Method for adjusting energy consumption of water heater

Abstract

The invention discloses a water heater energy consumption adjusting method for solar cell production. Aiming at the energy consumption problem of a water heater in production, a monitoring system is built to analyze the current situation, and electric energy is wasted due to the fact that heating is performed according to the matched tank temperature during normal production and the actual tank body is low in maximum temperature. By selecting an intermediate relay and rewiring to optimize hardware, manufacturers are cooperated to change software logic. The energy consumption adjusting method comprises the following steps: acquiring a multi-parameter judgment working condition; selecting a heating mode according to working conditions, setting 92 DEG C for rapid heating during liquid change and tank preparation, and setting 65 DEG C for energy-saving constant temperature during normal production; continuously feeding back and adjusting the water temperature; and dynamically optimizing self-adaptive adjustment. The method has the advantages of obvious energy saving, daily electric quantity saving of about 44688 kw / h, improvement of production stability and product quality, simple operation, strong adaptability, and facilitation of cost reduction, and promotion of solar cell production energy saving technology progress.

Description

Technical Field

[0001] The present invention relates to the technical field of solar cell production and manufacturing, and in particular to a method for accurately adjusting the energy consumption of a water heater during the production of solar cells, so as to improve energy utilization efficiency and reduce production costs. Background Art

[0002] In the production process of solar cells, water heaters play an important role, which are used to provide hot water at a specific temperature to meet various needs in the production process, such as cleaning, etching, etc. However, the traditional operation mode of water heaters has obvious shortcomings in energy consumption management.

[0003] Through on-site observation and analysis, it was found that on the solar cell production line, when the machine is operating normally, the water heater often continues to heat at a fixed tank temperature (for example, 92°C). But in fact, in most normal production processes, the maximum temperature required for the tank is only about 65°C. This means that during a large amount of production time, the water heater consumes too much electricity to raise the water temperature to an unnecessary high level, resulting in serious energy waste. Only when the machine is performing a liquid replacement tank operation, it is really necessary to heat the hot water to a higher tank temperature (92°C).

[0004] As the global demand for clean energy continues to grow, the solar cell industry is expanding rapidly and the production scale is increasing. Under this circumstance, the problem of excessive energy consumption of water heaters has become increasingly prominent, which not only increases the operating costs of enterprises and reduces the market competitiveness of products, but also runs counter to the environmental protection concept of energy conservation and emission reduction. Therefore, the development of a water heater energy consumption adjustment method suitable for solar cell production is of vital importance to improve energy utilization efficiency, reduce production costs, and promote the sustainable development of the solar cell industry. Summary of the invention

[0005] In order to overcome the above problems or at least partially solve the above problems, the core of the present invention is to provide a method for regulating energy consumption of a water heater.

[0006] A method for regulating energy consumption of a water heater, characterized in that it comprises the following steps:

[0007] Initial monitoring and problem diagnosis

[0008] A comprehensive monitoring system for the working status of the water heater in the production of solar cells was built. The system can collect the key parameters of the water heater inlet temperature, outlet temperature, liquid level of each water tank (high level, medium level, low level), input voltage, and the tank request signal and overflow request signal related to the production process in real time. In the normal production process of solar cells, the temperature control related signals of the water heater are deeply analyzed. Through the X-point monitoring, it was found that the water heater has been heating according to the tank temperature because the tank request and overflow request signals were triggered at the same time. Further detailed inspection of the signal transmission between the module and the relay confirmed that the module triggered the relay signal normally, but the outlet water temperature of the water heater did not change after the overflow temperature was set, and it was still heated according to the tank temperature.

[0009] Hardware optimization and upgrade

[0010] Select an intermediate relay with stable performance, precise action and suitable for the solar cell production environment. Accurately determine the wiring position of the PLC in the machine control system, and rewire the PLC according to the redesigned circuit logic. During the wiring process, strictly follow the electrical installation specifications, select high-quality terminal blocks and high-temperature and corrosion-resistant wires to ensure that each connection point is firm and reliable, avoid problems such as false connection and short circuit, and prevent line failures from affecting the normal operation of the water heater or causing safety accidents. After the wiring is completed, use professional electrical testing equipment to conduct a comprehensive test of the new hardware architecture, simulate various signal inputs in the solar cell production process, verify the accuracy of the intermediate relay's action and the integrity and stability of the signal transmission, and provide a reliable hardware foundation for subsequent precise temperature control.

[0011] Software logic customization and optimization

[0012] We work closely with the supplier of the water heater control system to deeply customize the software trigger logic according to the special needs of the solar cell production process. When the machine enters the liquid replacement and tank preparation condition, the software system accurately receives the tank preparation request signal and quickly starts the corresponding control command to set the heating target temperature of the water heater to 92°C, ensuring the smooth progress of the liquid replacement and tank preparation operation and meeting the strict requirements of the production process for hot water temperature. When the machine is in normal production conditions, the software system intelligently identifies the overflow request signal and adjusts the outlet water temperature of the water heater to 65°C based on the preset optimization logic algorithm, accurately meeting the tank body's water temperature requirements during normal production. Through this optimization of software logic, independent and precise control of the tank preparation request and overflow request signals is achieved, enabling the water heater to achieve differentiated heating according to different production conditions, fundamentally achieving the goal of reducing consumption and energy saving.

[0013] Specific energy consumption adjustment steps

[0014] Signal acquisition and working condition judgment (step S1)

[0015] Using high-precision sensors installed in the water heater system, the water inlet temperature, water outlet temperature, water tank level signals, input voltage, tank allocation request signal, overflow request signal and other parameters of the water heater are collected in real time. The collected signals are transmitted to the signal processing module in the control system. The signal processing module uses advanced logic judgment algorithms to conduct a comprehensive analysis of the tank allocation request signal and the overflow request signal to determine the current working condition of the solar cell production machine. If the tank allocation request signal and the overflow request signal are received at the same time, or only the tank allocation request signal is received, it is determined that the machine is in the liquid replacement tank allocation working condition; if only the overflow request signal is received, it is determined that the machine is in the normal production working condition.

[0016] Heating mode selection and start (step S2)

[0017] According to the working condition judgment result in step S1, select the corresponding heating mode. If the machine is in the working condition of changing the liquid and preparing the tank, the control system sends precise instructions to the water heater, starts the rapid heating mode, and sets the heating target temperature of the water heater to 92°C. In this mode, the heating element of the water heater operates at maximum power, and the control system dynamically adjusts the heating power to ensure that the water temperature rises to the target temperature quickly and stably to meet the requirements of the hot water temperature and speed for changing the liquid and preparing the tank. If the machine is in normal production conditions, the control system starts the energy-saving constant temperature mode and stabilizes the outlet water temperature of the water heater to 65°C. In the energy-saving constant temperature mode, the heating element of the water heater accurately adjusts the heating power according to the difference between the water temperature and the target temperature through advanced fuzzy control algorithms, so that the water temperature is always maintained at around 65°C to avoid energy waste.

[0018] Temperature feedback and precise adjustment (step S3)

[0019] During the operation of the water heater, the temperature sensor continuously monitors the outlet water temperature of the water heater at a high frequency (for example, once per second) and feeds back the temperature data to the control system in real time. The control system quickly compares the feedback temperature data with the set target temperature (92°C under the condition of changing the liquid tank and 65°C under normal production conditions). If the outlet water temperature is lower than the target temperature, the control system sends an increase power instruction to the heating element of the water heater through the optimized control algorithm to accurately increase the heating speed; if the outlet water temperature is higher than the target temperature, the control system sends a power reduction instruction to reasonably slow down the heating speed or start the heat dissipation mechanism (such as using circulating water cooling or cooling fans, etc.) so that the water temperature gradually approaches and stabilizes within the target temperature range. At the same time, the control system will also use the predictive control algorithm to adjust the heating power in advance according to the rate and trend of water temperature changes, effectively reduce temperature fluctuations, and increase the temperature control accuracy to within ±1°C, ensuring that the hot water temperature always meets the stringent requirements of the solar cell production process.

[0020] Dynamic optimization and adaptive adjustment (step S4)

[0021] As the solar cell production process continues, considering the possible changes in the production process, the fluctuation of the ambient temperature, and the attenuation of the water heater's own performance, the control system regularly (for example, every 15 minutes) conducts a comprehensive analysis of the water heater's operating data, including parameters such as the inlet water temperature, outlet water temperature, heating power, water consumption, and production rhythm. Based on these data, it is determined whether the water heater's working efficiency is affected, such as whether there is a long heating time, excessive water temperature fluctuations, and abnormal increase in energy consumption. If it is found that the working efficiency has decreased, the control system automatically adjusts the control parameters and optimizes the heating strategy. For example, when the ambient temperature is low, the initial power of the heating element is appropriately increased to speed up the heating speed; when the production rhythm is accelerated and the water consumption increases, the heating power is increased in advance to meet the production needs while avoiding overheating. In addition, the control system can also learn the optimal temperature control mode under different production conditions based on the long-term operation data of solar cell production, automatically adapt to changes in the production process, and achieve continuous optimization of the water heater's energy consumption, ensuring that it always maintains an efficient and energy-saving operation state throughout the solar cell production cycle.

[0022] The embodiments of the present invention have at least the following advantages or beneficial effects:

[0023] 1. The present invention realizes intelligent adjustment of the water heater temperature by accurately distinguishing different working conditions of the solar cell production machine. In the normal production stage, unnecessary high-temperature heating is effectively avoided, and the overflow temperature is accurately controlled at 65°C, which greatly reduces energy consumption. According to actual production data statistics, the average daily electricity saving is about 44,688 kw / h, and the monthly electricity saving is about 1,340,647 kw / h. According to the current factory electricity price of 0.3 yuan / kWh, the company can save 13,406.4 yuan in electricity expenses every day, with a monthly income of up to 402,192 yuan and an annual income of 4,893,336 yuan. Such a significant energy-saving effect has greatly reduced the company's production costs and improved the market competitiveness of solar cell products. At the same time, it has made positive contributions to the company in energy conservation and emission reduction, and meets environmental protection requirements.

[0024] 2. The present invention is based on a reasonable temperature regulation strategy, and the working mode of the water heater is highly consistent with the actual needs of the solar cell production process. During normal production, the stable hot water temperature supply avoids the adverse effects of temperature fluctuations on the production process, such as incomplete cleaning, uneven etching, etc., and improves the stability of the production process and the consistency of product quality. A stable production process helps to reduce the scrap rate, improve production efficiency, further reduce production costs, and bring higher economic benefits to the enterprise.

[0025] 3. The method of the present invention is mainly based on the targeted improvement of the water heater system in the existing solar cell production equipment and the optimization and upgrading of the software logic. The operator can easily master the key points of operation without complex professional training. The operator only needs to follow the conventional solar cell production operation process, and the system can automatically adjust the temperature of the water heater according to the production conditions. In addition, both the hardware transformation plan and the software logic design have good flexibility and can adapt to solar cell production equipment of different models and specifications and different production process requirements. Whether it is a traditional crystalline silicon solar cell production line or an emerging thin-film solar cell production line, the method of the present invention can be effectively applied according to its actual situation, and it has wide applicability and promotion value. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0027] Figure 1 It is a schematic diagram of the film placing step of the present invention. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0029] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] Example 1

[0031] System configuration and modification

[0032] Install a temperature sensor with an accuracy of ±0.2℃, a high-sensitivity liquid level sensor, and a stable and reliable signal acquisition module in the water heater system to build a water heater working status monitoring system. Select an intermediate relay with an action response time of less than 0.5 seconds and a contact capacity that meets the system requirements, and rewire the PLC with high-temperature and corrosion-resistant wires.

[0033] Cooperate with the supplier of water heater control system to develop software logic with adaptive learning capability. The software can automatically optimize the temperature control algorithm according to production data, and the response time does not exceed 0.8 seconds when switching between different working conditions.

[0034] Energy regulation process

[0035] When the machine starts to change the liquid and prepare the tank, the monitoring system accurately receives the tank preparation request signal, and the control system immediately starts the rapid heating mode and sets the heating target temperature of the water heater to 92°C. The heating element operates at 110% of the rated power of the equipment, and the temperature sensor collects the outlet water temperature data once a second and feeds it back to the control system. Based on the temperature feedback, the control system adjusts the heating power through the optimized PID control algorithm, so that the water temperature rises rapidly and the fluctuation is controlled within ±0.8°C, ensuring that the tank temperature requirement of 92°C is reached within the specified time.

[0036] In the normal production stage, only the overflow request signal is received, and the system enters the energy-saving constant temperature mode, and the outlet water temperature is stabilized to 65°C. At this time, the heating power is dynamically adjusted according to the difference between the water temperature and the target temperature, and the adjustment step is 3% of the rated power. The control system predicts the trend 2 minutes in advance according to the water temperature change rate and adjusts the heating power to stabilize the water temperature within the range of 65°C±0.5°C to meet the production process requirements.

[0037] Every 15 minutes, the control system automatically analyzes the operating data of the water heater, including water inlet temperature, water outlet temperature, heating power, water consumption, production rhythm, etc. When the ambient temperature drops to 5°C, the control system automatically increases the initial power of the heating element by 8%; when the production rhythm is accelerated and the water consumption increases by 30%, the heating power is increased by 12% in advance to ensure a stable hot water supply with the lowest energy consumption.

[0038] Effect evaluation

[0039] After one month of continuous operation monitoring, the water heater saved an average of 45,000 kw / h of electricity per day after implementing the method of the present invention, and the energy saving rate was improved compared with that before the transformation. The cleaning quality of silicon wafers in the production process of solar cells was significantly improved, the problem of incomplete cleaning due to unstable temperature was reduced, and the product yield rate was improved.

[0040] Example 2

[0041] System configuration and modification

[0042] For the water heater of another solar cell production line, choose another suitable water heater model. Install temperature sensors and liquid level sensors with an accuracy of ±0.3℃, and use signal acquisition modules with higher anti-interference capabilities. Select intermediate relays with high action stability and long life, and conduct strict electrical performance tests after rewiring to ensure accurate signal transmission.

[0043] The customized software logic has a 100% accuracy rate in judging different working conditions, and can conduct deep learning based on the historical data of the production line to continuously optimize the temperature control strategy.

[0044] Energy regulation process

[0045] When changing the liquid and dispensing the tank, after the dispensing request signal is triggered, the water heater quickly enters the fast heating mode, and the heating target temperature is set to 92°C. The maximum power output of the heating element is 115% of the rated power of the equipment. During the heating process, the temperature sensor feeds back data in real time, and the control system adjusts the power through the fuzzy control algorithm to make the water temperature rise steadily, with an overshoot of no more than 2°C, reaching 92°C in a short time and maintaining stability.

[0046] In normal production, the outlet water temperature is stable at 65°C in energy-saving constant temperature mode, and the temperature fluctuation range is within ±0.6°C. The heating power is adjusted dynamically according to the water temperature change, and the adjustment step is 4% of the rated power. The control system predicts and adjusts the water temperature change 3 minutes in advance to ensure that the water temperature always meets the strict requirements of the etching process for hot water temperature stability.

[0047] Analysis of the operating data every 15 minutes shows that the heating strategy can be adjusted in time when the ambient temperature changes. For example, when the ambient temperature is 8°C, the initial power of the heating element is increased by 6%; when the production rhythm fluctuates and the water consumption changes between 20% and 40%, the heating power is adjusted in advance between 8% and 14%, effectively balancing the hot water supply and energy consumption.

[0048] Effect evaluation

[0049] Data from two months of continuous operation show that the water heater saves an average of about 44,800 kw / h of electricity per day, with significant energy-saving effects. In the etching process, due to the precise control of hot water temperature, the etching uniformity is greatly improved, the photoelectric conversion efficiency of the product is improved, and the scrap rate caused by temperature-related problems on the production line is reduced.

[0050] 2. Comparison

[0051] Comparative Example 1 (Traditional fixed temperature heating mode)

[0052] System configuration and operation mode

[0053] The same model of water heater as in the embodiment is used, but the original control system and temperature setting method are maintained, that is, the water heater always heats at a fixed temperature of 92° C., without distinguishing between liquid replacement and tank preparation and normal production conditions.

[0054] No additional signal acquisition and operating condition judgment equipment was installed, and the water heater operated in a preset single heating mode with a constant power output of the heating element.

[0055] Effect evaluation

[0056] After one month of operation, the energy consumption of the water heater remained high, with an average daily power consumption of about 45,000 kw / h higher than that of Example 1. In the production process of solar cells, due to the high water temperature during normal production, excessive cleaning occurred during the silicon wafer cleaning process, causing damage to the silicon wafer surface, and the product yield was only 80%, far lower than 95% in Example 1. At the same time, due to long-term high-temperature operation, the heating element of the water heater aged faster, and the equipment maintenance cost increased.

[0057] Conclusion: The traditional fixed temperature heating mode cannot adjust the water temperature according to actual needs in the production of solar cells, resulting in energy waste and negatively affecting product quality and equipment life, highlighting the necessity and advantages of the energy consumption adjustment method of the present invention.

[0058] Comparative Example 2 (Manually Switching Heating Temperature Mode)

[0059] System configuration and operation mode

[0060] The hardware of the water heater is the same as that of the embodiment, but the heating temperature is switched manually. According to the production plan, the operator manually sets the temperature of the water heater to 92°C when changing the liquid tank, and manually adjusts it to 65°C during normal production.

[0061] No automatic monitoring and control system has been established, and the system relies entirely on manual operation and experience-based judgment, which results in large human errors and operational delays.

[0062] Effect evaluation

[0063] During the one-month operation period, the hot water temperature fluctuated greatly due to the untimely and inaccurate manual operation. During normal production, the water temperature often exceeded the range of 65°C ± 2°C, affecting the stability of the production process. The yield rate of the product was only 88%, lower than 95% in Example 1. At the same time, the average daily power consumption was about 15,000 kw / h more than that in Example 1, and the energy-saving effect was far inferior to that of the method of the present invention. In addition, manual operation increased the labor intensity, was prone to misoperation, and reduced production efficiency.

[0064] Conclusion: Although manually switching the heating temperature mode attempts to reduce energy consumption to a certain extent, it is unable to achieve precise temperature control and efficient energy consumption management due to the interference of human factors, and there is a significant gap compared with the automatic intelligent energy consumption adjustment method of the present invention.

[0065] Comparative Example 3 (Simple Logic Control Mode)

[0066] System configuration and operation mode

[0067] The water heater is equipped with a basic temperature sensor and a simple logic controller. When the water tank level is detected to be lower than a certain set value, the heating is started, and the heating is stopped after heating to 92°C. When the water temperature drops below 65°C, the heating is started again, and the cycle is repeated. The unified temperature control logic is used without distinguishing between liquid replacement and normal production conditions.

[0068] The functions of the logic controller are relatively simple and cannot be dynamically adjusted according to changes in production processes and actual needs.

[0069] Effect evaluation

[0070] After one month of operation, the water heater has high energy consumption, with an average daily power consumption of about 30,000 kw / h more than that of Example 1. In the production of solar cells, due to the lack of flexibility in water temperature control, the temperature rise rate is slow when changing the liquid tank, affecting the production progress. In the normal production process, the water temperature fluctuates frequently, resulting in unstable product quality, and the yield rate is about 85%, which is lower than 95% in Example 1. Moreover, the frequent heating and stopping of heating operations have a great impact on the heating elements and control system of the water heater, reducing the reliability and service life of the equipment.

[0071] Conclusion: The simple logic control mode performs poorly in terms of energy consumption regulation and production adaptability, and cannot meet the requirements of solar cell production for efficient and stable operation of water heaters. This further proves the superiority of the method of the present invention in optimizing the energy consumption of water heaters and ensuring production quality.

[0072] It will be apparent to those skilled in the art that the present application is not limited to the details of the exemplary embodiments described above, and that the present application can be implemented in other specific forms without departing from the spirit or essential features of the present application. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the present application is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present application. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A method for regulating energy consumption of a water heater in solar cell production, characterized in that: The following steps are involved: Build a water heater working status monitoring system to collect parameters such as inlet water temperature, outlet water temperature, liquid level signals of each water tank, input voltage, tank allocation request signal and overflow request signal in real time, and judge the current working condition of the machine according to the tank allocation request signal and the overflow request signal. If both the tank allocation request signal and the overflow request signal are received at the same time or only the tank allocation request signal is received, it is determined to be a liquid replacement tank allocation condition; if only the overflow request signal is received, it is determined to be a normal production condition. Select the heating mode according to the working conditions. If it is a liquid replacement tank condition, start the rapid heating mode and set the water heater heating target temperature to 92°C; if it is a normal production condition, start the energy-saving constant temperature mode and stabilize the water outlet temperature of the water heater to 65°C. During the operation of the water heater, a temperature sensor is used to continuously monitor the outlet water temperature and feed it back to the control system. The control system adjusts the heating power based on the comparison between the feedback temperature and the set target temperature. If the temperature is lower than the target temperature, the power is increased; if it is higher than the target temperature, the power is reduced. At the same time, adjustments are made in advance based on the predicted trend of the water temperature change rate to stabilize the water temperature. Regularly analyze the water heater operation data, including water inlet temperature, water outlet temperature, heating power, water consumption, production rhythm, etc., automatically adjust the control parameters according to the analysis results, optimize the heating strategy, adapt to changes in production processes, and achieve continuous optimization of energy consumption.

2. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: When building a monitoring system, the accuracy error of the sensors used shall not exceed ±0.5°C.

3. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: When judging the working condition, the logic judgment response time of the signal processing module does not exceed 1 second.

4. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: In the rapid heating mode, the maximum power of the water heater heating element shall not exceed 120% of the rated power of the device.

5. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: In energy-saving constant temperature mode, the heating power adjustment step does not exceed 5% of the rated power.

6. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: The temperature sensor feeds back temperature data at a frequency not less than once per second.

7. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: When the control system adjusts the heating power in advance according to the predicted trend of the water temperature change rate, the predicted time advance shall not exceed 5 minutes.

8. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: The time interval for regular analysis of running data is 15 minutes.

9. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: When optimizing the heating strategy, if the ambient temperature is below 10°C, the initial power of the heating element shall not be increased by more than 10% of the rated power.

10. The method for regulating energy consumption of a water heater in solar cell production according to claim 1, characterized in that: When optimizing the heating strategy, when the production cycle is accelerated and the water consumption increases by more than 20%, the heating power should be increased in advance by no more than 15% of the rated power.

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