: G05B 2219/49092 Vary, change controlled parameter as function of detected power
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A processing machine processes a work and repeats processes on the work, thereby consuming energy. Within the consumed energy, room for improvement is computed by an energy monitoring device and is referred to as an amount of energy that can be improved. An energy monitoring device includes a power data acquirer that acquires a time-series power data measured by a power meter, a cycle detector that detects a single-cycle power data from the power data acquired by the acquirer, a divider that divides the single-cycle power data detected by the detector into an added-value creating portion and an unproductive portion, and a computing unit that computes an amount of energy consumed in the unproductive portion divided by the divider and defines it as the amount of energy to be improved.

Claims

1. An energy monitoring device that computes an amount of energy to be reduced within energy consumed by equipment, the device comprising:

a power data acquirer that acquires time-series data of a physical quantity related to the consumed energy;

a memory that pre-stores waveform model information indicating a waveform model of single-cycle time-series data, wherein the single-cycle time-series data is time-series data in a single-cycle from a start to an end of a predetermined process by the equipment;

a cycle detector that detects the single-cycle time-series data within a predetermined period from the time-series data acquired by the power data acquirer, and determines whether or not the single-cycle time-series data is detected;

a divider that divides the single-cycle time-series data detected by the cycle detector into an added-value creating portion and an unproductive portion, only when the cycle detector determines that the single-cycle time-series data is detected, wherein the added-value creating portion creates an added-value in the predetermined process, and the unproductive portion does not produce any added-value in the predetermined process; and

a computer that computes an amount of energy consumed in the unproductive portion as the amount of energy to be reduced, wherein

the cycle detector extracts waveform feature data from the time-series data acquired by the power data acquirer, performs pattern matching between the waveform feature data and the waveform model information stored in the memory, and detects the single-cycle time-series data in which the waveform feature data matches the waveform model information.

2. The energy monitoring device according to claim 1, wherein the time-series data of the physical quantity includes one of electric energy and electric current.

3. The energy monitoring device according to claim 1, wherein

the memory pre-stores the waveform model information in association with a dividing condition to divide the single-cycle time-series data into the added-value creating portion and the unproductive portion by the divider, wherein

the divider divides the single-cycle time-series data into the added-value creating portion and the unproductive portion based on the dividing condition associated with the waveform model information and stored in the memory.

4. The energy monitoring device according to claim 3, further comprising:

a waveform model generator that generates the waveform model information using the time-series data of the physical quantity acquired by the power data acquirer.

5. The energy monitoring device according to claim 1, wherein

the memory pre-stores a cycle-time design value that is a design value for a period from the start to the end of the predetermined process by the equipment, and

wherein the cycle detector comprises a cycle start detector that detects a start-point of the single-cycle time-series data based on the cycle-time design value.

6. The energy monitoring device according to claim 5, wherein the memory stores waveform pattern information indicating a waveform pattern of the single-cycle time-series data, and wherein

the cycle start detector detects a start-point of the single-cycle time-series data by detecting single-cycle time-series data compatible with the waveform pattern information stored in the memory.

7. The energy monitoring device according to claim 1, wherein

the memory stores a waveform pattern information related to a waveform pattern of the single-cycle time-series data;

a waveform pattern generator that generates the waveform pattern using a plurality of single-cycle time-series data detected by the cycle detector, and stores the waveform pattern in the memory.

8. The energy monitoring device according to claim 1, wherein the divider further comprises:

a feature value computer that computes a feature value to divide the single-cycle time-series data at a point in time based on the single-cycle time-series data detected by the cycle detector; and

a transition time determiner that identifies a start-point of the unproductive portion based on the feature value computed by the feature value computer.

9. The energy monitoring device according to claim 1, wherein the computer further computes an amount of energy consumed in the added-value creating portion.

12. The energy monitoring device according to claim 3, wherein the memory pre-stores a cycle-time design value that is a design value for a period from the start to the end of the predetermined process by the equipment, and

wherein the cycle detector comprises a cycle start detector that detects a start-point of the single-cycle time-series data based on the cycle-time design value.

13. The energy monitoring device according to claim 4, wherein the memory pre-stores a cycle-time design value that is a design value for a period from the start to the end of the predetermined process by the equipment, and

wherein the cycle detector comprises a cycle start detector that detects a start-point of the single-cycle time-series data based on the cycle-time design value.

14. The energy monitoring device according to claim 12, wherein the memory stores waveform pattern information indicating a waveform pattern of the single-cycle time-series data, and wherein

the cycle start detector detects a start-point of the single-cycle time-series data by detecting single-cycle time-series data compatible with waveform pattern information stored in the memory.

15. The energy monitoring device according to claim 13, wherein the memory stores waveform pattern information indicating a waveform pattern of the single-cycle time-series data, and wherein

the cycle start detector detects a start-point of the single-cycle time-series data by detecting single-cycle time-series data compatible with waveform pattern information stored in the memory.

16. The energy monitoring device according to claim 3, wherein the memory stores a waveform pattern information related to a waveform pattern of the single-cycle time-series data, and wherein

a waveform pattern generator generates the waveform pattern using a plurality of single-cycle time-series data detected by the cycle detector, and stores the waveform pattern in the memory.

17. The energy monitoring device according to claim 4, wherein the memory stores a waveform pattern information related to a waveform pattern of the single-cycle time-series data, and wherein

a waveform pattern generator generates the waveform pattern using a plurality of single-cycle time-series data detected by the cycle detector, and stores the waveform pattern in the memory.

18. The energy monitoring device according to claim 5, wherein the memory stores a waveform pattern information related to a waveform pattern of the single-cycle time-series data, and wherein

a waveform pattern generator generates the waveform pattern using a plurality of single-cycle time-series data detected by the cycle detector, and stores the waveform pattern in the memory.

19. The energy monitoring device according to claim 5, wherein the cycle detector further comprises:

a frequency analyzer that analyzes the time-series data of the physical quantity detected by the power data acquirer to obtain a fundamental frequency using the cycle-time design value; and

a filter that determines a filter function based on the fundamental frequency, and applies the filter function to the time-series data of the physical quantity to obtain filtered time-series data;

wherein the cycle start detector calculates a second-order differential of the filtered time-series data, determines a power data threshold value and a second order differential threshold value using the second-order differential, and detects the start-point of the single-cycle time-series data based on the power data threshold value, the second order differential threshold value, the filtered time-series data and the second-order differential.

20. The energy monitoring device according to claim 6, wherein the cycle detector further comprises:

a frequency analyzer that analyzes the time-series data of the physical quantity detected by the power data acquirer to obtain a fundamental frequency using the cycle-time design value; and

a filter that determines a filter function based on the fundamental frequency, applies the filter function to the time-series data of the physical quantity to obtain filtered time-series data, and applies the filter function to the waveform pattern to obtain filtered waveform pattern,

wherein the cycle start detector performs pattern matching between the filtered time-series data and filtered waveform pattern, and detects a start-point of a portion of the filtered time-series data that most closely matches the filtered waveform pattern, as the start-point of the single-cycle time-series data.

21. The energy monitoring device according to claim 1, wherein the single-cycle time-series data is time-series data from a start of processing a single workpiece to an end of the processing of the single workpiece by the equipment.

10. A method that controls an energy monitoring device to compute an amount of energy to be reduced within an energy consumed by equipment, the method comprising:

acquiring, by a processor, time-series data of a physical quantity related to the consumed energy;

pre-storing waveform model information indicating a waveform model of single-cycle time-series data, wherein the single-cycle time-series data is time-series data in a single-cycle from a start to an end of a predetermined process by the equipment;

detecting, by a processor, the single-cycle time-series data within a predetermined period from the acquired time-series data;

determining whether or not the single-cycle time-series data is detected;

dividing, by a processor, the detected single-cycle time-series data detector into an added-value creating portion and an unproductive portion, only when it is determined that the single-cycle time-series data is detected, wherein the added-value creating portion creates an added-value in the predetermined process, and the unproductive portion does not produce any added-value in the predetermined process; and

computing, by a processor, an amount of energy consumed in the unproductive portion as the amount of energy to be reduced, wherein

the detecting of the single-cycle time-series data extracts waveform feature data from the acquired time-series data, performs pattern matching between the waveform feature data and the waveform model information stored in the memory, and detects the single-cycle time-series data in which the waveform feature data matches the waveform model information.

11. A non-transitory computer readable storage medium having computer instructions stored thereon comprising an energy monitoring program that operates an energy monitoring device to compute an amount of energy to be reduced within an energy consumed by equipment, the program causing a computer to perform:

acquiring time-series data of a physical quantity related to the consumed energy;

re-storing waveform model information indicating a waveform model of single-cycle time-series data, wherein the single-cycle time-series data is time-series data in a single-cycle from a start to an end of a predetermined process by the equipment;

detecting the single-cycle time-series data within a predetermined period from the acquired time-series data;

dividing the detected single-cycle time-series data into an added-value creating portion and an unproductive portion, only when it is determined that the single-cycle time-series data is detected, wherein the added-value creating portion creates an added-value in the predetermined process, and the unproductive portion does not produce any added-value in the predetermined process; and

computing an amount of energy consumed in the unproductive portion as the amount of energy to be reduced, wherein

the detecting of the single-cycle time-series data extracts waveform feature data from the acquired time-series data, performs pattern matching between the waveform feature data and the waveform model information stored in the memory, and detects the single-cycle time-series data in which the waveform feature data matches the waveform model information.