JP7675593B2 - Energy unit calculation support device - Google Patents

Description

The present invention relates to an energy intensity calculation support device that supports the calculation of the energy intensity of manufactured products.

Manufacturing equipment for producing beverage products such as black tea in PET bottles has multiple types of process equipment that differ for each process. Examples of process equipment include an extractor used in the extraction process to extract tea leaf extract, a blending device used in the blending process, and a filling device used in the filling process to fill black tea into PET bottles.

Manufacturing equipment for producing beverage products often includes a cleaning device that cleans the inside of the process equipment (tanks, piping, etc.) (see, for example, Patent Document 1). This cleaning device has a cleaning pump that pumps cleaning liquid such as detergent or warm water into the inside of the process equipment. When producing beverage products, the cleaning device drives the cleaning pump before and after use of each process equipment to clean the inside of the process equipment (so-called CIP). This keeps each process equipment, and ultimately the manufacturing equipment, in a hygienic and clean state.

Patent No. 5098321

In order to ascertain the manufacturing costs of a product, the amount of energy consumed in its production is sometimes calculated as the energy intensity. To calculate the energy intensity, it is necessary to accurately ascertain the operating status of the process equipment used in each process involved in the production of the product. Incorporating equipment for ascertaining the operating status of each process equipment into existing manufacturing equipment is not preferred at manufacturing sites, as this in itself is costly and time-consuming.

The energy unit calculation support device for solving the above problem has multiple types of process equipment that differ for each process, and a cleaning device that cleans the inside of the process equipment by driving the same cleaning pump before and after use of the multiple types of process equipment, and is applied to a manufacturing device that manufactures products using the multiple types of process equipment and the cleaning device, and is equipped with a pump detection unit that detects an index value of the power consumption of the cleaning pump, a storage unit that stores in advance conditions for identifying the process equipment to be cleaned when the cleaning device is operating, a target equipment identification unit that identifies the process equipment to be cleaned and the operating period of the cleaning pump for cleaning the process equipment based on the index value of the power consumption when the transition of the power consumption index value detected by the pump detection unit satisfies the conditions, and a unit period setting unit that determines a unit period for calculating the amount of energy consumed in conjunction with the operation of the process equipment to be cleaned based on the process equipment to be cleaned and the operating period identified by the target equipment identification unit.

In the above configuration, the cleaning devices are driven by a common cleaning pump. However, if the process devices to be cleaned are different, the cleaning manner of the process devices is different, and therefore the driving manner of the cleaning pump is also different.
According to the above configuration, it is possible to grasp in advance the characteristic behavior of the wash pump (specifically, the transition of the power index value) of each process device when the washing device is operating, and store the conditions that can identify the characteristic behavior as the conditions for identifying the process device to be washed. Therefore, based on the above conditions, it is possible to grasp the characteristic behavior of the index value of the power consumption of the wash pump and identify the process device to be washed by the washing device. Moreover, it is also possible to identify the operation period of the wash pump for washing the process device to be washed from the transition of the index value of the power consumption of the wash pump.

The "unit period," which is the period to be calculated when calculating the amount of energy consumed in the operation of each process equipment, is determined by the period during which the process equipment is operated and the period during which the cleaning equipment is operated to clean the same process equipment before or after use. Therefore, the above-mentioned unit period can be defined as the period from the start (or end) of operation of the cleaning equipment for the current operation of the process equipment to the start (or end) of operation of the cleaning equipment for the next operation of the same process equipment.

According to the above configuration, the target equipment identification unit can identify the operating period of the cleaning pump for cleaning the process equipment to be cleaned, and this operating period can be used to determine the unit period. The unit period can be determined, for example, from the start (or end) timing of the operating period for cleaning immediately before the operation of the process equipment to the start (or end) timing of the operating period for cleaning immediately after the operation of the same process equipment. Moreover, according to the above configuration, it is possible to determine the unit period by adding a pump detection unit, which is configured to detect an index value for the power consumption of the cleaning pump. The unit period determined in this manner can then be used to calculate the energy consumption rate.

Therefore, according to the above configuration, it is possible to assist in the calculation of the energy intensity while minimizing changes to the manufacturing equipment.
In the above-mentioned energy unit calculation support device, it is preferable that the device further includes a process detection unit which detects power consumption index values of each of the multiple types of process equipment, and the target equipment identification unit identifies the process equipment to be cleaned and the operating period based on the power consumption index value of the cleaning pump and the power consumption index value of any of the process equipment when a trend in the power consumption index value detected by the pump detection unit and a trend in the power consumption index value of any of the multiple types of process equipment detected by the process detection unit both satisfy the condition.

There is a type of manufacturing apparatus in which a cleaning device is operated to clean the process equipment. With the above configuration, in such a manufacturing apparatus, in addition to using an index value for the power consumption of the cleaning pump as a parameter for specifying the conditions for identifying the process equipment to be cleaned, an index value for the power consumption of the process equipment can be used. This allows the above conditions to be set in detail, making it possible to accurately identify the process equipment to be cleaned and the operating period of the cleaning pump for cleaning the process equipment.

In the above energy intensity calculation support device, the product is a beverage product.
In the manufacturing equipment for manufacturing beverage products, the parts through which the ingredients pass are sealed, so that it is difficult to grasp the operating status. According to the above-mentioned configuration, in such a manufacturing equipment, the process equipment to be cleaned by the cleaning device and the operating period of the cleaning pump for cleaning the process equipment can be accurately identified.

In the above energy intensity calculation support device, the plurality of types of process equipment includes a filling equipment that fills beverages into containers.
According to the above configuration, the unit period for calculating the amount of energy consumed in the operation of the filling device can be obtained with high accuracy.

The present invention can assist in the calculation of energy intensity while minimizing changes to manufacturing equipment.

1 is a schematic configuration diagram of an energy intensity calculation support device according to an embodiment; 1 is a flowchart showing a process for producing a beverage product by a production apparatus to which an energy intensity calculation support device is applied.

An embodiment of the energy intensity calculation support device will be described below.
First, a manufacturing device to which the energy consumption rate calculation support device of the present embodiment is applied will be described. The manufacturing device of the present embodiment is a device for manufacturing a beverage product (e.g., black tea product) as a product. More specifically, by using the manufacturing devices in sequence, multiple types of beverage products are manufactured.

As shown in Figures 1 and 2, the manufacturing equipment 10 has multiple types of process equipment, including an extractor 11, a centrifuge 12, a storage tank 13, a blending device 14, a sterilization device 15, an aseptic tank 16, a filling device 17, a labeling device 18, a packaging device 19, and a boxing device 20.

(Extraction process)
When producing a beverage product, first, a brewing process is carried out (step S1 in FIG. 2).
In this extraction process, process equipment such as an extractor 11, a centrifuge 12, and a storage tank 13 are used. In the extraction process, first, an extract (tea leaf extract) is extracted from the raw material (tea leaves) by the extractor 11. Then, after being clarified by the centrifuge 12, this extract is sent to the storage tank 13 and temporarily stored therein.

(Mixing process)
After the extraction step, a preparation step is carried out (step S2 in FIG. 2).
In the blending process, a blending device 14 is used as a process device. In the blending process, the blending device 14 mixes (blends) the extract and other ingredients in a predetermined ratio to produce a blended liquid (beverage).

(Filling process)
After the blending step, the filling step is carried out (step S3 in FIG. 2).
In the filling process, process equipment such as a sterilizer 15, a sterile tank 16, and a filling device 17 are used. In the manufacturing apparatus 10 of this embodiment, steam can be supplied from a boiler 21 (FIG. 1) installed in the factory to the sterilizer 15 and the sterile tank 16. The sterilizer 15 is structured to heat and sterilize the preparation using this steam. The sterile tank 16 is structured to keep its inside sterile by using the steam supplied from the boiler 21.

In the filling process, the compounded liquid is first sent from the compounding device 14 to the sterilizing device 15, where it is sterilized, and then sent to the sterile tank 16 where it is temporarily stored. The compounded liquid is then sent from the sterile tank 16 to the filling device 17, where it is filled into beverage containers (e.g., plastic bottles).

(Finishing process)
After the filling step, a finishing step is carried out (step S4 in FIG. 2).
In the finishing process, a labeling device 18, a packaging device 19, and a boxing device 20 are used. In the finishing process, first, the labeling device 18 attaches a product label to the outer surface of the beverage container filled with the blended liquid. Then, the packaging device 19 packages the beverage product, and the boxing device 20 boxes the beverage product.

In the manufacturing device 10 of this embodiment, a beverage product is manufactured through an extraction process, a blending process, a filling process, and a finishing process. In addition, in the manufacturing device 10 of this embodiment, each process is carried out in such a way that the adjacent processes partially overlap each other in order to efficiently manufacture the beverage product.

(Cleaning device)
As shown in Fig. 1, the manufacturing apparatus 10 of this embodiment has a cleaning apparatus 30 that cleans the inside of the process equipment. The cleaning apparatus 30 is an apparatus that performs stationary cleaning, so-called CIP (Cleaning in Place). More specifically, the cleaning apparatus 30 has equipment (such as a cleaning liquid tank, piping, and a pump) that is pre-installed in the manufacturing apparatus 10. The cleaning apparatus 30 utilizes the above equipment to send a cleaning liquid into the inside of the process equipment and collect it, thereby automatically cleaning the inside of the process equipment.

The cleaning device 30 includes a cleaning liquid tank 31 , a first pipe 32 , a first pump 33 , a second pipe 34 , and a second pump 35 .
The cleaning liquid tank 31 is a tank that stores a cleaning liquid used for cleaning the process equipment. In this embodiment, the cleaning liquid tank 31 includes a plurality of tanks that store different types of cleaning liquid, such as a tank that stores warm water as the cleaning liquid, a tank that stores an alkaline cleaning liquid, and a tank that stores an acidic cleaning liquid. When cleaning the inside of the process equipment, the cleaning liquid is sent from one of the plurality of cleaning liquid tanks to the process equipment through the operation of the cleaning device 30 by an operator. Note that only one cleaning liquid tank 31 is shown in FIG. 1.

The first pipe 32 is extended in such a manner that it selectively connects the cleaning liquid tank 31 to either the extractor 11 or the blending device 14. The first pipe 32 is provided with the first pump 33 and a switching valve (not shown). The first pump 33 is an electric pump that pressure-feeds the cleaning liquid in the cleaning liquid tank 31 to the extractor 11 or the blending device 14. The switching valve provided in the first pipe 32 is a valve for switching between a state in which the cleaning liquid tank 31 and the extractor 11 are connected by the first pipe 32 and a state in which the cleaning liquid tank 31 and the blending device 14 are connected by the first pipe 32.

In the cleaning device 30, the switching valve of the first pipe 32 is operated and then the first pump 33 is driven, so that the cleaning liquid is selectively sent to either the extractor 11 or the blending device 14, and the inside of the extractor 11 or the blending device 14 is automatically cleaned. In this way, the cleaning device 30 of this embodiment is configured to clean the inside of the extractor 11 and the inside of the blending device 14 by driving the same cleaning pump (specifically, the first pump 33).

On the other hand, the second pipe 34 is extended in such a manner that the cleaning liquid tank 31 is connected to the sterilizer 15, the sterile tank 16, and the filling device 17. The second pipe 34 is provided with a second pump 35. The second pump 35 is an electric pump that pressure-feeds the cleaning liquid in the cleaning liquid tank 31 to the sterilizer 15, the sterile tank 16, and the filling device 17. In the cleaning device 30, by driving the second pump 35, the cleaning liquid is sent to the sterilizer 15, the sterile tank 16, and the filling device 17 through the second pipe 34, so that the insides of the sterilizer 15, the sterile tank 16, and the filling device 17 are automatically cleaned.

Each process device, such as the extractor 11, centrifuge 12, storage tank 13, blending device 14, sterilization device 15, aseptic tank 16, filling device 17, labeling device 18, packaging device 19, boxing device 20, and cleaning device 30, is equipped with an operation panel. When the manufacturing device 10 manufactures beverage products, the operation of the process device corresponding to the operation panel is controlled by the operator operating each operation panel.

(Energy unit calculation support device)
The energy intensity calculation support device of this embodiment includes a computer 40. The computer 40 includes an input device operated by a user, a display device that displays information to the user, and the like. Note that as the computer 40, it is possible to adopt a personal computer such as a desktop type, notebook type, or tablet type, or a portable computer such as a smartphone.

The computer 40 is capable of executing an assistance program that assists in the calculation of the energy intensity of the beverage product manufactured by the manufacturing apparatus 10 .
(Storage part)
The computer 40 includes a storage unit 41 that stores various data. The storage unit 41 stores an assistance program and various calculation results by the computer 40. The storage unit 41 also stores conditions for identifying a process equipment to be cleaned when the cleaning equipment 30 is in operation, more specifically, conditions A1 to A3, conditions B1 to B4, and conditions C1 and C2, which will be described later.

(Target device identification unit, unit period setting unit)
The computer 40 includes, as functional units, a target device specifying unit 43 and a unit period setting unit 44 .

When the transition in the power consumption P1 of the first pump 33 and the transition in the power consumption PA of the extractor 11 both satisfy the above conditions (more specifically, conditions A1 to A3), the target device identification unit 43 identifies the following based on the power consumption P1 and PA. That is, it identifies that the target to be cleaned by the cleaning device 30 at this time is the extractor 11. It also identifies the operating period T1 of the first pump 33 in the current cleaning of the extractor 11. This operating period T1 is stored in the memory unit 41.

On the other hand, when the transition of the power consumption P1 of the first pump 33 and the transition of the power consumption PB of the blending device 14 satisfy the above conditions (more specifically, conditions B1 to B4), the target device identification unit 43 identifies the following based on the power consumption P1 and PB. That is, it identifies that the target to be cleaned by the cleaning device 30 at this time is the blending device 14. It also identifies the operating period T2 of the first pump 33 when cleaning the blending device 14 this time. This operating period T2 is stored in the memory unit 41.

On the other hand, when the change in the power consumption P2 of the second pump 35 satisfies the above conditions (more specifically, conditions C1 and C2), the target device identification unit 43 identifies the following based on the power consumption P2. That is, it identifies that the objects to be cleaned by the cleaning device 30 at this time are the sterilization device 15, the aseptic tank 16, and the filling device 17. It also identifies the operating period T3 of the second pump 35 in the current cleaning process. This operating period T3 is stored in the memory unit 41.

The unit period setting unit 44 determines a "unit period" which is the calculation period when calculating the amount of energy consumed in the operation of the process equipment to be cleaned identified by the target equipment identification unit 43.

When the cleaning target identified by the target device identification unit 43 is the extractor 11, the unit period setting unit 44 reads out the operating period T1 of the first pump 33 in cleaning the extractor 11 from the memory unit 41, and determines the unit period based on the operating period T1 as follows. That is, the unit period TA is determined to be the period from the end timing of the operating period T1 in the cleaning process immediately before the operation of the extractor 11 to the end timing of the operating period T1 of the first pump 33 in the cleaning process immediately after the operation of the extractor 11. In this embodiment, this unit period TA is used as the calculation target period when calculating the amount of energy consumed in conjunction with the operation of the extractor 11.

On the other hand, when the cleaning target identified by the target device identification unit 43 is the blending device 14, the unit period setting unit 44 reads out the operating period T2 of the first pump 33 in cleaning the blending device 14 from the memory unit 41, and determines the unit period based on the operating period T2 as follows. That is, the unit period TB is determined to be the period from the end timing of the operating period T2 of the first pump 33 in the cleaning process immediately before the operation of the blending device 14 to the end timing of the operating period T2 in the cleaning process immediately after the operation of the blending device 14. In this embodiment, this unit period TB is used as the calculation target period when calculating the amount of energy consumed in conjunction with the operation of the blending device 14.

On the other hand, when the cleaning target identified by the target device identification unit 43 is the sterilizer 15, the sterile tank 16, and the filling device 17, the unit period setting unit 44 determines the unit period based on the operation period T3 of the second pump 35 during cleaning as follows: That is, the operation period T3 is read from the memory unit 41. Then, the unit period TC is determined as the period from the end timing of the operation period T3 in the cleaning process immediately before the operation of the sterilizer 15, the sterile tank 16, and the filling device 17 to the end timing of the operation period T3 in the cleaning process immediately after the operation. In this embodiment, this unit period TC is used as the calculation target period when calculating the amount of energy consumed in the operation of the sterilizer 15, the sterile tank 16, and the filling device 17.

(Process detection unit, pump detection unit)
The energy unit calculation support device of this embodiment includes current sensors 50 to 59 described below. That is, the device of this embodiment includes a current sensor 50 for detecting the current consumption of the extractor 11, a current sensor 51 for detecting the current consumption of the centrifuge 12, and a current sensor 52 for detecting the current consumption of the blending device 14. The device of this embodiment also includes a current sensor 53 for detecting the current consumption of the sterilizing device 15, a current sensor 54 for detecting the current consumption of the filling device 17, and a current sensor 55 for detecting the current consumption of the labeling device 18. The device of this embodiment also includes a current sensor 56 for detecting the current consumption of the packaging device 19, and a current sensor 57 for detecting the current consumption of the boxing device 20. In addition, the device of this embodiment also includes a current sensor 58 for detecting the current consumption of the first pump 33, a current sensor 59 for detecting the current consumption of the second pump 35, and the like.

All of the current sensors 50-59 are attached to the manufacturing equipment 10 after it has been installed in the factory. The output signals of the current sensors 50-59 are input to the computer 40. The computer 40 calculates the power consumption of the equipment corresponding to the current sensors 50-59 based on the output signals of the current sensors 50-59, and uses the calculated power consumption for various calculations. In this embodiment, the current sensor 58 provided in the first pump 33 corresponds to a pump detection unit that detects the index value of the power consumption of the cleaning pump. In this embodiment, the current sensor 50 provided in the extractor 11 and the current sensor 51 provided in the blending device 14 correspond to process detection units that detect the index values of the power consumption of multiple types of process equipment separately.

The energy intensity calculation support device of this embodiment is equipped with steam flowmeters 60, 61 described below. A steam flowmeter 60 is provided on a first boiler pipe 62 connecting the boiler 21 and the sterilizer 15 to detect the amount of steam supplied to the sterilizer 15. A steam flowmeter 61 is provided on a second boiler pipe 63 connecting the boiler 21 and the sterile tank 16 to detect the amount of steam supplied to the sterile tank 16. The output signals of the steam flowmeters 60, 61 are input to the computer 40. The computer 40 uses the amount of steam detected by the steam flowmeters 60, 61 for various calculation processes such as the calculation process of the energy intensity.

The energy consumption rate calculation support device of this embodiment has an optical sensor 70 for detecting and counting beverage products sent from the filling device 17 to the labeling device 18. The output signal of the optical sensor 70 is input to the computer 40. The computer 40 determines the execution period during which the filling device 17 is filling beverage containers with beverages based on the output signal of the optical sensor 70. The computer 40 determines that the filling device 17 is filling beverages when the optical sensor 70 detects the passage of a beverage product. The computer 40 also determines that the filling device 17 is not filling beverages when the optical sensor 70 does not detect the passage of a beverage product. The computer 40 also detects the number of beverage containers filled with beverages during the execution period based on the output signal of the optical sensor 70.

(Calculation procedure for energy intensity)
The procedure for calculating the energy intensity for the production of a beverage product will be specifically described below.

In the energy consumption unit calculation support device of this embodiment, the sum of the amounts of energy consumed A, B, C, D, and E described below divided by the number of beverage products manufactured F ([A+B+C+D+E]/F) is calculated as the energy consumption unit.

(Amount of energy consumed A) The total amount of energy consumed in the operation of the extractor 11 and the centrifuge 12 in the extraction process.
(Amount of energy consumed B) The total amount of energy consumed in the operation of the blending device 14 in the blending process.

(Amount of energy consumed C) The total amount of energy consumed in the operation of the sterilization device 15, the sterile tank 16, and the filling device 17 in the filling process.
(Energy consumption amount D) The total amount of energy consumed in the operation of the labeling device 18, the packaging device 19, and the boxing device 20 in the finishing process.

(Amount of energy consumed E) The total amount of energy consumed in the operation of the cleaning device 30 performed in the cleaning process immediately after the operation of the process equipment in the extraction process, the cleaning process immediately after the operation of the process equipment in the blending process, and the cleaning process immediately after the operation of the process equipment in the filling process.

(Calculation procedure for consumed energy amount A)
The manner in which the amount of consumed energy A is calculated will be described below.
In this embodiment, the target device identification unit 43 of the computer 40 identifies the extractor 11 as the device to be cleaned by the cleaning device 30 when all of the following conditions A1, A2, and A3 are satisfied.

(Condition A1) The average value of the power consumption of the extractor 11 over a specified period of time (e.g., several tens of minutes) is equal to or greater than a specified value AA1. Note that the specified value AA1 is set to a value greater than the power consumption AA2 of the extractor 11 during normal operation for extracting the extract (AA1>AA2).

(Condition A2) The average value of the power consumption of the first pump 33 over a predetermined period of time (e.g., several minutes) is equal to or greater than a predetermined value AA3.
(Condition A3) From a state where both Condition A1 and Condition A2 are satisfied, the average power consumption of the first pump 33 over a predetermined period of time (e.g., several minutes) becomes equal to or less than a predetermined value AA4 (e.g., approximately 0 kW).

In this embodiment, the inventors and others verify the operating history data of the manufacturing apparatus 10 to determine in advance the transition in power consumption of the first pump 33 and the transition in power consumption of the extractor 11 that characteristically appear when the cleaning apparatus 30 cleans the extractor 11. The inventors and others then determine in advance conditions (conditions A1 to A3) that can identify the emergence of such characteristic transitions in power consumption of the first pump 33 and the extractor 11, and store the conditions A1 to A3 in the memory unit 41. As a result, when all of the conditions A1, A2, and A3 are satisfied, it becomes possible to accurately identify that the object to be cleaned by the cleaning apparatus 30 is the extractor 11.

In the manufacturing apparatus 10 of this embodiment, when the extractor 11 is cleaned by the cleaning device 30, the first pump 33 of the cleaning device 30 is operated, and the extractor 11 is also operated. In light of this, in this embodiment, conditions A1 to A3 are set, which are conditions in which the power consumption of the first pump 33 and the power consumption of the extractor 11 are parameters.

When it is determined that the object to be cleaned is the extractor 11, the unit period setting unit 44 of the computer 40 determines a "unit period TA", which is the calculation period for calculating the amount of consumed energy A, based on the operating period T1 stored in the memory unit 41.

In the extraction process, before the extractor 11 extracts the extract, the extractor 11 is cleaned by the cleaning device 30. In this embodiment, the completion timing of the cleaning of the extractor 11 is set to the start timing of the unit period TA. In the extraction process, after the extractor 11 finishes extracting the extract, the cleaning device 30 cleans the extractor 11 for the next extraction process. In this embodiment, the completion timing of the cleaning of the extractor 11 is set to the end timing of the unit period TA. Therefore, the unit period TA is determined to be the period from the end timing of the operation period T1 of the first pump 33 in the cleaning process immediately before the operation of the extractor 11 to the end timing of the operation period T1 in the cleaning process immediately after the operation of the extractor 11.

In the manufacturing apparatus 10 of this embodiment, after the cleaning device 30 has completed cleaning the extractor 11, the extractor 11 is in a standby state until the extractor 11 starts extracting the extract liquid. Since the extractor 11 consumes energy such as electricity even in the standby state, the standby energy of the extractor 11 must be taken into consideration when calculating the amount of consumed energy A. In this embodiment, the unit period TA is determined to include such a standby period.

In this embodiment, the amounts of various types of energy consumed in a unit period TA are accumulated, and the accumulated value is calculated as the "amount of consumed energy A." Examples of the various types of energy include the power consumption of the extractor 11, the power consumption of the centrifuge 12, the amount of steam used (more specifically, the amount of gas consumed by the boiler 21 to supply the same amount of steam), and the amount of water used.

In this embodiment, the computer 40 can automatically detect various calculation parameters using sensors provided in each part of the manufacturing apparatus 10 and calculate the amount of consumed energy A based on the calculation parameters. In addition, various calculation parameters obtained separately can be input to the computer 40 through the operation of an input device, and the calculation of the amount of consumed energy A based on the calculation parameters can be performed through arithmetic processing by the computer 40. According to this embodiment, the unit period TA is determined in the above-mentioned manner, so that it becomes possible to calculate the amount of consumed energy A with this unit period TA as the calculation target period.

(Calculation procedure for consumed energy amount B)
Next, the manner in which the consumed energy amount B is calculated will be described.
In this embodiment, the target apparatus identifying unit 43 of the computer 40 identifies the compounding apparatus 14 as the apparatus to be cleaned by the cleaning apparatus 30 when all of the following conditions B1, B2, B3, and B4 are satisfied.

(Condition B1) The first pump 33 is operating, and the power consumption of the blending device 14 is equal to or greater than a predetermined value BB1 for a predetermined period of time or more. Note that the predetermined value BB1 is set to a value greater than the power consumption BB2 of the blending device 14 during normal operation for blending (BB1>BB2).

(Condition B2) From a state in which condition B1 is satisfied, the power consumption of the blending device 14 temporarily drops to a predetermined value BB3 or less.
(Condition B3) Immediately after condition B2 is satisfied, the first pump 33 is operated and the power consumption of the mixing device 14 is equal to or greater than a predetermined value BB1 for a predetermined period of time (e.g., several tens of minutes).

(Condition B4) The state in which condition B3 is satisfied is changed to a state in which the first pump 33 is stopped.
In this embodiment, the inventors, etc., have previously obtained the transition in power consumption of the first pump 33 and the transition in power consumption of the blending device 14, which characteristically appear when the cleaning device 30 cleans the blending device 14, through verification of the operation record data of the manufacturing apparatus 10 by the inventors, etc. Then, the inventors, etc., have previously determined conditions (conditions B1 to B4) that can identify the appearance of such characteristic transition in power consumption of the first pump 33 and the transition in power consumption of the blending device 14, and have stored the conditions B1 to B4 in the storage unit 41. As a result, when all of the conditions B1, B2, B3, and B4 are satisfied, it is possible to accurately identify that the target to be cleaned by the cleaning device 30 is the blending device 14.

In the manufacturing apparatus 10 of this embodiment, when the cleaning device 30 cleans the blending device 14, in addition to the first pump 33 of the cleaning device 30 operating, the blending device 14 also operates. In light of this, in this embodiment, conditions B1 to B4 are set, which are conditions that use the power consumption of the first pump 33 and the power consumption of the blending device 14 as parameters.

When it is determined that the mixing device 14 is to be cleaned, the unit period setting unit 44 of the computer 40 determines the "unit period TB", which is the calculation period for calculating the amount of consumed energy B, based on the operating period T2 stored in the memory unit 41.

In the blending process, prior to blending by the blending device 14, cleaning of the blending device 14 is performed by the cleaning device 30. In this embodiment, the completion timing of cleaning of the blending device 14 is set to the start timing of the unit period TB. In addition, in the blending process, after blending by the blending device 14 is completed, cleaning of the blending device 14 is performed by the cleaning device 30 for the next blending process. In this embodiment, the completion timing of cleaning of the blending device 14 is set to the end timing of the unit period TB. Therefore, the unit period TB is set to the period from the end timing of the operation period T2 of the first pump 33 in the cleaning process immediately before the operation of the blending device 14 to the end timing of the operation period T2 in the cleaning process immediately after the operation of the same blending device 14.

In the manufacturing apparatus 10 of this embodiment, after the cleaning device 30 has completed cleaning the blending device 14, the blending device 14 is in a standby state until the blending device 14 starts blending the blended liquid. Since the blending device 14 consumes energy such as electricity even in a standby state, the standby energy of the blending device 14 must be taken into consideration when calculating the amount of consumed energy B. In this embodiment, the unit period TB is determined to include such a standby period.

In this embodiment, the amounts of various types of energy consumed in the unit period TB are accumulated, and the accumulated value is calculated as the "amount of consumed energy B." Examples of the various types of energy include the power consumption of the blending device 14 and the amount of water used.

In this embodiment, the process of detecting various calculation parameters using sensors provided in each part of the manufacturing apparatus 10 and the process of calculating the amount of consumed energy B based on the calculation parameters can be automatically executed by the computer 40. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then calculate the amount of consumed energy B based on the calculation parameters through arithmetic processing by the computer 40. According to this embodiment, since the unit period TB is determined in the above-mentioned manner, it becomes possible to execute the calculation of the amount of consumed energy B with this unit period TB as the calculation target period.

(Calculation procedure for consumed energy amount C)
Next, the manner in which the consumed energy amount C is calculated will be described.
In this embodiment, the target apparatus identification unit 43 of the computer 40 identifies the objects to be cleaned by the cleaning apparatus 30 as the sterilization apparatus 15, the sterile tank 16, and the filling apparatus 17 when both of the following conditions C1 and C2 are satisfied.

(Condition C1) The power consumption of the sterilization device 15 is equal to or less than a predetermined value. In other words, the operation of the sterilization device 15 is stopped.
(Condition C2) The power consumption of the second pump 35 is equal to or greater than a predetermined value, and then the operation of the second pump 35 is stopped.

In this embodiment, the inventors and others verify the operation record data to determine in advance the transition in power consumption of the second pump 35 and the transition in power consumption of the sterilizer 15, which characteristically appear when the cleaning device 30 cleans the sterilizer 15, the sterile tank 16, and the filling device 17. The inventors and others then determine in advance conditions (conditions C1 and C2) that can identify the emergence of such characteristic transitions in power consumption of the second pump 35 and the sterilizer 15, and store conditions C1 and C2 in the memory unit 41. As a result, when both conditions C1 and C2 are satisfied, it is possible to accurately identify that the objects to be cleaned by the cleaning device 30 are the sterilizer 15, the sterile tank 16, and the filling device 17.

When the object to be cleaned is identified in this manner, the unit period setting unit 44 of the computer 40 determines the "unit period TC", which is the calculation period for calculating the amount of consumed energy C, based on the operating period T3 stored in the memory unit 41.

In the filling process, before the filling device 17 fills the beverage container with the beverage, the cleaning device 30 cleans the sterilizer 15, the sterile tank 16, and the filling device 17. In this embodiment, the completion timing of this cleaning is set to the start timing of the unit period TC. In the filling process, after the filling device 17 has finished filling, the cleaning device 30 cleans the sterilizer 15, the sterile tank 16, and the filling device 17 for the next filling process. In this embodiment, the completion timing of this cleaning is set to the end timing of the unit period TC. Therefore, the unit period TC is set to the period from the end timing of the operation period T3 of the second pump 35 in the cleaning process immediately before the operation of the filling device 17 to the end timing of the operation period T3 in the cleaning process immediately after the operation of the same filling device 17.

In the manufacturing apparatus 10 of this embodiment, after the cleaning device 30 has completed cleaning of the sterilizer 15, the sterile tank 16, and the filling device 17, the sterilizer 15, the sterile tank 16, and the filling device 17 are in a standby state until the filling device 17 starts filling. Since the sterilizer 15, the sterile tank 16, and the filling device 17 consume energy even in a standby state, the energy consumed for such standby must be taken into account when calculating the amount of energy consumed C. In this embodiment, the unit period TC is determined to include such a standby period.

In this embodiment, the amounts of various types of energy consumed in a unit period TC are accumulated, and the accumulated value is calculated as the "amount of consumed energy C." Examples of the various types of energy include the power consumption and steam usage of the sterilizer 15, the power consumption and steam usage of the aseptic tank 16, and the power consumption of the filling device 17.

In this embodiment, the computer 40 can automatically detect various calculation parameters using sensors provided in each part of the manufacturing apparatus 10 and calculate the amount of consumed energy C based on the calculation parameters. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then calculate the amount of consumed energy C based on the calculation parameters through arithmetic processing by the computer 40. According to this embodiment, the unit period TC is determined in the above-mentioned manner, so that it becomes possible to calculate the amount of consumed energy C with this unit period TC as the calculation target period.

(Calculation procedure of consumed energy amount D)
Next, the manner in which the consumed energy amount D is calculated will be described.
In this embodiment, the amounts of various types of energy (such as power consumption) consumed by the labeling device 18, the packaging device 19, and the packing device 20 during a unit period TC are accumulated, and the accumulated value is calculated as the "amount of consumed energy D."

In this embodiment, the process of detecting various calculation parameters using sensors provided in each part of the manufacturing apparatus 10 and the process of calculating the amount of consumed energy D based on the calculation parameters can be automatically executed by the computer 40. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then calculate the amount of consumed energy D based on the calculation parameters through arithmetic processing by the computer 40. According to this embodiment, the unit period TC is determined in the above-mentioned manner, so that it is possible to execute the calculation of the amount of consumed energy D with this unit period TC as the calculation target period.

(Calculation procedure for the amount of consumed energy E)
Next, the manner in which the consumed energy amount E is calculated will be described.
First, in a series of processes such as the extraction process, the preparation process, and the filling process, specifically, in the period from the start timing of the unit period TA to the end timing of the unit period TC, an integrated value of the amount of various types of energy consumed in the operation of the cleaning device 30 is calculated. Then, the integrated value is calculated as the consumed energy amount E. The various types of energy may include the power consumption of the first pump 33, the power consumption of the second pump 35, the amount of cleaning liquid used, etc.

In this embodiment, the process of detecting various calculation parameters using sensors provided in each part of the manufacturing apparatus 10 and the process of calculating the amount of consumed energy E based on the calculation parameters can be automatically executed by the computer 40. It is also possible to input various calculation parameters obtained separately into the computer 40 through the operation of an input device, and then calculate the amount of consumed energy E based on the calculation parameters through arithmetic processing by the computer 40. According to this embodiment, since the unit periods TA, TB, and TC are determined in the manner described above, it becomes possible to calculate the amount of consumed energy E based on the unit periods TA, TB, and TC.

(Calculation procedure for energy intensity)
Next, the manner in which the energy consumption rate is calculated will be described.
In the energy unit calculation support device of this embodiment, the number of beverage products (production number F) produced in a series of processes (extraction process, blending process, filling process, finishing process) is detected by the optical sensor 70. Then, in the device of this embodiment, the energy unit is calculated by adding up the consumed energy amounts A, B, C, D, and E and dividing the sum by the production number F ([A+B+C+D+E]/F).

In this embodiment, the process of calculating the energy consumption rate in this manner can be automatically executed by computer 40. It is also possible to manually calculate the energy consumption rate using the separately calculated amounts of energy consumption A to E and the production number F detected by optical sensor 70.

According to this embodiment, the following advantageous effects can be obtained.
(1) The manufacturing apparatus 10 is provided with a current sensor 58 for detecting the power consumption of the first pump 33. The storage unit 41 of the computer 40 stores in advance conditions for identifying the process equipment (extractor 11 or blending device 14) to be cleaned during the operation of the cleaning apparatus 30. When the transition of the power consumption of the first pump 33 satisfies the conditions, the target equipment identification unit 43 identifies the process equipment (extractor 11 or blending device 14) to be cleaned by the cleaning apparatus 30 and the operation period of the first pump 33 for cleaning the process equipment based on the power consumption. The unit period setting unit 44 determines a unit period for calculating the amount of energy consumed in association with the operation of the process equipment based on the process equipment to be cleaned identified by the target equipment identification unit 43 and the operation period of the first pump 33 for cleaning the process equipment.

In the manufacturing apparatus 10, the cleaning device 30 is driven by a common first pump 33 when cleaning the extractor 11 and the blending device 14. However, if the process equipment to be cleaned (extractor 11 or blending device 14) is different, the cleaning mode of the process equipment is different, and therefore the driving mode of the first pump 33 is also different.

In this embodiment, the characteristic behavior of the first pump 33 (specifically, the transition of power consumption) during operation of the cleaning device 30 is grasped in advance for each of the extractor 11 and the blending device 14. Then, conditions that can identify the characteristic behavior of the first pump 33 are stored in the memory unit 41 as conditions for identifying the process equipment to be cleaned. Therefore, according to this embodiment, based on the above conditions, the characteristic behavior of the first pump 33 can be captured and the process equipment to be cleaned by the cleaning device 30 can be identified. Moreover, the operation period of the first pump 33 for cleaning the process equipment to be cleaned can also be identified from the transition of power consumption of the first pump 33.

The unit periods TA and TB for calculating the amount of energy consumed in the operation of the process equipment (extractor 11 or blending equipment 14) are determined by the period during which the process equipment is operated and the operation periods T1 and T2 during which the cleaning equipment 30 is operated to clean the process equipment after use. Based on this, in this embodiment, the unit periods TA and TB are set as the period from the end of operation of the cleaning equipment 30 before the current use of the process equipment to the end of operation of the cleaning equipment 30 for the next operation of the process equipment.

According to this embodiment, the target device identification unit 43 can identify the operation period T1 of the first pump 33 for cleaning the extractor 11 and the operation period T2 of the first pump 33 for cleaning the blending device 14. Therefore, the period from the end timing of the operation period T1 of the first pump 33 in the cleaning immediately before the operation of the extractor 11 to the end timing of the operation period T1 in the cleaning immediately after the operation of the extractor 11 can be determined as the unit period TA for the consumed energy amount A. In addition, the period from the end timing of the operation period T2 of the first pump 33 in the cleaning immediately before the operation of the blending device 14 to the end timing of the operation period T2 in the cleaning immediately after the operation of the blending device 14 can be determined as the unit period TB for the consumed energy amount B. Moreover, according to this embodiment, the unit periods TA and TB can be determined by adding a current sensor 58 for detecting the power consumption of the first pump 33. The unit periods TA and TB thus determined can be used to calculate the amounts of consumed energy A and B, and can also be used to calculate the energy intensity. Therefore, according to this embodiment, it is possible to assist in the calculation of the energy intensity while minimizing changes to the manufacturing apparatus 10.

(2) If the change in the power consumption of the first pump 33 and the change in the power consumption of the extractor 11 satisfy conditions A1 to A3, the extractor 11 is identified as the process equipment to be cleaned and the operation period T1 of the first pump 33 for cleaning the extractor 11 is identified based on the power consumption. If the change in the power consumption of the first pump 33 and the change in the power consumption of the blending device 14 satisfy conditions B1 to B4, the change in the power consumption of the first pump 33 and the change in the power consumption of the blending device 14 are identified as the process equipment to be cleaned and the operation period T2 of the first pump 33 for cleaning the blending device 14 is identified based on the power consumption.

Both the extractor 11 and the blending device 14 are process devices of the type that operate when the cleaning device 30 is operated to clean the extractor 11 or the blending device 14 .
According to the present embodiment, in addition to using the power consumption of the first pump 33, the power consumption of the extractor 11 can be used as a parameter for defining the conditions A1 to A3 for specifying that the process equipment to be cleaned is the extractor 11. This allows the above conditions A1 to A3 to be set in detail, so that it is possible to accurately specify that the process equipment to be cleaned is the extractor 11 and the operation period T1 of the first pump 33 for cleaning the extractor 11. Furthermore, in addition to using the power consumption of the first pump 33, the power consumption of the blending device 14 can be used as a parameter for defining the conditions B1 to B4 for specifying that the process equipment to be cleaned is the blending device 14. This allows the above conditions B1 to B4 to be set in detail, so that it is possible to accurately specify that the process equipment to be cleaned is the blending device 14 and the operation period T2 of the first pump 33 for cleaning the blending device 14.

(3) The energy unit calculation support device of this embodiment is applied to a manufacturing apparatus 10 that manufactures beverage products. The manufacturing apparatus 10 that manufactures beverage products has a structure in which the parts through which the ingredients pass are sealed, making it difficult to grasp the operating status of each process device. According to this embodiment, in such a manufacturing apparatus 10, it is possible to accurately identify the process devices to be cleaned by the cleaning device 30 and the operating period of the first pump 33 for cleaning the process devices.

(Modification)
The above embodiment can be modified as follows: The above embodiment and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

- The optical sensor 70 can be provided at a position where it can detect the beverage products sent from the labeling device 18 to the packaging device 19, or where it can detect the beverage products sent from the packaging device 19 to the boxing device 20. With this configuration, the computer 40 can determine the execution period during which the filling device 17 is filling beverage containers with beverage based on the output signal of the optical sensor 70, and can detect the number of beverage containers filled with beverage during that execution period (manufacturing number F).

-Instead of the optical sensor 70, a proximity sensor or an image processing device may be provided. The proximity sensor or image processing device can also detect the passage of the beverage product sent from the filling device 17 to the labeling device 18.

- The current sensors 50 to 59 are not limited to those that are added later to the manufacturing equipment 10 installed in the factory, but can be those that are originally installed in the manufacturing equipment 10.

- As parameters defining the conditions for identifying the process equipment to be cleaned, it is possible to use not only the power consumption of the first pump 33 or the power consumption of the process equipment, but also the current consumption of the first pump 33 or the current consumption of the process equipment.

- If it is possible to detect index values for the power consumption of the process equipment, the first pump 33, and the second pump 35, a power sensor that detects the power consumption itself or a voltage sensor that detects the voltage as an index value for the power consumption can be provided instead of the current sensors 50 to 59.

Instead of or in addition to calculating the consumed energy amount A for the unit period TA as the calculation target period, a value (consumed energy amount Aa) may be calculated by accumulating the amounts of various types of energy consumed in the operation of the extractor 11 in the unit period TA. Also, a value (consumed energy amount Ab) may be calculated by accumulating the amounts of various types of energy consumed in the operation of the centrifuge 12 in the unit period TA. With this configuration, it is possible to perform an investigation of the consumed energy amount for each process device, such as examining the consumed energy amount Aa for efficient operation of the extractor 11, or examining the consumed energy amount Ab for efficient operation of the blending device 14.

Instead of or in addition to calculating the consumed energy amount C for the unit period TC as the calculation target period, a value (consumed energy amount Ca) may be calculated by accumulating the amounts of various types of energy consumed in the operation of the sterilization device 15 in the unit period TC. Also, a value (consumed energy amount Cb) may be calculated by accumulating the amounts of various types of energy consumed in the operation of the sterile tank 16 in the unit period TC. Furthermore, a value (consumed energy amount Cc) may be calculated by accumulating the amounts of various types of energy consumed in the operation of the filling device 17 in the unit period TC. According to the above configuration, it is possible to perform an investigation of the consumed energy amount for each process device, such as examining the consumed energy amount Ca for efficient operation of the sterilization device 15 and examining the consumed energy amount Cb for efficient operation of the sterile tank 16.

Instead of or in addition to calculating the amount of consumed energy D for the unit period TD as the calculation target period, a value (amount of consumed energy Da) may be calculated by accumulating the amount of various types of energy consumed in the operation of the labeling device 18 in the unit period TD. A value (amount of consumed energy Db) may also be calculated by accumulating the amount of various types of energy consumed in the operation of the packaging device 19 in the unit period TD. Furthermore, a value (amount of consumed energy Dc) may also be calculated by accumulating the amount of various types of energy consumed in the operation of the boxing device 20 in the unit period TD. According to the above configuration, it is possible to perform an investigation of the amount of consumed energy for each process device, such as examining the amount of consumed energy Da for efficient operation of the labeling device 18 and examining the amount of consumed energy Db for efficient operation of the packaging device 19. In addition, the energy intensity for the labeling device 18 may be calculated based on the amount of consumed energy Da, and the energy intensity for the packaging device 19 may be calculated based on the amount of consumed energy Db. It is also possible to calculate the energy consumption rate for the packing device 20 based on the above-mentioned energy consumption amount Dc.

The energy unit calculation support device according to the above embodiment can also be applied to a manufacturing device that performs "cleaning of the extractor 11", "cleaning of the blending device 14", and "cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17" by driving the same cleaning pump. The energy unit calculation support device according to the above embodiment can also be applied to a manufacturing device that performs "cleaning of the extractor 11" and "cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17" by driving the same cleaning pump. In addition, the energy unit calculation support device according to the above embodiment can also be applied to a manufacturing device that performs "cleaning of the blending device 14" and "cleaning of the sterilization device 15, the sterile tank 16, and the filling device 17" by driving the same cleaning pump. In either configuration, by setting conditions for identifying the process device to be cleaned for each process device, the characteristic behavior of the power consumption of the cleaning pump and the power consumption of the process device can be captured based on these conditions, and the process device to be cleaned by the cleaning device 30 can be identified.

The energy unit calculation support device according to the above embodiment can be applied to any manufacturing equipment having multiple types of process equipment through which liquid raw materials pass, and a cleaning device that cleans the inside of the process equipment using a cleaning liquid by driving the same cleaning pump. With this configuration, by setting conditions for identifying the process equipment to be cleaned for each process equipment, it is possible to identify the process equipment to be cleaned by the cleaning device by capturing characteristic trends in the power consumption of the cleaning pump and the process equipment based on these conditions. Examples of such manufacturing equipment include manufacturing equipment that produces beverage products other than black tea, such as juice, coffee, and milk, manufacturing equipment that produces food products such as mayonnaise, and manufacturing equipment that produces pharmaceuticals. Other examples include manufacturing equipment that produces cosmetics, manufacturing equipment that produces toiletries, and manufacturing equipment that produces soap.

- The conditions for identifying the process equipment to be cleaned when the cleaning device 30 is operating can be changed as desired. The above conditions may be defined as follows. The transition in power consumption of the first pump 33 and the transition in power consumption of the process equipment that characteristically appear when the cleaning device 30 cleans the process equipment are determined in advance. Then, conditions that can identify the emergence of such characteristic transition in power consumption of the first pump 33 and the transition in power consumption of the process equipment are defined and stored in the memory unit 41.

- The condition for identifying the process equipment to be cleaned when the cleaning device 30 is operating may be determined without using the change in the power consumption of the process equipment as a parameter. In this case, the condition may be determined as follows. The change in the power consumption of the first pump 33 that appears characteristically when the cleaning device 30 cleans the process equipment is determined in advance. Then, a condition that can identify the appearance of such a characteristic change in the power consumption of the first pump 33 is determined and stored in the memory unit 41.

- The unit periods TA and TB may be defined as the period from the start of the operation period T1 and T2 of the first pump 33 in the cleaning process immediately before the operation of the process equipment to the start of the operation period T1 and T2 in the cleaning process immediately after the operation of the same process equipment. The unit period TC may be defined as the period from the start of the operation period T3 of the second pump 35 in the cleaning process immediately before the operation of the process equipment (sterilization equipment 15, aseptic tank 16, filling equipment 17) to the start of the operation period T3 in the cleaning process immediately after the operation.

In the above configuration, for example, the unit period TA can be determined as follows. That is, the operation period T1 of the first pump 33 in cleaning the extractor 11 is read from the memory unit 41. Then, the period from the start timing of the operation period T1 in the cleaning process immediately before the operation of the extractor 11 to the start timing of the operation period T1 in the cleaning process immediately after the operation of the same extractor 11 is determined as the unit period TA. Also, the unit period TB can be determined as follows. That is, the operation period T2 of the first pump 33 in cleaning the blending device 14 is read from the memory unit 41. Then, the period from the start timing of the operation period T2 in the cleaning process immediately before the operation of the blending device 14 to the start timing of the operation period T2 in the cleaning process immediately after the operation of the same blending device 14 is determined as the unit period TB.

REFERENCE SIGNS LIST 10 manufacturing device 11 extractor 14 blending device 15 sterilization device 16 aseptic tank 17 filling device 30 cleaning device 33 first pump 40 computer 41 memory unit 43 target device identification unit 44 unit period setting unit 50 to 59 current sensors

Claims (4)

The present invention is applied to a manufacturing apparatus having a plurality of types of process equipment that differ for each process and a cleaning device that cleans the inside of the process equipment by driving the same cleaning pump before and after use of the plurality of types of process equipment, and that manufactures a product by using the plurality of types of process equipment and the cleaning device,
a pump detection unit that detects an index value of power consumption of the wash pump;
a storage unit that stores in advance conditions for identifying the process equipment to be cleaned during operation of the cleaning apparatus;
a target device identification unit that identifies the process device to be cleaned and an operation period of the cleaning pump for cleaning the process device based on the power consumption index value when a transition of the power consumption index value detected by the pump detection unit satisfies the condition;
a unit period setting unit that determines a unit period for calculating an amount of energy consumed in operation of the process equipment to be cleaned, based on the process equipment to be cleaned identified by the target equipment identification unit and the operating period,
The amount of energy does not include the amount of energy consumed in operating the cleaning device.
Energy unit calculation support device. a process detection unit for detecting index values of power consumption of each of the plurality of types of process devices,
2. The energy unit calculation support device according to claim 1, wherein the target equipment identification unit identifies the process equipment to be cleaned and the operating period based on the power consumption index value of the cleaning pump and the power consumption index value of any of the process equipment when a change in the power consumption index value detected by the pump detection unit and a change in the power consumption index value of any of the multiple types of process equipment detected by the process detection unit both satisfy the condition. The energy consumption rate calculation support device according to claim 1 or 2, wherein the product is a beverage product. The energy consumption rate calculation support device according to claim 3 , wherein the plurality of types of process equipment includes a filling equipment that fills beverages into containers.

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