Lithium battery factory public equipment energy-saving system

Abstract

The invention discloses a lithium battery factory public equipment energy-saving system, and belongs to the technical field of factory equipment energy conservation, and the lithium battery factory public equipment energy-saving system comprises a sensing layer, an execution layer and a control layer. The execution layer comprises a dehumidifier, a refrigerator, an air compressor and a vacuum pump which are modified according to a preset modification strategy; the control layer comprises a programmable logic controller (PLC), is matched with an edge calculation module, is embedded with a particle swarm optimization algorithm, and is used for receiving information of the sensing layer and controlling the execution layer; the sensing layer comprises a plurality of sensors arranged on the execution layer and is used for collecting production environment data. Through multi-device cooperative energy management and control, the use energy consumption of the dehumidifier, the refrigerator, the air compressor and the vacuum pump is effectively reduced, and the green benefits of enterprises are improved; and under a closed-loop regulation and control system mechanism, the service life of each power device can be effectively prolonged, and the maintenance cost is reduced.

Description

Technical Field

[0001] This application belongs to the field of energy-saving technology for factory equipment, and in particular relates to an energy-saving system for public equipment in a lithium battery factory. Background Technology

[0002] In the lithium battery production process, dehumidifiers, refrigeration units, air compressors, and vacuum pumps are core public equipment that ensure the stability of the production environment and the continuity of the process, and are widely used in various key processes of lithium battery production.

[0003] Currently, lithium battery factories mostly manage such public equipment using a "single-machine independent operation + manual control" model. According to industry statistics, the energy consumption of this type of equipment accounts for about 40%-50% of the total energy consumption of a lithium battery factory. Among them, the energy consumption of dehumidifier regeneration heating, air compressor waste heat loss, and vacuum pump idle energy consumption are the main energy waste points. For example, the regeneration heating energy consumption of traditional rotary dehumidifiers accounts for more than 60% of their total energy consumption, and they use a fixed electric heating mode, which cannot be adjusted according to the dynamic humidity requirements of the workshop; the waste heat generated during the operation of air compressors (accounting for about 80% of the compression work) is mostly dissipated directly through air cooling or water cooling without effective recovery; when vacuum pumps switch between different processes, due to the lack of a negative pressure buffer mechanism, the idle operation time accounts for more than 30%, resulting in redundant energy consumption.

[0004] As the lithium battery industry increasingly demands cost reduction, efficiency improvement, and green production, the traditional independent operation mode of equipment can no longer meet the industry goal of "reducing energy consumption per unit of production capacity." There is an urgent need to build a multi-equipment collaborative energy-saving and emission-reduction system to achieve tiered energy utilization and dynamic equipment adaptation.

[0005] Problems with existing technology: 1. Equipment operates independently with low energy efficiency: Each piece of public equipment operates independently without coordination. For example, there is no energy interaction between the dehumidifier for heat dissipation and the refrigeration unit, or between the air compressor for waste heat and the dehumidifier. The overall energy efficiency is less than 70%.

[0006] 2. Poor adaptability to operating conditions and serious energy redundancy: The dehumidifier has a fixed regeneration temperature (80-100℃), resulting in energy redundancy when the air humidity is low; the fixed-frequency compressor of the refrigeration unit cannot adapt to changes in heat load (30% increase in summer and 20% decrease in winter), resulting in wasted cooling capacity; the vacuum pump operates at a fixed speed, resulting in energy redundancy in the low vacuum process.

[0007] 3. Structural design flaws and significant energy losses: The dehumidifier rotor regeneration zone is an integral unit with a temperature difference of ±8℃ or more; the air compressor pipeline is prone to leakage, with "high pressure and low flow" accounting for more than 30%; the vacuum pump gas ballast valve has a fixed opening, resulting in reduced pumping efficiency at low humidity.

[0008] Therefore, it is necessary to provide a new energy-saving system for public facilities in lithium battery factories to solve the above-mentioned technical problems. Summary of the Invention

[0009] The purpose of this disclosure is to provide an energy-saving system for public facilities in lithium battery factories in order to solve the above-mentioned problems.

[0010] This disclosure achieves the above objectives through the following technical solutions: An energy-saving system for public equipment in a lithium battery factory includes a sensing layer, an execution layer, and a control layer; The execution layer includes a dehumidifier, a refrigeration unit, an air compressor, and a vacuum pump that have been modified according to a preset modification strategy; The control layer includes a programmable logic controller (PLC), an edge computing module, and an embedded particle swarm optimization algorithm, used to receive information from the perception layer and control the execution layer. The perception layer includes multiple sensors mounted on the execution layer for collecting production environment data.

[0011] As a further optimization of this disclosure, the perception layer includes: A temperature and humidity sensor installed on the dehumidifier's outlet pipe is used to collect air parameters in real time after dehumidification; A temperature sensor installed at the outlet of the condenser of a refrigeration unit is used to monitor the condensing temperature; A pressure sensor installed on the air compressor's exhaust manifold is used to collect exhaust pressure. A vacuum sensor installed on the vacuum pump's suction port is used to monitor the vacuum level.

[0012] As a further optimization of this disclosure, the preset modification strategy includes: The dehumidifier retrofit strategy includes: replacing the traditional electric heating regeneration device with a combination device of air compressor waste heat exchanger and auxiliary electric heating; and replacing the drive motor with a permanent magnet synchronous variable frequency motor. The refrigeration unit retrofit strategy includes: replacing the fixed-frequency compressor with a variable-frequency compressor, and adding an electric three-way valve at the condenser outlet to connect the cooling tower and the workshop air duct respectively; The modification strategy for air compressors includes: installing a staged pressure regulating valve on the exhaust manifold, replacing all joints with conical seal quick-connect couplings, and replacing the motor with a variable frequency motor. Vacuum pump modification strategies include: installing a negative pressure buffer tank at the outlet, replacing the motor with a variable frequency motor, and adding an electromagnetic variable gas ballast valve to the suction port.

[0013] As a further optimization of this disclosure, the dehumidifier's rotor body is divided into a processing zone and a regeneration zone; the regeneration zone is further divided into a high-temperature regeneration zone and a low-temperature regeneration zone by an adjustable partition, and the adjustable partition is driven by a servo motor to adjust the area ratio of the high-temperature regeneration zone and the low-temperature regeneration zone. A waste heat introduction channel with a spiral structure is provided on one side of the shell of the regeneration zone. The inner wall of the waste heat introduction channel is welded with a baffle plate. The inlet of the waste heat introduction channel is connected to the outlet of the waste heat exchanger of the air compressor through a flange, and the outlet of the waste heat introduction channel faces the regeneration zone.

[0014] As a further optimization of this disclosure, the area ratios of the processing area and the regeneration area are 70% and 30%, respectively.

[0015] As a further optimization of this disclosure, the staged pressure regulating valve of the air compressor is a pilot-operated regulating valve with a built-in pressure sensor. When the terminal air consumption drops to a preset percentage, the staged pressure regulating valve automatically reduces the exhaust pressure from the first preset pressure to the second preset pressure. The conical sealing quick connector adopts a double compression fitting connection with an inner conical angle of 60°, which fits tightly with the outer conical surface of the pipe. The sealing element is made of nitrile rubber.

[0016] As a further optimization of this disclosure, the electromagnetic variable gas ballast valve of the vacuum pump adopts a brass valve body and has a built-in electromagnetic coil. The coil current is adjusted by PWM signal to realize linear adjustment of the gas ballast opening. The electromagnetic variable gas ballast valve is linked with a humidity sensor to adjust the opening according to the humidity of the pumped gas.

[0017] As a further optimization of this disclosure, the objective function of the particle swarm optimization algorithm is to minimize the energy consumption per unit lithium battery production capacity, and the constraints include that the workshop temperature and humidity, vacuum degree and air compressor exhaust pressure are all within the corresponding preset range.

[0018] As a further optimization of this disclosure, the constraints include: The workshop temperature is between 20℃ and 25℃, and the humidity is between 35% and 45%; the vacuum degree is ≤ -0.09MPa; and the air compressor exhaust pressure is between 0.6MPa and 0.8MPa.

[0019] As a further optimization of this disclosure, the particle swarm optimization algorithm is set to run for 10 seconds, and the data collected by the perception layer is analyzed once per cycle, and adjustment instructions are output.

[0020] The beneficial effects of this disclosure are as follows: 1. Reduced energy consumption: Through multi-device collaborative energy management, the energy consumption of dehumidifiers, refrigeration units, air compressors, and vacuum pumps is effectively reduced, improving the company's green benefits.

[0021] 2. Improved stability: Under the three-level architecture system of "real-time perception - closed-loop control - precise execution", the consistency and control accuracy of workshop temperature and humidity, vacuum and compressed air pressure can be effectively improved, thereby increasing production efficiency and ensuring product quality consistency.

[0022] 3. Extended lifespan: Under the closed-loop control system mechanism, the service life of various power equipment can be effectively improved and maintenance costs reduced. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall system architecture in an embodiment of this disclosure; Figure 2 This is a schematic diagram of the dehumidifier partition regeneration rotor in an embodiment of this disclosure; Figure 3 This is an air compressor-dehumidifier energy synergy path diagram in an embodiment of this disclosure. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] like Figure 1 As shown, an energy-saving system for public equipment in a lithium battery factory includes a sensing layer, an execution layer, and a control layer. The execution layer includes a dehumidifier, a refrigeration unit, an air compressor, and a vacuum pump that have been modified according to a preset modification strategy; The control layer includes a programmable logic controller (PLC), an edge computing module, and an embedded particle swarm optimization algorithm, used to receive information from the perception layer and control the execution layer. The perception layer includes multiple sensors mounted on the execution layer for collecting production environment data.

[0027] The perception layer specifically includes: A temperature and humidity sensor (measurement range -40-125℃, humidity 0-100%RH, accuracy ±2%RH) installed on the dehumidifier outlet pipe collects air parameters in real time after dehumidification. A temperature sensor (accuracy ±0.1℃) installed at the condenser outlet of the refrigeration unit monitors the condensing temperature; A pressure sensor (range 0-1MPa, accuracy ±0.5%FS) installed on the exhaust manifold of the air compressor collects the exhaust pressure. A vacuum sensor (range 1-1000 mbar, accuracy ±0.1 mbar) is installed on the vacuum pump inlet to monitor the vacuum level.

[0028] The control layer uses a PLC paired with an edge computing module and embeds a particle swarm optimization algorithm. The objective function is set as "minimize the energy consumption per unit lithium battery production capacity (kWh / kg)". The constraints include workshop temperature and humidity (temperature 20-25℃, humidity 35%-45%), vacuum degree (≤-0.09MPa), and air compressor exhaust pressure (0.6-0.8MPa).

[0029] The algorithm runs for 10 seconds, analyzing the sensing data once per cycle and outputting adjustment commands: for example, when the workshop humidity is 65%, the dehumidifier rotor high-temperature regeneration zone area is instructed to reach 70%, and the air compressor waste heat is introduced at the same time; when the workshop temperature is 28℃, the refrigeration unit condenser three-way valve is instructed to fully open the cooling tower.

[0030] The execution layer specifically includes: Dehumidifier: The traditional electric heating regeneration device is replaced with a combination device of "air compressor waste heat exchanger + auxiliary electric heating". The heat exchanger adopts a 304 stainless steel shell and tube structure (heat exchange area 5m²). 2 Heat transfer coefficient 1200W / (m 2 ℃), auxiliary electric heating power 5kW (only turned on when residual heat is insufficient); the drive motor was replaced with a permanent magnet synchronous variable frequency motor (energy efficiency rating IE4).

[0031] like Figure 2 As shown, the dehumidifier's rotor body is divided into a treatment zone (70%) and a regeneration zone (30%). The regeneration zone is further divided into a high-temperature regeneration zone and a low-temperature regeneration zone by an adjustable baffle (made of 304 stainless steel, 5mm thick). The baffle is driven by a servo motor (100W power, positioning accuracy ±0.1mm), which can continuously adjust the area ratio of the two zones from 30% to 70%.

[0032] The waste heat introduction channel is located on the side shell of the regeneration zone (made of PPR), employing a spiral structure (e.g., 100mm pitch, 80mm inner diameter). A 5mm high baffle plate (spaced 50mm apart) is welded to the inner wall of the channel to improve heat exchange efficiency. The channel inlet is connected to the outlet of the air compressor waste heat exchanger via a flange. Figure 3 As shown, the outlet faces the rotary regeneration zone to ensure uniform coverage of waste heat.

[0033] Refrigeration unit: Replace the fixed-frequency compressor (50HP) with a variable-frequency compressor (50HP, frequency range 0-50Hz), and add an electric three-way valve (response time ≤1s) at the condenser outlet, connecting it to the cooling tower and the workshop air duct respectively.

[0034] Air compressor: Install a graded pressure regulating valve (adjustment accuracy ±0.02MPa) on the exhaust main pipe, replace all joints with conical sealing quick-connect joints (sealing pressure 1.6MPa, leakage rate ≤0.1L / min); replace the motor with a variable frequency motor (speed range 1000-2900r / min).

[0035] The graded pressure regulating valve adopts a pilot-operated regulating valve with a built-in pressure sensor (range 0-1MPa). When the gas consumption at the end drops to 50% (such as during assembly process operation), the valve automatically reduces the exhaust pressure from 0.8MPa to 0.6MPa, with a pressure regulation response time of ≤2s.

[0036] The conical sealing quick-connector adopts a double compression fitting connection with an inner conical angle of 60°, which fits tightly with the outer conical surface of the pipe. The sealing element is made of nitrile rubber (temperature resistant -20-120℃), with a disassembly time of ≤30s and stable repeated sealing performance (≥50 disassembly and assembly cycles without leakage).

[0037] Vacuum pump: Install a 100L negative pressure buffer tank (working pressure -0.1MPa) at the outlet, and replace the motor with a variable frequency motor (speed range 500-1450r / min); install an electromagnetic variable gas ballast valve at the suction port (opening adjustment range 0-100%, response time ≤0.5s).

[0038] The electromagnetic variable gas ballast valve uses a brass valve body and has a built-in electromagnetic coil (voltage 24VDC, power 5W). The coil current is adjusted (0-1A) by PWM signal to achieve linear adjustment of the gas ballast opening from 0-100%. The valve has a diameter of DN25 and a maximum flow capacity of 10m³ / h. It is linked with a humidity sensor. When the humidity of the gas being pumped is >60% RH, the opening is adjusted to 80%, and when the humidity is <30% RH, the opening is adjusted to 0%.

[0039] The advantages of this disclosure are: 1. Three-level collaborative management and control architecture: Construct a three-level architecture of "real-time perception - closed-loop control - precise execution" to link workshop process signals with equipment operating parameters, realize real-time matching of "energy consumption - operating conditions", break the traditional single-machine control mode, and realize multi-device collaborative decision-making.

[0040] 2. Multi-device energy synergy path: (1) Create a two-way utilization path of "air compressor waste heat - dehumidifier regeneration", which reduces the energy consumption of dehumidifier regeneration and improves the dryness of air intake of air compressor, thus achieving dual energy saving.

[0041] (2) Construct a two-way switching mechanism for condensing heat of the refrigeration unit, and flexibly allocate condensing heat to the workshop or cooling tower according to the temperature and humidity requirements of the workshop, so as to avoid energy waste from "refrigeration + heating" running at the same time.

[0042] 3. Optimization of key equipment structure: (1) Optimize the dehumidifier zone regeneration rotor, realize the dynamic distribution of the regeneration zone area through adjustable baffles, and improve the uniformity of regeneration temperature by combining the spiral waste heat introduction channel.

[0043] (2) Improve the cone-shaped sealing leak-proof quick-connect coupling and add a graded pressure regulating valve to reduce the leakage rate of the air compressor pipeline and improve the compression efficiency.

[0044] (3) Introduce an electromagnetic variable gas ballast valve to dynamically adjust the opening degree according to the water vapor content, thereby reducing the loss of pumping efficiency.

[0045] The embodiments described above are merely examples of several implementations of this disclosure, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent disclosure. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this disclosure, and these modifications and improvements all fall within the protection scope of this disclosure.

Claims

1. A lithium battery plant common equipment energy saving system, characterized in that, The system comprises a perception layer, an execution layer and a control layer; The execution layer comprises dehumidifiers, refrigerators, air compressors and vacuum pumps which are retrofitted according to preset retrofit strategies; The control layer comprises a programmable logic controller (PLC) which is combined with an edge computing module and embedded with a particle swarm optimization algorithm, and is used for receiving information from the perception layer and controlling the execution layer; The perception layer comprises a plurality of sensors arranged on the execution layer and used for collecting production environment data.

2. The energy saving system for public facilities in a lithium battery factory according to claim 1, characterized in that, The perception layer comprises: A temperature and humidity sensor installed on the outlet pipeline of the dehumidifier for collecting real-time air parameters after dehumidification; A temperature sensor installed on the outlet of the condenser of the refrigerator for monitoring the condensing temperature; A pressure sensor installed on the exhaust manifold of the air compressor for collecting exhaust pressure; A vacuum degree sensor installed on the suction port of the vacuum pump for monitoring the vacuum degree.

3. The energy saving system for public facilities in a lithium battery factory according to claim 1, characterized in that, The preset retrofit strategies comprise: The retrofit strategy of the dehumidifier comprises: replacing the traditional electric heating regeneration device with a combined device of the waste heat exchanger of the air compressor and auxiliary electric heating; and replacing the driving motor with a permanent magnet synchronous variable frequency motor; The retrofit strategy of the refrigerator comprises: replacing the fixed-frequency compressor with a variable-frequency compressor, and adding an electric three-way valve at the outlet of the condenser and connecting the cooling tower and the workshop air duct, respectively; The retrofit strategy of the air compressor comprises: installing a stepped pressure regulating valve on the exhaust manifold, and replacing all joints with conical sealing type quick joints; and replacing the motor with a variable frequency motor; The retrofit strategy of the vacuum pump comprises: installing a negative pressure buffer tank at the outlet, and replacing the motor with a variable frequency motor; and adding an electromagnetic variable gas ballast valve at the suction port.

4. The energy saving system for public facilities in a lithium battery factory according to claim 3, characterized in that, The runner body of the dehumidifier is divided into a treatment zone and a regeneration zone; the regeneration zone is divided into a high-temperature regeneration zone and a low-temperature regeneration zone by an adjustable partition plate driven by a servo motor, for adjusting the area ratio of the high-temperature regeneration zone to the low-temperature regeneration zone; One side of the shell of the regeneration zone is provided with a waste heat introduction channel in a spiral structure, and the inner wall of the waste heat introduction channel is welded with a spoiler; the inlet of the waste heat introduction channel is connected with the outlet of the waste heat exchanger of the air compressor through a flange, and the outlet of the waste heat introduction channel is opposite to the regeneration zone.

5. The energy saving system for a lithium battery plant common equipment according to claim 4, characterized in that, The area ratios of the treatment zone and the regeneration zone are 70% and 30%, respectively.

6. The energy saving system for a lithium battery plant common equipment according to claim 3, characterized in that, The stepped pressure regulating valve of the air compressor is a pilot type regulating valve with a built-in pressure sensor, which automatically reduces the exhaust pressure from a first preset pressure to a second preset pressure when the amount of gas at the end decreases to a preset percentage; The conical sealing type quick joint adopts a double sleeve type connection, the inner conical surface angle is 60°, and is tightly fitted with the outer conical surface of the pipeline, and the sealing element is made of nitrile rubber.

7. The energy saving system for public facilities in a lithium battery factory according to claim 3, characterized in that, The electromagnetic variable gas ballast valve of the vacuum pump adopts a brass valve body with an embedded electromagnetic coil, and the coil current is adjusted by a PWM signal to realize linear adjustment of the opening degree of the gas ballast; the electromagnetic variable gas ballast valve is linked with a humidity sensor to adjust the opening degree according to the humidity of the extracted gas.

8. The energy saving system for public facilities in a lithium battery factory according to claim 1, characterized in that, The objective function of the particle swarm optimization algorithm is to minimize the energy consumption per unit lithium battery production capacity, and the constraint conditions include that the workshop temperature and humidity, the vacuum degree and the air compressor exhaust pressure are all within the corresponding preset ranges.

9. The energy saving system for a lithium battery plant common equipment according to claim 8, characterized in that, The constraint conditions comprise: The temperature of the workshop humidity is 20-25℃, the humidity is 35%-45%, the vacuum degree is less than or equal to -0.09MPa, and the exhaust pressure of the air compressor is 0.6-0.8MPa.

10. The energy saving system for a lithium battery plant common equipment according to claim 1, characterized in that, The particle swarm optimization algorithm is set to run for 10s, the data collected by the sensing layer is analyzed once every cycle, and the adjustment instruction is output.

Images