WO2009083142A1

WO2009083142A1 - Method and apparatus for analysing the power consumption in a machine

Info

Publication number: WO2009083142A1
Application number: PCT/EP2008/010728
Authority: WO
Inventors: Thomas Buerger; Günther LANDGRAF
Original assignee: Robert Bosch Gmbh
Priority date: 2007-12-21
Filing date: 2008-12-17
Publication date: 2009-07-09
Also published as: JP2011506987A; DE102007062058A1; JP5312475B2

Abstract

A method for analysing the power consumption in machines, wherein one method step involves a multiplicity of data items being recorded which are characteristic of a plurality of sub-procedures in an operating procedure and also a multiplicity of data items being recorded which are characteristic of a power consumption for the machine. Another step involves the data items for the sub-procedures of the machine and the data items which are characteristic of the power consumption of the machine being stored in a memory device (10). Finally, the power consumption is ascertained from the data items recorded in a memory device (10) and the power consumption is displayed, the power consumption for at least two sub-procedures being able to be shown separately.

Description

Method and device for analyzing the energy consumption of a machine

description

The present invention relates to a method and apparatus for analyzing the energy consumption of machines. More recently, there has been an increasing demand for systems that reduce the power consumption of machines. Thus, it has long been known from the prior art to provide electricity meters which detect the energy consumption of an entire system. However, these current measuring devices have the disadvantage that they make no reference to the actual machine sequence, to procedures, to the tools, to main or auxiliary times and the like allow, but only spend a somewhat averaged consumption value.

The present invention is therefore based on the object to enable a more accurate analysis of machines in terms of their energy consumption. This is inventively achieved by a method according to claim 1 and an apparatus according to claim 11. Advantageous embodiments and further developments are the subject of the dependent claims.

In a method according to the invention for analyzing the energy consumption of machines, a multiplicity of data is initially recorded, which are characteristic of a plurality of partial sequences of a workflow of the machine. Furthermore, a variety of data is recorded that is characteristic of the power consumption of the machine. Furthermore, the data that is characteristic of the sub-processes of the machine and also the data that is characteristic of the power consumption of the machine, stored in a memory device. Furthermore, the energy consumption is determined and displayed from the data recorded in the storage device, wherein the energy consumption for at least two sub-processes is separately represented or displayed. Thus, the inventive method allows a detailed representation of energy consumption of the machine, not only the total consumption of the machine is issued, but a division, for example, in different sub-processes or different working units of this machine is possible. Through this

Representation of the different machine parts, it is possible to identify those processes or drive parts, which are particularly energy-intensive and may reduce the corresponding processes in terms of their energy consumption.

Preferably, the data or quantities which are characteristic for the energy consumption of the machine are measured by means of sensor devices. By means of the invention it is possible to record the energy consumption of machines with a concrete relation to a mechanical process, to graphically display and consequently to reduce this energy consumption, this being possible both in manual and in automated form. Such energy recording and analysis methods are not known in the field of automation. Although it is known to record individual signals as part of a signal analysis, such as the motor current, but a concrete evaluation of the motor current with reference to procedures for the purpose of output of an energy characteristic is not known. While therefore in the prior art no relation to the process, to the process, to the tools or to the main and

Nebenzeit and the like is possible, the present invention allows these references.

In another preferred method, the data characteristic of the energy consumption is compared with reference data. In this case, it is possible, for example, to compare the measured characteristic data, such as the motor currents, with nominal currents, in order thus to conclude an increased energy consumption. Furthermore, it is also possible not to measure the energy consumption directly, but to capture the relevant for energy consumption variables, this also with the help of other sizes is possible, for example, allow conclusions about energy consumption, such as the engine torque, in the motor current and the like , From these quantities, the energy consumption is subsequently determined using mathematical methods and, finally, the user is preferably given a graphical representation of the energy consumption. In addition to electrical quantities, mechanical quantities for determining the energy consumption can also be measured. Two different partial sequences may, for example, be two different method steps of a method. It would also be possible to represent processes for two different tools or drives in order to allow conclusions about the energy consumption of the machine in this way. In another preferred method, a value representative of the comparison between the characteristic data and the reference data is output. In this way, the user is shown whether the measured energy consumption is equal to, or higher than, an expected value, for example.

So it is possible, for example, a power consumption of individual machine components, such as machinery units (hydraulics, pneumatics, coolant) single, web, auxiliary axes and spindles in a relationship with a programmed sequence sequence, processing, a process, the tools, an on and Departure strategy, the NC blocks, the main, secondary, tool and

Tool change times to set, and this can be done in particular in graphical form.

In another preferred method, work instructions are issued based on performed comparisons. It becomes possible, for example, to automatically analyze the data measured and stored in the memory device and to give suggestions to a user as to how energy savings can be achieved. It would also be possible to provide self-optimization of consumption.

In another preferred method, the machine is controlled or regulated taking into account the data characteristic of the power consumption. More specifically, it is possible to optimize individual sub-processes based on the data obtained. For example, it can be determined by means of a control for a coolant pump that it has a relatively high energy consumption. On the other hand, it would be possible to reduce the power consumption of this coolant pump without at the same time impairing the process to be carried out with the machine. In this way, this energy consumption can be reduced by a precise analysis of the energy consumption and subsequent concrete measures. The quantities to be measured are for example, motor currents, motor voltages, motor torque, rotational speed of an engine, and the like.

Preferably, the sub-processes are temporal subsections of the workflow. In this case, an entire run is divided temporally with respect to different process sections and these individual sections are analyzed with regard to their energy consumption.

Furthermore, it would also be possible for the sub-sequences to be characteristic processes for different tools of the machine. This means that, for example, several

Drives of a machine can be analyzed exactly with regard to their energy consumption and in this way energy-intensive units of the machine can be identified. Furthermore, it is possible to determine the energy consumption over time, in which case a reference to the sequence program is possible, as well as this can be done without reference to the sequence program. It is also possible to observe the energy consumption over the path, for example via the path of a particular tool element with or without reference to a sequence program. As mentioned, however, the energy consumption can also be differentiated according to the respective tool or also according to the respective time type, for example the presence of a main time, an idle time, a tool change time, a workpiece change time, an operating time and the like. Also, the power consumption with respect to the control channels can be observed separately.

By storing the above-mentioned data, it is possible that a later accurate analysis of the recorded data takes place. It is also possible that the energy consumption is compared between different records and in this way an optimization can be carried out. Finally, it is also possible to distinguish the energy consumption per sequence, processing cycle, subcycle or layer.

The representation of the energy consumption can be made in a variety of diagram types, such as in the context of a bar chart or a pie chart. Furthermore, it is possible that the analysis is done using the Internet. For example, a machine user at a certain location could store the data characteristic for the energy consumption and access the database for the evaluation of this data via the Internet, in which, for example, data from a data sheet is stored.

In a further preferred method, the data which is characteristic of several sub-sequences of a workflow of the machine and the data which is characteristic of a power consumption of the machine are repeatedly recorded and stored.

For example, the energy data could be cyclically (e.g., weekly) recorded, stored and processed over a longer period of time. In this way, e.g. by outputting a trend graph) early damage of the components can be detected and thus condition monitoring is possible.

By way of example, three measurements or recordings of energy-relevant data of individual components could be carried out, with the corresponding machine being switched on during a first measurement but no movement taking place, in a further measurement the machine is operating without a workpiece (ie traveling in the air) and at one third measurement the machine processes a workpiece.

With the help of these measurements, the energy for the process can be deduced by subtracting the energy determined during the second measurement from the energy determined during the third measurement. It is also possible to deduce the energy for the machine movement by subtracting the energy determined during the first measurement from the energy determined during the second measurement.

If one carries out these measurements cyclically, one can purposefully close on the condition of the components or the process.

The present invention is further directed to a machine, this machine having at least one sensor unit which outputs characteristic values for an energy consumption of the machine, an output device which is responsible for partial processes of a machine Workflow the machine characteristic data and outputs for the energy consumption of the machine characteristic values and a memory device, which stores the data and values characteristic of the sub-processes and the energy consumption. Furthermore, a processor device is provided, which assigns the individual sub-processes different energy consumption and an output device which represents the energy consumption of at least two sub-processes separately. The output device may in particular be a display device such as a display or a monitor.

Thus, the machine according to the invention also allows a representation of different sub-processes in terms of their energy consumption. In turn, the partial sequences may be, for example, different subsystems such as different drives, but also different temporal or local partial sequences of one or more drives.

The sensor device may be, for example, a current measuring device which measures a specific motor current of a drive. Preferably, a plurality of such sensor devices are provided, and preferably, each drive element of this machine has its own sensor unit.

By the assignment of the respective data for the energy consumption characteristic data to the sub-processes, as mentioned above, an analysis of the power consumption of the machine is simplified.

In a further preferred embodiment, the machine has an input device in order to input further data describing the machine into the memory device. This may be, for example, a PC via which data from data sheets, such as desired currents or setpoint torques and the like, can be entered. With the help of this data, an analysis of the energy consumption can be facilitated. Also, estimates can be made using these data.

Furthermore, the machine preferably has a plurality of drive elements and the output device outputs the energy consumption of each drive element characteristic data separately. Also in this way it is possible to make a detailed analysis of the energy consumption of a machine divided according to different drive elements.

In a further advantageous embodiment, the machine has a

Control means which controls the machine, said control means for the control of the machine outputs characteristic data to the memory means. This may be, for example, a PLC control, which controls the machine. The characteristic of the control of the machine data are not only output to the machine for their control, but also to the memory device. These PLC data can also be taken into account when assessing the energy consumption of the machine and also allow a more detailed analysis of this energy consumption.

Further advantages and embodiments will be apparent from the attached drawings:

Show:

Fig. 1 is a block diagram illustrating a method according to the invention;

Fig. 2 is a first diagram of an energy consumption of a machine;

3 shows a second variant of a representation to illustrate the energy consumption of a machine; and

Fig. 4 is another illustration for illustrating the power consumption of a machine.

FIG. 1 shows a block diagram for illustrating an inventive device

Process. In this case, a (real) machine 1 is provided, which has a plurality of drives. In addition, at least one and preferably a multiplicity of sensor devices are provided, which record characteristic data or measured variables for the energy consumption. The reference numeral 4 refers to an output device via which characteristic motor data such as a motor current, a rotational speed of the motor, an engine torque and the like are output to a receiving device. Generally, drive bus data is output through this output device. Conversely, however, data can also be passed on to the real machine or the drive via the input 6, in particular drive-specific data.

The reference numeral 5 refers to a further output device, via which characteristics of sensors 2 can be output, for example characteristics of position sensors, temperature sensors, pressure sensors and the like.

These data are also received by an input 7. The data thus transmitted to the inputs are output to a memory device or data collecting device 10, which stores these data. Thus, characteristic data are stored in the memory device 10 for energy consumption of the machine. In addition, data are stored, which directly characterize a movement sequence of the engine, for example, operating times of an engine, tool change times and the like.

In this way, it is possible to store within the memory device 10 an association between, for example, time sections of a method and the respective characteristic data for the energy consumption. The reference numeral 16 refers to a control device which serves to control the real machine in normal operation. This is in particular a PLC control. The data used to control the real machine 1 is also stored in the memory device 10. In this way, an assignment to control-specific data can be made.

Reference numeral 18 refers to an input device such as a personal computer through which, for example, data from data sheets characteristic of this machine 1 can be input. The reference numeral 22 refers to a further input device via which, for example, internal NC data, for example data which describe the relevant tools, are output to the memory device 10 become. Thus, the reference numeral 20 refers to the (real) control system (for the engine 1) in its entirety.

In the block designated 25, a processing of the data stored in the memory device 10 takes place. More specifically, here the data stored in the memory device are analyzed with the aid of mathematical aids and in this way measurement for the energy consumption is output, whereby this energy consumption can be output separately for different parts of the real machine. In particular, energy consumption of each individual drive can be output, including pump drives and the like. In addition, the energy consumption can also be in

Relation to be generated, for example, a generated pressure. Reference numeral 12 denotes a corresponding data preparation unit.

Via a display device 14 is a graphical representation of the energy consumption of the system.

For example, it is possible to output a current actual value P _ist (t) for the electric power according to the following relationship:

P ₁₁₁ (0 = t / ", (0 • '*, (')

Accordingly, the following relationship can be expressed for the energy:

Instead of the actual current voltage U _ist (t) or the current actual current l _ist (t), other particularly proportional variables could be used for an approximate calculation, such as a _setpoint voltage U _50n , an average value of a voltage U _M i _tt eiwert or a sheet taken from a voltage U _Dat enbiatt- Accordingly, the sizes l (a taken-out of the sheet current value or a curve) could be _as u, iMitteiw _ert or bate _nb i _at t be used. In particular, the determination of the energy consumption PLC-controlled units can be done quite easily in this way, z. B. for a hydraulic unit or an electric actuator. More precisely, it is possible to use a measured quantity, for example U _fSt (t) and an approximately determined variable, eg l, _st (t), for the calculation of the power.

As an alternative to the electrical power, the mechanical power can also be detected

P _H * (O = F _m )) - v _m {t) + M _m (O - ω _ιst {t)

FIG. 2 shows a first possible representation for energy consumption. Here, the energy consumption is broken down according to different time types, d. H. after a main time I, an idle time Il or a tool change time III. The different bars characterize different drives or systems of the machine. In this way it can be evaluated, for example, that the drives designated A and D require a high level of power during the main time. This analysis may attempt to reduce these benefits. In each case the power P is plotted on the y-axis.

Figure 3 is another possible representation for the analysis of energy consumption. In this case, the energy consumption F - K for a given machining operation is shown for different tools. Furthermore, it would also be possible to refine the representation insofar as it is still subdivided by working steps of individual tools. Within the representations, a tool can be called up and further analyzed.

FIG. 4 shows a further possible illustration of the energy consumption. Here, the power consumption E (t) and power consumption P (t) of a particular machine component (eg, an electric drive) is plotted over time (curve 30). In the lower part of Figure 4, a flow is shown, so that not only a connection with the time can be output, but also in the context of the respective sequence program or the individual command lines of this program. In this way, an analysis can also be made of which executions or commands of a sequence program are particularly energy-intensive. More precisely, an NC sequence analysis can be carried out here, wherein the individual sentences can be viewed separately from an energy point of view. In particular, by using the data from the control device, it is possible to identify particularly energy-efficient processes and in this way to determine how energy can be saved. For example, it was found for a particular system that a surprisingly high proportion of the energy consumption is used for a coolant pump. At the same time, it was found that the coolant pressure maintained by the coolant pump was higher than was absolutely necessary for the proper operation of the engine. By corresponding modification of the control of the coolant pump could be significantly reduced in this way the energy consumption of the machine.

All disclosed in the application documents features are claimed as essential to the invention, provided they are new individually or in combination over the prior art.

LIST OF REFERENCE NUMBERS

1 machine

2 sensor device

4, 5 output device

6, 7 entrance

10 data collection device

12 data processing device

14 display device

16 control device

18 input device

20 control system

22 more input device

25 block

30 curve

I main time

Il secondary time

III tool change time

A ₁ B .C ₁ D ₁ E Power consumption for drives

F, G, H ₁ I ₁ K Power or energy consumption for tools

P performance

Claims

claims

1. Method for analyzing the energy consumption of machines with the steps:

- Recording a variety of data, which are characteristic of several sub-sequences of a workflow of the machine; - Recording a variety of data that are characteristic of an energy consumption of the machine;

- storing the data that is characteristic of the sub-processes of the machine and the data that is characteristic of the power consumption of the machine in a storage device; Determining the energy consumption from the data recorded in the storage device, and displaying the energy consumption, wherein the energy consumption for at least two partial processes can be displayed separately.

2. Method according to claim 1, characterized in that the data characteristic for the energy consumption are compared with reference data.

3. The method according to claim 2, characterized in that a value representative of the comparison between the characteristic data and the reference data is output.

4. The method according to at least one of the preceding claims 2-3, characterized in that issued due to performed comparisons work instructions.

5. The method according to at least one of the preceding claims, characterized in that the machine taking into account the characteristic of the energy consumption Data is controlled or regulated.

6. The method according to at least one of the preceding claims, characterized in that the sub-processes are temporal subsections of the workflow.

7. The method according to at least one of the preceding claims 1 -5, characterized in that the sub-processes are local subsections of the workflow.

8. The method according to at least one of the preceding claims 1 -5, characterized in that the sub-processes for different tools of the machine are characteristic processes.

9. The method according to at least one of the preceding claims 2-8, characterized in that the data of various workflows are compared.

10. The method according to at least one of the preceding claims, characterized in that the analysis of the energy consumption is carried out using the Internet.

11. The method according to at least one of the preceding claims, characterized in that the data which are characteristic of several sub-sequences of a workflow of the machine and the data which are characteristic of an energy consumption of the machine, repeatedly recorded and ^{1 are} stored.

12. Machine (1) with at least one sensor unit (2) which outputs at least one characteristic of a power consumption of the machine, an output device (4, 5), which characteristic of sub-sequences of a workflow of the machine characteristic data and energy consumption of the machine Outputs values, with a memory device (10), which the for the Saving sub-sequences and the data and values characteristic of the energy consumption, a processor device (12), which assigns the individual sub-processes different energy consumption and an output device (14), which represents the energy consumption of at least two sub-processes separately.

13. Machine (1) according to claim 12, characterized in that the machine (1) has an input device (18) for inputting further data describing the machine (1) into the memory device (10).

14. Machine according to claim 1, characterized in that the machine has a plurality of drive elements and the output device separately outputs the data characteristic of the energy consumption of these drive elements.

15. Machine according to at least one of the preceding claims 12-14, characterized in that the machine has a control device (16) which controls this machine, said control device (16) for the control of the machine characteristic data to the memory device (10). outputs.