System and method for monitoring energy efficiency of drive system

Abstract

A system for monitoring the energy efficiency of at least one drive system, the system comprising: a memory storing machine executable components; a processor operatively coupled to the memory and configured to execute a machine executable component; and an interface (DCA) configured to query and receive real-time sensor data from a driver (AU1,..., AUN) of at least one drive system, where the sensor data is based on measurements performed by sensors comprised by the driver and represents an operating state of the at least one drive system, wherein the machine executable component comprises a drive system analyzer (DSA) component configured to receive the sensor data via the interface (DCA), execute an energy efficiency model (EEM) on the sensor data to calculate at least one energy efficiency related key performance indicator-energy efficiency related KPI of at least one drive system, providing at least one energy efficiency related KPI of the at least one drive system.

Description

Technical Field

[0001] The presently disclosed subject matter relates to systems and methods for monitoring the energy efficiency of at least one drive system, in particular at least one electromechanical drive system.

[0002] The presently disclosed subject matter also relates to a computer program comprising instructions for performing the above-mentioned method, and to a computer-readable medium comprising such a computer program. Background Art

[0003] When "drive" is referred to in the present invention, it refers to a variable frequency drive (VFD), also known as inverter, adjustable frequency drive (AFD), adjustable speed drive (ASD), variable speed drive (VSD), AC drive, micro drive, inverter drive or simply drive.

[0004] In the context of the present invention, a drive system is a drive and an electric machine, for example an electric machine, such as a three-phase electric machine, for example an asynchronous machine. The drive directly supplies power to the electric machine in the context of electric drive technology. The frequency and amplitude can be derived from the operating state of the electric machine.

[0005] Sustainability is becoming increasingly important in our society and regulations affecting energy-related products are being updated accordingly. Different sustainability targets are set that apply not only to energy consumption and savings but also to CO 2 Emissions and material economy. Electric drive systems are completely influenced by these activities as energy-related products.

[0006] In particular, for the purpose of energy efficiency monitoring, it is usually necessary to install external, cost-intensive sensors for power and energy consumption determination with respect to the high-frequency spectrum introduced from the frequency converter.

[0007] Monitoring energy consumption and sustainability-related KPIs is undoubtedly the first step in establishing a green footprint. However, as global energy resources are limited, reducing power consumption and the energy saving potential that state-of-the-art products can achieve and show in the final application is an added value. In addition, a recommended system for operating existing drives in a more efficient way is provided. Summary of the invention

[0008] The present disclosure aims to provide a system for monitoring the energy efficiency of one or more drive systems in real time.

[0009] The object is achieved by a system, the system comprising: a memory storing machine executable components; a processor operatively connected to the memory and configured to execute the machine executable components; and an interface configured to query and receive and / or collect real-time sensor data from a drive of at least one drive system, wherein the sensor data is based on measurements performed by sensors included in the drive and represents an operating state of the at least one drive system. The machine executable components include a drive system analyzer component, the drive system analyzer component being configured to:

[0010] - receiving sensor data via an interface,

[0011] - executing an energy efficiency model on the sensor data to calculate at least one energy efficiency related key performance indicator (KPI) of at least one drive system, and

[0012] - Providing at least one energy efficiency related KPI of at least one drive system.

[0013] The sensor data is collected by sensors that already exist within the drive, rather than by some external sensor and / or hardware device. This is very advantageous, as each external sensor adds cost and also increases the energy consumption and CO of the monitoring system. 2 Footprints.

[0014] In an embodiment, the interface is configured to query sensor data at an interface-specific sampling frequency (e.g., 100 milliseconds). "Interface-specific" means that sampling is performed at the maximum sampling frequency that can be achieved using this specific interface. This usually depends on the hardware of the interface.

[0015] In an embodiment, the interface comprises one or more data buses.

[0016] In an embodiment, the drive system analyzer component is configured to aggregate sensor data over a predetermined period of time, such as five minutes.

[0017] In an embodiment, the real-time sensor data includes torque, speed, frequency (output frequency of the drive), actual current (RMS current), rated drive current, rated drive supply voltage, power factor (cosψ), DC link voltage.

[0018] In an embodiment, executing the energy efficiency model includes determining at least one of the following:

[0019] - the mechanical power of an electric machine of at least one drive system,

[0020] - driver utilization (converter utilization),

[0021] - power loss of the drive, and

[0022] - Power loss of the reference drive.

[0023] The description of the reference driver and its losses can be taken from a standard or another specification. In particular, this information is obtained from standards set by the IEC (International Electrotechnical Commission), for example from the standard IEC61800-9-2.

[0024] In an embodiment, executing the energy efficiency model further comprises determining at least one of the following:

[0025] - power losses of an electric machine based on the mechanical power of the electric machine of at least one drive system,

[0026] - the power consumption of the at least one drive system based on the power losses of the drive, and

[0027] - based on the power losses of the drive and the power losses of the reference drive, the power loss ratio in the drive and / or the power saving due to / by using the drive when compared with using the reference drive.

[0028] In an embodiment, executing the energy efficiency model further comprises determining at least one of the following:

[0029] - based on the power saving, the energy saving resulting from using the drive system compared to using the reference drive, and

[0030] - based on the power consumption of the at least one drive system, the energy consumption of the at least one drive system.

[0031] In an embodiment, executing the energy efficiency model further comprises determining at least one of the following:

[0032] - Based on the saved energy, the at least one drive system costs and / or CO 2 savings, and

[0033] - based on the energy consumption of the drive system, the operating cost of the at least one drive system and / or the CO generated by the at least one drive system 2 Emissions / footprint.

[0034] In an embodiment, the energy efficiency related KPI is from the following group: power loss of the drive, power loss of a reference drive, power loss of the electric machine of the at least one drive system, utilization of the drive, power consumption of the drive, energy consumption of the at least one drive system, operating cost, CO 2 Equivalent emissions, power loss ratio, power saving, energy saving, CO 2 Savings, cost savings.

[0035] In an embodiment, the system further comprises a user interface configured to receive user commands for:

[0036] - configuring the drive system analyzer component to determine which sensor data the interface is to query / collect from the drives of the at least one drive system, and / or

[0037] -Configure the energy efficiency model.

[0038] In this case, configuring the drive system analyzer component may also include configuring the interface via the drive system analyzer component. In an embodiment, the interface may include a data collector, which may be designed as a software component and may be configured via a (first) user interface, which may be directly connected to the data collector.

[0039] In an embodiment, the machine executable components include a recommendation component configured to:

[0040] a) propose eco-friendly operating settings for the drive / inverter, and / or

[0041] b) propose actions to bypass or shut down the drive / inverter to reduce resource consumption, and / or

[0042] c) Indicates the energy savings if more energy efficient electric machines (e.g. IE5 PEM motors, SynRM motors, etc.) and / or more energy efficient drives / inverters and / or drives / inverters with regenerative capabilities are installed.

[0043] Proposing an environmentally friendly operating setting may include but is not limited to: changing the switching frequency of the drive based on one or more KPIs, proposing a control technique aimed at optimizing the motor flux, and proposing the selection of a suitable pulse modulator, especially in the field of overmodulation.

[0044] In an embodiment, the machine-executable component comprises a visualization component configured to provide at least one signal based on at least one energy-efficiency-related KPI to visualize the at least one energy-efficiency-related KPI.

[0045] In an embodiment, the at least one signal is designed to be visualized in the form of at least one widget.

[0046] In an embodiment, the signal includes at least information about a power loss ratio KPI, and the widget includes an area for visualizing a current efficiency mode, the area being defined based on a preset limit value (in percentage) of the power loss ratio KPI.

[0047] In an embodiment, the area is designed as a circle, and if the power loss ratio is less than or equal to a first preset limit value, the circle may be painted green; if the power loss ratio is greater than the first preset limit value and less than or equal to a second preset limit value, the circle may be painted yellow; and if the power loss ratio is greater than the second preset limit value, the circle may be painted red.

[0048] The object is also achieved by a computer-aided method for monitoring the energy efficiency of at least one drive system, in particular at least one electromechanical drive system, comprising:

[0049] - receiving real-time sensor data from a drive of at least one drive system, e.g. via an interface or through an interface query, and e.g. at a drive system analyzer, wherein the sensor data is based on measurements performed by sensors comprised by the drive and represents an operating state of the at least one drive system,

[0050] - executing an energy efficiency model on the sensor data to calculate at least one energy efficiency related key performance indicator (KPI) of the at least one drive system, for example at the drive system analyzer, and

[0051] - at least one energy efficiency related KPI of the at least one drive system is provided, for example at the interface or at a user interface.

[0052] In an embodiment, the method further comprises configuring an energy efficiency model.

[0053] In an embodiment, the method further comprises configuring the drive system analyzer component to determine which sensor data the interface is to query / collect from a drive of the at least one drive system.

[0054] In an embodiment, the method further comprises: performing the following operations based on at least one energy efficiency-related KPI of the at least one drive system:

[0055] a) propose eco-friendly operating settings for the drive / inverter, and / or

[0056] b) propose actions to bypass or shut down the drive / inverter to reduce / save resources, and / or

[0057] c) represents the energy savings if more energy efficient electric machines (e.g. IE5 PEM motors, SynRM motors, etc.) and / or more energy efficient drives / inverters and / or drives / inverters with regenerative capabilities are installed. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The above and other aspects and advantages of the subject matter disclosed herein will be further discussed in conjunction with the accompanying drawings, which indicate only some possible ways in which it may be practiced. Like reference numerals in the drawings refer to like parts throughout.

[0059] Figure 1 shows an example of an OT infrastructure,

[0060] Figure 2 shows a KPI visualization in the form of a widget, and

[0061] Figure 3 An energy efficiency model is shown. DETAILED DESCRIPTION

[0062] Figure 1 An exemplary OT (operational technology) infrastructure for implementing the presently disclosed subject matter is shown.

[0063] The infrastructure comprises a plurality (1, 2, 3, 4, ..., N) of drive systems and at least one industrial PC (personal computer) IPC.

[0064] Those skilled in the art will appreciate that the industrial PC may be replaced by any locally deployed and / or cloud computing device.

[0065] Each drive system comprises a drive unit AU1, ..., AUN, such as a frequency converter, which drives an electric machine, such as an electric motor.

[0066] The industrial PC IPC can be designed as an edge device, including one or more ports, a data bus DBUS, a data connector CC, and interfaces, such as user interfaces UI1, UI2, UI2, etc.

[0067] Specifically, the industrial PC IPC includes a data collector DCA which may be designed as a software program (eg, application).

[0068] The data collector app DCA is configured to query and / or collect real-time sensor data from a plurality of actuators AU1 , . . . , AUN of a corresponding drive system.

[0069] In an embodiment, the data collector DCA may have several different data connectors DCONN, such as HF, LF (for high / low frequency) connectors, fingerprint connectors, etc. to query specific data from the drivers AU1, ..., AUN. The configuration of the data connector DCONN may be provided by an API (Application Programming Interface).

[0070] The sensor data are based on a plurality of measurements performed by sensors comprised by the corresponding drive AU1, ..., AUN and represent an operating state of the at least one drive system. In particular, the data are relevant for determining an energy efficiency of the at least one drive system.

[0071] For example, the sensor data may include torque T, speed n, frequency f (output frequency of the drive), actual current I (RMS current), rated drive current I N , Rated drive power supply voltage U N , power factor (cos of ψ), DC link voltage U.

[0072] Other data may be provided to or queried by the data collector DCA.In an embodiment, a machine-readable product name of each drive AU1, ..., AUN, a nominal grid frequency, etc.

[0073] In an embodiment, raw data is continuously provided / queried, for example, in the form of a time series.

[0074] The data collector DCA may comprise a first user interface UI1 configured to receive user commands for configuring which sensor data to collect and / or which sampling frequency to use. The sampling frequency is data collector specific. In an embodiment, the sampling frequency depends on the hardware characteristics of the data bus, which the industrial PC IPC uses to collect / query data from the drivers AU1, ..., AUN.

[0075] In an embodiment, the user U may connect to the first user interface UI1 via the Internet (eg, by using the http protocol).

[0076] The data collector app DCA passes the data (raw data) for further data processing DH. In an embodiment, the MQTT protocol is used for communication between the data collector DCA and the data processing stage DH. The data processing DH may be performed via a data bus DBUS, which may be connected to one or more connectors CC (e.g., cloud connectors), e.g., via http, a PLC (e.g., via MQTT, etc.).

[0077] In an embodiment, the data bus DBUS may be connected to a second user interface UI2, which is configured to receive user commands for data routing. For example, it may be configured to forward a portion of the original data to a cloud service, for example, for model training, etc. In an embodiment, the user U may connect to the second user interface UI2 via the Internet (e.g., by using the http protocol).

[0078] The data processing module DH may provide resources for various other data services or for the information hub.

[0079] The sensor data is forwarded to the drive system analyzer DSA via the data bus DBUS. The MQTT communication protocol can also be used here. In an embodiment, the drive system analyzer is a software component. In an embodiment, the drive system analyzer DSA can be designed as an app, for example, an edge app.

[0080] In an embodiment, the drive system analyzer DSA may include a data aggregation module DAM configured to buffer a predetermined amount of data. In an embodiment, the data aggregation module is configured to cache the sensor data for five minutes. By selecting an appropriate sampling frequency, enough sensor data can be aggregated within five minutes to produce a single data point.

[0081] The drive system analyzer DSA provides an environment for executing one or more models (eg, a runtime for the Python programming language). For example, the drive system analyzer DSA may include models for condition estimation CE of a drive and / or an electric machine, such as an electric motor.

[0082] In order to estimate the energy efficiency of each drive system, the drive system analyzer DSA includes an executable energy efficiency model EEM.

[0083] In an embodiment, the drive system analyzer DSA may include a database DB storing different models, configurations, previous analysis results of different models, and the like.

[0084] The energy efficiency model EEM is designed to receive (aggregated) sensor data and calculate at least one energy efficiency-related key performance indicator (KPI) of the corresponding drive system.

[0085] The drive system analyzer DSA and its modules (eg, data aggregation module DAM, energy efficiency model EEM, etc.) may be configured via the third user interface UI3.

[0086] The third user interface UI3 can also be used to provide KPIs to the user U. The user U can configure the model and adjust its settings with the help of the third user interface UI3. For example, the user U can set the price per kWh, the CO emitted per kWh, and the KPIs of the model. 2 , setting mains frequency and / or voltage, etc. This is useful for visualizing energy efficiency.

[0087] In an embodiment, the energy efficiency related KPI is from the following groupings: power loss of the drive, power loss of a reference drive, power loss of the electric machine of the at least one drive system, utilization of the drive, power consumption of the drive, energy consumption of the at least one drive system, operating cost, CO 2 Equivalent emissions, power loss ratio, power saving, energy saving, CO 2 Savings, cost savings.

[0088] In an embodiment, at least one KPI may be forwarded to a cloud service for further analysis or training of an AI model.

[0089] In an embodiment, the KPI or KPIs may be forwarded to the user U via the third user interface UI3 for monitoring purposes and / or further analysis.

[0090] In an embodiment, the drive system analyzer DSA comprises a visualization component configured to provide at least one signal based on at least one energy efficiency related KPI to visualize the at least one energy efficiency related KPI. The signal may be sent to a display device UD of a user U.

[0091] In an embodiment, the user U can access the first, second and third user interfaces by using a computing device, for example via http. This means that the user U does not have to be physically present at the place of use of the drive system and can be elsewhere.

[0092] In an embodiment, the user U is able to configure the energy efficiency model EEM—adjust its settings.

[0093] In an embodiment, the drive system analyzer DSA can include an application programming interface API that allows configuration of the drive system analyzer DSA. In an embodiment, it allows configuration of the energy efficiency model EEM (and other models), and / or data processing within the drive system analyzer DSA, such as data aggregation, providing energy efficiency KPIs, visualization, etc.

[0094] In an embodiment, the drive system analyzer DSA can include a recommendation component configured to receive as input one or more energy efficiency related KPIs of at least one drive system and to propose eco-friendly operating settings for the frequency converter based on the KPI values.

[0095] In an embodiment, the recommendation component is configured to propose actions for bypassing or shutting down the frequency converter to reduce / save resources.

[0096] In an embodiment, the recommendation component is configured to indicate energy savings under new installations of the most efficient products (eg, IE5 PEM motors, SynRM motors, etc.).

[0097] A signal for the visualization of one or more KPIs may be sent to the computing device of the user U and visualized on its display UD.

[0098] Figure 2An example of two widgets that can be provided to a user U via a display device UD is shown. The widgets relate to different industrial applications and show the daily power consumption in kW over time. The efficiency mode of the corresponding drive system can be specified, for example, by a colored circle. In an embodiment, the circle can be green, yellow or red, depending on the efficiency of the operating mode.

[0099] In an embodiment, these widgets provide daily developments on KPIs (energy consumption, CO 2 emissions, costs) and information on their historical behavior.

[0100] Reference now Figure 3 , an example of calculating energy efficiency KPIs through the energy efficiency model EEM is presented as a flow chart.

[0101] As discussed above, the energy efficiency model EEM can receive the torque T, the speed n, the RMS value of the current I, the rated current I N , machine-readable product name MLFB, output frequency f of the drive, power factor cos(φ) and rated line supply voltage U N .

[0102] The energy efficiency model EEM can be pre-configured by the user U. Specifically, the user U may be required to input the line voltage, CO 2 Emission factors, electricity prices, etc.

[0103] Based on the input sensor data and based on the user's configuration, the energy efficiency model may determine at least one of the following:

[0104] - the mechanical power of the motor of the corresponding drive system,

[0105] - driver utilization (converter utilization),

[0106] - power loss of the drive, and

[0107] - Power loss of the reference drive.

[0108] In an embodiment, the energy efficiency model may determine the power loss of the corresponding electric machine based on the mechanical power of the electric machine.

[0109] In an embodiment, the energy efficiency model may determine the power consumption of each drive system based on the power losses of the drive.

[0110] In an embodiment, the energy efficiency model may determine a power loss ratio in the drive and / or power savings due to / by using the drive based on the power loss of the drive and the power loss of the reference drive when compared to using the reference drive.

[0111] In an embodiment, based on a power loss ratio.

[0112] In an embodiment, the energy efficiency model may determine, based on the power savings, energy savings resulting from using a driver in the drive system compared to using a reference driver.

[0113] In an embodiment, the energy efficiency model may determine the energy consumption of each drive system based on the power consumption of the drive system.

[0114] In an embodiment, the energy efficiency model may determine the cost and / or CO of each drive system based on the energy saved. 2 save.

[0115] In an embodiment, the energy efficiency model may determine the operating cost of at least one drive system and / or the CO generated by at least one drive system based on the energy consumption of the drive system. 2 Emissions / footprint.

[0116] The above embodiments of the present disclosure are presented for purposes of illustration and not limitation. Specifically, the embodiments described with respect to the drawings are several examples of the embodiments described in the introduction. The technical features described with respect to the system can be applied to enhance the method disclosed in the present invention and vice versa.

Claims

1. A system for monitoring the energy efficiency of at least one drive system, the system include: - memory, storing machine executable components; - a processor operatively coupled to said memory and configured to execute said machine-executable components, and - an interface (DCA) configured to query and receive real-time sensor data from an actuator (AU1, ..., AUN) of at least one drive system, wherein the sensor data are based on measurements performed by sensors comprised by the actuator and are representative of an operating state of the at least one drive system, wherein The machine-executable components include a drive system analyzer (DSA) component configured to: - receiving said sensor data via said interface (DCA), - executing an energy efficiency model (EEM) on the sensor data to calculate at least one energy efficiency related key performance indicator - energy efficiency related KPI - of the at least one drive system, and - providing at least one said energy efficiency related KPI of said at least one drive system.

2. The system according to claim 1, in, The interface (DCA) is configured to query the sensor data at an interface specific sampling frequency.

3. The system according to claim 1 or 2, in, The interface includes one or more data buses.

4. The system according to any one of claims 1 to 3, in, The drive system analyzer component (DSA) is configured to aggregate the sensor data over a predetermined period of time.

5. The system according to any one of claims 1 to 4, in, The real-time sensor data includes torque, rotation speed, frequency, actual current, rated drive current, rated drive power supply voltage, power factor, and DC link voltage.

6. The system according to any one of claims 1 to 5, in, The energy efficiency related KPIs are from the following groups: power loss of the drive, power loss of the reference drive, power loss of the electric machine of the at least one drive system, utilization of the drive, power consumption of the drive, energy consumption of the at least one drive system, operating costs, CO 2 Equivalent emissions, power loss ratio, power saving, energy saving, CO 2 Savings, cost savings.

7. The system according to any one of claims 1 to 6, further comprising a user interface configured to receive user commands for: - configuring the drive system analyzer component to determine which sensor data the interface is to query / collect from the drive of the at least one drive system, and / or -Configuring the energy efficiency model.

8. The system according to any one of claims 1 to 7, in, The machine-executable component comprises a recommendation component configured to, based on at least one of the energy efficiency-related KPIs of the at least one drive system: a) propose eco-friendly operating settings for said drives (AU1, ..., AUN), and / or b) propose actions for bypassing or shutting down said drivers (AU1, ..., AUN) to save resources, and / or c) Indicates the energy savings if more efficient electrical machinery is installed.

9. The system according to any one of claims 1 to 8, in, The machine-executable component comprises a visualization component configured to provide at least one signal based on at least one of the energy-efficiency-related KPIs to visualize at least one of the energy-efficiency-related KPIs.

10. The system according to claim 9, in, The at least one signal is designed to be visualized in the form of at least one widget.

11. A computer-aided method for monitoring the energy efficiency of at least one drive system, the method include: - querying and receiving real-time sensor data from an actuator (AU1, ..., AUN) of said at least one drive system, wherein said sensor data are based on measurements performed by sensors comprised by said actuator and are representative of an operating state of said at least one drive system, - executing an energy efficiency model (EEM) on said sensor data to calculate at least one energy efficiency related key performance indicator (KPI) of said at least one drive system, and - Providing at least one energy efficiency related KPI of said at least one drive system.

12. The method according to claim 11, further comprising: include: The energy efficiency model (EEM) is configured.

13. The method according to claim 11 or 12, further comprising based on the at least one energy efficiency related KPI of the at least one drive system: a) proposing an eco-friendly operating setting for said drives (AU1, ..., AUN), b) propose actions for bypassing or shutting down said drives (AU1, ..., AUN) to save resources, or c) Indicates the energy savings if more energy-efficient electrical machinery is installed.

14. A computer program comprising instructions which, when executed by a system according to any one of claims 1 to 10, cause a computer to perform a method according to any one of claims 11 to 13.

15. A computer readable medium comprising a computer program according to claim 14.

Images