System and method for factory lighting energy-saving control

Abstract

The invention relates to the technical field of industrial lighting control, and discloses a system and method for factory lighting energy-saving control, and the method comprises the steps: 1, monitoring the environment state in each working region in real time through employing a distributed sensor; the environment state comprises illumination intensity, a personnel activity state and an equipment operation state; 2, establishing an illumination demand judgment rule, carrying out fusion processing on the collected multi-source data, and analyzing the illumination demand of each region according to the judgment rule; 3, corresponding illumination intensity is selected according to the illumination requirement, and the illumination brightness in each area is dynamically adjusted; and step 4, a control decision is optimized in combination with a set production mode, and the illumination brightness in each area is regulated and controlled according to the optimized control decision. According to the invention, through intelligent multi-unit cooperative control, high-efficiency energy-saving and accurate management of factory lighting is realized, the management efficiency is improved while the energy consumption is reduced, and the safety and stability of production operation are ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent production control, and particularly relates to a system and method for energy-saving control of factory lighting. Background Art

[0002] In an industrial production environment, workshop lighting is an important infrastructure for ensuring safe production and improving operation efficiency. However, the traditional workshop lighting control method mainly relies on operators to actively control the switching of lamps to turn on and off the lighting. However, this method is mainly dependent on the subjective judgment of operators and is prone to improper lighting management due to negligence or delay. For example, in unoccupied work areas or where natural light is sufficient, lighting equipment may still remain on, causing unnecessary power waste; while in low-light conditions or during night operations, the work environment may be dim due to failure to adjust the light source in a timely manner, affecting personnel operations and even increasing safety hazards.

[0003] Secondly, since workshops are usually spacious with complex area divisions, personnel need to conduct frequent inspections and operations during control, which not only increases the labor intensity of the staff but also may lead to low lighting management efficiency. Especially in large manufacturing workshops or multi-story factories, it is difficult for personnel to achieve precise and real-time lighting adjustment, resulting in some areas being in a state of over-illumination or under-illumination for a long time, wasting energy and affecting the comfort of the production environment.

[0004] In addition, traditional lighting control methods lack intelligence and automation capabilities and cannot adaptively adjust according to environmental light intensity, personnel activities, or production requirements. For example, when natural light is sufficient, it is unable to automatically dim or turn off some lamps; during unoccupied operation periods, it is also unable to automatically turn off the lighting to save energy. This extensive management mode not only increases the electricity cost of enterprises but also does not conform to the development trend of modern industrial intelligence and greening. Summary of the Invention

[0005] The present invention aims to provide a system and method for energy-saving control of factory lighting to solve the problems of existing factory lighting such as energy waste, single control method, and inability to adapt to complex working conditions.

[0006] To achieve the above object, the present invention adopts the following technical solutions. A method for energy-saving control of factory lighting includes the following steps.

[0007] Step 1, using distributed sensors to continuously monitor the environmental status in each working area; the environmental status includes light intensity, personnel activity status, and equipment operation status.

[0008] Step 2, establishing a light demand determination rule, fusing and processing the collected multi-source data, and analyzing the light demand of each area according to the determination rule.

[0009] Step 3: Select the corresponding lighting intensity according to the lighting requirements, and dynamically adjust the lighting brightness in each area.

[0010] Step 4: Optimize the control decision in combination with the set production mode, and implement the regulation of the lighting brightness in each area according to the optimized control decision.

[0011] Meanwhile, this solution also provides a system for energy-saving control of factory lighting, which is applied to the above-mentioned method for energy-saving control of factory lighting. The system includes sensors distributed in each area of the factory building and a control module connected to the sensors. The control module includes an operation terminal, a data processing unit, a decision control unit, a scheduling optimization unit, and an equipment monitoring unit.

[0012] The principle and advantages of this solution are as follows:

[0013] This solution collects multi-dimensional data such as ambient light, personnel activities, and equipment status in real time, generates optimal control instructions based on a three-dimensional fuzzy decision algorithm, dynamically adjusts the lighting brightness and area switches, and realizes efficient data transmission and rapid response of instructions. It can automatically adjust the lighting according to actual needs, avoiding energy waste or insufficient lighting caused by misoperations. At the same time, it supports remote monitoring and strategy adjustment, completely solving the problems of forgetting or misoperation that may occur in personnel management, and ensuring the safety, reliability, high efficiency, and energy saving of lighting management. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic flow chart of a method for energy-saving control of factory lighting according to the present invention.

[0015] Figure 2 It is a schematic framework diagram of a system for energy-saving control of factory lighting according to the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016] The following is a further detailed description through specific embodiments:

[0017] Embodiment 1

[0018] In this embodiment, a method for energy-saving control of factory lighting establishes a lighting requirement determination rule through modular control, production linkage, and full life cycle management, enabling it to dynamically adjust the lighting intensity, independently identify different production scenarios, and match the optimal lighting strategy, thereby solving the problems of lagging lighting control response, low energy efficiency, and easy energy waste in industrial scenarios. In this embodiment, as shown in the attached Figure 1 figures, the control method includes the following steps:

[0019] S1. Use distributed sensors to monitor the environmental status in each working area in real time. Among them, the environmental status includes light intensity, personnel activity status, and equipment operation status.

[0020] According to the different equipment and uses in the production plant, the plant is divided into multiple working areas according to functions, such as including ordinary processing areas, precision processing areas, special processing areas, storage areas, passage areas, etc. Install corresponding sensor devices in each working area through a distributed installation method. For example, use photosensitive sensors to monitor the light intensity in each working area in real time, use infrared motion sensors to detect the personnel activity status, and collect the machine tool operation status signal and workbench operation signal, etc. through control devices or sensors.

[0021] Obtain the environmental status information in each working area in real time through various sensors installed in each working area. Among them, the light intensity is sampled once every 5 seconds and sliding average filtering is performed, and the width of its sliding window is 10. The personnel activity status is triggered and monitored according to the sensors installed in each area. When a person enters the area, a mobile detection signal is started, and the stay duration of the person in the area is determined. When the stay duration is greater than the set threshold, it is determined that there is personnel activity in the current area. In this embodiment, the set stay threshold is 30s.

[0022] At the same time, collect the equipment operation status through the control device and the set sensors. The current equipment operation status can be obtained by collecting the equipment current once every 1 second, and it is determined whether it is in the working state.

[0023] In this embodiment, all sensor devices in each working area are also included. When it is determined that the area is in the non-production mode, it enters the energy-saving mode, that is, the sampling frequency is reduced by 50%, and the motion sensor switches to the low-power state, such as the detection interval is extended to 2 minutes, etc.

[0024] S2. Establish a light demand determination rule, perform fusion processing on the collected multi-source data, and analyze the light demand of each area according to the determination rule.

[0025] In this embodiment, according to the set environmental status, a light demand determination rule is established. Among them, the demand determination rule includes high-demand mode, medium-demand mode, and low-demand mode. The high-demand mode is that there are personnel activities in the area and the equipment is running, and at the same time the environmental light < 300 Lux. If it is determined to be the high-demand mode, the highest level of lighting is provided. The medium-demand mode is that there are personnel activities in the area, but the equipment is in the standby state and the environmental light is between 300 and 500 Lux. If it is determined to be the medium-demand mode, medium-intensity lighting is provided. The low-demand mode is that there are no personnel activities in the area, but the environmental light > 500 Lux. If it is determined to be the low-demand mode, the lowest necessary lighting is maintained or the lighting is turned off.

[0026] For the currently acquired environmental status data, the D-S evidence theory algorithm is used to perform credibility fusion on multi-sensor data, and uncertain information is processed through the basic probability assignment (BPA) and Dempster combination rule, thereby comprehensively determining the status of the current working area and accurately matching the required lighting demand pattern. In this embodiment, first, a set of all possible propositions, that is, the frame of discernment, is established for the acquired data, then the basic credibility is assigned to each sensor data, and finally, the multi-source evidence is fused into a unified decision through a specific combination rule.

[0027] Specifically, it can be set that the frame of discernment contains three propositions, namely, the need to increase lighting, maintain the current lighting, and the need to reduce lighting. The data collected by each sensor will be converted into a credibility assignment for these propositions.

[0028] Thus, according to the measured value of each sensor, a credibility evaluation is given. For example, when the photosensitive sensor detects that the current working area is 300 Lux, then at this time, the credibility of the need to increase light is given as 0.7, and the remaining 0.3 uncertainty is assigned to the entire frame of discernment. At the same time, when the motion sensor detects human activities, it may assign a credibility of 0.8 to the compound proposition of "the need to increase light or maintain the status quo".

[0029] Thus, the Dempster combination rule is used to fuse the credibility assignments of different sensors. Its mathematical expression is

[0030]

[0031] In the formula, m1 and m2 are the basic probability assignment functions of two independent sensors; B and C are subsets of the frame of discernment, representing the propositions supported by the sensors; A is the target proposition to be calculated, that is, the lighting action of the decision; K is the conflict coefficient between the evidences of each sensor, which can be expressed as

[0032]

[0033] In the formula, It means that the propositions supported by the two sensors are mutually exclusive. When the two sensors strongly support mutually contradictory propositions, that is, if one detection result indicates the need to increase light and the other detection result indicates the need to reduce light, then the value of K is close to 1, thus indicating a high degree of conflict. By traversing all proposition combinations that satisfy B∩C = A, multiplying the corresponding BPA values and summing them, and finally normalizing the result to ensure the effectiveness of the fused probability distribution, the decision-making problem when multi-sensor data is inconsistent in the industrial scenario is solved, providing accurate and clear data support for the mode judgment of intelligent lighting control.

[0034] At this time, when encountering height conflicts, the historical accuracy rate of the sensors is used as the weight to perform weighted averaging on the data, and the sensor data with higher reliability is preferentially considered to solve the dilemma when encountering height conflicts. Finally, the confidence intervals of each proposition are calculated, including the minimum confidence level supporting the proposition and the possible maximum confidence level. When the minimum confidence value exceeds the preset value and the range of the confidence interval is relatively narrow, the corresponding control instruction is executed. If the working area is an area that requires quick response, an approximate calculation method can be further adopted, such as using the geometric mean to simplify the combination operation, further improving the response efficiency and reducing the calculation amount.

[0035] Meanwhile, in this embodiment, it also includes analyzing the confidence weight of the current sensor based on the long-term historical data of the sensor and dynamically adjusting the confidence weight according to the confidence accuracy rate. For example, if the accuracy rate of a certain sensor reaches 95% in the past 30 days, its weight will be automatically increased.

[0036] By fusing multi-sensor data in this way, the data misjudgment rate is greatly reduced, and the fusion calculation of multi-sensor data can be completed within 50 milliseconds to promptly respond to environmental changes. Even when sensor data conflicts occur, the success rate of resolving the conflicts reaches 98%. It can not only make full use of the advantages of each sensor but also effectively handle the contradictions between data, ensuring the reliability of demand determination.

[0037] S3. Select the corresponding illumination intensity according to the lighting demand and dynamically adjust the illumination brightness in each area.

[0038] After analyzing and determining the lighting demand required for the current working area based on the acquired environmental status data, select the corresponding illumination intensity according to the lighting demand mode to dynamically adjust the illumination brightness in each area.

[0039] In this embodiment, when adjusting the illumination brightness in each area, it also includes adjusting the illumination intensity in the transition area. Specifically, the time decay model can be used for the transition area adjustment. The transition area is the area where the illumination intensity changes. For example, when a person leaves the working area, the lighting system will not be immediately turned off, but gradually reduce the brightness in an exponential decay manner to avoid discomfort caused by sudden light and dark changes to vision, while taking into account the energy-saving requirements.

[0040] Specifically, the activity status of personnel is continuously monitored through a motion sensor. When it is detected that a person leaves, the recorded time is t0, that is, the time when the adjustment condition is triggered. At the same time, the basic brightness P0 of the current area is obtained. Then the adjustment method of the brightness over time can be expressed as

[0041]

[0042] Wherein, P(t) is the illumination brightness at time t; λ is the attenuation rate constant, with a value range of 0.02 - 0.05; t - t0 is the duration after the person leaves. When the brightness decays to the safety threshold, such as 50 Lux or when it is detected that the person re - enters, the attenuation stops immediately; if the brightness drops below the threshold and no one returns, the lighting is completely turned off. In this embodiment, the value of λ can be dynamically adjusted according to the requirements of different working areas.

[0043] S4. Combine the set production mode to optimize the control decision, and implement the regulation of the lighting brightness in each area according to the optimized control decision.

[0044] In this embodiment, after determining the required lighting intensity of the current area, select the corresponding control decision in combination with the production mode of the current area, optimize the control decision, and then perform the final lighting adjustment to achieve precise and intelligent lighting management. Among them, the production modes include the normal production mode, the equipment maintenance mode, and the non - production mode.

[0045] The normal production mode is generally the basic lighting for the whole area and enhanced lighting for the working area. Among them, the whole area is the core operation area in production, including direct production areas such as assembly lines and precision machining. During normal production, first perform basic lighting for the whole area according to the determined lighting requirements. When it is detected that a person enters the corresponding local working area, the illuminance of this area is dynamically increased through the luminous flux compensation algorithm. At the same time, according to the divided working areas, monitor whether there are high - temperature equipment in this area and the surrounding environment of the high - temperature equipment. When the infrared sensor detects abnormal thermal radiation, trigger the lighting enhancement plan for this area.

[0046] The maintenance mode is local area lighting and safety passage lighting. In this embodiment, the maintenance mode is the operation activities such as maintenance and detection of equipment outside normal production. At this time, according to the set plan information such as inspection and patrol, activate the lighting in the maintenance area and perform lighting adjustment in a progressive lighting - up manner. Specifically, first turn on the safety passage lighting to 200 Lux, and then sequentially activate the local lighting according to the movement trajectory of the maintenance personnel. At the same time, for the working conditions involving the maintenance of dangerous equipment, the emergency lighting will be maintained at 100% brightness additionally, and all energy - saving strategies will be disabled to ensure the safety of the maintenance personnel.

[0047] The non - production mode is the mode corresponding to non - working hours, and only the safety lighting is retained. However, for special areas such as those involving dangerous equipment or dangerous goods storage areas, the dynamic patrol lighting method is adopted, such as automatically lighting up the whole area for 5 minutes every 30 minutes, and cooperating with a thermal imager for safety patrol to ensure the safety and stability of the production environment.

[0048] In this embodiment, multi-modal sensor fusion data is adopted to solve the problem of difficult fusion processing of multi-data, reduce the computational amount while improving the processing efficiency, and innovatively introduce the equipment operation state as a judgment criterion, effectively solving the problems of easy misjudgment and poor environmental adaptability of existing single sensors. Secondly, a judgment method that links the personnel movement trajectory with the equipment state is adopted to break through the limitations of the existing mechanical regulation of timing and zoning control, realize adaptive dynamic transition regulation, ensure the lighting intensity requirement while reducing energy consumption, ensure production safety, and achieve precise control.

[0049] Embodiment 2

[0050] In this embodiment, a system for energy-saving control of factory lighting is provided, which is applied to a method for energy-saving control of factory lighting. As shown in the appendix Figure 2 It includes sensors distributed and installed in various areas of the factory building, and a control module connected to the sensors.

[0051] In this embodiment, the sensors include photosensitive sensors, motion sensors, and equipment status monitoring sensors. Among them, the photosensitive sensors continuously monitor the light intensity of each working area. Specifically, industrial-grade light sensors can be selected, such as those with a measurement range of 0-2000 Lux and an accuracy of ±5%. One sensor is arranged for every 50-80㎡ in each working area, and the installation height is 1.5-2m from the working surface for installation and layout. Thus, the light intensity of each working area is monitored and transmitted to the control module.

[0052] At the same time, if there are high-temperature equipment (such as welding stations) and dangerous equipment (such as stamping machines) in the area, additional explosion-proof lighting and red warning light belts are also required.

[0053] The motion sensors continuously monitor the personnel activity status in each working area. In this embodiment, for conventional areas, that is, areas with a relatively wide field of vision and no obstruction, pyroelectric infrared sensors can be selected, with a detection angle of 120°; for elevated or multi-obstacle areas, microwave radar sensors can be selected, with a detection radius of 8m. Three to five sensors are arranged for every 200㎡ for installation and layout to form cross-coverage. Whether there are personnel activities in the working area is continuously monitored by the motion sensors, and the monitoring information is transmitted to the control module.

[0054] The equipment status monitoring sensors continuously collect the operation status of the equipment and the workbench operation signals. In this embodiment, the equipment start-stop signals are obtained through the DI module of the PLC, and at the same time, equipment such as current transformers is added to monitor the motor load rate, so as to obtain the operation status of the equipment, and the equipment status information is transmitted to the control module.

[0055] In this embodiment, the control module includes an operation terminal, a data processing unit, a decision-making control unit, a scheduling optimization unit, and an equipment monitoring unit.

[0056] The operation terminal is a remote control terminal, which can be installed on the master console or the mobile phone terminal, facilitating remote operation and control for inputting monitoring or adjustment instructions. The data processing unit is used to collect and preprocess multi-source sensor data in real time, complete data standardization, outlier filtering, feature extraction, etc., and output the cleaned structured data stream. The decision-making and control unit is used to analyze and judge the processed data, select the corresponding control decision, and generate the corresponding real-time control instruction. The scheduling and optimization unit is used to optimize the control decision based on the selected control method and the set production mode analyzed, forming the final adjustment method. The equipment monitoring unit is used to obtain the operating status of the equipment and the operation signals of the workbench in real time.

[0057] In this embodiment, by introducing automation control strategies such as light sensing, human body infrared sensing, timing control, or remote centralized management, the workshop lighting management can be effectively optimized, energy consumption can be reduced, human intervention can be minimized, and the comfort and safety of the production environment can be improved.

[0058] Embodiment 3

[0059] In this embodiment, on the basis of Embodiment 1, it further includes establishing a health status model of lighting equipment, judging the health status of lighting equipment according to the monitored current status of lighting equipment, and performing fault analysis according to the health status. In this embodiment, the health status assessment of lighting equipment is mainly based on electrical parameter analysis and performance degradation model. Through the intelligent monitoring module installed on each lighting circuit, parameters such as the working current of the equipment and its harmonic components, input voltage fluctuation, power factor change trend, and surface temperature of the lamp are collected in real time to establish the real-time health index of the equipment, which can be expressed as

[0060]

[0061] where I i is the current value of the i-th sampling; I m is the rated working current; ΔT is the abnormal value of temperature rise; β is the weight coefficient. According to the health index HI, the health status is divided into four grades, namely excellent status (HI≥85), attention status (75≤HI<85), warning status (60≤HI<75), and dangerous status (HI<60).

[0062] When it is monitored that the health index enters the attention status, diagnostic analysis is carried out, and the analysis result including the fault type and maintenance suggestions is pushed to the maintenance personnel terminal.

[0063] At the same time, energy consumption is measured according to the health status of lighting equipment, and the lighting intensity is adjusted according to the measurement result.

[0064] Dynamically adjust the lighting control strategy according to the health status of the device to achieve a balance between safety and energy efficiency. Among them, when the lighting device is in good condition, the standard energy-saving strategy is adopted, allowing the brightness to be adjusted within the range of 100% - 30%; when the lighting device is in the attention state, the maximum brightness is limited to 80% to reduce the workload and extend the service life; when the lighting device is in the warning state, the brightness output is fixed and the dimming function is disabled to avoid accelerating damage due to working condition fluctuations; when the lighting device is in the dangerous state, the power supply is automatically cut off to prevent safety accidents, and replacement or repair is prompted. In this embodiment, the actual energy efficiency ratio of the device is also measured in real time. When the actual energy efficiency ratio is lower than 85% of the rated value, it is recommended to replace the lamp to avoid energy waste caused by continued use.

[0065] In this embodiment, on the basis of combining the lighting requirements and production mode, integrating the device health status monitoring and energy efficiency dynamic optimization analysis, it can not only intelligently adjust the lighting according to the environmental requirements, but also predict faults and optimize energy consumption by real-time monitoring of the device status, realizing the refined management of the entire life cycle of the lighting system. At the same time, for lighting devices in special areas such as high temperature and explosion-proof, more conservative health thresholds and adjustment strategies are adopted to ensure safety first, which not only ensures the reliability of the lighting system but also maximizes the energy utilization efficiency.

[0066] The above are only embodiments of the present invention. Specific technical solutions and / or common knowledge such as characteristics well known in the art are not described in detail here. It should be pointed out that for those skilled in the art, without departing from the technical solution of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the implementation effect of the present invention and the practicality of the patent. The protection scope required by this application shall be subject to the content of its claims, and the specific implementation manners described in the specification can be used to explain the content of the claims.

Claims

1. A method for energy-saving control of factory lighting, characterized in that, It includes the following steps: Step 1, using distributed sensors to monitor the environmental status in each working area in real time; the environmental status includes light intensity, personnel activity status, and equipment operation status; Step 2, establishing a light demand determination rule, and performing fusion processing on the collected multi-source data, and analyzing the light demand of each area according to the determination rule; Step 3, selecting the corresponding lighting intensity according to the light demand, and dynamically adjusting the lighting brightness in each area; Step 4, optimizing the control decision in combination with the set production mode, and implementing the regulation of the lighting brightness in each area according to the optimized control decision.

2. The method for energy-saving control of factory lighting according to claim 1, characterized in that: The demand determination rule includes a high-demand mode, a medium-demand mode, and a low-demand mode; among them, the high-demand mode is that there are personnel activities and the equipment is running in the area, and at the same time the environmental light < 300 Lux; the medium-demand mode is that there are personnel activities in the area, but the equipment is in the standby state and the environmental light is between 300 and 500 Lux; the low-demand mode is that there are no personnel activities in the area, but the environmental light > 500 Lux.

3. A method for energy-saving control of factory lighting according to claim 1, characterized in that: The production mode includes a normal production mode, an equipment maintenance mode, and a non-production mode; the normal production mode is full-area basic lighting and enhanced lighting in the working area; the equipment maintenance mode is local area lighting and safety passage lighting; the non-production mode is to only retain safety lighting.

4. A method for energy-saving control of factory lighting according to claim 1, characterized in that: In Step 3, it also includes adjusting the lighting intensity of the transition area, and using a time decay model for the transition area adjustment; its brightness adjustment method is Wherein, P0 is the base brightness; t0 is the time at the time of trigger adjustment; λ is the decay rate constant.

5. A method for energy-saving control of factory lighting according to claim 1, characterized in that: It also includes establishing a health status model of lighting equipment; judging the health status of lighting equipment according to the monitored current status of lighting equipment, and performing fault analysis according to the health status.

6. A method for energy-saving control of factory lighting according to claim 3, characterized in that: In the normal production mode, different control decisions are selected for different production areas, and the production areas are divided according to production functions; the non-production mode is the mode corresponding to non-working hours.

7. A method for energy-saving control of factory lighting according to claim 5, characterized in that: It also includes calculating energy consumption according to the health status of lighting equipment, and adjusting the lighting intensity according to the calculation result.

8. A system for energy-saving control of factory lighting, characterized in that: Applied to a method for energy-saving control of factory lighting according to any one of claims 1-7, it includes sensors distributed in each area of the factory building, and a control module connected to the sensors; the control module includes an operation terminal, a data processing unit, a decision control unit, a scheduling optimization unit, and an equipment monitoring unit.

9. The system for energy-saving control of factory lighting according to claim 8, characterized in that: The sensors include photosensitive sensors, motion sensors, and equipment status monitoring sensors.

10. A system for energy-saving control of factory lighting according to claim 9, characterized in that: The photosensitive sensors monitor the light intensity in each working area in real time; the motion sensors monitor the personnel activity status in each working area in real time; the equipment status monitoring sensors collect the operation status of the equipment and the workbench operation signals in real time.

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