Noise power generation integrated system for industrial factory building

Abstract

The invention discloses a ventilation noise reduction and multi-source energy recovery integrated system for an industrial factory building. The ventilation noise reduction and multi-source energy recovery integrated system comprises a ventilation air duct, a multi-band resonance cavity adjusting system, a sound-induced energy collection assembly, a heat energy power generation assembly arranged on an exhaust section, a sensing and monitoring unit and a power conditioning and energy management unit. Parameterization design is carried out on the cavity volume, the neck length and the sectional area, so that the resonant frequency covers the main noise frequency band of the factory building, and the resonance panel is coupled with the energy collection unit to recover sound-induced vibration energy; meanwhile, heat energy power generation is carried out by utilizing the temperature difference between exhaust air and the environment, and energy is rectified, MPPT and a combiner box to a DC bus to supply power to a low-power-consumption load. Under the constraint that the additional pressure drop delta P is smaller than or equal to 100 Pa, the device obtains insertion loss larger than or equal to 3 dB and 5-24 V direct current output, noise reduction and energy supply are achieved, and the device is suitable for scenes such as fan rooms, stamping workshops and roof clerestory.

Description

Technical Field

[0001] This invention relates to the field of industrial ventilation and energy recovery technology, specifically to an integrated system that synergistically integrates ventilation noise reduction structure, acoustic energy harvesting, and waste heat power generation. Background Technology

[0002] During production, industrial plants generate significant noise from the operation of various mechanical equipment. This noise not only pollutes the surrounding environment but also affects the health of workers and reduces work efficiency. Currently, common noise reduction methods in industrial plants include installing sound barriers and sound-absorbing materials. However, these devices are limited in function, only achieving noise reduction without recovering or utilizing noise or other usable energy within the plant.

[0003] Meanwhile, equipment in industrial plants generates energy such as vibration, airflow, and heat during operation, which is often wasted. With the increasing prominence of energy shortages, how to achieve energy recycling has become a hot research topic. Most existing power generation units are independently installed, separate from noise reduction devices, which not only occupies a large space but also incurs high installation and maintenance costs, making it difficult to meet the actual needs of industrial plants.

[0004] Therefore, there is an urgent need to develop an integrated system that combines noise reduction and power generation. This system can directly power low-power devices, reducing energy consumption in industrial plants while possessing core advantages such as compact structure, multiple functions, and convenient installation, thus effectively solving the pain points of existing technologies in practical applications. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated noise reduction and power generation system for industrial plants to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following solution:

[0007] An integrated noise generation system for industrial plants includes a ventilation duct 1, a multi-band resonant cavity adjustment system 2, an acoustic energy harvesting component 3, a thermal power generation component 4, a sensing and monitoring unit 5, and a power conditioning and energy management unit 6. Its features are:

[0008] The ventilation duct 1 includes an air inlet section 7, a processing section 8, and an exhaust section 9. The channel wall of the processing section 8 is provided with several side-mounted cavity mounting positions for installing the multi-band resonant cavity adjustment system 2. This design ensures that the device can effectively guide and process airflow, while providing installation positions for the multi-band resonant cavity adjustment system 2.

[0009] The multi-band resonant cavity adjustment system 2 is connected to the processing section 8 via the neck tube 12. Each resonant cavity has a cavity volume V, an effective neck length L, and a neck cross-sectional area A. These parameters satisfy the target resonant frequency. The design conditions fall within the main noise frequency band of the factory building, which enables the device to recover energy from multiple target noise frequency bands.

[0010] The multi-band resonant cavity array 11 in the multi-band resonant cavity adjustment system 2 adopts an electrically controlled adjustable structure. Through the collaboration of three core adjustable mechanisms and the sensing and monitoring unit 5, dynamic adaptation of the resonant frequency is achieved. The cavity volume adjustment mechanism drives the nested cavity wall to extend and retract via a stepper motor, covering low-frequency noise. The effective neck length adjustment mechanism controls the piston displacement via a servo motor, achieving precise fine-tuning in the mid-frequency band. The neck cross-sectional area adjustment mechanism drives the louver blades to open and close via an electromagnetic actuator, assisting in adaptation to the high-frequency band. The sensing feedback unit collects noise spectrum, vibration amplitude, and adjustment position data in real time. The intelligent control unit calculates the optimal parameters based on the resonant frequency formula and ensures that the resonant cavity always resonates with the current main noise frequency band through closed-loop adjustment.

[0011] The acoustic energy harvesting component 3 is installed at the vibration coupling position of the multi-band resonant cavity adjustment system 2 or the channel wall. It has a built-in adjustable piezoelectric unit to collect and generate electricity from noise >500Hz. The multi-band resonant cavity adjustment system 2 amplifies and resonates the mid-to-high frequency noise >500Hz, causing directional micro-vibration at the coupling position. This vibration is transmitted to the elastic diaphragm of the adjustable piezoelectric unit, driving the piezoelectric material to undergo mechanical deformation. The piezoelectric effect is used to excite the separation of polarized charges inside the material. Then, the electrical energy is extracted and stored through the electrodes and energy storage circuit integrated by the unit, ultimately completing the conversion of noise into electrical energy.

[0012] The thermal power generation component 4 is arranged in the exhaust section 9, including a hot end that exchanges heat with the exhaust airflow and a cold end that exchanges heat with the environment. The two are connected to the heat sink through a heat-conducting interface to form a heat conduction path. When the temperature difference is ≥10℃, the thermoelectric module starts to work and generates preliminary electrical energy. This component uses the thermoelectric effect to convert the thermal energy of the exhaust airflow into electrical energy, further improving the energy recovery efficiency of the device.

[0013] The sensing and monitoring unit 5 includes at least sensors for wind pressure 13, position 14, temperature 15, noise frequency 16, and vibration 17, a real-time monitoring device operating status, and an intelligent computing module 18 for intelligent analysis and calculation of the collected data. After processing by the central processing unit 19 and the intelligent computing module 18, the data processing 20, real-time monitoring 21, energy storage switching 22, and stable output modules work together to achieve monitoring, analysis, and stable control of relevant physical quantities.

[0014] The power conditioning and energy management unit 6 comprises five parts: an input layer 24, a processing layer 25, an output layer 26, a control unit 27, and a protection unit 28. It executes an energy path optimization and safety protection strategy based on multi-sensor data, optimizing the energy path in real time through multi-sensor data analysis. The input layer 24 includes three energy harvesting methods: vibration energy harvesting 32, piezoelectric energy harvesting 33, and thermal energy harvesting 34, responsible for collecting different forms of energy from the environment to provide energy input to the system. The core module of the processing layer 25 is the MPPT35, which optimizes the energy harvested by the input layer to ensure maximum energy harvesting efficiency, followed by rectification to prepare for subsequent energy storage and output. The output layer 26 includes an energy storage module bus 36 and a voltage output module (DC bus 12V / 24V, +5V / 12V) 37. The energy storage module bus 36 is responsible for integrating and storing energy, and finally outputting DC voltages of various specifications to meet the power supply needs of different devices. The control unit 27 realizes multi-sensor optimization with a control cycle of 10-100ms. It monitors and regulates the entire system in real time to ensure that each module works together efficiently. The protection unit 28 has overvoltage, overcurrent, overtemperature, and undervoltage protection functions. When the system experiences abnormal conditions such as excessive voltage, excessive current, or excessive temperature, the protection mechanism is activated in time to prevent system damage.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1. Multi-technology synergistic integration: Solving the pain points of space and energy complementarity in existing independent devices. In existing technologies, acoustic noise reduction devices, piezoelectric energy harvesting devices, and thermoelectric power generation devices are all set up independently, occupying a large total area, and their energy cannot be complemented. This invention integrates the three into a ventilation duct, reducing the footprint and significantly saving factory space. At the same time, it constructs a complementary "acoustic energy-thermal energy" power supply system. When the noise intensity is <60Hz (such as when the equipment load is reduced at night) but the temperature difference is ≥10℃, thermal power generation can supplement the power supply, solving the problem of unstable power supply from a single energy harvesting device. The energy recovery rate per unit space is improved compared to existing technologies.

[0017] 2. Dynamic Resonance Adjustment: Overcoming the limitations of efficiency and adaptability of existing manual adjustment. Existing adjustable resonant cavities require manual adjustment. This invention improves energy harvesting efficiency and can adapt to the dynamic changes in factory noise frequency bands in real time through "multi-sensor feedback + electronic closed-loop adjustment" and "coarse adjustment-fine adjustment-compensation" collaborative logic.

[0018] 3. Parametric design of ventilation ducts and acoustic resonance cavities: By precisely adjusting the volume, neck length, and cross-sectional area of ​​the resonance cavities, maximum energy harvesting efficiency is ensured within the factory noise frequency band (e.g., 125Hz or 250Hz). Simultaneously, the resonant frequency of each resonance cavity is adjusted using a 1 / 3 octave band method to achieve optimal noise harvesting performance.

[0019] 4. Thermal power generation tailored to the characteristics of industrial plants: Compared with existing technologies, it achieves significant improvements in adaptability to a wide temperature difference of 10-30℃, energy recovery efficiency, long-term operational stability, multi-source power supply coordination, and integrated installation adaptability, effectively solving pain points in industrial scenarios and reducing overall costs.

[0020] Through these technological optimizations, this invention can not only effectively reduce noise pollution in the factory, but also recover waste heat and mechanical vibration energy through an intelligent adjustment system, providing a continuous power supply for low-power loads, which has significant economic benefits and environmental value. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the integrated system structure of the present invention;

[0022] Figure 2 This is a schematic diagram showing the installation relationship between the processing section and the resonant cavity array of the present invention;

[0023] Figure 3 This is a schematic diagram of the thermal power generation component and the heat conduction path at the hot and cold ends of the present invention;

[0024] Figure 4 This is a structural diagram of the sensing and monitoring unit of the present invention;

[0025] Figure 5 This is a functional block diagram of the power conditioning and energy management unit of the present invention. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0027] This invention proposes an integrated noise generation system for industrial plants. This device is applied to noisy industrial plants, utilizing the plant's ventilation channels. A multi-band resonant cavity adjustment system 2 and an acoustic energy harvesting component 3 are arranged within the ventilation channels. A thermal power generation component 4 is placed at the exhaust vent, equipped with a sensing and monitoring unit 5 and a power conditioning and energy management unit 6. While reducing energy consumption in industrial plants, it possesses core advantages such as compact structure, diverse functions, and convenient installation, aligning with the concept of green environmental protection.

[0028] Air inlet section 7 is responsible for introducing airflow and noise into the device, and for initial control and adjustment of the airflow speed. This section is designed with a rectangular cross-section, with an equivalent hydraulic diameter of 800mm, and is equipped with a removable maintenance port and protective mesh for easy subsequent maintenance and cleaning.

[0029] Processing section 8 is the core processing part. After wind and noise enter, they are optimized for noise and harvested through the multi-band resonant cavity adjustment system 2. The design parameters of the multi-band resonant cavity adjustment system 2 (cavity volume V, effective neck length L, and neck cross-sectional area A) are matched with the target frequency. At this frequency, the system can absorb and convert noise energy to the maximum extent. Simultaneously, the acoustic energy harvesting component 3 includes a piezoelectric energy harvesting unit. Utilizing the cantilever beam structure of the PZT piezoelectric sheet, an adjustable pre-tightening mechanism with a butterfly spring is designed at the connection interface between the panel and the acoustic energy harvesting component. This mechanism is specifically installed at the fixed support positions at both ends of the piezoelectric beam and mainly consists of butterfly spring washers and adjusting bolts. In actual commissioning, by precisely adjusting the tightening torque of the bolts, the boundary support conditions are changed, forcing the first-order vibration mode of the resonant cavity panel to couple with the second-order vibration mode of the piezoelectric beam. This modal coupling effect can effectively break the limitation of a single resonance peak, extending the system's energy harvesting bandwidth to over 500Hz, significantly enhancing the device's capture efficiency for mid-to-high frequency industrial noise. Meanwhile, the inner wall of the cavity is also lined with a porous sound-absorbing lining to suppress unwanted high-order harmonic modes and ensure the purity and stability of energy output.

[0030] The exhaust section 9 recovers heat energy from the exhaust airflow through the thermal power generation component 4. A Bi2Te3-based thermoelectric module 29 is combined with a finned heat exchanger 30, with heat pipes and heat sinks 31 facilitating heat exchange between the cold and hot ends. In this way, the heat in the exhaust airflow is effectively converted into electrical energy, further improving the system's energy efficiency.

[0031] In addition, the device is equipped with a sensing and monitoring unit 5 and a power conditioning and energy management unit 6. The sensing and monitoring unit 5 is connected to sensors including at least wind pressure 13, position 14, temperature 15, noise frequency 16 and vibration 17 to monitor the working status of the device in real time, as well as an intelligent computing module 18 for intelligent analysis and calculation of the collected data. After processing by the central processing unit 19 and the intelligent computing module 18, the data processing 20, real-time monitoring 21, energy storage switching 22, and stable output 23 work together to form a complete working system of "noise reduction - energy conversion - intelligent management".

[0032] The power conditioning and energy management unit 6 comprises five parts: an input layer 24, a processing layer 25, an output layer 26, a control unit 27, and a protection unit 28. It executes energy path optimization and safety protection strategies based on multi-sensor data analysis, optimizing the energy path in real time. The input layer 24 includes three energy harvesting methods: vibration energy harvesting 32, piezoelectric energy harvesting 33, and thermal energy harvesting 34, responsible for collecting different forms of energy from the environment to provide energy input to the system. The core module of the processing layer 25 is the MPPT35, which optimizes the energy harvested by the input layer to ensure maximum energy harvesting efficiency, followed by rectification to prepare for subsequent energy storage and output. The output layer 26 includes an energy storage module bus 36 and a voltage output module (DC bus 12V / 24V, +5V / 12V) 37. The energy storage module bus 36 is responsible for integrating energy and storing and managing it, and finally outputting DC voltages of various specifications to meet the power supply needs of different devices. The control unit 27 realizes multi-sensor optimization and has a control cycle of 10-100ms. It monitors and regulates the entire system in real time to ensure that each module works together efficiently. The protection unit 28 has overvoltage, overcurrent, overtemperature and undervoltage protection functions. When the system has abnormal conditions such as excessive voltage, excessive current or excessive temperature, the protection mechanism is activated in time to prevent system damage.

[0033] In the entire workflow, airflow first enters the system through the inlet section and undergoes initial regulation, then enters the processing section. In this section, noise is optimized through acoustic resonance chambers and converted into usable electrical energy by piezoelectric units. Finally, in the exhaust section, the system recovers heat energy through a thermal energy module and converts it into electricity to power the equipment. Through precise coordination, the various technical modules ensure the efficient operation of the entire system, achieving optimal energy recovery and utilization.

[0034] Practical application cases

[0035] Taking an industrial plant as an example, the main noise frequency band in the plant is 125Hz, and the temperature difference between the exhaust air and the ambient temperature during equipment operation is approximately 20℃. Based on the above design, the noise-generating integrated system of this invention was installed. After actual operation testing, with the temperature difference adaptation strategy of this invention activated, when a temperature fluctuation of 12℃ is detected, the system automatically reduces speed by 15%, and the average output power of the thermoelectric module increases to 5.1W, an increase of 45.7%. Furthermore, the air quality monitoring in the workshop shows that the ventilation rate still meets the standards. Simultaneously, the additional pressure drop ΔP in the processing section of the device remains stable at 80Pa, the airflow attenuation is only 2%, and the insertion loss reaches 4dB within the target frequency band. The stable DC voltage output range is 12V, providing a stable power supply for low-power devices such as sensors and gateways in the plant; after conversion by the inverter, the output is 220V AC, which can meet the needs of conventional electrical equipment such as lighting and sockets in the plant.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. All equivalent structural changes made based on the description and drawings of the present invention should be included within the scope of patent protection of the invention.

Claims

1. An integrated noise generation system for industrial plants, comprising a ventilation duct (1), a multi-band resonant cavity adjustment system (2), an acoustic energy harvesting component (3), a thermal power generation component (4), a sensing and monitoring unit (5), and a power conditioning and energy management unit (6), characterized in that: The ventilation duct (1) adopts a three-section structure design, including an air intake section (7), a treatment section (8) and an exhaust section (9), which are connected in sequence along the airflow direction. The air intake section (7) only performs the function of air intake treatment. The treatment section (8) is used to install a multi-band resonant cavity adjustment system (2) and a acoustic energy harvesting component (3) to recover acoustic vibration energy. The exhaust section (9) is equipped with a thermal power generation component (4) to recover the thermal energy in the exhaust airflow. The two construct a sound-heat complementary energy supply system. The multi-band resonant cavity adjustment system (2) includes a multi-band cavity body (10) and a multi-band resonant cavity array (11), which is connected to the processing section (8) through a neck tube (12). Each resonant cavity has parameters such as cavity volume V, effective neck length L, and neck cross-sectional area A. These parameters satisfy the design condition that the target resonant frequency f falls within the main noise frequency band of the factory building. The multi-band resonant cavity array (11) adopts an electrically controlled adjustable structure with a 1 / 3 octave band tuning design. Through the collaboration of three core adjustable mechanisms and the sensing and monitoring unit (5), the resonant frequency is dynamically adapted to accurately match the low-frequency band (0-125Hz), mid-frequency band (125-250Hz), and high-frequency band (250-500Hz) of the main noise of the factory, and energy recovery is carried out in multiple target noise frequency bands. The acoustic energy harvesting component (3) is installed at the vibration coupling position of the multi-band resonant cavity adjustment system (2) or the channel wall, and has a built-in adjustable piezoelectric unit to achieve the collection and power generation of >500Hz noise; The exhaust section (9) is equipped with a thermal power generation component (4), which includes a hot end that exchanges heat with the exhaust airflow and the environment. The two form a heat conduction path through a heat conduction interface and a radiator, and at the same time, the temperature difference between the exhaust air and the environment is used to generate thermal power. The sensing and monitoring unit (5) executes a sound-heat coordinated control strategy based on monitoring data: on the one hand, it dynamically adjusts the geometric parameters of the multi-band resonant cavity adjustment system (2) through electronic control commands so that its resonant frequency tracks the main noise frequency band of the factory in real time; on the other hand, it adjusts the airflow speed in the duct according to the exhaust temperature difference to match the optimal heat exchange efficiency of the thermal power generation component (4); thereby constructing a coupled energy supply system of acoustic noise reduction, sound energy recovery and heat energy recovery. The power conditioning and energy management unit (6) includes five parts: input layer (24), processing layer (25), output layer (26), control unit (27) and protection unit (28). It executes energy path optimization and safety protection strategies based on multi-sensor data and optimizes the energy path in real time through multi-sensor data analysis. The structure and control parameters of the device together meet the following engineering constraints: the additional voltage drop ΔP of the processing section (8) is ≤100Pa, the percentage attenuation for the design air volume is ≤3%, the insertion loss in the target frequency band is ≥3dB, and the output stable DC voltage range is 5~24V.

2. The apparatus according to claim 1, characterized in that, The treatment section (8) of the ventilation duct (1) has a rectangular or circular cross-section, with an equivalent hydraulic diameter D. h =400~1600mm, with a removable maintenance port and protective mesh on the inner wall; the whole machine meets the IP54 and above protection level, and the explosion-proof shell and isolated power supply design are adopted for places with explosion-proof requirements.

3. The apparatus according to claim 1, characterized in that, The tuning of the multi-band resonant cavity adjustment system (2) satisfies: (where c is the air speed at 20-25℃, taken as 343m / s), and f0 is selected in the range of 63-500Hz according to the noise spectrum of the factory equipment, preferably the center frequency band of 125Hz or 250Hz; the f0 of the multi-band resonant cavity array (11) is segmented according to 1 / 3 octave band to ensure coverage of the low, medium and high frequency bands of the main noise of the factory.

4. The apparatus according to claim 1, characterized in that, The multi-band resonant cavity panel is made of aluminum alloy or composite material; a butterfly spring adjustable pre-tightening mechanism is set between the panel and the piezoelectric beam, which is installed at the supports at both ends of the beam to change the coupling stiffness between the panel and the piezoelectric beam. By adjusting the bolt compression, the first mode of the panel is coupled with the second mode of the beam, thereby expanding the bandwidth to ≥500Hz; a microporous sound-absorbing liner is provided on the inner wall of the cavity to suppress higher-order modes.

5. The apparatus according to claim 1, characterized in that, The adjustable piezoelectric unit is designed as a prestressed cantilever beam structure with a natural frequency f. n Coinciding with the target range of f0 ± 20%; each beam includes a mass block and a limiting damping structure to enhance bandwidth and durability; the elements are arranged in an array along the airflow direction with a spacing of L. r Set to 1 / 4 of the noise wavelength to ensure the vibration energy is superimposed.

6. The apparatus according to claim 1, characterized in that, The electrically controlled adjustable structure is equipped with a sensing feedback unit and an intelligent computing architecture. The sensing and monitoring unit (5) includes a noise frequency sensor (16) installed at the neck tube inlet, a vibration sensor (17) attached to the coupling position of the cavity panel, a position sensor (14), and wind pressure (13) and temperature (15) sensors. The unit also integrates an intelligent computing module (18) and a central processing unit (19), which work together with data processing (20), real-time monitoring (21), energy storage switching (22), and stable output (23) modules to intelligently analyze the collected data and realize the monitoring and stable control of relevant physical quantities.

7. The apparatus according to claim 1, characterized in that, The multi-band resonant cavity adjustment system (2) adopts a parameterized closed-loop adjustment mechanism, and the sensing and monitoring unit (5) calculates the target resonant frequency based on the Helmholtz resonance principle formula. For different noise frequency bands, the system implements a graded adjustment strategy: (1) coarse adjustment in the low frequency band, the cavity wall is extended and retracted by a stepper motor to change the cavity volume V and cover the low frequency noise; (2) fine adjustment in the mid frequency band, the piston displacement in the neck tube is controlled by a servo motor to change the effective length L of the neck and achieve precise alignment in the mid frequency; (3) high frequency band assistance, the louvers of the neck opening are opened and closed by an electromagnetic actuator to change the neck cross-sectional area A, adapt to the high frequency band and perform impedance matching; the system control cycle is set to 10-100ms, and the residual noise after adjustment is fed back by a noise frequency sensor (16) to form a closed-loop control for real-time correction.

8. The apparatus according to claim 1, characterized in that, The thermal power generation component (4) adopts a Bi2Te3-based thermoelectric module (29). Its hot end exchanges heat with the exhaust airflow through a finned heat exchanger (30), and its cold end exchanges heat with the environment through a heat pipe + heat sink (31). When the temperature difference is ≥10℃, the thermoelectric module starts to work and generates preliminary electrical energy. The total thermal resistance Rth between the hot end and the cold end is ≤0.25K / W (equivalent to a single module), and a detachable filter and an anti-oil mist coating are provided to reduce the pollution thermal resistance.

9. The apparatus according to claim 1, characterized in that, The sensing and monitoring unit (5) executes a temperature difference adaptation strategy based on temperature monitoring data: when the temperature difference between the exhaust air and the environment is 10-15℃, the fan speed is reduced to extend the residence time of the exhaust air in the heat exchanger at the hot end and improve the temperature difference utilization rate; when the temperature difference is 15-30℃, the rated speed of the fan is maintained to ensure a balance between ventilation and power generation efficiency.

10. The apparatus according to claim 1, characterized in that, The power conditioning and energy management unit (6) includes an input layer (24), a processing layer (25), an output layer (26), a control unit (27), and a protection unit (28). The input layer (24) collects three types of energy: vibration, piezoelectric, and thermal energy. The processing layer (25) optimizes and rectifies the energy through MPPT (35). The output layer (26) includes an energy storage module bus (36), which consists of a supercapacitor and a lithium iron phosphate battery. It is responsible for integrating energy and providing a nominal 12V or 24V DC bus voltage, as well as two regulated output interfaces of 5V and 12V for use by low-power devices.

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